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BACKGROUND OF THE INVENTION
The present invention relates to load current detection circuits, and in particular to a load current detection circuit capable of changing its detection sensitivity by switching resistors while restraining the generation of noise spikes with minimal circuitry.
A load current detection circuit applies a predetermined voltage, proportional to an input voltage applied to an input amplifier, to a load and detects a voltage across a current detection resistor connected to the load in series in order to determine the current through the load from the predetermined voltage. In this circuit current detection resistors are switched to change current detection sensitivity as the load current changes in response to the voltage applied to the load or in response to the impedance of the load. However, when the current detection resistors are switched, a noise spike may be generated due to the response delay of the input amplifier. If the load is a semiconductor device, it may be damaged by the noise spike.
Japanese Patent Publication No. 64-8310 describes a conventional current detection circuit with a resistor switching circuit where generation of noise spikes is restrained. With this circuit an input voltage is applied to an inverting input of an operational amplifier having a high gain through an input resistor. An output current from the operational amplifier is applied to a load through a first current detection resistor and through a series circuit including a field effect transistor (FET), a second current detection resistor, and a first switch. The series circuit is connected in parallel with the first current resistor. The gate of the FET is connected to one terminal of a sawtooth signal generator which has another terminal connected to a common terminal of a second switch. The common terminal of the second switch is selectively connected to a first contact connected to the output of the operational amplifier, a second contact connected to an output of a voltage follower circuit and a third contact connected to a reference potential point. The voltage produced at the load also is applied to the inverting input of the operational amplifier through the voltage follower circuit and a third resistor for negative-feedback operation so that the voltage corresponding to the input voltage is applied to the load.
In operation the first switch is turned on while the FET is turned off by adjusting the output voltage of the sawtooth generator to be its maximum negative voltage. Then the output voltage of the saw tooth generator is increased at a constant rate smaller than the slew rate of the operational amplifier. The increase of current through the FET increases the voltage across the load, i.e., the load voltage. The output voltage of the operational amplifier decreases in response to the increase of the load voltage so that the gate voltage of the FET is kept at the pinch-off voltage to turn off the FET. Thus, since the current detection resistors are switched slowly, any noise spike is not applied to the load circuit.
However, this circuit needs multiple circuits consisting of an FET, a current detection resistor, a switch and a sawtooth generator, one for each sensitivity range. It may be possible to use one sawtooth generator for a plurality of FETs, but the gate of the FETs not connected to the sawtooth generator must be connected to a voltage source to keep the FETs in an off-state. Therefore the number of components increases as the number of switching ranges increases, raising the manufacturing cost.
What is desired is a load current detection circuit capable of restraining generation of noise spikes, produced when switching current detection sensitivity, which uses fewer components.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a load current detection circuit having an architecture for restraining the generation of noise spikes. The circuit uses a plurality of series resistors for selecting current detection sensitivity. A negative feedback voltage amplifier provides a load voltage. The plurality of resistors form a current detection sensitivity selection circuit, and are connected between the load and the output of the voltage amplifier, the voltage amplifier being connected to a floating potential. A voltage detection circuit detects a voltage difference across the current detection sensitivity selection circuit and applies the voltage difference to an analog-to-digital converter (ADC). A control processor provides the output data from the ADC to a digital-to-analog converter(DAC). The output voltage from the DAC is substantially equal to the load voltage, so no noise spike is generated even when a first switch, connected between the load and the DAC, is switched off. The control processor gradually changes the output voltage of the DAC to the floating potential. A second switch connected across one of the resistors is switched on to change the current detection sensitivity. At this time no noise spike is generated since there is no voltage difference across the first switch. The control processor then changes the output voltage of the DAC to a value equal to the load voltage. The first switch then is switched off. At this time also no noise spike is generated since there is no voltage difference across the first switch.
The objects, advantages and other novel features of the present invention are apparent from the following detailed description when read in conjunction with the appended claims and attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a circuit diagram of a load current detection circuit according to the present invention.
FIG.2 is a timing chart for illustrating the operation of the circuit of FIG.1.
FIG.3 is a flow chart for describing the operation of the circuit of FIG.1.
FIG.4 is a circuit diagram of the load current detection circuit according to another embodiment of the present invention.
FIG.5 is a timing chart for illustrating the operation of the circuit of FIG.4.
FIG.6 is a flow chart for describing the operation of the circuit of FIG.4.
FIG. 7 is a circuit diagram for partially modifying the circuit of FIG.4.
FIG. 8 is a timing chart for illustrating the operation of the circuit as modified by the circuit of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 a circuit diagram of a load current detection circuit is shown having a central processor unit (CPU) or control processor 10 as a control means. The CPU 10 communicates with other components of the load current detection circuit through a bus 12 and operates switches in response to input commands from a conventional interface (not shown).
A digital-to-analog converter (DAC) 14 receives digital voltage data from the CPU 10 in accordance with an input command. The DAC 14 converts the digital voltage data into a corresponding analog input voltage Vin which is applied to an inverting input terminal of a high gain operational amplifier 18 through an input resistor 16. The output of the operational amplifier 18 is coupled to one end of a load 24, the other end of the load being at a fixed potential such as ground, through series-connected sensitivity resistors 20, 22. A first switch 26 is connected across one of the resistors. The current detection sensitivity is selectively changed by closing (rendering conductive) or opening (rendering nonconductive) the switch 26. A load voltage Vl, applied by the operational amplifier 18 to the load 24, also is coupled to the inverting input of the operational amplifier through a voltage follower circuit 28 and a feedback resistor 30 to provide negative feedback operation. Assuming that the input and feedback resistors 16, 30 have respective resistance values R1, R2, the load voltage Vl is proportional to the input voltage Vin, i.e., Vl=(-R2/R1)*Vin.
The inverting input terminal of a differential amplifier 32, which acts as a voltage detector, is coupled to the output of the voltage follower 28. The non-inverting input of the differential amplifier 32 is coupled to the output of the operational amplifier 18 in order to detect a voltage across the sensitivity resistors 20, 22 and first switch 26. The detected voltage is provided to an analog-to-digital converter (ADC) 34 to be converted into digital data, the digital data being provided to the CPU 10 over the bus 12. A second DAC 36 converts digital data from the CPU 10 over the bus 12 as described below into an analog voltage, the analog voltage being provided to the load 24 through a second voltage follower 38 and second switch 40.
The DACs 14, 36, the voltage followers 28, 38, the differential amplifier 32 and the operational amplifier 18 operate with reference to a floating potential Vf. The floating potential also is applied to the output of the operational amplifier 18 which is coupled to the non-inverting input of the differential amplifier 32. Thus, even when an excessive high voltage is applied to the load 24 for high voltage measurements, the in-phase components of the input voltages to the differential amplifier 32. increase to prevent the differential amplifier from being damaged.
FIGS. 2 and 3 show a timing chart and a flow chart for the operation of the circuit of FIG. 1, as described below. Assuming that in an initial state the switches 26, 40 are both open then the first switch 26 needs to be closed to decrease the current detection sensitivity. When the CPU 10 receives the input command to decrease the current detection sensitivity (Step 100), it receives digital data representing the difference voltage Vl-Vf from the ADC 34 and provides digital data to the second DAC 36 to provide an analog output voltage Vout substantially equal to voltage V1 (Step 102). Then the CPU 10 closes the second switch 40 at time t1 (Step 104) so that the output voltage Vout from the second DAC 36 is provided to the load 24 through the second voltage follower 38 and switch 40. Since the voltage Vout=Vl is provided to the load 24 prior to time t1, there is no voltage difference across the second switch 40, so no noise spike is generated when switching the second switch.
The CPU 10 changes the digital data applied to the second DAC 36 to gradually change the output voltage Vout at a rate sufficiently slower than the slew rate of the operational amplifier 18 until the output voltage equals the floating potential Vf (Step 106). Since the voltage across the sensitivity resistors 20, 22 decreases as the output voltage of the second DAC 36 gets closer to the floating potential Vf, the currents I R1 , I R2 flowing through the sensitivity resistors decrease. The positive or negative current I A flowing from the second voltage follower 38 to the load 24 increases because of the decrease of the currents I R1 , I R2 thereby keeping the load voltage Vl constant. When the output voltage Vout from the second DAC 36 equals the floating potential Vf, then the currents I R1 , I R2 flowing through the sensitivity resistors 20, 22 are zero. At time t2 the CPU 10 closes the first switch 26. Now since the potentials at both ends of the sensitivity resistors 20, 22 are equal to the floating potential Vf, there is no voltage difference across the resistors so that no noise spike is generated when closing the first switch 26 (Step 108). If in the initial state the first switch 26 is closed and the current sensitivity is to be increased, the first switch is opened. In this case also no noise spike is generated.
The CPU 10 changes the digital data provided to the second DAC 36 to gradually change the output voltage from the second DAC at a rate sufficiently slower than the slew rate of the operational amplifier 18 until the output voltage rout equals the load voltage Vl again (Step 110). Since the voltage across the first sensitivity resistor 20 increases as the output voltage Vout gets closer to the load voltage Vl, the current I R1 increases. The current I A flowing from the second voltage follower 38 to the load 24 decreases because of such increase of the current I R1 , so the load voltage Vl is kept constant. When the output voltage from the second DAC 36 equals the load voltage Vl, the current I A is zero. Therefore, the digital data that the second DAC 36 receives from the CPU 10 to provide the voltage Vl is different from that at time t1.
When the second switch 40 is open at time t3 by the CPU 10 (Step 112), a noise spike due to the switching of the second switch 40 is not generated since there is no potential difference across the switch. Thus, the generation of noise spikes during the switching of current detection sensitivity is restrained.
FIG. 4 shows a circuit diagram of the load current detection circuit for another embodiment according to the present invention. This circuit includes a field effect transistor (FET) 39 and a third DAC 42 in addition to the circuit shown in FIG. 1. The FET 39 is inserted between the second voltage follower circuit 38 and second switch 40 by coupling the source of the FET to the output of the second voltage follower and the drain to the switch. The gate of the FET 39 is coupled to the output of the third DAC 42 which converts digital data from the CPU 10 into an analog voltage.
FIGS. 5 and 6 show a timing chart and a flow chart for the operation of the circuit in FIG. 4. The steps in FIGS. 3 and 6 represented by the same numbers are identical to each other. In addition to the steps in FIG. 3, FIG. 6 adds step 114 between steps 104, 106 and step 116 between steps 110, 112. Assuming that in the initial state switches 26, 40 are both open, then the first switch 26 needs to be closed to decrease the current detection sensitivity. At this time the FET 39 is held off by a negative voltage at the gate provided by the third DAC 42. When the CPU 10 receives the input command to decrease the current detection sensitivity (Step 100), it receives digital data representing the voltage difference Vl-Vf from the ADC 34 and provides digital data to the second DAC 36 which converts the digital data into the analog output voltage Vout (Step 102). However, the input digital data may include a digital error such that the output voltage Vout may not exactly be equal to the load voltage Vl. This may cause a little noise spike when closing or opening the second switch 40.
After closing the second switch 40 at time t1 (Step 104), the CPU 10 begins increasing at time t2 the output voltage from the third DAC 42, i.e. the gate voltage VG1 of the FET 39 increases gradually, for example at a rate of 5 V/200 ms. When the FET 39 turns on at the time t3 (step 104), the output voltage Vout of the second DAC 36 is provided to the load 24 through the source and drain connection of the FET 39 and the second switch 40. The output voltage Vout is slightly different from the load voltage Vl due to the digital error as described above. For example, the currents I R1 , I R2 flowing the sensitivity resistors 20,22 gradually decrease during the time interval from the time t2 to t3. The current I A gradually increases in response to the decrease of the currents I R1 , I R2 , so that the load voltage Vl in reference to ground level is kept constant. Thus, since the current I A gradually changes while the FET 39 is changing from the off-state to the on-state, no noise spike is generated.
As described with respect to the operation of FIG. 1, the CPU 10 begins changing the output digital data to the second DAC 36 to change the output voltage Vout starting at time t4 until it equals the floating potential Vf at the time t5 (Step 106). The CPU 10 closed the first switch 26 at time t6. At this time no noise spike is generated since there is no potential difference across the first switch 26.
The CPU 10 changes the output digital data to the second DAC 36 to gradually change the output voltage Vout to make it close to the load voltage Vl (Step 110) at time t7. The digital data is changed to reach the value at time t8 corresponding to the voltage produced when all the load current flows the first sensitivity resistor 20 only. The output voltage Vout may not equal the voltage Vl due to the digital error. Since the voltage across the first sensitivity resistor 20 as the output voltage gets closer to the voltage Vl increases, the current I R2 increases. The current I A decreases because of such increase of the current I R2 , keeping the load voltage Vl constant. The difference between the voltages V1 and Vout causes a slight current to flow.
The CPU 10 begins decreasing the gate voltage VG1 of the FET 39 gradually at time t9. As a result the current I A decreases and turns to zero when the FET 39 turns off at time t10. When the second switch 40 is opened at time t11, no noise spike is generated.
FIG. 7 shows a circuit for compensating for the voltage drop between the drain and the source of the FET 39 in FIG. 4. In this circuit the inverting input of the operational amplifier 38' which is used for the voltage follower 38 is connected to its output through a high resistance resistor 44 and to the source of a second FET 46. The drain of the second FET 46 is connected to the drain of the first FET 39 and the gate is connected to the output of the third DAC 42 through a delay device 48.
FIG. 8 shows a timing chart for the operation of FIG. 4 including the modified circuit shown in FIG. 7. All timing relations except the gate VG2 of the second FET 46 are the same as in FIG. 5. The delay device 48 has a delay time a little longer than the time interval between times t2 and t3 when the gate voltage VG1 increases, and the gate voltage VG2 of the second FET 46 increases during the time interval between times t3 and t4. In other words the second FET 46 turns on after the first FET 39 turns on and the drain voltage of the first FET 39 is fed back to the inverting input of the operational amplifier 38'. The drain voltage of the first FET 39 equals the input voltage of the operational amplifier 38' by the negative feedback action of the operational amplifier, and the voltage drop due to FET-on resistance is compensated for. The gate voltage VG2 decreases from the time t8 to time t9 to turn off the second FET 46 before the first FET 39 turns off.
Thus the present invention provides a load current detection circuit that changes detection sensitivity by changing incrementally the series resistance between the output of an operational amplifier and a load, the series resistance being used as a current detector.
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A load current detection circuit restrains the generation of noise spikes with a minimum of circuitry when changing between current detection sensitivity ranges by providing a plurality of sensitivity resistors between the output of a voltage source, such as a negative feedback voltage amplifier, and a load. Sensitivity range changing is performed via switches that increase or decrease the number of sensitivity resistors between the voltage source and the load. When a current detection sensitivity change is commanded, a voltage difference across the sensitivity resistors is measured, and a control processor generates a control voltage for changing voltage difference gradually until the voltage difference is zero without changing the voltage across the load. The sensitivity range switching then occurs when no current flows through the sensitivity resistors so that no noise spikes are produced. Then the control voltage is gradually changed until the full load current passes through the selected sensitivity resistors.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to European Patent Application No. 13 164 397.5, filed on Apr. 19, 2013, the entirety of which is incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present subject matter relates to an onboard unit for a traffic telematics system. The present subject matter further relates to an onboard system for a vehicle comprising such an onboard unit.
[0004] 2. Background Art
[0005] Onboard units (OBUs) are used in a large number of different applications of traffic telematics systems, whether for electronic identification of a vehicle or for payment of road, access, area or city tolls, for payment of parking fees, for access control (for example barrier systems), for electronic vehicle registration (EVR), etc. For this purpose, onboard units are often equipped with a short-range communication module, for example in accordance with the DSRC (dedicated short range communication) standard, so that they can be localised to the local radio coverage range of an interrogating radio beacon. Here, the communication module is supplied with power together with the rest of the electronics of the onboard unit by a battery installed in the onboard unit.
[0006] In order to save power and to achieve a long service life of the battery, onboard units or the communication module thereof generally have a power-supplied or power-consuming working and communication mode and a power-saving rest mode. By addressing the onboard unit by means of an external communication device, for example a radio beacon of a road toll system, an access barrier, a control device or the like, the onboard unit can be awakened from its rest mode and shifted temporarily into its working or communication mode; it then lapses back into the rest mode until the next communication. Commercially obtainable onboard units can currently achieve a battery service life of up to seven years in this way.
BRIEF SUMMARY
[0007] An object of the disclosed subject matter is to equip onboard units of the aforementioned type with further functionalities, in particular without impairing the battery service life of the onboard unit.
[0008] This object is achieved in a first aspect with an onboard unit for a traffic telematics system comprising:
[0009] a first communication module, designed for near-range radio communication with a first external communication device,
[0010] a second communication module, designed for far-range radio communication with a second external communication device, and
[0011] a non-volatile memory, which can be accessed both by the first and the second communication module,
[0012] wherein each communication module has a power-supplied communication mode and a powerless or power-saving rest mode, and
[0013] wherein the power supply of the memory during an access thereto is effected by the accessing communication module.
[0014] In accordance with an embodiment the onboard unit, in addition to the short-range communication module mentioned in the Background Art section, is also equipped with a further communication module which is designed for an even shorter radio range, referred to here as “near-range radio communication”. In the present description, near-range radio communication is understood to mean communication over a radio range of at most a few centimetres or a few tens of centimetres, as is implemented in particular by the NFC (near field communication) standard. For distinction, the conventional short-range communication module of the onboard unit will be referred to hereinafter as a “far-range communication module”. In the present description, such a far-range radio communication will be understood to mean communication over a far range of at most a few metres, a few tens of metres, or a few hundred metres, as is implemented for example by the DSRC (dedicated short range communication), CEN-DSRC, UNI-DSRC, IEEE 802.11p or WAVE (wireless access for vehicular environments) or ITS-G5 standards, including WLAN and Wifi®, Bluetooth® or also active and passive RFID (radio frequency identification) technologies.
[0015] In accordance with an embodiment the near-range communication module and the far-range communication module access a common non-volatile memory, for example a flash memory, wherein the near-range communication module, during use thereof, effects the power supply of the memory, such that there is no need to start up the power-intensive far-range communication module. Additional near-range functionalities can thus be created without increasing the power demand of the onboard unit, that is to say without significantly impairing the battery service life of the onboard unit. For example, configuration data for the onboard unit can thus be input via the near-range radio interface, or arbitrary data can be read out from the onboard unit, for example logfiles for inspection by the user or authorities, without “waking up” the main- or far-range communication components of the onboard unit and thus loading the battery.
[0016] Here, the power supply to the memory during the memory access can be effected in two ways. On the one hand the power can be supplied directly by the communication module accessing the memory if the communication module for example has its own power supply (battery) or can be supplied with power directly via radio (“passive transponder”), such as a passive NFC or RFID tag. It is particularly favourable if the near-range communication module is a passive NFC tag, that is to say functions in accordance with the NFC standard and can be supplied with power via radio. NFC requires a close proximity of the external communication device to the onboard unit in order to establish communication, which gives the user assurance of addressing precisely this onboard unit. Due to the radio power supply of the NFC tag, it is ensured that the battery of the onboard unit is in no way used during this process.
[0017] The second communication module may optionally be a passive RFID tag, which can be supplied with power via radio in order to save battery power.
[0018] On the other hand, the power supply to the memory during access to the memory can be effected by an activation or switching-on of a separate power supply, for example a battery, to the memory. For example, the onboard unit has its own or an external battery for power supply, and the respective communication module accessing the memory, said communication module being fed by this battery in the communication mode, actuates a switch during the memory access, said switch switching on the power supply to the memory at least only for the duration of the memory access. This also includes the case that the switch detects (“feels”) the memory access, for example over the memory access bus of the communication module, in order to then apply the power supply to the memory in a timely manner. These embodiments are favourable for those types of communication modules and memories in which a power supply via radio would not be sufficient to supply sufficient power to the communication module and/or the memory during the memory access.
[0019] The far-range communication module could in principle be of any type known in the art for onboard units, for example a mobile radio module for a cellular mobile network (public land mobile network, PLMN). The far-range communication module may, for example, be a DSRC or WAVE module or an active RFID tag, which is supplied with power by the battery of the onboard unit. Alternatively, the second communication module could also be supplied exclusively via radio power, for example in the form of a passive RFID tag.
[0020] The onboard unit or the memory may, for example, be designed to prioritise a memory access of the far-range communication module over a memory access of the near-range communication module. Alternatively the far-range communication module, if in the communication mode, can deactivate the first communication module. Collisions in the event of memory access can be prevented by these measures: The far-range radio communication thus always enjoys higher priority than the near-range radio communication, which prevents faults in the traffic telematics system.
[0021] As already mentioned briefly, the memory may, for example, contain configuration data for the traffic telematics system which can be written into the memory via the near-range communication module and can be read out from the memory via the far-range communication module. Here, the configuration data may be in particular one or more of the following elements: user identification, vehicle identification, tolling account identification, axle number, tolling parameters, load designation, account credit or account balance of an electronic purse of the onboard unit, cryptographic keys, or timestamps, in particular concerning vehicle use. If the external near-range communication device for example is a mobile telephone, smartphone or the like, which is equipped with an NFC transceiver and corresponding application software, the account balance of the electronic purse of the onboard unit can be charged in this way or the onboard unit can thus be configured in general for operation, for example.
[0022] Alternatively or additionally, the memory may contain transaction data of the traffic telematics system which can be written into the memory via the far-range communication module and can be read out from the memory via the first communication module. Here, the transaction data may be one or more of the following elements: location data, beacon identifications, load designation, tolling transactions, parking fee transactions, account balance of an electronic purse of the onboard unit, cryptographic keys, or timestamps, in particular concerning vehicle use. For example, logfiles, protocols, etc. can thus be read out via the near-range radio interface, for example into an NFC-enabled mobile telephone or smartphone belonging to the user or a controller.
[0023] In a further aspect an embodiment creates an onboard system for a vehicle which on the one hand comprises an onboard unit of the type presented here, of which the memory contains an identification of the onboard unit which can be read out via the first communication module, and on the other hand a further NFC tag, separate from the onboard unit, which contains an identification of the separate further NFC tag which can be read out via radio.
[0024] The onboard system enables the control of the vehicle linking of an onboard unit to a vehicle. Onboard units of the type mentioned here are generally attached releasably to the vehicle due to their autonomous power supply and therefore the need for an occasional battery exchange, which in itself runs the risk of manipulations if a clear association between the onboard unit on the one hand and vehicle on the other hand is required, for example for vehicle registration or charging purposes. Due to the use of a separate further NFC tag, which can be read out together with the near-range communication module of the onboard unit by the external communication device, the identification of the onboard unit on the one hand read out in such a way and the characterisation of the separate tag on the other hand can be checked for correct association.
[0025] It is particularly favourable if the further NFC tag is formed as an adhesive label, which, once adhered, can no longer be detached without being destroyed. The separate NFC tag thus produces a permanent vehicle linking between the tag identification and vehicle, whereas the associated identification of the onboard unit can be used for the corresponding purposes in the traffic telematics system, for example for toll or parking fee purposes, EVR purposes, access purposes, etc.
[0026] In accordance with an example variant the memory of the onboard unit may also contain the identification of the separate further NFC tag, which facilitates the checking of the NFC tag identification.
[0027] In yet a further aspect an embodiment creates an external near-range communication device for an onboard system of the type presented here, which is characterised in that it is formed as an NFC reader and is designed to read out the identification of the onboard unit from the onboard unit and to read out the identification of the separate further NFC tag from the separate further NFC tag and to check against a database of onboard unit identifications and NFC tag identifications associated with one another, or in that it is formed as an NFC reader and is designed to read out the identification of the separate further NFC tag from the memory of the onboard unit on the one hand and from the separate further NFC tag on the other hand and to check these against one another. The vehicle linking of an onboard unit attached (in fact releasably) in the vehicle can thus be checked using a single device, more specifically by jointly reading out the identification of the permanently attached NFC tag.
[0028] In yet a further aspect an embodiment lastly creates an onboard unit of the type presented here, which is characterised by a third communication module which is formed as an NFC reader and is designed to read out the identification of a further NFC tag, separate from the onboard unit, and to write this identification into the memory, wherein the far-range communication module of the onboard unit is formed as a DSRC, ITS-G5 or WAVE module and is designed to transmit the NFC tag identification read out in such a way to a second external communication device. The vehicle linking of the onboard unit can also be verified with these embodiments. The separate NFC tag may, for example, be again formed for this purpose as an adhesive label, which, once adhered, can no longer be detached without being destroyed.
[0029] The first communication module and the third communication module may, for example, be formed by a common NFC module which can be switched over between an operating mode as first communication module and an operating mode as third communication module.
[0030] Further features and advantages, as well as the structure and operation of various embodiments, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0031] The present subject matter will be explained in greater detail hereinafter with reference to exemplary embodiments illustrated in the accompanying drawings, in which:
[0032] FIG. 1 shows a schematic overview of an onboard system according to an embodiment for a vehicle, said onboard system being connected to external first and second communication devices.
[0033] FIG. 2 shows, in the form of a block diagram, a first embodiment of the onboard system from FIG. 1 connected to first and second external communication devices.
[0034] FIG. 3 shows, in the form of a block diagram, a second embodiment of the onboard unit connected to external first and second communication devices.
[0035] FIG. 4 shows, in the form of a block diagram, a third embodiment of the onboard unit connected to external first and second communication devices.
[0036] Embodiments will now be described with reference to the accompanying drawings.
DETAILED DESCRIPTION
[0037] FIG. 1 shows an onboard system 1 for a vehicle 2 , of which the only detail that is shown is the windscreen 3 . The onboard system 1 can be fitted in or on the vehicle 2 , for example adhered to the inner face of the windscreen 3 . The onboard system 1 comprises an onboard unit 4 and an NFC tag (near field communication tag) 5 separate therefrom, of which the function will be explained below in greater detail.
[0038] The onboard unit 4 serves for radio communication with a traffic telematics system 6 , of which only a communication device in the form of a roadside radio beacon 7 (roadside entity, RSE) is shown representatively and by way of example. The radio beacon 7 may be both stationary and mobile, for example arranged on a control vehicle or formed as a hand-held device for a controller, and handles radio communications 8 with the onboard unit 4 via a transceiver 7 ′, for example if the vehicle 2 passes the radio beacon 7 or vice versa.
[0039] If the radio coverage range of its radio communications 8 is limited to a local area, the radio beacon 7 can locate the onboard unit 4 in this area, for example in order to bill a location usage of the vehicle 2 in the form of road, access, area or city tolls, in order to collect a parking fee, in order to release an access barrier, or in order to record an identification of the vehicle 2 , its user, etc. read out from the onboard unit 4 etc., etc.
[0040] The onboard unit 4 of the onboard system 1 is also capable of handling radio communications with a further external communication device 10 of the user via a further radio interface 9 . For example, the communication device 10 may be a mobile telephone, smartphone, notebook PC or tablet PC, personal digital assistant (PDA), etc. belonging to the user of the vehicle or to a controller. The communication device 10 may also handle further radio communications 9 ′ with the separate NFC tag 5 .
[0041] The radio communications 9 , 9 ′ between the (“first”) external communication device 10 and the onboard system 1 , that is to say the onboard unit 4 and the NFC tag 5 , are designed exclusively for the near range, that is to say their radio range is limited to a few centimetres or a few tens of centimetres, such that the communication device 10 has to be brought into the immediate vicinity of the onboard unit 4 and of the NFC tag 5 in order to be able to carry out the radio communications 9 , 9 ′. By contrast, the radio communications 8 between the onboard unit 4 and the (“second”) external communication device 7 have a much larger range by comparison, for example a few metres, a few tens of metres, or a few hundred metres, such that they are also referred to here as “far-range” radio communications 8 , although this is also short-range radio here, for example in accordance with short-range radio standards such as DSRC (dedicated short range communication), CEN-DSRC, UNI-DSRC, WAVE (wireless access for vehicular environments) and IEEE 802.11p, ITS-G5, WLAN (wireless local area network), Wifi®, Bluetooth®, RFID (radio frequency identification) or the like.
[0042] FIG. 2 shows the structure of the onboard system 1 , of the first communication device 10 and of the second communication device 7 for handling the radio communications 9 , 9 ′ and 8 in detail. For the far-range radio communications 8 with the second communication devices 7 , for example radio beacons, the onboard unit 4 contains a corresponding far-range communication module 11 in accordance with the respective short-range radio standard DSRC, CEN-DSRC, UNI-DSRC, WAVE, IEEE 802.11p, ITS-® WLAN, Wifi®, Bluetooth® or RFID, which is supplied with power by a battery 12 of the onboard unit 4 (a communication module 11 according to the RFID standard which requires such a power supply 12 will also be referred to here as an “active” RFID tag). The battery 12 may also be part of an arrangement connected via a cable to the onboard unit 4 .
[0043] The far-range communication module 11 of the onboard unit 4 can access a memory 13 of the onboard unit 4 in order to prepare, generate or process the radio communications 8 , more specifically the data packets transmitted and/or received therein, said memory containing configuration and/or transaction data for this purpose. For example, the memory 13 contains configuration data for the correct functioning of the onboard unit 4 in the traffic telematics system 6 , or credits for the specified accounts, such as one or more of the following elements: a unique identification of the onboard unit 4 (OBU identification), a user identification of the driver of the vehicle 2 , a vehicle identification of the vehicle 2 , an identification of a toll or fee account of the user or of the vehicle, vehicle parameters such as axle number, weight, size, purpose etc. of the vehicle 2 , toll- or parking-fee-specific parameters such as fee class, passenger number or the specified vehicle parameters, etc., etc. The configuration data may also contain data, in particular the account balance, of an “electronic purse” in the onboard unit 4 or of a credit or debit account in the traffic telematics system 6 , or credits for the specified accounts. The configuration data may further also be load designations, with the result that the content of the memory 13 forms a load protocol; cryptographic keys for encrypted communications via the communication modules, and/or timestamps, in particular by the vehicle driver for temporal control of the vehicle use, with the result that the onboard unit forms an “electronic tachograph”. For such a timestamp recording, an OBU-internal clock is advantageous which can possibly be synchronised by the near-range and/or far-range radio communications 9 , 8 from the communications devices 10 , 7 , for example when passing radio beacons.
[0044] Additionally or alternatively, the memory 13 can contain transaction data, which it receives or collects during the operation of the onboard unit 4 in the traffic telematics system 6 , for example said data being constituted by one or more of the following elements: location data, which the onboard unit 4 records itself or receives from radio beacons 7 , beacon identifications of radio beacons 7 passed by the onboard unit, identifications of communication devices 7 encountered by the onboard unit, toll or parking fee transactions generated over the course of far-range radio communications 8 , for example when passing a roadside radio beacon 7 , transactions which influence or reproduce the account balance of an electronic purse of the onboard unit 4 or of a credit or debit account in the traffic telematics system 6 , for example debit transactions, or load designations, dangerous goods declarations, or the like. The transaction data may also be provided with corresponding timestamps, as explained previously for the configuration data.
[0045] A far-range radio communication 8 may cause a direct activation of the far-range communication module 11 and trigger there a processing procedure, for example a signing of data in the secure environment of the onboard unit 4 . This processed data may then be read out, for example immediately via a near-range radio communication 9 .
[0046] Of course, the onboard unit 4 is only illustrated in a highly simplified manner for this purpose; further components such as processors, hardware or software modules, etc., which are necessary for the cooperation described here between the communication module 11 and the memory 13 and for the handling of the radio communications 8 , 9 mentioned here, are not illustrated for reasons of clarity.
[0047] As illustrated symbolically by the arrow 14 , power can be supplied to the memory 13 during the write and/or read access ( 15 ) of the communication module 11 to the memory 13 by the communication module 11 (and therefore by the battery 12 in the embodiment shown in FIG. 2 ). Of course, the arrow 14 is only symbolic here; for example, power can be supplied to the memory 13 directly by the battery 12 , and the memory 13 can be supplied with power in a controlled manner correspondingly by the communication module 11 during the memory access 15 .
[0048] In order to save power and to maximise the service life of the battery 12 , the onboard unit 4 , in particular the far-range communication module 11 thereof, can be switched over between a power-saving or powerless rest mode and a power-supplied or power-draining communication mode. In other words, the onboard unit 4 or at least the far-range communication module 11 thereof lapses, in the breaks between chronologically interspaced far-range radio communications 8 , into a powerless or power-saving sleep or rest mode, from which it is woken up again for example by a new radio communication 8 , which starts from the second communication device 7 .
[0049] So as not to impair this energy-saving function and so as not to reduce the service life of the battery 12 , the onboard unit 4 , for near-range radio communications 9 , comprises a separate near-range communication module 16 , which, via the radio communications 9 , can be supplied with power by the first external communication device 10 , for example a mobile telephone belonging to the user (arrow 17 ). For this purpose, the communication device 10 has a reader/writer (transceiver) 18 , for example an NFC reader and/or writer, designed for near-range radio communications 9 . The near-range communication module 16 therefore in turn has a “powerless” rest mode when not addressed by the communication device 10 and is supplied from there with power, and a power-supplied communication mode, in which it is addressed by means of a near-range radio communication 9 and is simultaneously supplied with power from the transceiver 18 (arrow 17 ).
[0050] A near-range communication module 16 of this type can be produced for example as a passive NFC tag, wherein “passive” means that it is supplied with power via a radio communication 9 . Passive NFC tags can also be considered as passive RFID transponders for extremely short radio ranges from a few centimetres to a few tens of centimetres.
[0051] As soon as the near-range communication module 16 is in the radio power-supplied communication mode, it can access the memory 13 (arrow 19 ) and in so doing can supply power to the memory 13 (arrow 20 ). This is independent of whether or not the far-range communication module 11 is in the communication or rest mode and in turn supplies power ( 14 ) to the memory 13 , or whether or not the entire rest of the onboard unit 4 is in the rest or operating mode. The content of the memory 13 can thus be read and/or written via the near-range radio communication 9 and the passive communication module 16 , irrespective of whether the onboard unit 4 and/or the far-range communication module 11 thereof is working or sleeping.
[0052] For example, configuration data of the onboard unit 4 contained in the memory 13 can thus be input from the communication device 10 or changed, for example a user identification can be input, an axle number of the vehicle can be set, etc. The near-range communication device 10 serves here as an “input arrangement” so to speak for the onboard unit 4 . To this end, it needs merely to be held in the immediate vicinity of the onboard unit 4 in order to input data into the memory 13 via near-range radio communications 9 , even if the onboard unit 4 or the communication module 11 thereof is in the powerless or power-saving rest mode. The communication device 10 may have a physical keypad 21 or virtual keys on a touchscreen 22 for this purpose.
[0053] Similarly, transaction data can also be read out from the memory 13 into the communication device 10 via near-range radio communications 9 , for example logfiles concerning past location uses, toll and parking fee transactions, debit transactions, account balances, etc. In this sense, the communication device 10 can be used as an “output arrangement” so to speak for the onboard unit 4 and can display data thereof, for example on the display 22 , without the need for the onboard unit 4 to have its own display for this purpose. The aforementioned transaction data (logfiles, protocols) may also describe, for example, loads carried by lorries, that is to say any loaded freight is declared in the onboard unit 4 and, where necessary, is also signed electronically by the onboard unit 4 if this constitutes a trustworthy environment by means of physical and electronic access control. A signing by the onboard unit 4 can be implemented for example by means of a special write command from the near-range communication module 16 or by addressing a special memory region of the memory 13 , which initiates subsequent processing by the far-range communication module 11 . The processing by the far-range communication module 11 can be considered for example to be particularly trustworthy if increased mechanisms are implemented in the physical and electronic access control.
[0054] In a further embodiment only a part of the entire memory 13 is available to the near-range communication module 16 for reading and writing, other memory regions being additionally protected by physical or cryptographic access mechanisms where appropriate. The memory 13 may thus also be composed of a number of physically or logically separate memory modules.
[0055] In order to ensure that the far-range communications 8 , which the onboard unit 4 handles with the communication devices 7 , for example radio beacons, within the scope of the traffic telematics system 6 , are not impaired by the aforementioned near-range communication functionality, the memory access 15 of the far-range communication module 11 may optionally be prioritised over the memory access 19 of the near-range communication module 16 , for example by appropriate design of the memory 13 or programming of the processor (not illustrated) of the onboard unit 4 . Alternatively, the far-range communication module 11 , if in the communication mode, could directly deactivate the near-range communication module 16 (see arrow 23 ) in order to ensure its priority.
[0056] The near-range communication capability of the communication device 10 and of the onboard unit 4 can be utilised subsequently to secure the vehicle linking of an onboard unit 4 (which is usually fitted releasably in the vehicle 2 , not least due to the need to have to replace the battery 12 occasionally) with respect to the vehicle 2 . The separate NFC tag 5 , which together with the onboard unit 4 forms the aforementioned onboard system 1 , is used for this purpose.
[0057] The separate NFC tag 5 is formed for example as an adhesive label 24 , which, once adhered to the windscreen 3 , can no longer be detached therefrom without being destroyed and thus has a permanent vehicle linking.
[0058] The separate NFC tag 5 is equipped with a radio-readable unique identification TID, which can be read out by the near-range communication device 10 over the course of a further near-range radio communication 9 ′. If the adhesive label 24 and the onboard unit 4 are brought into close proximity on the vehicle 2 , near-range radio communications 9 , 9 ′ both with the NFC tag 16 of the onboard unit and with the separate NFC tag 5 of the adhesive label 24 can be established merely by holding out the communication device 10 , and the identification OID of the onboard unit 4 and the identification TID of the further NFC tag 5 can be read out and displayed on the display 22 , either simultaneously or in direct succession.
[0059] The user of the near-range communication device 10 , for example a controller, can thus check whether the identifications TID and OID in the traffic telematics system 6 have been recorded as being associated with one another, for example by checking a list. This may, for example, occur automatically since the communication device 10 has access to a device-internal or external database 25 , for example provided in a headquarters of the traffic telematics system 6 , of onboard unit identifications OID and associated NFC tag identifications, on the basis of which the vehicle linking to the onboard unit 4 , that is to say its use in the correct vehicle 2 equipped with the corresponding NFC tag 5 , can be checked.
[0060] The NFC tag identification TID of the separate NFC tag 5 may optionally also be stored in the onboard unit 4 , for example in the memory 13 on the occasion of the output or personalisation of the onboard unit 4 with simultaneous output of the respective NFC tag 5 , such that, via the near-range radio communication 9 , not only the onboard unit identification OID, but also the NFC tag identification TID stored for this purpose, can be read out and compared with the NFC tag identification TID interrogated from the adhesive label 24 via the near-range radio communication 9 ′. For example, the correct use of the onboard unit 4 can be checked, even without access to the database 25 .
[0061] A further possibility lies in equipping the onboard unit 4 with its own NFC reader and/or writer (transceiver) 26 . The transceiver 26 can, for its part, interrogate the further NFC tag 5 fitted in the vicinity via a further near-range radio communication 9 ″ and can read out the NFC tag identification TID thereof in the memory 13 . The read-out NFC tag identification TID can then be notified, for example together with the onboard unit identification OID, via a far-range radio communication 8 to the communication device 7 , for example a radio beacon. For example, the correct vehicle linking of the onboard unit 4 , that is to say its correct use in the correct vehicle 2 , can thus also be checked each time a radio beacon 7 of the vehicle telematics system 6 is passed.
[0062] The NFC transceiver 26 can also be provided jointly with the NFC tag 16 by the same physical device, for example an NFC module, which can be selectively switched over into an NFC tag operating mode for emulating the NFC tag 16 and an NFC transceiver operating mode for emulating the NFC reader and/or writer or NFC transceiver 26 . The switchover can be implemented for example upon request by one of the communication devices 7 , 10 .
[0063] FIG. 3 shows a variant of the embodiment of FIG. 2 , in which the far-range communication module 11 can also be supplied with power via radio, more specifically via the far-range radio communication 8 (arrow 27 ). The far-range radio communication 8 can be implemented here for example in accordance with the RFID standard, and the far-range communication module 11 is then a passive transponder, for example a passive RFID tag. This, if in the power-supplied communication mode, can also supply power via the (symbolic) path 14 to the memory 13 during memory access 15 .
[0064] The other components illustrated in FIG. 3 correspond to the structure of FIG. 2 . As can be seen, the separate NFC tag 5 or the adhesive label 24 can also be omitted, as can the battery 12 for the far-range communication module 11 ; further components (not illustrated) of the onboard unit 4 may also use a battery 12 , where appropriate.
[0065] FIG. 4 shows a variant of the embodiments of FIGS. 2 and 3 , in which the near-range and/or the far-range communication module 16 , 11 do not supply power directly (for example via their own radio power supply) to the memory 13 , but merely effect the switching-on of the power supply or battery 12 to the memory 13 (or the part of the memory 13 used for this purpose) during the memory access 19 , 15 . For this purpose, a switch is shown at 28 which is controlled by the communication module 16 and/or by the communication module 11 and effects the switching-on of the battery 12 to the memory 13 at least (and, for example, also only) for the duration of a memory access 19 or 15 .
[0066] Of course, the switch 28 is only symbolic; for example, the corresponding power supply of the memory 13 during the memory access 19 or 15 can be provided directly from the respective communication module 16 , 11 , which is in turn powered in the communication mode by the battery 12 . It is also possible for the switch 28 to detect itself the memory access 19 or 15 of a communication module 16 or 11 , for example over the memory access interface of the respective communication module 16 , 11 , in order to then switch on the battery 12 to the memory 13 in good time for the memory access 19 or 15 . All of these variants of the power supply of the memory 13 during the memory access of the respective communication module 16 , 11 are included here by the expression “effecting the power supply” of the memory 13 during the access 19 , 15 by the respective communication module 16 , 11 .
Conclusion
[0067] The invention is not limited to the presented embodiments, but includes all variants, modifications and combinations that fall within the scope of the accompanying claims.
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The present subject matter relates to an onboard unit for a traffic telematics system, comprising: a first communication module, designed for near-range radio communication with a first external communication device, a second communication module, designed for far-range radio communication with a second external communication device, and a non-volatile memory, which can be accessed both by the first and the second communication module, wherein each communication module has a power-supplied communication mode and a powerless or power-saving rest mode, and wherein the power supply of the memory during an access thereto is effected by the accessing communication module. The present subject matter further relates to an onboard system for a vehicle comprising such an onboard unit, and to a communication device for said system.
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BACKGROUND OF THE INVENTION
The present invention relates to the production of refractory linings or walls and has for an object a method of and apparatus for performing the sintering of refractory linings. The invention is more particularly applicable to the sintering of the linings of vessels utilised in metallurgy to contain, heat or process metals in the liquid state.
Vessels of this kind are formed from mixtures of refractory compounds in the form of compacted puddled clay tamped between the outer shell of the vessel and a metal former retaining the material at the inner side of the lining, or of hollow stacked bricks or else of a refractory coating applied by spraying on to a rigid carrier. These refractory materials are exposed to a sintering treatment which is essential to endow the refractory lining with a particular degree of mechanical strength before the first time it is used. This treatment does not have advantages only however, and the sintering conditions have a substantial bearing on the properties of the linings obtained, in particular on the service life of the walls or linings of metallurgical containers.
Commonly speaking, the refractory materials utilised in the applications of this nature are most frequently metal oxides such as silica, alumina, magnesia, zirconia, requiring sintering temperatures of the order of 1500° to 1700° C. which may as known be generated in homogenous manner in arc furnaces. The heating operation within an arc furnace is not appropriate for applications of this kind, however.
In the case of containers like metallurgical ladles and furnaces, which are intended to contain liquid metal, the prevailing trend is towards in situ sintering.
In the case of induction furnaces, this sintering action is obtained by heating by means of an air-gas burner installed in the container close to the inner surface of the linings, prior to infeed of the metal allowing of heating by induction, which may initially be cold and solid or liquefied beforehand.
In the case of ladles, this fritting action is secured by heating by means of an air-gas burner installed in the container close to the inner surface of the linings. The burners utilised do not however allow temperatures of the order of 1200° C. to be exceeded, and in all cases, it is consequently metal in the liquid state at approximately 1500° C. which is in contact with the refractory linings when the sintering action can begin; this liquid metal also originates from the melting of a non-recoverable mold or former, which melting action sets in before the onset of the sintering action as such. Because of this, it is unavoidable for liquid metal infiltrations to occur through the as yet unsintered pulverulent refractory materials.
These infiltrations certainly represent disadvantages: useless metal losses, power losses, irregular and uncertain course of the "fritting" action within the thickness of the linings, mechanical weak spots and heat bridges across the refractory material, premature attrition of the refractory material, substantial corrosion and even risks of metal leakages reaching the inductor and the cooling water ducts surrounding the containers, risks of perforations, unless a protective pulverulent layer of sufficient thickness is maintained around the sintered area. Since the sintering front forming a delimitation between these two areas progresses every time the vessel is utilised during induction heating of the liquid metal it receives, the infiltrations represent a primary factor in limiting the service life of the linings. This method also has the disadvantage that the former can never be recovered.
A more specific object of the invention is to allow the above-mentioned disadvantages to be prevented or minimised, and, contrary to the known techniques, it is possible to perform the sintering of the container linings in situ, over their inner surface prior to any contact with a liquid metal, in temperature and homogeneity conditions subsequently prevent infiltrations and restrict corrosion.
SUMMARY OF THE INVENTION
To fulfil these and other objects, the invention consists in a method for the production of refractory linings, according to which the said linings are formed from refractory material the sintering of which is at least partially performed by heating action, wherein, in order to provide said heating action, said linings are placed within an enclosure having a gas passage opening, a mixture formed from fuel gas and oxygen intended to form a heating flame is caused to pass through at least one of the said openings, the other openings serving the purpose of discharging the hot gases, and a diluting gas is injected during at least the first part of the sintering operation close to said flame in such manner as to engender a temperature increase of said refractory linings rendering it possible to reach a sintering temperature comprised between 1500° and 2000° C.
According to other features of the method, the diluting gas is air in particular: it is advantageously injected co-axially around the flame, and the temperature increase may be controlled by adjusting the intensity of the flame by action on the corresponding rates of flow of oxygen and fuel gas and on the other hand on the flow of diluting gas injected, in such manner as to raise the lining temperature homogenously in gradual manner from ambient temperature or a value of at most 500° to 1000° C., to a sintering temperature comprised between 1500° and 2000°, and preferably of the order of 1600° to 1700° C., and this temperature is maintained for a period of time.
The invention also consists in apparatus for sintering refractory linings, of the kind comprising means of shaping the said walls or linings from a refractory material and an enclosure with openings, at least one of these openings being provided with a burner, wherein the burner is a fuel gas and oxygen burner, the said enclosure being provided with means of injecting a diluting gas. The means of shutting the enclosure may in particular be formed by a cap which may be fitted on the aperture of a metal container, during application for sintering the linings of such containers on their inner surfaces.
Upon applying the invention, the injection of a diluting gas not only offers easy means of controlling the temperature by adjustment of the flow injected. It has as its result moreover that by diffusing the heat of the flame and increasing the volume of smokes, it assures a great degree of homogeniety of the heating action throughout the surface of the lining processed. Advantageously and for safety purposes, it is also possible to make use of gaseous fluids (for example air and oxygen) as burner coolants, in substitution for water.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood reference will now be made to the accompanying drawings which show certain embodiments of apparatus for carrying out the method according thereto and in which:
FIG. 1 is a diagrammatical view in vertical cross-section of a first embodiment of apparatus, and
FIGS. 2a and 2b when joined at the line a-b illustrate in cross-section a modified embodiment of a burner.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, according to FIG. 1, an induction furnace comprising a well or hearth 1 of generally cylindrical shape is intended to contain a metal in the liquid state, heated by an inductor 3 surrounding the furnace and cooled by the circulation of water.
A wall or lining 2 is formed by a refractory puddled clay partly sintered starting with its inner surface. It is known that the sintering front travels from the inner surface towards the outside of the furnace every time use is made of the furnace, and that the service life of the lining is a direction function of this progression. It is essential as a matter of fact that an unsintered pulverulent space be retained at the outer side of the lining to provide heat insulation and form a shield against possible infiltrations of liquid metal. The invention renders it possible to perform a first sintering operation on the linings over an appropriate depth, throughout the area of their inner surface 4, before the latter is first placed in contact with liquid metal.
This sintering operation is performed by means of apparatus which generally comprises a burner 5 installed on a removable bearing lid in the form of a cover 6 arranged to be fitted on to the furnace 1. This bearing lid has orifices 7 for outward extraction of smokes and a "nose" 7'.
The burner 5 is of the oxygen-gas type. The comburant oxygen is fed in via a pipe 8 and the fuel gas via a pipe 9 in such manner as to form a flame 10 situated within the enclosure formed by the furnace and its cover. Provision is made moreover for an annular injection around the flame of diluting air fed in via a pipe 11 leading into an annular space 12 co-axial with and outside the pipes 8 and 9.
The lining 2 of the furnace is initially formed by dry ramming of a refractory puddling clay based on silica between an outer shell or jacket 13 of the furnace, and a provisional metal former which is recoverable and retains the material at the inner side of the lining. Use may be made of conventional lining materials available commercially, which commonly contain 1.2% of boric acid, but it is preferred to select lining materials having a low proportion of mineralising elements, say for example a siliceous fireclay or lining material containing 0.3 to 0.9% of boric acid or its equivalent in boron or boric anhydride, that is a lining material free of mineralising elements.
The metal former (not shown in the Figure) is commonly extracted after a preliminary heating action has assured cohesion of the lining material thanks to an organic binder or by the mineralising element it may contain. This preliminary heating action itself may be performed by means of the same equipment as that used for the sintering operation. The former may also be withdrawn before any heating action is performed.
The combination of the oxygen-gas burner with the co-axial annular injection of air renders it possible to control the temperature of the refractory lining at the side of its inner surface to provide gradual heating according to a course controlled precisely from practically ambient temperature to the sintering temperature, even if the latter should be high, for example 1900° C. for particular products.
The temperature is raised at the rate of 100° C. to 200° C. per hour, the former is withdrawn at 400° C. and the temperature is raised to the sintering level at the hourly rate of 100° C. to 200° C. and, at the sintering temperature, a level of 1550°-1650° C. or more is maintained for an hour before allowing the lining to cool. It is also possible moreover to control the temperature drop and to keep the burner in operation to keep the furnace at high temperature until metal is fed in. A temperature level of one or two hours is preferably maintained at a temperature of the order of 500° C.
By way of example, for a siliceous lining material, a sintering temperature of 1550° C. was reached in 171/2 hours at the rate of 100° C. per hour, with a 2-hour stage at 500° C. and a 2-hour stage at 1550° C. For a siliceous lining material, the sintering temperature of 1550° C. was reached in 111/2 hours at the rate of 150° C./hour, with an hour's stage at 500° C. and an hour's stage at 1550° C. For an aluminous lining material, the temperature of 500° C. was reached at the rate of 150° C./hour, followed by an hour's stage at 500° C., the temperature then being raised at a rate comprised between 200° C./hour and 250° C./hour, and an hour's stage was maintained at 1650° C. in any event.
Throughout the heating period, the intensity of the flame was controlled by means of the rates of flow of fuel gas and oxygen fed to the burner. Furthermore, the correlative rates of flow are always adjusted so that the combustion always occurs with an oxidising flame, to prevent a reduction of the refractory material. For as long as air is injected at the same time around the burner, the flame 10 heats this air and a hot-air generator is produced within the furnace in this manner, within the partially shut enclosure, with a controllable and homogenous air temperature.
The evenness of the heating action on the linings which are to be sintered is assured by means of this injection of air during a first part of the temperature rise, for example up to 1100° C. Beyond this temperature, the injection of air is stopped whilst continuing to control the flame intensity to adhere to the temperature rise program. During this second heating stage, the evenness of the temperature at the surface of the lining which is to be sintered is assured by the radiation from the refractory material. The temperature of the lining may be measured by means of a thermoelectric chromelalumel couple placed against the lining up to 1100° C., and by means of an optical pyrometer beyond this level.
The method applied renders it possible to assure sintering the lining on its inner surface, and thus to provide mechanical strength and pore closure, prior to any contact with liquid metal. The elimination of the risks of infiltration considerably increases the service life of the linings. For example, it was observed in the case of induction furnaces, that power reductions of 20% to 30% were possible. The precision of temperature control and its homogenous nature render it possible to provide a high mechanical strength and surface resistance against thermal shocks and corrosion, more satisfactorily than by existing techniques. Analysis of the sintered refractory material demonstrates the absence of a vitreous phase and a total conversion of quartz into crystobalite. The quality of the surface-sintered lining is equally demonstrated by porosity readings yielding the following results:
______________________________________Distance from the inner surface 0 to 1 1 to 2 3.5 to 4.5 cm cms cmsTotal porosity 12.9% 20.1% 20.8%of whichradius >7.5 microns 45% 84% 63%radius <7.5 microns 55% 16% 37%______________________________________
The low total porosity throughout the sintered layer, and above all the low proportion of macropores at the locus of the sintering front, will be observed.
With reference to both FIGS. 2a and 2b, a sintering burner comprises:
a central tube 21 in which is fitted an ignition electrode 22, the tube 21 being connected to an axial passage 23 of a massive element forming a burner nozzle 24, the passage 23 itself opening into a central recess 25 of the burner nozzle 24. The ignition electrode 22 is fitted in the tube 21 via bearer rings 26 and its terminal portion is surrounded by an aluminium tube 27. Its free end 22' protrudes into the central recess 25.
a second tube 28 co-axial with the central tube 21 which with the latter forms a principal annular duct 29 for a fuel gas, this tube 28 being flared at its front end 28' for connection to a transverse plate 30 having a plurality of annularly-arranged perforations 31 acting as a carrier for a ring of distributor tubes 32 which at their other ends are engaged in perforations 33 of the burner nozzle 24; these perforations 33 open to the outside via calibrated bores 33'. The tube 28 has connected to it an extremity opposed to the nozzle 24, a fuel gas supply tube which is not shown; in the central duct 21 are formed several perforations 36 establishing communication between the annular duct 29 and the axial duct 37 formed by the tube 21 for transfer of fuel gas for the pilot light or for ignition.
a third tube 38 is situated co-axially at the outside of the second tube 28 and is engaged on the outer periphery of the burner nozzle 24. At an end distant from the burner nozzle, this tube 38 has connected to it an oxygen supply tube which is not illustrated, which thus, with the second tube 28, forms an annular oxygen duct 39 leading into a distribution chamber 40 delimited between the transverse plate 30 and the nozzle 24 and through which extend the terminal portion of the axial duct 21 and the annular array of tubes 32. This distribution chamber 40 opens at the outside into a first ring of narrow transverse passages 41 situated around and close to the axial passage 23, in such manner that for their part they open into the recess 25, and into a second ring of wide transverse passages 42 extending externally around and at a small distance from the ring of passages 33-33'.
a fourth tube 44 is placed co-axially around and at a distance from the third tube 38, is connected on the one hand to two air feed tubes 45 (of which one only is apparent in the drawing) the ends of which for connection to the tube 44 slope in a substantially tangential directional setting to impart a vortexial motion to the air immediately upon entering an annular duct 46 formed between the tubes 38 and 44. The tube 44 is secured around the extremity of the duct 24 by means of a ring 47 of vanes 48 which intensify the whirling action previously initiated by the directional setting of the tubes 45.
The whole thus described is fitted in a flange 50 which is secured on the burner support wall. During operation, an igniting flame is permanently formed in the recess 25 by combustion of the gas fed into the duct 37 of the tube 21 via the perforations 36 and originating from the principal fuel gas duct 39, this igniting flame itself being constantly exposed to the electrical discharges of the igniting electrode 22; the principal flame of the burner is formed around the igniting flame by combustion of the gas carried by the tubes 32 and the perforations 33-33' into the oxygen carried by the wide transverse passages 42. When air is set in motion in the duct 46, it issues around the principal flame in a whirling motion as stated earlier, which has the result of slowing down the axial speed of the principal flame and apart from the required diluting action, as to endow the flame with a more contact form more appropriate for the sintering operation.
It will be apparent that the invention is not limited to the example of application which has been described in particular in the foregoing. The method may be applied in analogous manner for in situ sintering of other refractory containers, for sintering lining materials applied by spraying to repair casting ladles or other containers, but also for sintering raw bricks or monolithic blocks for replacement of faulty refractory materials, and so on.
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This invention relates to the production of refractory linings. According to the method, the lining formed by refractory materials is heated to a temperature sufficient to cause the sintering of the materials on at least an internal surface of the said lining. To provide this heating action, a flame is produced from a fuel gas and oxygen, within a partially closed volume close to the lining which is to be sintered, and a diluting gas is injected between the flame and the lining, at least during the first part of the rise in temperature. The method is applicable to the sintering of the linings of vessels utilized in metallurgy, in particular of induction furnaces.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application 102 01 577.5, filed Jan. 17, 2002, herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a spinning device for producing a spun yarn by means of a circulating air flow.
A spinning device for producing a spun yarn by means of a circulating air flow is known from German Patent Publication DE 199 26 492 A1. A sliver to be spun is drawn into a nozzle body and passes a sliver guidance device. The sliver guidance device has sliver guide elements, which are spaced apart from each other and permit the free passage of a core fiber bundle. The sliver is subjected to an air flow circulating around the sliver at the inlet opening of a spindle. The free fiber ends of the sliver are wrapped around the conical spindle head by the circulating airflow at the inlet opening of the spindle. In the course of drawing the sliver into the hollow spindle, these fiber ends wrap themselves in a spiral shape to form wrapped fibers around the sliver, whereby a yarn is produced from the sliver and removed through the hollow spindle.
German Patent Publication DE 40 36 119 C2 also shows a device for producing a spun yarn by a circulating air flow by which free fiber ends of the sliver are wrapped around a conical spindle head at the inlet opening of the spindle by the circulating air flow. With this spinning device, the sliver guidance device is located inside the running fiber strand, so that the fibers of the sliver are arranged at the circumferential surface of the sliver guidance device.
Continuously increasing demands in regard to productivity and yarn properties are made on modern spinning frames. Such spinning devices, known from above-referenced. German Patent Publication DE 199 26 492 A1, or in another embodiment from above-referenced German Patent Publication DE 40 36 119 C2, are suitable for achieving high production speeds, along with good yarn properties. It is all the more bothersome if in the course of starting the processes at high withdrawal speeds, such as are employed during normal spinning operations, repetitions of the start of the spinning process are often made necessary because, at these high yarn speeds the spinning start process takes place relatively uncontrolled and with a greatly reduced assurance of a satisfactory spinning start.
It is known from rotor spinning to clearly lower the withdrawal speed during the spinning start process in comparison with the spinning operation in order to achieve a more easily controlled spinning start process and therefore greater spinning start assurance. However, if an attempt is made to utilize this type of operation from rotor spinning and to operate a circulating air flow spinning device at a lowered withdrawal speed of the yarn in the spinning start phase, a yarn is temporarily created thereby whose yarn strength could be unsatisfactory. Such yarn sections of reduced strength constitute undesired weak points. This increases the danger of yarn breaks and considerably reduces the interference-free processing of the yarn. In the least advantageous case a yarn break may occur already in the spinning start phase. This has very disadvantageous consequences with regard to the intention of achieving a good yarn quality along with high productivity when employing the air spinning method. It is therefore customary to perform the spinning start process at the high withdrawal speeds of the normal spinning operation and in the course of this start process to accept the disadvantages of frequent repetitions of the spinning start process.
The above described problems cannot be overcome by the known prior art, such as disclosed in German Patent Publications DE 199 26 492 A1 or in DE 40 36 119 C2.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to further develop the above mentioned prior art to provide improved devices for producing a spun yarn employing a circulating air flow.
Basically, the spinning device of the present invention produces a spun yarn by a circulating air flow, and for this purpose comprises a housing having an inlet opening for receiving a sliver, at least one sliver guidance element arranged downstream of the inlet opening, a hollow spindle through which a formed yarn is withdrawn, the spindle having a conical spindle head, and openings in the area of the spindle inlet for injecting into the housing a circulating air flow comprised of a linear airflow component essentially in a yarn traveling direction and a twisting airflow component essentially in a helical orientation about the yarn for wrapping free fiber ends of the sliver helically around the spindle head to subsequently be wrapped around the yarn at an acute angle in respect to the yarn traveling direction as the yarn is drawn off through the spindle. In accordance with the present invention, an adjustment device is provided for adjusting at least the linear airflow component as a function of the withdrawal speed of the yarn and controlling a helical wrapping angle of the fiber ends around the spindle head and the acute angle of wrapping of the fibers around the yarn; and a control device is provided for controlling the adjustment device between a setting for the spinning start process and at least one setting for normal spinning operations. For example, the injector effect of air nozzles or the vacuum in the housing can contribute to forming the air flow. At least a part of the air flow in the yarn running direction can be formed by air entering the inlet opening of the housing together with the sliver.
In accordance with one embodiment of the present invention, the adjustment device includes a positionable cover for the inlet opening such that the position of the cover determines the cross section of the inlet opening. The greater the cross section of the inlet opening, the greater the amount of air entering the housing together with the sliver, and therefore the proportion of the linear component of the circulating air flow in the area of the spindle head. If the cross section is reduced, the amount of air is correspondingly reduced. The linear component of the air flow is advantageously set by controlling the cross section of at least one air inlet opening for this air flow. A control of the air drawn in through the inlet opening offers the advantage that no additional amount of air needs to be made available to be blown into the housing.
An alternative embodiment for setting the linear component of the air flow is provided by a bypass of the inlet opening of the fiber conduit in the housing, which is directed in the yarn traveling direction, and whose cross section can be adjusted by means of the adjustment device. In spinning frames with a plurality of work stations, considerable costs can be avoided by means of the mutual advantage of these embodiments by not having to provide additional amounts of air.
In a further alternative embodiment, the housing has at least one injection conduit, which is directed in the yarn traveling direction and is connected with the compressed air source. The adjustment device is equipped for setting the air pressure of the supplied air. In this manner, the adjustment of the linear component of the air flow occurs in a particularly simple and rapid manner through the regulation of the pressure of the air supplied by the compressed air source. In particular, no mechanical devices are required, whose function could be reduced or hampered by dust or flying fibers.
The linear component of the air flow is advantageously set in such a way that the angle at which the wrapped fibers have been placed around the withdrawn yarn lies in the range between 20° to 35°, preferably at 27°. It is possible to empirically determine how the adjustment device must be set in each individual case for achieving the greatest yarn strength possible, and to store the appropriate settings, for example in a data memory of a control device, for retrieval and use in connection with identical spinning parameters. For this purpose, the control device includes a data memory for storing yarn data and is connected to a line through which the yarn data can be input to the memory. The adjustment device can be controlled as a function of the yarn data.
The provision of a single drive mechanism for each spinning station makes it possible to be able to immediately perform every spinning start process at each spinning station in the manner in accordance with the invention independently of other spinning stations of the spinning frame. Downtimes are reduced in this way.
It is possible by means of the invention to prevent an impermissible drop of the yarn strength during the spinning start process, which is performed with a clearly reduced withdrawal speed in comparison with the normal spinning operation which ensues following the spinning start. The assured reliability of the spinning start process is increased. The tendency toward faults in the further processing of the yarn can be reduced. A high productivity, along with good yarn quality, can be achieved by means of the invention.
When using the device in accordance with the invention in connection with batch changes, it is possible in some cases to omit the exchange of the housing, or portions of the housing, for meeting the new yarn parameters.
Further details, features and advantages of the present invention will be explained and understood from the following description of preferred embodiments of the invention with reference to the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial schematic elevational view, partially in longitudinal section, of a spinning device in accordance with the present invention, depicting the device during the spinning start phase,
FIG. 2 is another schematic view, similar to that of FIG. 1, of the present spinning device but depicting only a smaller portion thereof during normal spinning operations,
FIG. 3 is a simplified enlarged cross-sectional view of the spindle head of the present spinning device depicting a basic representation of the formation of the air flow in the area of the spindle head,
FIG. 4 is a perspective view of the spindle head of the present spinning device, depicting a greatly simplified basic representation of the position of the free fiber ends of the sliver wrapped around the spindle head during the spinning start phase,
FIG. 5 is another perspective view of the spindle head of the present spinning device, depicting a greatly simplified basic representation of the position of the free fiber ends of the sliver wrapped around the spindle head during the normal spinning operation,
FIGS. 6 to 9 are actual photographs of yarn structures produced by the spinning device of the present invention at different settings and withdrawal speeds,
FIGS. 10 and 11 are schematic elevational views, partially in longitudinal section, of further spinning devices in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The spinning station 1 represented in a partial view in FIG. 1 has a housing 2 , in which an air nozzle body 3 is mounted. A sliver 6 delivered by an arrangement of drafting rollers 4 , 5 passes through a sliver conduit 8 and sliver guidance elements 9 and is conveyed to the inlet opening 10 of a hollow spindle 11 . Air nozzles 12 formed in the nozzle body 3 blow air in the area of the inlet opening 10 of the spindle 11 , forming an air flow circulating around the sliver 6 and the spindle head 13 , which applies a twisting effect to the sliver 6 . Free fiber ends 14 of the sliver 6 are wrapped around the sliver 6 , as well as the spindle head 13 . An air flow 30 is generated in the sliver conduit 8 , or in the air gap 15 between the wall of the sliver conduit and the sliver 6 by the injector effect of the air blown in through the air nozzles 12 , as well as by the sliver 6 entering the inlet opening 7 at high speed. The air flow 30 moves in the longitudinal direction of the sliver 6 toward the spindle head 13 and forms a linear component of the air flow circulating around the spindle 11 . The yarn 16 formed from the sliver 6 is withdrawn through the spindle 11 . In the process, the free fiber ends 14 wrapped around the spindle head 13 are taken along and wrapped around the yarn 16 .
A further understanding of the basic structure and operation of the spinning station 1 can be taken from German Patent Publication DE 199 26 492 A1, or the corresponding U.S. Pat. No. 6,209,304, or from German Patent Publication DE 40 36 119 C2, or the corresponding U.S. Pat. No. 5,159,806, incorporated herein by reference.
A cover 18 which can be positioned by means of an adjustment device 17 , is associated with the inlet opening 7 . The adjustment device 17 acts via a toothed rack 19 on the cover 18 . A gear wheel, not represented, in a gear housing 20 acts together with the toothed rack 19 . The gear wheel is driven by an actuating motor 22 via an operative connection 21 . The actuating motor 22 is controlled by a control device 23 . The control device 23 controls a motor 25 through a line 24 , as well as a motor 27 through a line 26 . The control device 23 is connected through a line 28 with further elements, not represented for reasons of simplicity, of the spinning station and the spinning frame. The motor 25 drives the drafting rollers 4 , 5 , and the motor 27 drives the withdrawal rollers 29 , 29 A.
FIG. 1 shows the adjustment device 17 at the spinning station 1 during a spinning start phase of the spinning operation, with the cover 18 in a lifted position. It is possible in this manner to draw in a maximum amount of air through the inlet opening 7 , and through the sliver conduit 8 , which passes through the sliver conduit 8 in the form of an air flow 30 and which, as represented in FIG. 3, acts as a linear component of the circulating air flow 31 . The circulating air flow 31 wraps the free fiber ends 14 around the spindle head 13 .
FIG. 2 shows the spinning station during normal spinning operations. During normal spinning operations, the yarn traveling speed, i.e., the yarn withdrawal speed, is considerably higher in comparison with the spinning start phase. In this case, the cover 18 is in a lowered position. As a result, the air gap 15 has become narrower, and the amount of air drawn in through the inlet opening 7 , and through the sliver conduit 8 , is decreased in comparison with the setting represented in FIG. 1 .
The principle of the formation of the air flow in the area of the spindle head 13 can be understood from FIG. 3. A stronger air flow 30 , such as generated by the cover 18 in the raised position in accordance with the representation in FIG. 1 during the spinning start phase, combines with the air flow 32 comprised of air blown in through the air nozzle 12 , to collectively form the air flow 31 circulating around the spindle head 13 , both in respect to the strength as well as the direction of the air flow 31 . The direction of the circulating air flow 31 defines the position of the free fiber ends 14 wrapped around the spindle head 13 . In addition to indicating the air flow direction, the strength of the air flows 30 , 31 , 32 , 33 , 34 is indicated in FIG. 3 by the length of the arrows representing each of the air flows 30 , 31 , 32 , 33 , 34 .
The air flow 33 , which is created by the cover 18 in the lowered position in accordance with FIG. 2 during normal spinning operations, combines with the air flow 32 comprised of air blown in through the air nozzle 12 , to form the air flow 34 circulating around the spindle head 13 . The air flow 34 has a different direction than the air flow 31 . This respective direction determines the position of the free fiber ends 14 during normal spinning operations. The air flow 34 forms an acute angle α with respect to a line parallel to the center axis 35 of the yarn, which is greater than the angle α formed by the air flow 31 with respect to the same line parallel to the center axis 35 . Accordingly, the position of the free fiber ends 14 wrapped around the spindle head 13 is different during the spinning start phase than during normal spinning operations.
The change in the position of the free fiber ends 14 on the spindle head 13 of the spindle 11 are shown in perspective views in FIGS. 4 and 5. The direction, or position, of the free fibers ends 14 during the spinning start phase, when the stronger air flow 30 is present, can be seen in FIG. 4, while the direction, or position, of the free fibers ends 14 during normal spinning operations when the air flow 33 is present can be seen in FIG. 5 . The free fiber ends 14 wrapped around the spindle head 13 are represented longer than in actuality, for illustrative purposes of making the different positions clearer.
The yarn 36 represented in FIG. 6 was produced in accordance with the present invention at a withdrawal speed of 100 m/min and with a large opening during the spinning start phase with the cover 18 in the raised position represented in FIG. 1 . The yarn 36 has wrapped-around fibers which predominantly lie at an angle β of approximately 22° with a line parallel with the center axis of the yarn 36 . The strength of the yarn 36 was measured to be 15.5 cN/tex. In FIG. 6, the angle β is indicated by a horizontal line 70 and an obliquely extending line 71 representing the position of the wrapped-around fibers.
In each of FIGS. 7 to 9 the position of the wrapped-around fibers is similarly indicated by obliquely extending lines 72 , 73 and 74 .
The yarn 37 represented in FIG. 7 was produced in accordance with the present invention at a withdrawal speed of 300 m/min and with a narrow opening during normal spinning operations with the cover 18 in the lowered position represented in FIG. 2, has wrapped-around fibers which predominantly form an angle β of approximately 27° with a line parallel with the center axis of the yarn 37 . The strength of the yarn 37 was measured to be 13.4 cN/tex. The cross sectional area of the inlet opening formed for the air drawn into the housing 2 in the raised position of the cover 18 is called the large opening, and the cross sectional area of the inlet opening formed in the lower position of the cover 18 is called the narrow opening.
FIG. 8 shows a yarn 38 which was produced at a withdrawal speed of 300 m/min, instead of 100 m/min, with a large size of the opening unchanged from that used in producing the yarn of FIG. 6 . The wrapped-around fibers form an angle β of approximately 12°. The strength of the yarn 38 was measured to be 9.9 cN/tex.
FIG. 9 shows a yarn 39 which was produced at a withdrawal speed of 100 m/min, instead of 300 m/min, with a narrow size of the opening unchanged from that used in producing the yarn of FIG. 7 . The wrapped-around fibers form an angle β of approximately 52°. The strength of the yarn 39 was measured to be 10.7 cN/tex.
In each case, the clear decrease in yarn strength in comparison with yarn produced in accordance with the invention shows the result of yarn production in accordance with the known prior art where, for example, the withdrawal speed in the spinning start phase was lowered to 100 m/min in comparison with the withdrawal speed of 300 m/min during normal spinning operations. By dropping the withdrawal speed to a lower speed value it is intended for the spinning start process to run in a more controlled manner in order to increase the spinning start assurance in this manner. However, the reduced strength values of yarn produced in this manner do not satisfy the requirements and lead to the above mentioned defects, or disadvantages.
FIG. 10 shows an alternative embodiment of the present invention. A sliver 40 is transported through the arrangement of drafting rollers 41 , 42 and enters the housing 44 through the sliver conduit 43 . In the housing 44 , the sliver 40 is subjected to the action of a sliver guidance element 45 and a circulating air flow. The circulating air flow is generated by blowing air into the housing 44 through the air nozzles 46 , 47 . The circulating air flow wraps the free fiber ends 48 around the spindle head 49 of the hollow spindle 50 . In turn, the free fiber ends 48 are placed around the yarn 51 in the form of wrapped-around fibers.
The housing 44 has a passage, embodied as a bypass 52 of the sliver conduit 43 . The bypass 52 can be closed by means of a cover 53 . The cover 53 can be pivoted by means of the adjustment device 54 . The pivoting movement is generated with the aid of a lifting cylinder 55 , which is pneumatically actuated via lines 56 , 57 . A switching arrangement 58 charges the lines 56 and 57 alternatively with compressed air supplied from a compressed air source 59 . The switching arrangement 58 is actuated by a control device 60 , with which it is connected via a line 61 .
The bypass 52 is open in the representation of FIG. 10, so that air is drawn in through the sliver conduit 43 , as well as through the bypass 52 , and enters the circulating air flow as the linear component. This open setting of the bypass corresponds to the “large opening” setting of the sliver conduit 8 of the device represented in FIG. 1 as it is employed in the spinning start phase.
If the lifting cylinder 55 is charged with compressed air through the line 57 , the piston of the lifting cylinder 55 moves upward in the representation in FIG. 10 until the cover 53 takes up the position indicated by dashed lines. The inflow of air through the bypass 52 is thereby stopped, and air is only drawn in through the sliver conduit 53 . This setting corresponds to the “narrow opening” setting of the sliver conduit 8 in the device represented in FIG. 2, such as it is used in normal spinning operations.
FIG. 11 shows another alternative embodiment of the invention. A sliver 40 runs through an arrangement of drafting rollers 41 , 42 and enters a housing 63 through a sliver conduit 62 , is subjected to the effects of a circulating air flow and is drawn off through a spindle 50 . The circulating air flow wraps the free fiber ends 48 around the spindle head 49 . When drawing off the yarn 51 , the free fiber ends 48 are wrapped around the yarn 51 in the form of wrapped-around fibers. In contrast to the housing 44 represented in FIG. 10, the housing 63 has an air injection conduit 64 extending parallel with the sliver conduit 62 . Compressed air is blown in through the injection conduit 64 . For this purpose, the injection conduit 64 is connected through a line 65 with a compressed air source 65 . The control of the air pressure is performed by means of an adjustment device 66 . The adjustment device 66 is controlled through a line 67 by a control device 68 . The compressed air is injected during the spinning start phase, wherein the air pressure is set such that the wrapped-around fibers lie at a desired angle β around the yarn 51 , or that the desired yarn strength is achieved. The setting corresponds to a “large opening” setting of the sliver conduit 8 in the device represented in FIG. 1, such as is used in the spinning start phase. If, however, the compressed air supply is blocked, the setting corresponds to the “narrow opening” setting of the sliver conduit in the device as represented in FIG. 2, as it is employed in normal spinning operations.
For the spinning start process, the “large opening” setting is set, for example at a withdrawal speed of 100 m/min. Following the start of spinning, the withdrawal speed of the yarn 16 , 51 is increased to, for example, 300 m/min for a normal spinning operation and the “narrow opening” setting is set. One setting of the adjustment device 17 , 54 , 66 is sufficient for normal spinning operations.
Alternatively to the examples as described, it is possible by means of a regulation of the air pressure to adapt the linear component of the air flow following the spinning start process in intermediate steps or continuously during the increase of the withdrawal speed in such a way that a desired high yarn strength is maintained during the respective increases. Accordingly, a continuous, or alternatively also stepped displacement of the positionable cover 18 can also take place during the increase in yarn withdrawal speed.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A spinning device for producing a spun yarn by a circulating air flow in a housing has an adjustment device ( 17 ) for controlling the angular position of the fiber ends wrapped around a spindle head, and in turn, the angular position of the fibers wrapped around the produced yarn, by adjusting a linear component of an air flow into the spinning device as a function of the yarn withdrawal speed, whereby a yarn is produced of a required yarn strength even during a spinning start phase in the process of making the spun yarn.
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[0001] The disclosure incorporates the heavy duty piston having oil splash deflector and method of cooling a piston disclosed in provisional application No. 60/192,593, filed Mar. 28, 2000, whose priority date is claimed for this application.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to heavy duty pistons for diesel engine applications, and more particularly to the management of cooling oil in articulated pistons.
[0004] 2. Related Art
[0005] Articulated pistons of conventional construction are often formed with a circumferentially extending cooling gallery in the piston head which is open to the bottom and communicates with one or more oil spray nozzles which extend into the skirt of the piston from below and direct a spray of cooling oil into the cooling gallery as the piston reciprocates in the piston cylinder to provide cooling. Lubrication of the pin bores and wrist pin are usually taken care of by internal oil porting. Any cooling of the pin bores and wrist pin are derived from the lubricating oil. In some applications, the pin bosses, their pin bores, bushings and wrist pin can be heated above desired temperatures which can impair the performance and longevity of the piston.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0006] A piston assembly constructed according to the invention includes a piston head having an open bottom cooling gallery formed in a bottom surface of the piston head, a pair of pin bosses depending from the piston head and having pin bores for supporting a wrist pin of a connecting rod, a piston skirt coupled to the pin bosses for reciprocal movement with the piston head, and a stationary oil spray nozzle extending into the piston skirt and having an outlet position for directing a flow of cooling oil along a path toward the cooling gallery. An oil deflector shield is carried by the piston skirt in position to substantially obstruct the flow of cooling oil to the cooling gallery and to direct the obstructed flow onto the pin bosses when the piston head is moved to a lowered position. The oil deflector shield is positioned also to move substantially out of the path of the cooling oil to cause the cooling oil to be directed into the cooling gallery when the piston head is moved to a raised position.
[0007] The invention also contemplates a method of cooling a reciprocating piston which employs the mentioned deflector shield which operates to selectively obstruct the flow of cooling oil to the cooling gallery when the piston is at the bottom of stroke position in order to attain, during a portion of the piston stroke, direct cooling of the pin bore regions of the piston. This invention has the advantage of providing direct cooling to the cooling gallery of the piston head at times during the stroke of the piston when cooling of the head is needed most, namely when the piston is toward the top of stroke position where it sees the most heat and thus requires the most cooling. As the piston travels toward the bottom of stroke position, the piston head is moved away from the heat of combustion so as to lessen the cooling requirements and, according to the invention, the deflector is operative during this time to redirect the cooling oil onto the pin boss regions so that the pin boss regions are directly cooled at a time during the piston cycle when the cooling of the head is less critical.
[0008] The invention thus has the advantage of providing direct cooling of the pin boss regions without impairing the efficient cooling of the piston head.
[0009] The invention has the further advantage of achieving cooling of the piston head and pin bores with use of a single oil spray nozzle in conjunction with the deflector.
THE DRAWINGS
[0010] These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
[0011] [0011]FIG. 1 is a cross-sectional view of a piston assembly constructed according to the invention shown coupled to a fragmentarily illustrated connecting rod;
[0012] [0012]FIG. 2 is a plan view of the piston skirt as viewed generally along lines 2 - 2 of FIG. 1;
[0013] [0013]FIG. 3 is a sectional view taken generally along lines 3 - 3 of FIG. 2;
[0014] [0014]FIG. 4 is a sectional view taken generally along lines 4 - 4 of FIG. 2; and
[0015] [0015]FIG. 5 is a sectional view taken generally along lines 5 - 5 of FIG. 2 showing the piston skirt moved between the upper solid line position and the lower broken line position with the stroke of the piston.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to the drawings, FIG. 1 shows an articulated piston assembly 10 having a head or crown 12 and a separately formed skirt 14 coupled to the crown 12 in the usual manner by a wrist pin 16 .
[0017] Referring also to FIGS. 2 and 3, the crown 12 has a central dome portion 18 with a contoured upper surface defining a combustion bowl 20 . Surrounding the dome portion 18 is an annular ring belt portion 22 extending downwardly from an upper face 24 of the crown 12 to a lower face 26 . A plurality of ring grooves 28 are formed in an outer surface 30 of the ring belt portion 22 . Between the ring belt 22 and dome portion 18 , radially spaced walls 32 , 34 define an oil cooling chamber or gallery 36 which, in this particular illustrated embodiment, is open to the bottom for receiving cooling oil L into the gallery 36 from below issuing from one or more oil spray nozzles 38 of an engine (not shown) in which the piston is mounted.
[0018] Extending downwardly from the dome portion 18 are a pair of laterally spaced pin bosses 40 formed with aligned pin bores 42 for accommodating the wrist pin 16 . In many applications, including the illustrated embodiment, the pin bores 42 are lined with a bushing 44 to serve as a bearing surface for the wrist pin 16 . However, not all applications will require the bushing 44 and the present invention can be practiced with or without the bushing 44 . The wrist pin 16 , of course, couples the piston assembly 10 to the upper end of a connecting rod 45 (schematically shown in FIG. 1) in the usual manner for reciprocating the piston assembly 10 within a cylinder bore (not shown) in typical manner by means of a crank shaft (not shown) with which the other end of a connecting rod 45 is coupled. FIG. 4 illustrates the skirt 14 of the piston assembly 10 near the top of its stroke, whereas FIG. 3 illustrates the piston assembly 10 near a mid stroke and on the way to a bottom of stroke position within the cylinder. FIG. 5 shows the skirt in both positions, with the upper solid line position representing the location of the skirt 14 near top dead center, and the broken chain line position representing the position of the skirt 14 near bottom dead center. The positioned relationship of the skirt relative to the fixed direction flow path of cooling oil L is also illustrated in FIG. 5, as will be discussed further below. The oil spray nozzle 38 is fixed relative to the reciprocating piston in thus the piston assembly 10 moves toward and away from the nozzle 38 in operation.
[0019] The piston skirt 14 has a pair of partial-cylindrical skirt portions 46 spaced radially outwardly of the pin bosses 40 joined by a pair of end walls 48 extending across the pin bosses 40 in laterally outwardly adjacent relation thereto. The end walls 48 have pin boss openings 50 aligned with the pin bores 42 of the pin bosses 40 . Receipt of the wrist pin 16 in the pin boss openings 50 of the skirt operate to couple the skirt 14 to the crown 12 in articulated fashion, such that the skirt 14 is able to move or rock slightly relative to the crown 12 about the axis of the wrist pin 16 . The skirt 14 has an upper face 52 that is spaced from the lower face 26 of the crown such that the skirt 14 is uncoupled from the crown 12 and joined only through the wrist pin 16 . The crown 12 may be fabricated of steel, whereas the skirt 14 may be fabricated of aluminum or the like. Of course, other material selections are contemplated by the invention, including a steel crown in steel skirt, an aluminum crown and skirt, or variations thereof.
[0020] As best shown in FIG. 2, the upper end 52 of the skirt 14 is formed with at least one and preferably a plurality of oil reservoirs in the preferred form of cup formations 54 that project radially inwardly of the skirt portions 46 in circumferentially spaced relation to the oil spray nozzle or nozzles 38 , so as to lie outside of the direct spray path of the nozzle, assuring that the cups 54 do not obstruct the direct flow of cooling oil issuing from the nozzle 38 from below into the oil cooling gallery 36 . As the cooling oil runs out of the cooling gallery 36 through its open bottom, some of the oil is captured by the cups 54 so as to provide a “cocktail shaker action” which redirects the captured oil back into the cooling gallery 36 during rapid reciprocating movement of the piston assembly 10 during operation. The cups 54 are partitioned from one another such they form discrete reservoirs.
[0021] According to the invention, the skirt 14 is further fitted with an oil deflector 56 which operates at least during a portion of the stroke of the piston assembly 10 to direct all or some of the jet of cooling oil issuing from the spray nozzle 38 onto the wrist pin and pin boss portion 40 of the assembly 10 so as to cool the wrist pin 16 and the pin bosses 40 , particularly in the vicinity of the pin bores 42 so as to cool the bearing surface between the pin bosses and wrist pins 16 . In the illustrated example, the pin bores 42 are fitted with bushings 44 , and the deflected oil serves to cool the bushings during operation.
[0022] The deflector 56 is similar in construction to the oil cooling cups 54 , but is generally wider and oriented on the skirt 14 so as to lie in the path of the jet of cooling oil issuing from the spray nozzle 38 over a portion of the stroke S of the piston (see FIG. 5). The deflector 56 presents a deflector wall 58 projecting radially inwardly from the inner wall of the skirt portion 46 , as shown best in FIGS. 2, 3 and 5 . The deflector wall 58 is oriented relative to the oil spray nozzle 38 such that as the piston moves to an upper position toward the top of the stroke of the piston assembly 10 where the crown 12 is exposed to the hot combustion gases, (FIG. 3 and solid line position of FIG. 5) the angle of incidence of the oil spray issuing from the spray nozzle 38 allows a substantial flow of the oil L to pass by the deflector 58 and be directed into the cooling gallery 36 of the crown 12 , for cooling the upper surface 24 and ring belt portion 22 . Circumferentially adjacent the deflector 58 is a recess 59 which is positioned relative to the oil flow L so as to provide passage of the oil L around the deflector 58 and into the gallery 36 when the skirt 14 is moved with the piston to the upper position. As the piston moves downwardly in its stroke to a lowered position toward the bottom of stroke position, the deflector wall 58 enters the path of the oil stream L, as illustrated in FIGS. 2, 3 and 5 , causing obstruction of the flow to the cooling gallery 36 such that a substantial portion of the oil stream L is deflected radially inwardly so as to splash onto the wrist pin 16 , pin bosses 40 and the bushings 44 for cooling these regions of the piston assembly 10 during operation.
[0023] The nozzle 38 is disposed at an angle relative to the longitudinal axis of the piston skirt 14 (see FIG. 5) such that the oil flow L can bypass the deflector 58 as the piston 10 nears the top of stroke, while entering the path near the bottom of stroke to selectively deflect the oil flow.
[0024] The upper surface of the oil deflector 56 has a cup-like recess 60 which, like the cups 54 , serves to capture oil running out of the cooling gallery 36 for redirecting such supplemental oil back into the cooling gallery for enhanced cooling.
[0025] In the preferred embodiment, the oil deflector feature 56 is formed as one piece with the piston skirt 14 , and as such may be cast or forged therewith. Alternatively, the deflector feature 56 could take the form of a welded or bolted on component, although the one-piece structure is preferred.
[0026] Obviously, many modifications and variation of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. The invention is defined by the claims.
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A piston assembly includes a piston head having an open bottom cooling gallery and a pair of pin bosses depending from the head and supporting a wrist pin of a connecting rod. A skirt is coupled to the pin bosses for reciprocation with the piston head. A stationary oil spray nozzle extends into the piston skirt from below and cooperates with an oil splash deflector which, at a lowered position of the piston head, directs the flow of oil onto the pin bosses for direct cooling, and at raised position of the piston head, moves out of the way to allow the cooling oil to enter the cooling gallery and cool the piston head.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a non-provisional patent application claiming the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/260,357, filed on Nov. 11, 2009, and U.S. Provisional Patent Application Ser. No. 61/390,561, filed on Oct. 6, 2010, the entire contents of which are hereby expressly incorporated by reference into this disclosure as if set forth in its entirety herein.
FIELD
The present invention relates generally to medical devices and methods generally aimed at spinal surgery. In particular, the disclosed system and associated methods relate to performing spinal fixation with the use of a deformity system.
BACKGROUND
The spine is formed of a column of vertebra that extends between the cranium and pelvis. The three major sections of the spine are known as the cervical, thoracic and lumbar regions. There are 7 cervical vertebrae, 12 thoracic vertebrae, and 5 lumbar vertebrae, with each of the 24 vertebrae being separated from each other by an intervertebral disc. A series of about 9 fused vertebrae extend from the lumbar region of the spine and make up the sacral and coccygeal regions of the vertebral column.
The main functions of the spine are to provide skeletal support and protect the spinal cord. Even slight disruptions to either the intervertebral discs or vertebrae can result in serious discomfort due to compression of nerve fibers either within the spinal cord or extending from the spinal cord. If a disruption to the spine becomes severe enough, damage to a nerve or part of the spinal cord may occur and can result in partial to total loss of bodily functions (e.g. walking, talking, and breathing, etc. . . . ). Therefore, it is of great interest and concern to be able to both correct and prevent any ailments of the spine.
Fixation systems are often surgically implanted into a patient to aid in the stabilization of a damaged spine or to aid in the correction of other spinal geometric deformities. Spinal fixation systems are often constructed as framework stabilizing a particular section of the spine. Existing systems often use a combination of rods, plates, pedicle screws and bone hooks for fixing the framework to the affected vertebrae. The configuration required for each patient varies due to the patient's specific anatomical characteristics and ailments. As a result, there is a need for a modular spinal fixation system that allows for a large degree of custom configurations and that can assist the clinician in the corrective maneuvers often needed to rehabilitate severe deformities.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a spinal anchor assembly according to one example embodiment;
FIG. 2 is an exploded view of the spinal anchor assembly of FIG. 1 ;
FIG. 3 is a partial cross section view of the spinal anchor assembly of FIG. 1 ;
FIG. 4 is a perspective view of the receiver forming a part of the spinal anchor assembly of FIG. 1 ;
FIG. 5 is a top view of one example of a closure structure;
FIG. 6 is a perspective view of the closure structure of FIG. 5 ;
FIG. 7 is a perspective cross section view of the closure structure of FIG. 5 ;
FIG. 8 is a perspective view of a collet forming part of the receiver assembly of FIG. 1 ;
FIG. 9 is a top view of the collet forming part of the receiver assembly of FIG. 1 ;
FIG. 10 is side view of the collet forming part of the receiver assembly of FIG. 1 ;
FIG. 11 is a perspective view of another spinal anchor assembly according to a second example embodiment;
FIG. 12 is a partial cross section view of the spinal anchor assembly of FIG. 11 ;
FIG. 13 is an exploded view of the spinal anchor assembly of FIG. 11 ;
FIG. 14 is a perspective view of the receiver forming a part of the spinal anchor assembly of FIG. 11 ;
FIG. 15 is a top view of the collar forming part of the receiver assembly of FIG. 11 ;
FIG. 16 is a perspective view of the collar of FIG. 15 ;
FIG. 17 a top view of the cradle forming part of the receiver assembly of FIG. 11 ;
FIG. 18 is a perspective view of the cradle of FIG. 17 ;
FIG. 19 is a perspective view of an another anchor assembly according to a third example embodiment;
FIG. 20 is an exploded view of the anchor assembly of FIG. 19 ;
FIG. 21 is a perspective view of the bone screw forming part of an anchor assembly of FIG. 19 ;
FIG. 22 is a perspective view of the bone screw of FIG. 21 forming part of an anchor assembly of FIG. 10 ;
FIG. 23 is a perspective view of a receiver forming a part of the anchor assembly of FIG. 19 ;
FIG. 24 is a perspective view of one example collar forming part of the anchor assembly of FIG. 19 ;
FIG. 25 is a perspective view of another example collar forming part of the anchor assembly of FIG. 19 ;
FIG. 26 is a partial cross section view of the collar of FIG. 24 ;
FIG. 27 is a partial cross section view of the collar of FIG. 25 ;
FIG. 28 is a top view of the collar of FIG. 24 ;
FIG. 29 is a top view of the collar of FIG. 25 ;
FIG. 30 is a partial cross section view of the anchor assembly of FIG. 19 ;
FIG. 31 is a perspective view of a partial cross section view of a spinal anchor assembly according to a fourth embodiment of the present invention
FIG. 31 is a perspective view of another spinal anchor assembly, according to a fourth example embodiment;
FIG. 32 is a partial cross section view of the spinal anchor assembly of FIG. 31 ;
FIG. 33 is a partial cross section view of the spinal anchor assembly in an unlocked position, according to a fifth embodiment of the present invention;
FIG. 34 is a partial cross section view of the spinal anchor assembly of FIG. 33 in the locked position;
FIG. 35 is a perspective view of the loading ring of FIG. 33 ;
FIG. 36 is a perspective view of the collet of FIG. 33 ;
FIG. 37 is a partial cross section view of a spinal anchor assembly in an unlocked position according to the sixth embodiment of the present invention;
FIG. 38 is a partial cross section view of the spinal anchor assembly of FIG. 37 in the locked position;
FIG. 39 is a perspective view of the split ring of FIG. 37 ;
FIG. 40 is a perspective view of the loading ring of FIG. 37 ;
FIG. 41 is a perspective view of one example of a spinal anchor assembly, according to a seventh embodiment of the present invention;
FIG. 42 is a partial cross section view of the spinal anchor assembly of FIG. 41 ;
FIG. 43 is a perspective view of one an arched transverse connector according to one example embodiment;
FIG. 44 is a top view of an arched transverse connector of FIG. 43 ;
FIG. 45 is a side view of an arched transverse connector of FIG. 43 ;
FIG. 46 is a partial section view of an arched transverse connector of FIG. 43 ;
FIG. 47 is a perspective view of an eccentric pin of the arched transverse connector of FIG. 43 ;
FIG. 48 is a side view of an eccentric pin of the arched transverse connector of FIG. 43 ;
FIG. 49 is a perspective view of an arched transverse connector according to a second example embodiment;
FIG. 50 is a cross section view of the arched transverse connector of FIG. 49 ;
FIG. 51 is a side view of an arched transverse connector according to a third example embodiment of the present invention;
FIG. 52 is a cross section view of arched transverse connector of FIG. 51 ;
FIG. 53 is an exploded view of the arched transverse connector of FIG. 51 ;
FIG. 54 is a perspective view of a slide arm of the arched transverse connector of FIG. 51 ;
FIG. 55 is a perspective view of a securing block of the arched transverse connector of FIG. 51 ;
FIG. 56 is a perspective view of a reduction tower, according to an example embodiment;
FIG. 57 is a cross section view of the reduction tower of FIG. 56 ;
FIG. 58 is a perspective view of a locking tool according to one example embodiment for use with the spinal anchor assembly of FIG. 1 ;
FIG. 59 is another perspective view of the locking tool of FIG. 58 ;
FIG. 60 is a perspective view of one example of a tooling assembly, according to a first embodiment of the present invention;
FIG. 61 is a cross section view of a tooling assembly of FIG. 60 ;
FIG. 62 is a partial cross section view of a tooling assembly of FIG. 60 ;
FIG. 63 is a perspective section view of one example of a reduction tower grasping a spinal anchor assembly and reducing a rod;
FIG. 64 is a perspective partial section view of one example of a reduction tower grasping a spinal anchor assembly and reducing a rod;
FIG. 65 is a perspective view of one example of a reduction tower, according to a second embodiment of the present invention;
FIG. 66 is a cross section view of the reduction tower of FIG. 65 ;
FIG. 67 is a perspective view of the reduction tower link in the open position;
FIG. 68 is an exploded perspective view of the reduction tower link of FIG. 67 ;
FIG. 69 is a detailed view of the ratcheting mechanism of the reduction tower link of FIG. 67 ;
FIG. 70 is a detailed view of the ratcheting mechanism with the outer and inner cylinders of FIG. 67 removed;
FIG. 71 is a perspective view of the reduction tower link of FIG. 67 with arrows indicating the direction of movement when the arms are squeezed together; and
FIG. 72 is an exemplary configuration of a deformity spinal fixation assembly.
DETAILED DESCRIPTION
Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as a compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. The spinal anchor assembly disclosed herein boasts a variety of inventive features and components that warrant patent protection, both individually and in combination.
FIG. 1 illustrates an example of a spinal anchor assembly 10 according to a first embodiment of the present invention. The spinal anchor assembly 10 includes a bone screw 11 and a receiver assembly 12 . A closure structure 13 (shown in FIGS. 5-7 ) is used to capture a rod within the receiver assembly 12 . The spinal anchor assembly 10 and closure structure 13 are composed of a metal (e.g. titanium, stainless steel, etc.).
The bone screw 11 of the present invention is configured to attach securely within a bony structure (e.g. pedicle of a vertebra) and to allow the receiver assembly 12 to provisionally lock into position relative to the bone screw 11 after placement of the bone screw 11 within a bony structure. The receiver assembly 12 and bone screw 11 are configured to engage with full polyaxial motion. The receiver assembly 12 and bone screw 11 can also be provisionally locked (that is, fixed relative to each other prior to final capture and locking of a spinal rod into the receiver), as will be described in more detail below. This versatile engagement between the receiver assembly 12 and bone screw 11 provides both the ease of positioning and rod placement associated with polyaxial screws and the ability to leverage the bone anchor 10 to manipulate the vertebral body (e.g. parallel distraction and compression and/or vertebral body derotation) associated with fixed-axis anchors.
By way of example, the bone screw 11 of the spinal anchor assembly 10 may be engaged within a pedicle of a vertebra and aligned with a spinal rod connecting other anchors. A clinician may then engage an instrument to the receiver assembly 12 and provisionally lock the screw 11 and receiver 12 . With the screw locked, the clinician can utilize the instrument to apply a force upon the vertebra to correct the deformity prior to fixing the construct and thus the spinal column in a desired position. The ability to utilize the spinal anchor assembly 10 to reposition segments of the spine to correct deformities simplifies the procedure for the clinician by limiting the amount of tools and time required.
With reference to FIGS. 1-3 , the bone screw 11 of the spinal anchor assembly 10 is comprised of a shank 17 , a body 8 , and a capture structure 16 . At least one helically-wound bone implantable thread 18 extends radially from the body 8 and functions to secure the placement of the bone screw 11 within a bony structure. The capture structure 16 includes at least one tool engaging feature 14 that can be used, for example, to engage and attach various tooling for aligning and advancing the bone screw 11 into a bony structure. The generally spherical shape of the capture structure 16 allows it, for example, to articulate within the collet 40 to achieve the polyaxial motion between the bone screw 11 and the receiver assembly 12 . The surface of the capture structure 16 may be textured (e.g. scored or knurled) for enhancing frictional engagement with the collet 40 that secures the positioning of the bone screw 11 relative to the receiver assembly 12 .
The receiver assembly 12 is configured to receive an elongate structure (e.g. a rod) and the closure structure 13 is designed to secure the rod within the receiver assembly 12 . Once the receiver assembly 12 and bone screw 11 are securely oriented in the desired orientation and the rod is captured in the receiver assembly 12 , the closure structure 13 can engaged to lock the rod in the receiver assembly 12 .
The receiver assembly 12 is typically provided in an assembled state (best shown in FIG. 3 ) and includes a receiver 20 and a retaining and articulating structure or collet 40 . The receiver 20 has a generally U-shaped appearance with a generally cylindrical inner profile and a faceted outer profile. A base 26 , with a pair of upstanding arms 29 forms a U-shaped cradle which define U-shaped openings 27 through the faceted sides of the receiver 20 . Receivers may be provided in a variety of dimensions depending on the size and shape of the rod that it will be in secured frictional engagement with.
Both arms 29 have at least one helically-wound guide and advancement structure 25 at least partially situated along their internal walls beginning from the top surface 28 end of the receiver 20 . The guide and advancement structure 25 of the receiver 20 are configured to mate with at least one exterior helically-wound guide and advancement structure 72 of the closure structure 13 . When the internal and external guide and advancement structures 25 , 72 of the closure structure 13 and receiver 20 are interlocked, their connection prevents the arms 29 of the receiver 20 from spreading open due to the mating features of the guide and advancement structures 25 and 72 . This interlocked configuration prevents splaying of the arms 29 .
As illustrated in FIG. 4 , the outer surface of the receiver 20 includes tooling attachment features, such as grip bores 21 , on the outer surface of both arms 29 which function to allow a variety of tools to engage the receiver assembly 12 for subsequent positioning and implantation of the spinal anchor assembly 10 . Additional features of the receiver 20 include two sweeping steps 38 recessed inwardly from the inside walls of the arms 29 (with one sweeping step 38 situated on each arm 29 ). The sweeping steps 38 are utilized during the assembly of the receiver assembly 12 by allowing the locking ledges 55 of the collet 40 to be guided into position within the receiver 20 . Once the collet 40 is assembled within the receiver 20 , the collet 40 is allowed limited movement. By way of example, each sweeping step 38 includes a notch 39 that prevents the locking ledge 55 from backing out of the sweeping step 38 once it has traveled past the notch 39 . Additionally, the top and bottom walls of each sweeping step 38 restricts the longitudinal translation of the collet 40 relative to the receiver by restricting the longitudinal translation of the locking ledge to only between the top and bottom walls of the sweeping step 38 . By way of example only, each sweeping step 38 spans at least a portion of the inside wall of an arm 29 and are positioned generally 180 degrees apart from one another.
Located within the base 26 of the receiver 20 is a tapered cavity 34 that is sized and shaped for slidable mating and eventual frictional engagement with the tapered feature 48 of the collet 40 , as will be described in more detail below. By way of example only, the tapered cavity 34 may have a taper of approximately 2-3 degrees (shown as angle Y in FIG. 3 ). The taper feature 48 of the collet 40 is shown as angle Z in FIG. 10 . When the collet 40 is forced generally in the direction of the base 26 of the receiver 20 along its longitudinal axis, the tapered feature 48 of the collet will become frictionally secured (wedged) within the tapered cavity 34 .
FIGS. 8-10 illustrate an example of a collet 40 according to a first embodiment. The collet 40 includes a top surface 41 , a bottom surface 42 , an inner spherical surface 49 , a tapered feature 48 , locking ledges 55 , a saddle 46 , and a tooling engagement feature 52 . Notably, the collet 40 is not continuous, and instead includes a slot 44 . The slot 44 is dimensioned to be a distance X (best shown in FIG. 9 ) and allows the collet 40 to be temporarily expanded or compressed to receive the capture structure 16 and to secure the capture structure 16 within the inner spherical surface 49 .
During assembly of the spinal anchor assembly 10 , the collet 40 receives, and permanently captures, the capture structure 16 within the inner spherical surface 49 . Once the capture structure 16 is captured within the inner spherical surface 49 , the collet 40 and associated bone screw 11 is assembled to the receiver 20 . This is accomplished by leading the distal end of the bone screw 11 through the center of the receiver until the locking ledges 55 are aligned with the sweeping step 38 of the receiver 20 . As described above, the locking ledges 55 travel along the sweeping steps 38 until they pass the notch 39 , where the collet 40 then becomes permanently limited in movement relative to the receiver 20 . At this point, the collet 40 is able to travel a limited distance along its longitudinal axis. Additionally, the bone screw 11 is able to articulate relative to the receiver assembly 12 achieve poly axial motion of the receiver assembly. By way of example, the bone screw 11 is able to articulate and form an angle between its longitudinal axis and the longitudinal axis of the receiver 20 of up to approximately 20 degrees in any direction. When the desired angular orientation is achieved, the receiver assembly 12 is locked into position relative to the bone screw 11 . For this to occur, the collet 40 is wedged into the receiver 20 which compresses the slot 44 and causes the inner spherical surface 49 to frictionally engage and secure the capture structure 16 . This permanently fixes the configuration of the receiver 20 , collet 40 , and bone screw 11 .
As discussed, the anchor assembly 10 can be both provisionally locked and finally locked. By way of a first example, the spinal anchor assembly 10 can be finally locked by driving a rod (e.g. rod 60 ) into the collet 40 and receiver 20 by engaging and advancing a closure structure 13 into the receiver 20 . As the closure structure 13 advances, the rod is forced down into the collet 40 and the collet 40 in turn is driven down and wedges into the tapered cavity 34 . At this point, the collet 40 is locked into position relative to the receiver 20 and the rod is securely locked between the closure structure 13 and collet 40 .
The spinal anchor assembly 10 can be provisionally locked by fully reducing the rod 60 ) into the collet 40 and receiver 20 with an instrument, such as the reduction tower 900 (described below). The reduction tower 900 releasably attaches to the receiver 20 and an arm directs the rod 60 into the receiver 20 , forcing the rod into the collet 40 which is driven down and wedges into the tapered cavity 34 . At this point, the collet 40 , receiver 20 , and bone screw 11 are locked into position relative to each other, however, the rod is not locked within the receiver assembly 12 , and the bone anchor can be used to adjust the position or orientation of the vertebra to which the anchor assembly 10 is attached (e.g. parallel distraction and compression or derotation). The closure structure 13 can be advanced in to the receiver 20 when it becomes desirable to secure the rod within the receiver assembly 12 .
By way of another example, the spinal anchor assembly 10 can be provisionally locked by driving a rod-like tooling feature into the rod into the collet 40 . Again, this provisional locking feature provides a platform for the clinician to utilize the screw to manipulate the position or orientation of the vertebra while still allowing the receiver to be adjusted for easier reception of the rod.
The tooling engagement features 52 of the collet 40 allow the user to unlock the anchor assembly 10 from the provisionally locked configuration, if necessary. A tool can engage the tooling engagement features 52 to, for example, compress and/or pull on the collet 40 in order to release the frictional engagement between the tapered feature 48 of the collet 40 and tapered cavity 34 of the receiver 20 .
The saddle 46 of the collet 40 provides a contouring surface for mating with a rod within the receiver assembly 12 . By way of example only (and best shown in FIG. 8 ), the saddle 46 has two U-shaped surfaces that are generally shaped to receive a rod. The saddle 46 may be any number of shapes and sizes necessary to accommodate a particular rod, without departing from the scope of this invention. Furthermore, the shape and dimensions of the collet 40 and its features may be any number of shapes and dimensions without departing from the scope of this invention.
FIGS. 5-7 illustrate one example embodiment of a closure structure 13 . The closure structure 13 is shown by way of example to include a top surface 70 , a base 71 , and at least one exterior guide and advancement structure 72 . The top surface 70 includes at least one generally recessed tool engaging feature 73 which functions to engage a variety of tooling that assist in aligning and securing the closure structure 13 to the receiver assembly 12 . A recessed slot 75 on the top surface 70 functions to provide the clinician with an aligning mechanism for screwing the closure structure 13 into the receiver 20 . For example, the recessed slot 75 of the closure structure 13 should be aligned with the recessed slot 24 of the receiver 20 prior to advancing the closure structure 13 to facilitate proper engagement. Positioned centrally within the base 71 of the closure structure 13 is a point force feature 74 that applies a point force to secure a portion of an rod (e.g. rod 60 ). The point force feature 74 deforms upon final tightening of the screw and improves resistance to translation and centers the locking stress within the receiver 12 . It will be appreciated that while the closure structure 13 shown may be preferred, closure structures utilizing a number of other suitable structures and features may be utilized without departing from the scope of this invention.
FIG. 11 illustrates an example of a spinal anchor assembly 100 according to a second embodiment of the present invention. The spinal anchor assembly 100 includes a bone screw 111 and a receiver assembly 112 . By way of one example, a closure structure 13 (shown in FIGS. 5-7 ) is used to capture a rod within the receiver assembly 112 . The spinal anchor assembly 100 is preferably composed of a metal (e.g. titanium, stainless steel, etc.).
The spinal anchor assembly 100 of the present invention is available to a clinician in a pre-assembled state such that the receiver assembly 112 is jointly attached to the capture structure 116 of the bone screw 111 . The receiver assembly 112 and bone screw 111 are able configured to engage with limited axial movement. More specifically, the receiver member 112 may articulate along a single plane (i.e. uniplanar movement), and can ultimately be secured at any number of angles within the single plane. Similar to the provisional locking anchor assembly 10 , the uniplanar engagement between the receiver assembly 112 and the bone screw 111 permits some flexibility for positioning the rod, while still providing the ability to leverage the anchor assembly to manipulate the vertebra to correct positioning and alignment of the vertebra. By way of example, the anchor assembly may be implanted such that the articulating plane is the sagittal plane (i.e. movement is cranial-caudal). Positioned as such, force may be applied to the screw in the transverse plane (i.e. medial/lateral direction) to derotate a vertebra. One advantage of limiting the angled articulation between the receiver assembly 112 and bone screw 111 to only along a single plane is so that force can be applied upon the spinal anchor assembly 100 in any direction that is along a non-articulating plane. By way of example, the bone screw 111 of the spinal anchor assembly 100 would be first secured within a pedicle of a vertebra. A clinician may engage an instrument to the receiver assembly 112 and to apply the correcting force.
With reference to FIGS. 11-13 , the spinal anchor assembly 100 is comprised of a shank 117 , a body 108 , and a capture structure 116 . At least one helically-wound bone implantable thread 118 extends radially from the body 108 and functions to secure the placement of the bone screw 111 within a bony structure. Additionally, the capture structure 116 includes flat surfaces 119 on opposing sides of the capture structure 116 . The flat surfaces 119 restrict rotation between the bone screw 111 and the collar 140 to the plane parallel to the flat side 19 . Preferably, the articulating plane is aligned with the side openings 127 such the uniplanar movement is in line with the rod.
The capture structure 116 includes at least one tool engaging feature 114 that can be used, for example, to engage and attach various tooling for aligning and advancing the bone screw 111 into a bony structure. The generally spherical shape portions of the capture structure 116 allow the capture structure 116 , for example, to articulate within the collar 140 along a single plane. The surface of the capture structure 116 may be textured (e.g. scored or knurled) for enhancing frictional engagement with the collar 140 , which assists in securing the position of the bone screw 111 relative to the receiver assembly 112 , as will be discussed in more detail below.
FIG. 12 illustrates an example embodiment of a receiver assembly 112 . The receiver assembly 112 is typically provided in an assembled state (as shown in FIGS. 11 and 12 ) and includes a receiver 120 , a retaining and articulating structure or collar 140 , and a cradle 160 . The receiver 120 has a generally U-shaped appearance with a generally cylindrical inner profile and a faceted outer profile. A base 126 , with a pair of upstanding arms 129 forms a U-shaped cradle which define U-shaped openings 127 through the faceted sides of the receiver 120 . Alternatively, receiver 120 may be provided with openings having any of a variety of shapes and dimensions depending, in part, on the size and shape of the rod to be received.
Both arms 129 have at least one helical wound guide and advancement structure 125 at least partially situated along their internal walls beginning from the top surface 128 end of the receiver 120 . The guide and advancement structure 125 of the receiver 120 are configured to mate with at least one exterior helically-wound guide and advancement structure of a closure structure (not shown in this embodiment), which assist in preventing the arms from spreading open. The closure structure 13 described in the anchor assembly 10 may be used with anchor assembly 110 to secure a portion of a rod within a receiver assembly 112 . Again, it should be appreciated that while the closure structure 13 shown may be preferred, closure structures utilizing a number of other suitable structures and features may be utilized without departing from the scope of this invention.
The outer surface of the receiver 120 includes tooling attachment features, such as grip bores 121 , on the outer surface of both arms 129 . Grip bores 121 function, for example, to allow a variety of tools to engage the receiver assembly 112 for subsequent implantation and positioning of the receiver assembly 112 and spinal anchor assembly 100 . Additional features of the receiver 120 include two steps 138 extending inwardly from the inside walls of the arms 129 (with one step 138 situated on each arm 129 ). By way of example only, each step 138 spans at least a portion of the inside wall of an arm 129 and is positioned generally 180 degrees apart from the other. Located within the base 126 end of the receiver 120 is a cavity that is defined by a generally spherical surface and is sized and shaped for slidable mating and eventual frictional engagement with the retaining and articulating structure or collar 140 , as described below. Along the walls of the cavity within the base 126 of the receiver is a pair of rounded pivot features 135 . The rounded pivot features 135 are located approximately 180 degrees apart from one another the wings 147 of the collar 140 and permit the collar 140 to articulate generally along a single plane.
FIGS. 15-16 illustrate an example of an embodiment of a retaining and articulating structure or collar 140 . The collar 140 is comprised of a top surface 141 , a bottom surface 149 , an outer convex surface 152 , an inner concave surface 145 , and a radial protrusion 148 . Notably, the collar 140 is not continuous, and instead includes a slot 144 extending from the top surface 141 to bottom surface 149 . The length of the slot 144 is dimensioned to be a distance X (best shown in FIG. 16 ) and allows the collar 140 to be temporarily expanded or compressed to secure the collar 140 around the capture structure 160 , as described below.
Wings 147 protrude from opposing sides of the outer convex surface 152 of the collar 140 . The wings 147 and are sized and shaped to mate with the pivot feature 135 of the receiver 120 . By way of example, the wings 147 may be D-shaped, but may be any size and shape suitable for directing and limiting the pivot direction of the collar 140 (and associated bone screw 111 ). When mated, the wings 147 assist in both positioning the collar 140 within the receiver 120 and restricting the pivot directions of the collar 140 to along a single plane. The wings 147 also restrict relative rotation between the collar 140 and receiver 120 along their longitudinal axis. The bone screw 111 and associated collar 140 are able to pivot relative to the receiver 120 along a single plane for subsequent secure positioning and implantation. Interior protrusions 108 extend inwardly from opposing sides of the inner concave surface 145 of the collar 140 . The interior protrusions 108 function to mate with the flat surfaces 119 on a capture structure 116 to prevent the rotation of a bone screw 111 relative to the collar 140 along their longitudinal axis.
FIGS. 17-18 illustrate an example embodiment of a cradle 160 . The cradle 160 is comprised of a top surface 167 , spherical inner walls 166 , concave supports 165 , and a base 168 . Additional features of the cradle 160 include first outer diameter notches 163 , second outer diameter notches 191 , locking protuberances 190 , a central opening 164 , locking ledges 162 , and tool engaging features 161 . As previously noted, the receiver assembly 112 is typically acquired by a user in an assembled state. Furthermore, before the cradle 160 is assembled to the receiver 120 , the collar 140 is first assembled to the receiver 120 .
During assembly of the receiver assembly 112 , the collar 140 is positioned within the base of the receiver 120 so that the outer convex surface 152 rests generally along the spherical cavity located within the base 126 of the receiver 120 . The collar 140 is positioned within the receiver 120 such that the top surface 141 of the collar 140 is facing the top surface 128 of the receiver 120 . Even when the collar 140 is in its circumferentially compressed state, the collar 140 cannot exit the receiver 120 through its central opening 137 . Additionally, the pair of wings 147 protruding from the outer convex surface 152 of the collar 140 is generally mated with the pair of rounded pivot features 135 within the receiver. As mentioned above, the wings 147 mated with the pivot features 135 function to secure the positioning of the collar 140 and permit the collar 140 to articulate generally along a single plane relative to the receiver 120 .
Once the collar 140 is assembled to the receiver 120 , the cradle 160 can then be placed above the receiver 120 such that the bottom surface 26 of the cradle 160 is facing the top surface 28 of the receiver 120 . The cradle 160 is then dropped into the center of the receiver 120 (between the arms 129 ) until the cradle 160 rests generally circumferentially within the round inner walls of the receiver 120 and the base 168 of the cradle 160 sits on the steps 138 . The cradle 160 is then aligned (a tool may be engaged into the tool engaging features 161 to accomplish this) so that the first outer diameter notches 163 of the cradle 160 are aligned over the steps 138 of the receiver 120 . This allows the cradle 160 to travel past the steps 138 towards the base 126 of the receiver 120 until the base 168 of the locking ledges 162 rest against the inside wall of the receiver 120 and prevent the cradle 160 from traveling further down towards the bottom surface 126 end of the receiver 120 . At this point, the cradle 160 can be rotated along its central axis in the clockwise direction (again, a tool may be engaged into the tool engaging features 161 to accomplish this) so that the locking ledges 162 travel clockwise beneath the steps 138 of the receiver 120 . The cradle 160 is rotated clockwise until the steps 138 are forced past the locking protuberances 190 of the cradle 160 and the steps 138 are situated within the second outer diameter notches 191 . When the steps 138 of the receiver are situated within the second outer diameter notches 191 , the cradle 160 is permanently secured into place and the receiver assembly 112 is generally complete (and best shown in FIG. 12 ).
The final step in assembling the spinal anchor assembly 100 during manufacturing and before being released for use is assembling the bone screw 111 to the receiver assembly 112 . To accomplish this, a capture structure 116 of a bone screw 111 is generally concentrically aligned with the central opening 137 of a receiver. The capture structure 116 is then passed through the central opening 137 of the receiver 120 , which has a larger diameter than the capture structure 116 .
As the capture structure 116 passes through the central opening 137 it pushes against the bottom surface 149 of the collar 140 until the collar 140 is pushing up against the base 168 of the cradle 160 . The capture structure 116 can then advance past the inner chamfer 46 of the collar 140 by forcing the collar 140 to increase circumferentially (by further lengthening the slot 144 ) until the largest diameter of the capture structure 116 passes through the inner protruding ring 151 . Once the capture structure 116 passes through the inner protruding ring 151 , the collar 140 begins to generally return to its original circumference and capture the capture structure 116 (best shown in FIG. 12 ). Proper orientation is ensured such that the interior protrusions 108 are mated with the flat surfaces 119 on the capture structure 116 .
At this point, the connection between the bone screw 111 and receiver assembly 120 resembles a ball-and-socket joint, but with limited articulation to only along a single plane. More specifically, the capture structure 116 is free to articulate along a single plane relative to the collar 140 and the collar is able to articulate along a single plane relative to the receiver 120 . Thus, the collar 140 , bone screw 111 and receiver 120 are able to articulate relative to each other along a single plane until they are locked into position. By way of example, the bone screw is able to articulate and form an angle between its longitudinal axis and the longitudinal axis of the receiver 120 of approximately 30 degrees in either direction, for a total of 60 degrees of movement) in the articulating plane.
Therefore, a clinician may configure a spinal fixation system using at least one spinal anchor assembly 100 , at least one additional bone screw assembly (i.e. fixed, provisionally locking, polyaxial), and at least one rod. The clinician is able to easily align the rod with the receiver assembly 112 of the spinal anchor assembly 100 . Additionally, the clinician may leverage the uniplanar screw to direct a correcting force to the associated vertebra to correct positioning or alignment of the vertebra (e.g. derotation). Thereafter, the closure structure 13 can be engaged to press the rod against the cradle 160 , which in turn presses the capture structure 116 against collar 140 , and the collar 140 against the receiver 112 . Ultimately, the frictional engagement between the closure structure 13 , rod, cradle 160 , capture structure 116 , cradle 140 , and cavity of the receiver 120 are such that the bone screw 111 and receiver assembly 112 are secured in a desired final position relative to each other.
FIGS. 19-30 illustrate an example of a spinal anchor assembly 200 according another embodiment of a uniplanar spinal anchor. The spinal anchor assembly 200 includes a bone screw 211 , a receiver assembly 212 , and a closure structure 13 (shown in FIGS. 5-7 ). The spinal anchor assembly 200 is preferably composed of a metal (e.g. titanium, stainless steel, etc.).
The bone screw 211 of the present invention is configured to securely engage within a bony structure (e.g. pedicle of a vertebra). The receiver assembly 212 is able to articulate relative to the bone screw 211 along a single plane. This uniplanar engagement between the receiver assembly 212 and the bone screw 211 permits some flexibility for positioning the rod, while still providing the ability to leverage the anchor assembly 200 to manipulate the vertebra to correct positioning and alignment of the vertebra. By way of example, the anchor assembly may be implanted such that the articulating plane is the sagittal plane (i.e. movement is cranial-caudal). Positioned as such, force may be applied to the screw in the transverse plane (i.e. medial/lateral direction) to derotate a vertebra.
FIG. 21 illustrates an example embodiment of the bone screw 211 . The bone screw 211 of the spinal anchor assembly 200 is comprised of a shank 217 , a body 208 , and a capture structure 216 . At least one helically-wound bone implantable thread 218 extends radially from the body 208 and functions to secure the placement of the bone screw 211 within a bony structure. Additionally, the capture structure 216 includes flat surfaces 219 on opposing sides of the capture structure 216 . The flat surfaces 219 function to assist in restricting the rotation between the bone screw 211 and the collar 240 along its longitudinal axis, as will be discussed in more detail below.
The capture structure 216 includes at least one tool engaging feature that can be used, for example, to engage and attach various tooling for aligning and advancing the bone screw 211 into a bony structure. The generally spherically-shaped portions 215 of the capture structure 216 allow the capture structure 216 , for example, to articulate within the collar 240 along a single plane. The surface of the capture structure 216 may be textured (e.g. scored or knurled) for enhancing frictional engagement with the collar 240 , which assists in securing the position of the bone screw 211 relative to the receiver assembly 212 , as will be discussed in more detail below.
FIGS. 23 and 30 illustrate an example embodiment of a receiver assembly 212 . The receiver assembly 212 is typically provided in an assembled state (as shown in FIG. 19 ) and includes a receiver 220 , a retaining and articulating structure or collar 240 , and a cradle 160 . The receiver 220 has a generally U-shaped appearance with a generally cylindrical inner profile and a faceted outer profile. A base 226 , with a pair of upstanding arms 229 forms a U-shaped cradle which define U-shaped openings 227 through the faceted sides of the receiver 220 . It will be appreciated however, that receiver 220 may be provided having side openings selected from variety of suitable shapes and dimensions depending, in part, on the size and shape of the rod to be received.
Both arms 229 have at least one helical wound guide and advancement structure 225 at least partially situated along their internal walls beginning from the top surface 228 end of the receiver 220 . The guide and advancement structure 225 of the receiver 220 are configured to mate with at least one exterior helically-wound guide and advancement structure of a closure structure (not shown in this embodiment), which assist in preventing the arms from spreading open. The closure structure 13 described in the first embodiment may be used with this second embodiment of the present invention to achieve the securing of at least a portion of a rod within a receiver assembly 212 . Moreover, any variation of closure structures may be used to secure at least a portion of a rod within the receiver assembly 212 , without departing from the scope of this invention.
The outer surface of the receiver 220 includes tooling attachment features, such as grip bores 221 , on the outer surface of both arms 229 . Grip bores 221 function, for example, to allow a variety of tools to engage the receiver assembly 212 for subsequent implantation and positioning of the receiver assembly 212 and screw assembly 200 . Additional features of the receiver 220 include two steps 238 extending inwardly from the inside walls of the arms 229 (with one step 238 situated on each arm 229 ). By way of example only, each step 238 spans at least a portion of the inside wall of an arm 229 and are positioned generally 180 degrees apart from each other. Located within the base 126 end of the receiver 120 is a cavity that is defined by a generally spherical surface and is sized and shaped for slidable mating and eventual frictional engagement with collar 240 , as described below. Along the walls of the cavity within the base 226 of the receiver is a pair of rounded features 235 . The rounded features 235 are located approximately 180 degrees apart from each other and function to secure the positioning of the collar 240 .
FIGS. 24-29 illustrate example embodiments of a retaining and articulating structure or collar 240 . The collar 240 is comprised of a top surface 241 , a bottom surface 249 , an outer convex surface 252 , an inner concave surface 245 , an interior faceted surface 246 , and an exterior faceted surface 248 .
In its preferred embodiment, the bone screw 211 may be assembled to the receiver assembly 212 by passing the distal end of the bone screw through the top opening of the receiver 212 and collar 240 (and before the cradle is assembled to the receiver 220 ) until the capture structure 216 is resting in the collar 240 (which is resting in the base of the receiver 220 ) forming collar assembly 280 . In one embodiment of collar 240 , the inner concave surfaces 245 has helical recesses 247 shaped into said inner concave surface 245 . Helical recesses 247 facilitate the placement of the bone screw 211 through the aperture 255 of the collar 240 . By way of example, helical recesses 247 allow for screws whose advancement structure 218 have diameters larger than aperture 255 to be used in bone screw assembly 200 . The helical thread 218 of a large diameter bone screw is threaded through helical recesses 247 until shank 217 has passed through the aperture 255 of collar 240 . Proper orientation is ensured such that the interior faceted surface 246 are mated with the flat surfaces 219 on the capture structure 216 .
Exterior faceted surfaces 248 are situated on opposing sides of the outer convex surface 252 of the collar 240 . Exterior faceted surface 248 is sized and shaped to mate with the rounded feature 235 of the receiver 220 . By way of example, the exterior faceted surfaces 248 may be D-shaped, but may be any size and shape suitable for limiting the movement of the collar 240 (and associated bone screw 211 ). When mated, the exterior faceted surface 248 assist in positioning the collar 240 within the receiver 220 . The bone screw 211 is able to pivot relative to the receiver 220 along a single plane for subsequent secure positioning and implantation, as described above and will be described in more detail below. Interior faceted surfaces 246 situated inwardly on opposing sides of the inner concave surface 245 of the collar 240 . By way of example, the interior faceted surfaces 246 may be D-shaped, but may be any size and shape suitable for directing and limiting the pivot direction of the capture structure 216 (and associated bone screw 211 ). The interior faceted surfaces 246 function to mate with the flat surfaces 219 on a capture structure 216 to prevent the rotation of a bone screw 211 relative to the collar 240 along their longitudinal axis.
Furthermore, the cradle 260 in the present embodiment is generally identical in feature and function as the cradle 60 described in the second embodiment, and thus will not be repeated in detail again here.
At this point, the connection between the bone screw 211 and receiver assembly 220 resembles a ball-and-socket joint, but with limited articulation in only a single plane. More specifically, the capture structure 216 is free to articulate along a single plane relative to the collar 240 . The collar 240 , bone screw 211 and receiver 220 are able to articulate relative to each other along a single plane until they are locked into position, as will be described in detail below. By way of example, the bone screw is able to articulate and form an angle between its longitudinal axis and the longitudinal axis of the receiver 220 of approximately 30 degrees in either direction, for a total of 60 degrees, along the single articulating plane.
Therefore, a clinician may configure a spinal fixation system using at least one spinal anchor assembly 200 , at least one additional bone screw assembly of any variety of constraints (e.g. fixed, provisionally locking, polyaxial), and at least one rod. The clinician is able to easily align the rod with the receiver assembly 212 of the spinal anchor assembly 200 . Additionally, the clinician may leverage the uniplanar screw to direct a correcting force to the associated vertebra to correct positioning or alignment of the vertebra (e.g. derotation). Thereafter, the closure structure 13 can be engaged to press the rod against the cradle 160 , which in turn presses the capture structure 216 against collar 240 , and the collar 240 against the receiver 212 . Ultimately, the frictional engagement between the closure structure 13 , rod, cradle 260 , capture structure 216 , cradle 240 , and cavity of the receiver 220 are such that the bone screw 111 and receiver assembly 112 are secured in a desired final position relative to each other.
FIGS. 31 and 32 illustrate an example of a spinal anchor assembly 300 according to another embodiment of the present invention. The spinal anchor assembly 300 includes a bone screw 311 , and a receiver assembly 312 . The spinal anchor assembly 300 is preferably composed of a metal (e.g. titanium, stainless steel, etc.). The spinal anchor assembly 300 may be available to a clinician in a pre-assembled state such that the receiver assembly 312 is jointly attached to the capture structure 316 of the bone screw 311 and has full polyaxial motion. That is, the receiver assembly 312 and bone screw 311 are able to articulate in all directions and can ultimately be secured at any number of angles relative to each other and in any directions.
When the desired angular orientation is achieved to facilitate rod capture and the rod is received therein, the receiver assembly 312 is locked into position relative to the bone screw 311 . For this to occur, a closure structure 13 is engaged and presses down on the rod which presses down on the cradle 360 which presses down on the capture structure 316 . The capture structure presses down on the collet 340 and collet in turn presses into the receiver 320 which compresses the slot 344 and causes the inner spherical surface 349 to frictionally engage and secure the capture structure 316 . This permanently fixes the orientation of the receiver 320 relative to the bone screw 311 .
The bone screw 311 of the present invention is configured to attach securely within a bony structure (e.g. pedicle of a vertebra) with the receiver assembly 312 assembled to the capture structure 316 of the bone screw 311 . The receiver assembly and bone screw 311 are configured to engage in with full polyaxial motion. This polyaxial engagement between the receiver assembly 312 and bone screw 311 provides for simplified positioning and rod placement. The receiver assembly 312 is configured to receive a rod and a closure structure 13 secures the rod within the receiver assembly 312 . Once the rod is positioned in the receiver assembly 312 a closure structure 13 will lock the rod in the receiver assembly 312 , which also inhibits additional movement between the receiver assembly 312 and the bone screw 311 .
The bone screw 311 of the spinal anchor assembly 300 is comprised of a shank 317 , a body 308 , and a capture structure 316 . At least one helically-wound bone implantable thread 318 extends radially from the body 308 and functions to secure the placement of the bone screw 311 within a bony structure. The generally spherical shape of the capture structure 316 allows it, for example, to ultimately be frictionally engaged with the generally spherical features within the receiver assembly 312 . The surface of the capture structure 316 may be textured (e.g. scored or knurled) for enhancing frictional engagement with the retaining and articulating structure or collar 340 .
The receiver assembly 312 is typically provided in an assembled state and includes a receiver 320 , a retaining and articulating structure or collar 340 , and a cradle 360 . The receiver 320 has a generally U-shaped appearance with a generally cylindrical inner profile and a faceted outer profile. A base 326 , with a pair of upstanding arms 329 forms a U-shaped cradle which define U-shaped openings 327 through the faceted sides of the receiver 320 . It should be appreciated that side openings in the receiver may be provided in a variety of suitable shapes and dimensions depending on the size and shape of the rod to be received. Both arms 329 have at least one helically-wound guide and advancement structure 325 at least partially situated along their internal walls beginning from the top surface 328 end of the receiver 320 . The guide and advancement structure 325 of the receiver 320 are configured to mate with at least one exterior helically wound guide and advancement structure 72 of the closure structure 13 . Although an embodiment of a closure structure is described in detail herein, any number of closure structures may be used without departing from the scope of this invention. When the internal and external guide and advancement structures 325 , 72 of the closure structure 13 and receiver 320 are interlocked, their connection prevents the arms 329 of the receiver 320 from spreading open due to the mating features of the guide and advancement structures 325 and 72 . This interlocked configuration prevents splaying of the arms 329 .
The outer surface of the receiver 320 includes tooling attachment features, such as grip bores 321 on the outer surface of both arms 329 . These tooling attachment features function, for example, to allow a variety of tools to engage the receiver assembly 312 . Additional features of the receiver 320 include two steps 338 extending inwardly from the inside walls of the arms 329 (with one step 338 situated on each arm 329 ). By way of example only, each step 338 spans at least a portion of the inside wall of an arm 329 and are positioned generally 180 degrees apart from each other. Located within the base 326 end of the receiver 320 is a cavity that is defined by a generally spherical surface which is sized and shaped for slidable mating and eventual frictional engagement with the retaining and articulating structure or collar 340 , as described below.
The collar 340 is comprised of a top surface 341 , a bottom surface 349 , an outer convex surface 352 , an inner concave surface 345 , and a radial protrusion 348 . Notably, the collar 340 is not continuous, and instead includes a slot (similar to the slot 44 discussed and illustrated in the second embodiment of the spinal anchor assembly 300 ) extending from the top surface 341 to bottom 342 . The slot is dimensioned to be a distance X and allows the collar 340 to be temporarily expanded or compressed to receive the capture structure 316 and to secure the collar 340 around the capture structure 316 , similar to the collar 40 described above, and thus will not be repeated in detail again here. Furthermore, the cradle 360 in the present embodiment is generally identical in feature and function as the cradle 60 described in the second embodiment, and thus will not be repeated in detail again here.
As discussed above, the connection between the bone screw 311 and receiver assembly 320 resembles a ball-and-socket joint before being locked into a configuration. This ball-and-socket characteristic enables the receiver assembly 320 to accommodate and capture a rod by rotating to achieve various angular positions relative to the fixed bone screw 311 . Therefore, as a clinician configures a spinal fixation system using at least one polyaxial bone screw assembly 300 , at least one additional bone screw assembly (i.e. fixed, provisional locking, polyaxial), and at least one rod, the clinician is able to easily align the rod with the receiver assembly 312 of the spinal anchor assembly 300 . The steps for locking in place of the spinal anchor assembly 300 in a desired position, in addition to the locking of the spinal anchor assembly 300 with the rod(s) are generally the same as the steps detailed in the second embodiment of the spinal anchor assembly 200 , and thus will not be repeated here.
FIGS. 33-36 illustrate an example of a spinal anchor assembly 1400 according to another embodiment of a provisional locking assembly. The spinal anchor assembly 1400 includes a bone screw 1410 and a receiver assembly 1412 similar in functions and features to the embodiment of the spinal anchor assembly 10 disclosed herein. Like features and functions will not be repeated. The spinal anchor assembly 1400 differs from the spinal anchor assembly 10 in that it includes a load ring 1414 engaged with the collet 1416 ( FIGS. 33-34 ).
As shown in FIG. 35 , the load ring 1412 snaps into the collet 1416 and prevents the collet 1416 from compressing on the bone screw 1410 and or capture structure 13 . This allows the polyaxial motion of the bone screw 1410 relative to the receiver assembly 1412 to be maintained even after reduction of the collet 1416 into the receiver 1418 . Thus, the collet 1416 can become securely engaged (or wedged) into the receiver 1418 while the bone screw 1410 is able to still articulate within the collet 1416 to provide full polyaxial motion between the bone screw 1410 and receiver assembly 1412 .
When sufficient force is applied onto the load ring 1414 , the load ring 1414 disengages from the collet 1416 (as shown in FIG. 35 ), thus enabling the collet 1416 to securely engage the capture structure 1420 of the bone screw 1410 , which inhibits additional movement between the receiver assembly 1412 and the bone screw 1411 .
FIGS. 37-40 illustrate an example of a spinal anchor assembly 1500 according still another embodiment of invention provisional locking assembly. The spinal anchor assembly 1500 includes a bone screw 1510 and a receiver assembly 1512 similar in functions and features to the embodiment of the spinal anchor assembly 1410 . Like features and functions will not be repeated here. The spinal anchor assembly 1500 differs from the spinal anchor assembly 10 in that it includes a load ring 1514 and a split ring 1516 (as shown in FIGS. 39-40 ).
The loading ring 1514 snaps into the split ring 1516 and prevents the split ring 1516 from compressing on the bone screw 1510 and/or capture structure 1518 of the bone screw 1510 . This allows the polyaxial motion of the bone screw 1510 relative to the receiver assembly 1512 to be maintained even after reduction of the split ring 1516 into the receiver 1520 . Thus, the split ring 1516 can become securely engaged (or wedged) into the receiver 1520 while the bone screw 1510 is able to still articulate within the split ring 1516 .
To lock the receiver assembly 1512 relative to the bone screw 1511 , additional force is applied by engaging a capture structure 1518 (or lock screw) into the receiver assembly 1512 . As the capture structure 1518 is further engaged into the receiver 1514 , the bottom surface 71 of the closure structure 1518 is forced down upon the spring elements 1522 of the loading ring 1514 (best shown in FIGS. 37-38 ). As the spring elements 1522 compress, they apply increasing force onto the split ring 1516 , thus permanently fixing the position of the bone screw 1510 relative to the receiver assembly 1512 . Furthermore, the bottom surface 71 of the capture structure 13 forces down upon the captured rod. Ultimately, the rod 60 , receiver assembly 1512 , and bone screw 1510 will be finally fixed relative to each other.
FIGS. 41 and 42 illustrate an example of a spinal anchor assembly 400 according to a seventh embodiment. The spinal anchor assembly 400 includes a bone screw 411 , a receiver assembly 412 having a collar 440 and a cradle 460 . The spinal anchor assembly 400 is largely similar to the spinal anchor assembly 300 and like features will not be further described herein. The spinal anchor assembly 400 differs from the spinal anchor assembly 300 in that it includes a close-topped receiver assembly 412 . The close topped receiver assembly 412 includes circular openings 427 to receive the rod. The rods slide through the circular shaped openings 427 and are locked with a closure structure. Any number of closure structures (including the closure structure 13 described herein) may be engaged into the receiver assembly 412 to secure the rod. Because the receiver assembly 412 is closed, the closure member may preferably be void of anti-splay features.
FIGS. 43-48 illustrate an example of an arched transverse connector 500 according to one example embodiment. The arched transverse connector 500 connects two rods that form a part of a spinal fixation assembly (for an example, refer to FIG. 72 ) situated on either side of the spinal column. The arched transverse connector 500 includes a cross joint 502 with an eccentric pin 504 , and a pair of connector heads 506 located at the distal ends of connector arms 508 . The eccentric pin 504 in the cross joint 502 enables a user to simply lengthen and shorten the distance between the arched recesses 510 along the tubular joint collar 512 . Rotation of the eccentric pin 504 locks and unlocks the cross joint 502 to prohibit or allow translation of one connector arm relative to the other.
The transverse connector 500 is generally arched (as best viewed in FIGS. 43 and 45 ) with the cross connector arms 508 following a radial arc. The generally arched shape of the transverse connector 500 avoids any unnecessary dural impingement when the arched transverse connector 500 is implanted. This is particularly important when the arched transverse connector 500 is assembled to a posterior spinal fixation assembly. By way of example only, the distance between the center of the arched recesses 510 may range approximately between 25-100 mm (and shown as dimension X in FIG. 45 ). Preferably, the arched transverse connector 500 is composed of a metal (e.g. titanium, stainless steel, etc.), but may also be of a polymer (e.g. poly-ether-ether-ketone (PEEK)) or any other material suitable for the applications of the present invention. Additionally, the arched transverse connector 500 may be composed of a combination of both metal and polymer materials.
Each connector head 506 includes an eccentric pin 514 that is retained within a cavity 516 of the housing by a retaining c-ring 518 . The cavity 516 extends generally perpendicular from the front surface 520 of the connector head 506 to at least partially through the connector head 506 . The retaining c-ring 518 engages the circumferential step 522 on the outer surface of the eccentric pin 514 and the annular step 524 within the cavity 516 , which restricts longitudinal movement of the eccentric pin 514 relative to the cavity 516 . The engagement of the retaining c-ring 520 allows rotational movement of the eccentric pin 524 relative to the cavity 526 . A connector head 506 includes an arched recess 520 that is shaped and dimensioned to allow the secure placement of a rod (e.g. rod). By way of example, rotation of the eccentric pin 514 secures a portion of a rod within an arched recess, as will be described in greater detail below.
The surfaces within the arched recesses 510 provide frictional engagement to a rod when eccentric pins 514 engage the rod along their engagement surfaces 526 . Furthermore, the engagement surface 526 of the eccentric pins 514 and/or the surfaces within the arched recesses 510 may have surface features, or surface roughening, to enhance the frictional engagement between the arched transverse connector 500 and rods for enhanced security. By way of example, the eccentric pin 514 is shown as having a generally annular concavity to its engagement surface 526 (and best shown in FIG. 48 ). The generally annular concavity allows for a greater surface area contact between the eccentric pin 514 and a generally cylindrical shaped rod. However, the engagement surface 526 of an eccentric pin 514 may be provided in a variety of shapes and dimensions necessary for providing optimal contact between a variety of shaped and sized rods, without departing from the scope of this invention. For example, pin 504 may be threadably received through an end of the connector arm 508 , such that as it is threaded into the connector arm, it squeezes the cross joint 502 to prohibit translation of the cross arms.
An eccentric pin 514 includes a top surface 528 , a bottom surface 530 , an engagement surface 526 and a positioning indicator 532 . A tooling engaging feature 534 is centrally positioned along the top surface 528 , which enables a variety of tools to engage the eccentric pin 514 and rotate it along its longitudinal axis (labeled as axis Y in FIG. 48 ). At least one positioning indicator 532 indicates to the user the relative rotational positioning of the eccentric pin 514 relative to the connector head 506 . Additionally, at least one positioning indicator 536 may be on the front surface 520 of the connector head 506 to further assist the user in properly aligning the eccentric pin 514 relative to the connector head 506 , for example, to securely engage a rod. By way of example, if the user aligns the positioning indicators 532 , 536 of the eccentric pin and the connector head 506 adjacent to each other, the eccentric pin 514 will be in the appropriate rotational position relative to the connector head 506 to securely engage an rod within the adjacent arched recess 510 . By way of further example, if the user rotates the eccentric pin 514 approximately 180 degrees from the previously described position (such that the positioning indicators 532 and 536 are aligned but not adjacent to each other), the eccentric pin 512 will be in the appropriate rotational position relative to the connector head 506 to release or accept an rod within the adjacent arched recess 510 .
FIGS. 46-48 further illustrate the eccentric pin 514 , which includes a positional stop 538 and a locking protuberance 540 that radially extend out along a portion of the circumference of the top surface 528 . The locking protuberance 540 locks the rotational positioning of the eccentric pin 514 once the locking protuberance 540 has passed a head notch 542 (and best shown in FIG. 44 ). This helps prevent the eccentric pin 514 from unfavorably rotating and releasing the rod from the associated arched recess 510 . The positional stop 538 functions to limit the rotation of the eccentric pin 514 when the positional stop 538 comes into contact with the bumper 544 .
Furthermore, the eccentric pin 514 includes an annular recess 546 centrally located along the longitudinal axis (Y) and adjacent the bottom surface 530 of the eccentric pin 514 . The annular recess 546 functions to support the positioning of the bottom end of the eccentric pin 516 against the ledge 548 of the connector head 506 . Specifically, since the eccentric pin 506 is generally eccentric, the annular recess 546 is a non-eccentric feature which maintains the alignment of the eccentric pin 514 within the connector head 506 . Upon rotation of the eccentric pin 514 along its central axis within the connector head 506 , the eccentric body of the pin acts as a cam and forces the protruding side of the eccentric pin 515 (relative to its longitudinal axis Y) against an rod captured in the associated arched recess 510 .
Assembly of the arched transverse connector 500 to a pair of rods (i.e. rods) begins with a section of a first rod being captured within an unlocked first arched recess 510 and then a section of a second rod is captured within an unlocked second arched recess 510 . The arched transverse connector 500 is then operated by rotating the eccentric pins 514 into their locked positions to permanently secure the rods as described above.
FIGS. 49-50 illustrate another example embodiment of an arched transverse connector 600 . The arched transverse connector 600 is assembled during a surgical procedure to two rods and provides support between at least two rods that form a part of a spinal fixation assembly (for an example, refer to FIG. 72 ). The arched transverse connector 600 includes an eccentric pin 602 , a pair of connector heads 604 , and connector bridge 606 .
The transverse connector 600 is generally arched (as best viewed in FIG. 50 ) with the center axis of the connector bridge following a radial arc. The generally arched shape of the transverse connector 600 assists in avoiding any unnecessary dural impingement once the arched transverse connector 600 is implanted, particularly when the arched transverse connector 600 is assembled to a posterior spinal fixation assembly. Preferably, the arched transverse connector 600 is composed of a metal (e.g. titanium, stainless steel, etc.), but may also be of a polymer (e.g. poly-ether-ether-ketone (PEEK)) or any other material suitable for the applications of the present invention. Additionally, the arched transverse connector 600 may be composed of a combination of both metal and polymer materials.
This embodiment has minimal moving parts so that a clinician may optionally perform a minimal amount of adjustments to secure the arched transverse connector 600 to a pair of rods. Each connector head 604 includes an eccentric pin 602 that is retained within a cavity 608 of the housing by a retaining c-ring 610 . The cavity 610 extends generally perpendicular from the front surface 612 of the connector head 604 to at least partially through the connector head 604 . The retaining c-ring 610 and eccentric pin 623 have essentially the same features and functions as the retaining c-ring 518 and eccentric pin 514 of the first embodiment of the arched transverse connector 500 , such that their descriptions will not be repeated here. Similarly, the connector heads 604 (which include, for example, positioning indicators 614 and annular recess 616 ) have essentially the same features and functions as the connector heads 506 of the first embodiment of the arched transverse connector 500 , such that their descriptions will also not be repeated here.
FIGS. 51-55 illustrate another example embodiment of an arched transverse connector 700 . The arched transverse connector 700 is assembled during a surgical procedure to two rods (e.g. rods 60 ) and provides support between at least two rods that form a part of a spinal fixation assembly (for an example, refer to FIG. 72 ). This embodiment of the arched transverse connector 700 enables the user to configure it in a multitude of configurations so that the arched transverse connector 700 may best accommodate the rods that it may attach to. The arched transverse connector 700 includes set screws 702 , a pair of housings 704 , connector arms 706 , and a set of securing blocks 708 . The arched transverse connector 700 has a number of adjustable connections, including; between the two connector arms 708 , and between the housings 706 and connector arms 708 . These adjustable connections enable various degrees of movement and linear translation of the arched transverse connector 700 , which will be discussed in more detail below.
The transverse connector 700 is generally arched (as best viewed in FIGS. 51 and 52 ) with the center axis of the connector arms 706 following a radial arc. The generally arched shape of the transverse connector 700 assists in avoiding any unnecessary dural impingement once the arched transverse connector 700 is implanted. This is particularly the case when the arched transverse connector 700 is assembled to a posterior spinal fixation assembly. Preferably, the arched transverse connector 700 is composed of a metal (e.g. titanium, stainless steel, etc.), but may also be of a polymer (e.g. poly-ether-ether-ketone (PEEK)) or any other material suitable for the applications of the present invention. Additionally, the arched transverse connector 700 may be composed of a combination of both metal and polymer materials.
The housing 704 includes a partially threaded cavity 710 which extends generally at an angle from the front surface 712 of the housing 704 to at least partially through the housing 704 . The partially threaded cavity 710 provides at least one internal helical thread 714 for the engaging and advancing a set screw 702 into the housing 704 . The advancement of the set screw 702 into the housing 704 assists in binding the securing block 708 and a rod captured within the arched recess 716 of the housing 704 , as will be described in greater detail below.
Permanently securing the placement of rods within the arched recesses 716 involves further engagement of the set screws 702 into the housings 704 and associated securing blocks 708 . When a set screw 702 is further engaged into a housing 704 and associated securing block 708 , the securing block 708 binds a number of components within the arched transverse connector 700 . This ultimately results in the secure engagement of a rod within the arched recesses 716 and locking the configuration of the arched transverse connector 700 , which will be discussed in more detail below. Although the arched recesses 716 are shown as having an arched profile, any size and shaped recess suitable for securing any size and shaped rod can be implemented into the housing 704 without departing from the scope of the present invention.
At least one exterior helical thread 714 radially extends from the outer surface of the set screw 702 which allows the set screw 702 to engage and advance into the housing 704 . Upon advancement of the set screw 702 along its central axis into the housing 704 and associated securing block 708 , the securing block becomes bound into the housing 704 . The set screw 702 threadably engages the securing block 708 by way of the threaded through hole 718 of the securing block 708 . If a rod is captured within the arched recess 716 , the securing block also secures the rod within the arched recess 716 . The securing block includes a tongue 720 which at least partially functions to capture and securely engage a rod within the arched recess when the securing block 708 is bound to the housing 704 . Surface features on the engagement surfaces 722 of the securing blocks 708 and on the arched recesses 716 may be used to increase the frictional engagement between the securing blocks 708 , housing 704 , and rods.
Engagement of a set screw 702 into the housing 704 and associated securing block 708 also locks the configuration between the housing 704 and the adjacent connector arm 706 . The distal end of a connector arm 706 includes a spherical joint 724 and a keying feature 726 . The spherical joint 724 enables the connector arm 706 to articulate relative to the housing 704 . The keying feature 726 restricts the radial articulation of the housing 704 relative to the connector arm 706 so that there is not an unnecessary amount of articulation between the connector arm 706 and housing 704 . By way of example, the housing 704 is able to rotate approximately 20 degrees in both directions relative to the connector arm 706 . The keying feature 726 restricts the rotational movement by mating with the key slot 728 in the housing 706 , which provides limited space for the keying feature 726 to rotate. This provides a user with the ability to make relatively slight configuration adjustments between the housing 706 and connector arm 704 , while not making the adjustable connection too cumbersome for the user.
The connector arms 706 mate with each other at their medial ends, where a set screw 702 controls the locked and unlocked configuration between them. Both connector arms have features at their medial ends which function to enable the connector arms 706 to linearly translate relative to each other as well as slightly angle themselves relative to each other. The features which function to guide and limit the translation and angulation between the connector arms 706 may be any feature necessary to enable the configuration between the two connector arms 706 without departing from the scope of this invention. By way of example, a first connector arm may have a threaded hole 732 (shown best in FIG. 53 ) that enables a connector arm set screw 702 to engage. The loosening and tightening of the set screw 702 would allow the second connector arm 706 to linearly translate to either expand or shorten the distance between the housings 704 . By way of example only, the distance between the center of the arched recesses 716 may range approximately between 40-75 mm (and shown as dimension X in FIG. 51 ).
A slot 732 extending across at least part of the second connector arm 706 enables the relative linear translation between the two connector arms 706 , while also limiting their linear translation to the confines of the slot 732 . Additionally, the extruded guide 734 assists in maintaining alignment between the connector arms by mating with the slot 732 . The extruded guide 734 is not completely circular in cross section and, instead, includes flat extensions 736 (best shown in FIG. 54 ) which limit the relative angulations between the two connector arms 706 . By way of example, the connector arms 706 are able to angle approximately 15 degrees in either direction about the center axis of the threaded hole 730 . This provides a user with the ability to make configuration adjustments between the housing 704 and connector arm 706 , while not making the adjustable connection too cumbersome for the user. Generally, the medial ends of both of the connector arms 706 have relatively flat surfaces in order to accommodate smooth linear translation between their mating features (i.e. extruded guide 734 and slot 732 ).
As best shown in FIG. 53 , a split collar 738 is secured around the distal end of the connector arm 706 . The split collar 738 functions to enable the spherical joint 724 to articulate within the spherical socket 740 of the securing block 708 while maintaining a secure connection between the connector arm 706 and the housing 704 . Flanges 742 radially extending from the split collar 738 mate with an annular step 744 located in the inside walls of the side through hole 746 of the housing 704 .
As mentioned above, when the housing set screws 702 are engaged into their associated housings 704 and securing blocks 708 , the securing blocks 708 ultimately become fixed within the housings 704 . When a securing block 708 becomes fixed within a housing 704 , the securing block 708 also fixes the jointed configuration between the adjacent housing 704 and connector arm 706 . The further engagement of the set screw 702 into the securing block 708 causes the securing block 708 to bind into the housing cavity 748 which ultimately securely engages the distal end of the adjacent connector arm 706 . Ultimately, the securing block 708 forces against the distal end of the connector arm 706 (which pushes the connector arm 706 in a direction away from the housing 704 ) until the split collar 738 restricts any further movement of the connector arm 706 . The split collar 738 is confined to expanding only to the size of the annular step 744 , which is sized to restrict the split collar 738 from expanding enough to allow the distal end of the connector arm 706 from losing its connection with the housing 704 . By way of example, when the housing set screw 702 is generally fully engaged within the housing 704 and associated securing block 708 , the securing block 708 is forcing the permanent fixation of the connector arm 706 relative to the housing 704 . Furthermore, secure fixation of a securing block 708 within a housing 704 also secures a rod captured within the adjacent arched recess 716 , as described above.
FIGS. 56-64 illustrate an example of an embodiment of a reduction tower 900 . The reduction tower 900 comprises a proximal end 906 and a distal end 907 and includes a housing 901 , an interior shaft 902 , and a grasping element 910 . The housing 901 and interior shaft element 902 are both hollow to allow the passage of various tooling and/or parts through their centers, generally along their shared longitudinal axis. By way of example, a locking tool 1000 (as shown in FIGS. 58 and 59 ) may be inserted through the center of the housing 901 and interior shaft 902 and attached at the proximal end of the housing 901 to form a tooling assembly 1100 (as shown by way of example in FIGS. 60-62 ). This tooling assembly 1100 can be used to lock a bone screw assembly configuration (as described herein), and will be discussed in more detail below. A variety of tooling and parts may be combined with the reduction tower 900 to perform a variety of functions, as described below. Furthermore, the reduction tower 900 may also function to lock bone screw configurations without the addition of accessory tooling (i.e. locking tool 1000 ), which will also be discussed in more detail below.
The grasping element 910 of the reduction tower 900 includes a spring element 920 , a finger grip 911 , a latch 921 , and a grasping arm 922 . Grasping features 904 are located at the distal end of the grasping arm 922 and housing 901 and function to engage, for example, the receiver 20 (of receiver assembly 12 ) of a anchor assembly 10 . One advantageous use of the reduction tower 900 is the ability to lock any of the provisional locking screws without using a closure structure.
As described above, when the bone screw assembly 10 is secured to a bony structure in its unlocked position, the receiver assembly 12 can articulate freely relative to the bone screw 11 . After determining the necessary orientation of the receiver assembly 12 relative to the bone screw 11 to receive the rod and positioning the rod in the receiver, the clinician may use the reduction tower 900 to provisionally lock the bone screw assembly 10 orientation without using a closure member.
To provisionally lock the bone screw assembly 10 , for example, the clinician positions the open (unlocked) distal end 907 of the reduction tower 900 adjacent and generally concentric to the receiver assembly 12 of the spinal anchor assembly 10 . The user then advances the distal end 907 of the reduction tower 900 over at least a portion of the receiver assembly 12 and generally aligns the grasping features 904 of the reduction tower 900 with the tool engaging features (i.e. grip bores 21 ) of the receiver 20 . The clinician then locks the reduction tower 900 by compressing the grasping element 910 towards the housing 901 , for example, by pressing on the grasping arm 922 until the latch 921 engages the latch keeper 930 . When the latch 921 is fully engaged with the latch keeper 930 , the grasping features 904 can fully engage the tool engaging features of the receiver 20 (as illustrated in FIGS. 58 and 59 ), thus securing the receiver 20 within the distal end 907 of the reduction tower 900 .
Once the reduction tower 900 is securely mated to the receiver assembly 12 of a spinal anchor 10 , the interior shaft 902 can be advanced in the direction of the distal end 907 of the reduction tower 900 . This can be accomplished in a number of different ways, such as, for example, by attaching a T-handle or a torquing tool (not shown) to the proximal end of the interior shaft 902 and forcing the interior shaft 902 to rotate along its longitudinal axis. At least a portion of the interior shaft has exterior threads 923 that engage interior threads 925 along at least a portion of the interior wall of the housing 901 (and best shown in FIG. 62 ). This threaded engagement allows the interior shaft 902 to translate along its longitudinal axis relative to the housing 901 when the interior shaft 902 is rotated in either direction.
As depicted in FIGS. 63-64 , in order to lock the configuration of the spinal anchor assembly 10 , the interior shaft 902 is advanced in the direction of the distal end 907 of the reduction tower 900 . The interior shaft 902 is advanced until the distal end of the interior shaft 902 is forcing down upon the rod (such as a rod 60 ) captured within the receiver assembly 12 (and best shown in FIGS. 63 and 64 ). The distal end of the interior shaft 902 continues to force down upon the rod until the collet 40 has securely wedged itself into the receiver 20 such that the bone screw 11 , collet 40 and receiver 20 are no longer able to move independently of each other. As described above, when the collet 40 becomes securely wedged into the receiver 20 , the collet 40 compresses and secures the capture structure 16 of the bone screw 11 within its interior spherical surface 49 . By way of example, a feature within the reduction tower 900 may produce an audible indicator (i.e. a clicking sound) once the interior shaft 902 has advanced the necessary distance to lock the configuration of the spinal anchor assembly 10 . Any number of different mechanisms or features (i.e. visual markers, break-away torquing tool adapters) may be used to indicate to the user that the interior shaft 902 has advanced far enough so that the spinal anchor assembly 10 is now locked into its configuration, without departing from the scope of the present invention.
Once the interior shaft 902 has advanced the necessary distance to lock the configuration of the bone screw assembly 10 , the user may then advance the finger grip 911 to release the latch 921 from the latch keeper 930 , thus unlocking the grasping element 910 and releasing the engagement between the reduction tower 900 and receiver assembly 12 . The rod used to lock the configuration of the bone screw assembly 10 can then be removed from the receiver assembly 12 , as necessary, while the spinal anchor assembly 10 remains in the locked configuration. This allows the clinician to use the spinal anchor assembly 10 , for example, as a tool to assist in positioning the spine (i.e. de-rotation of the spine) and correcting spinal deformities. A rod may be secured within the receiver assembly 12 at a later time when the user is prepared to secure the positioning of the bone screw assembly 10 relative to an rod.
Optionally, and by way of example, a locking tool 1000 may be adapted to the reduction tower 900 to lock the spinal anchor assembly 10 into a desired configuration. The locking tool 1000 may be used instead of the distal end of the interior shaft 902 to lock the configuration of the bone screw assembly 10 . By way of example, the locking tool 1000 may be adapted to the reduction tower 900 by inserting its distal end into the proximal end 906 of the reduction tower 900 (through the hollow centers of the housing 901 and interior shaft 902 ). The distal end of the locking tool 1000 is advanced through the reduction tower 900 until the adapter 1002 of the locking tool 1000 is securely engaged to the proximal end 906 of the reduction tower 900 . The adapter 1002 includes two spring clips 1003 that allow the adapter 1002 to slide over the proximal end of the reduction tower 900 and engage the engaging ends 1006 of the spring clips 1003 into the tool locking features 912 at the proximal end of the housing 901 . The engaging ends 1006 of the spring clips 1003 mate with the tool locking features 912 of the housing 901 such that the locking tool 1000 is constrained from movement relative to the reduction tower 900 , both rotationally and along their shared longitudinal axis.
Once the locking tool 1000 is securely engaged at the proximal end 906 of the reduction tower 900 , a torquing tool (not shown), for example, can be adapted to the torque adapter 1004 at the proximal end of the tooling shaft 1005 . In order to lock the configuration of the spinal anchor assembly 10 , the tooling shaft 1005 is advanced in the direction of the distal end 907 of the reduction tower 900 . The tooling shaft 1005 is advanced by rotating the tooling shaft (i.e. by rotating the torque adapter 1004 ). The locking tool 1000 includes a threaded guide 1010 that functions to assist in the positioning of the tooling shaft 1005 . The tooling shaft 1005 also is partially threaded 1011 along a portion of its proximal end. Threaded engagement of the threaded guide 1010 with the tooling shaft 1005 enables the tooling shaft 1005 to linearly translate along its longitudinal axis when rotated along its longitudinal axis.
The tooling shaft 1005 is rotated and advanced toward the spinal anchor assembly 10 until at least a portion of the distal face 1007 is forcing down upon a rod captured within the receiver assembly 12 . The distal face 1007 of the tooling shaft 1005 continues to force down upon the rod (which subsequently forced down upon the collet 40 ) until the collet 40 has securely wedged itself into the receiver 20 such that the bone screw 11 , collet 40 and receiver 20 are no longer able to move independently of each other. Any number of different mechanisms or features (i.e. visual markers, break-away torquing tool adapters) may be used to indicate to the user that the tooling shaft 1005 has advanced far enough so that the bone screw assembly 10 is now locked into its configuration, without departing from the scope of the present invention.
Furthermore, the distal end of the locking tool 1000 is shaped and dimensioned such that it may advance into a receiver assembly 12 and lock the configuration of the associated bone screw assembly 10 without a rod captured within the receiver assembly 12 . This is accomplished generally similar to the steps for locking the configuration of the bone screw assembly 10 , as described above, but instead of the distal face 1007 of the tooling shaft 1005 forcing down on a rod, the distal face 1007 forces down upon generally the top surface 41 of the collet 40 . As described above, the tooling shaft 1005 is advanced until the collet 40 is securely wedged within the receiver 20 , thus locking the configuration of the bone screw assembly 10 .
The tooling assembly 1100 may be disassembled by compressing the spring clips 1003 , thus disengaging the engaging ends 1006 of the spring clips 1003 from the locking tool 1000 . The locking tool 1000 may be removed from the tool locking features 912 at the proximal end of the housing 901 . This releases the rotational and translational fixation between the locking tool 1000 and the reduction tower 900 so that the locking tool 1000 can slide out and away from the reduction tower 900 . The locking tool 1000 may be assembled to the reduction tower 900 before, during, or after the reduction tower 900 becomes securely engaged to a receiver assembly 12 . Furthermore, the reduction tower 900 may adapt and remove any number of various tooling throughout its use without departing from the scope of this invention.
When necessary, the receiver 12 may be released from the distal end 907 of the reduction tower 900 by advancing the finger grip 911 towards the distal end. A spring 931 is housed within the finger grip 911 which forces the finger grip 911 back to its original position once the user is no longer forcing it towards the distal end of the reduction tower 900 . Although shown as a spring 931 , any number of features may be associated with the finger grip 911 and/or latch 930 to allow the user to release the grasping element 910 from its locked position, without departing from the scope of this invention.
The grasping arm 922 is spring loaded by means of a cantilever spring 920 , but may be spring loaded using any number of elements that force the grasping arm 922 back to its original unlocked position. Although a cantilever spring 920 is shown in this example, any number of features or mechanisms may be used to assist in controlling the movement and placement of the grasping arm 922 without departing from the scope of this invention.
FIGS. 65-66 illustrate an example of a second embodiment of a reduction tower 1200 . The reduction tower 1200 includes a housing 1201 , an interior shaft 1202 and a grasping element 1210 . This second embodiment of a reduction tower 1200 is essentially the same in features and functions as the first embodiment of a reduction tower 900 , as described in detail above. Therefore, a repeated discussion of the similar features and functions of the reduction tower 1200 will not be repeated here. However, the reduction tower 1200 presented herein includes a release button 1203 . The release button 1203 functions to position a partially threaded 1204 feature relative to the interior shaft 1202 . The positioning of the partially threaded 1204 feature enables either a guided or free linear translation of the interior shaft 1202 . By way of example, engaging the release button 1203 disengages the partially threaded 1204 feature from its threaded engagement with the interior shaft 1202 . This enables the interior shaft 1202 to freely and quickly linearly translate along its longitudinal axis relative to the housing 1201 . This is desirable for quick positioning of the interior shaft 1202 relative to the housing 1201 . By way of further example, disengagement of the release button 1203 engages the partially threaded 1204 feature to the exterior threads on the outer wall of the interior shaft 1202 . This threaded engagement limits the linear translation of the interior shaft 1202 relative to the housing 1201 to only when the interior shaft 1202 is being rotated along its longitudinal axis.
For instances in which de-rotation of one or more vertebral bodies is desired, a reduction tower link 1300 is also provided. In accordance with a preferred embodiment of the present invention, engaging the reduction tower link 1300 to two or more reduction towers 900 allows derotation of all of the vertebrae together via a ratcheting mechanism. As shown in FIGS. 67-71 , the reduction tower link 1300 includes a stationary arm 1302 , a moving arm 1304 , and a ratchet mechanism 1306 . Stationary arm 1302 further comprises a terminal groove 1308 and a receiving aperture 1310 at either end. The terminal grooves 1308 are sized and dimensioned to receive a ratchet pawl 1312 . Ratchet pawl 1310 is spring-loaded 1328 to engage the moving arm 1304 (or ratchet arm). The aperture 1310 is sized and dimensioned to receive the ratchet post 1322 as described below. Additionally, the inner face 1330 of the stationary arm 1302 is comprised of a softer, malleable material (including, but not limited to, silicone) to provide leeway as reduction tower link 1300 interacts with the reduction towers 900 .
The moving arm (or ratchet arm) 1304 also contains terminal grooves 1314 and a receiving aperture 1316 at either end as well as a malleable inner face 1318 . The terminal grooves 1314 which are sized and dimensioned to receive a final lock nut 1320 . As the final lock 1320 is turned, it draws the ratchet post 1322 through its receiving aperture 1316 . The inner face 1318 is also comprised of a softer, malleable material (including, but not limited to, silicone) to provide leeway as the reduction tower link 1300 interacts with the reduction towers 900 .
Ratcheting mechanism 1306 contains an inner ratchet post 1322 and an outer portion comprised of an outer cylinder 1324 and an inner cylinder 1326 .
As depicted in FIGS. 69 and 71 , squeezing the arms 1302 , 1304 together causes the ratchet 1306 , moving arm 1304 , and inner cylinder 1326 to move towards the stationary arm 1302 as indicated as arrow A. The spring-loaded ratchet pawl 1312 prevents release of the ratcheting mechanism 1306 . The final lock nuts 1320 may be tightened to achieve final positioning of the reduction tower link 1300 . Pushing the ratchet pawl 1312 disengages the spring-loaded mechanism and releases the arms 1302 , 1304 .
According to a second embodiment, instead of a ratcheting mechanism, a cam may be used to bring the stationary arm 1302 and moving arm 1304 together around the reduction towers 900 . A knob on each arm 1302 , 1304 may be used to adjust the distance between the bars 1302 , 1304 in addition to the travel created by the cams.
An example surgical procedure is described below for use with, for example, the anchor systems and related tools described herein. The surgical procedure described herein is not intended to be exhaustive, such that additional steps that are not discussed herein may be incorporated to the procedure without departing from the intended scope.
The procedure begins, in pertinent part, by placing a spinal anchor (e.g. bone screw 11 ) into each of a plurality of pedicles. For each pedicle, the desired entry point is located and the cortex is perforated using an awl or burr. Next, a pilot hole is created by passing, for example, a narrow or lumbar gearshift prove through the pedicle and into the vertebral body. Care should be taken to ensure the instrument(s) do not breach the cortical wall of the pedicle, as the pilot hole will ultimately determine the final position of the screw. The pilot hole should be inspected for perforations by using a ball-tip probe to palpate the pedicle wall on all sides. Pedicle markers may also be placed into the pilot holes followed by lateral and anterior-posterior imaging to verify proper positioning.
In patients with dense bone or where tapping is preferred, depth gauging may be accomplished using the markings on the instrument shaft in conjunction with fluoroscopy. If depth gauging is performed, the ball-tip probe should again be used to inspect the pilot hole for perforation. After the appropriate screw length is determined, a screwdriver is used to drive the screw into the pilot hole and advance it until the desired depth is reached. A screw adjuster may be used if subsequent x-ray or fluoroscopy indicate that screw depth adjustment is necessary.
After the spinal anchors (e.g. bone screw 11 ) and receiver assemblies (e.g. receiver assembly 12 ) are secured to the desired pedicles, the rods 60 are prepared for placement. The systems described herein include an array of straight and pre-bent (lordosed) rods. Measurements are taken to determine the appropriate rod lengths using a rod template. The corresponding straight or pre-bent rod from the implant tray may then be selected and additional contouring may be performed as needed with any one of an array of rod benders: (e.g., French benders, in-situ sagittal benders, in-situ coronal benders, and plate style benders).
A rod holder may then be used to sequentially insert the rod 60 into each of the receiver assemblies (e.g. receiver assemblies 12 ) until the rod 60 is lying at the bottom of all of the receiver assemblies 12 . With a portion of a rod 60 fully seated in the receiver assemblies 12 , capture structures (e.g. capture structure 16 ) are engaged into the receiver assemblies 12 . By way of example, the clinician aligns the recessed slot 75 of the closure structure 13 with the recessed slot 24 of the receiver (e.g. receiver 20 ). The alignment of the recessed slots 24 , 75 prevents incorrect engagement of the interior and exterior guide and advancement structures. Alternately, a lock screw starter guide may be used to capture the receiver assembly 20 (or closure structure 13 ) followed by introduction of the lock screw starter.
If the rod 60 is difficult to fully seat in the receiver assembly 120 , the rod 60 may be reduced using, for example, a rocker, persuader, or reduction tower 900 , 1200 . When only a small amount of reduction is required, the rocker or the persuader is preferably utilized. Using the rocker, the receiver assembly 12 is grasped via the oval grip bores 21 on either side of the receiver assembly 20 . The rocker may then be deflected downward until the spinal anchor assembly 10 is levered up and the rod 60 is fully seated into position within the receiver assembly 12 . A closure structure 13 may then be inserted using a lock screw starter. Alternatively, a persuader may be used. To do so, the tip of the persuader is slid over the top of the receiver assembly 12 . To reduce the rod 60 , downward force is applied to the persuader while compressing the handle ratchet closed. Once the rod 60 is fully seated in the receiver assembly 12 , a lock screw starter may be used to place the closure structure 13 . The persuader may be disengaged from the receiver assembly 12 by releasing the ratchet and pulling up on the persuader.
A reduction tower 900 is preferably used whenever a large amount of reduction is required. Prior to using the reduction tower 900 , the grasping element 910 should be in the open position. To use the reduction tower 900 , the distal end 907 is placed over the rod 60 and around the receiver assembly 112 so that the grasping elements 910 rest on the capture structure 16 and the oval grip bores 21 are aligned. The receiver assembly 112 may be grasped via the grasping features 904 on the grasping element 910 by slowly closing the grasping element 910 towards the housing 901 as described above. With the reduction tower 900 securely engaged with the screw 11 , the T-handle attached to the proximal end 906 of the reduction tower 900 may be slowly turned until the rod 60 is fully seated in the capture structure 16 . A lock screw starter may be used to insert a closure structure 13 through the interior of the reduction tower 900 to hold the implant 10 in position. Following placement of the closure structure 13 , the lock screw starter may be removed, the reduction tower grasping arm 922 may be released and removed from the spinal anchor assembly 10 .
According to one aspect, rod rotation and vertebral derotation techniques may be utilized to correct coronal and rotary deformities in the spine. The system of the present invention offers a rod rotation wrench, a reduction tower 900 , 1200 , and derotation guides (lock screw guides) to perform these operative techniques. In connection with the reduction tower 900 , 1200 or a derotation guide, derotation of the spine may be achieved by using these instruments as an extended moment arm to rotate the vertebral bodies in the axial plane.
With the rod 60 fully reduced into the receiver assemblies 12 and the closure structures 13 are placed loosely, the rod 60 may be rotated into its desired position. A rod gripper may be placed over the rod 60 and its handle compressed to achieve rigid fixation. Two rod grippers may be used to transform the coronal deformity into kyophosis or lordosis within the sagittal plane. After the rod 60 has been rotated into the desired position, the closure structures 13 may be tightened.
Rods 60 may be rotated using a rod rotation wrench. The rod rotation wrench may be placed over the hex at the end of the rod 60 and rotated to the desired amount. Vertebral body rotation may be accomplished via the uniplanar, fixed, or provisional locking screws of the present invention. To apply rotational forces to the uniplanar or fixed screws, the lock screw guide is slid over the capture structure 16 of the screw 10 . The guide may then be moved in the medial-lateral direction to rotate the vertebral body in the axial plane.
To apply rotational forces to a provisional locking screw, the provisional locking screw must first be locked into a fixed position, preferably using the reduction tower 900 . To lock the provisional locking screw, the reduction tower 900 must be rigidly engaged to the capture structure 16 with the rod 60 fully reduced. To do so, a counter-torque instrument may be slid into the tool locking features 912 on the cranial/caudal sides of the reduction tower 900 . Next, the locking tool 1000 is inserted into the center of the reduction tower 900 The T-handle attached to the proximal end 906 of the reduction tower 900 may be turned in a clockwise direction until the breakaway torque is achieved. The provisional locking tool may be removed as described above.
With the provisional locking screw in a fixed position, the reduction tower 900 is leveraged in a medial/lateral direction to rotate the vertebral body in the axial plane. Once the amount of de-rotation is achieved, a closure structure 13 may be inserted (preferably using a lock screw starter) and provisionally tightened to hold the rod 60 in a fixed orientation. To minimize the chances of pedicle fracture during vertebral body de-rotation, it is preferable to spread the rotational forces over a series of adjacent pedicle screws. This is accomplished via the reduction tower link 1300 as described above with reference to FIGS. 67-71 .
The reduction tower link 1300 is placed over two or more reduction towers 900 such that the reduction towers 900 are positioned between the inner face 1312 of the stationary arm 1302 and the inner face 1318 of the moving arm 1304 . Next, the arms 1302 , 1304 are squeezed together via the ratcheting mechanism 1306 until the desired amount of vertebral body de-rotation has been achieved. The final lock nuts 1320 may then be tightened to achieve the final positioning of the reduction tower link 1300 . Pushing the ratchet pawls 1312 disengages the arms 1302 , 1304 so that the reduction tower link 1300 may be removed from the reduction towers 900 .
If compression or distraction is desired, the closure structures 13 on one side of the motion segment should be tightened, leaving the other closure structure 13 loose to allow movement along the rod 60 . The compressor or distractor may be placed over the rod 60 and against the capture structures 16 of both spinal anchor assemblies 10 . With the compressor or distractor properly engaged, the desired amount of compression or distraction may be imparted upon the rods and the second closure structure 13 may be provisionally tightened to hold the construct in position prior to final tightening of the entire construct.
Once the necessary reduction, de-rotation, compression, and/or distraction is achieved, the entire construct is tightened. Beginning with the cephalad screw, the counter-torque is placed over the closure structure 13 until the slots at the distal end of the instrument are completely seated over the rod 60 . With a torque T-handle engaged, the lock screw driver is inserted through the counter-torque until it is securely seated in the closure structure 13 . Final tightening may then be delivered and these steps may be repeated on the remaining screws.
Next, fixed 600 and adjustable length 500 , 700 transverse connectors may be placed to provide torsional stability to the construct. The appropriate length transverse connector is determined preferably by measuring the distance between the rods 60 using measurement calipers. If necessary, transverse connector benders can be used to make fine adjustments to the length of the fixed transverse connectors 600 .
According to the embodiment illustrated in FIG. 23 , eccentric pins 514 (locking cams) are used to secure the transverse cross connector 500 . Prior to inserting the transverse cross connector 500 , the eccentric pins 514 should be in the fully open position. To open them, a transverse connector driver is used to rotate both eccentric pins 514 until the positioning indicators 532 are positioned toward the center of the transverse cross connector 500 .
With the transverse connector holder still attached, the transverse connector 500 is placed over the rods. Once the connector 500 is seated on both rods 60 , a transverse connector driver is used to turn the eccentric pins 514 180 degrees until the positioning indicators 532 on the eccentric pins 514 face laterally and align with the positioning indicator 536 . The eccentric pins 514 are then fully locked to the rods 60 .
A distractor may be placed over the transverse connector 500 such that it engages the medial aspect of the retaining c-ring 518 . Final locking is performed by distracting each ring 518 laterally until it is fully seated as described above.
While not specifically described above, it will be understood that various other steps may be performed in using and implanting the devices disclosed herein, including but not limited to creating an incision in a patient's skin, distracting and retracting tissue to establish an operative corridor to the surgical target site, advancing the implant through the operative corridor to the surgical target site, removing instrumentation from the operative corridor upon insertion of the implant, and closing the surgical wound. Furthermore, procedures described, for example only, may be applied to any region of the spine without departing from the scope of the present invention and dimensioning of the implant may be adjusted to accommodate any region.
While this invention has been described in terms of a best mode for achieving this invention's objectives, it will be appreciated by those skilled in the art that variations may be accomplished in view of these teachings without deviating from the spirit or scope of the invention.
Although described with respect to specific examples of the different embodiments, any feature of the spinal anchor system disclosed herein by way of example only may be applied to any of the embodiments without departing from the scope of the present invention. Furthermore, procedures described, for example only, involving specific regions of the spine (e.g. thoracic and lumbar) may be applied to another region of the spine without departing from the scope of the present invention and dimensioning of the implant may be adjusted to accommodate any region.
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The present application describes a pedicle fixation system and methods for correcting deformities of the spine and fixing the corrected portion of the spine in a corrected position. The disclosed system and associated methods include at least one pedicle screw in which a receiver portion of the pedicle screw is coupled to a screw portion of the pedicle screw in a manner such that the receiver portion is initially movable relative to the screw portion in a polyaxial fashion and subsequently lockable relative to the screw portion prior to locking a rod in the housing. Instruments for locking the receiver portion relative to the screw portion are also described.
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PRIORITY
[0001] Priority is claimed to U.S. provisional application No. 61/695,460, filed Aug. 31, 2012, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The field of the present invention relates to the collection and presentation of sports performance data particularly live football game data. The football games of particular relevance are American football and the rugby codes.
BACKGROUND TO THE INVENTION
[0003] In all sports and in particular the various football codes coaches and players need statistical data and information related to patterns of play in order to identify aspects of their own teams game and also aspects of their opponent teams games. The spectators particularly those viewing television broadcasts find the addition of such information informative and useful in enhancing their viewing experience.
[0004] U.S. Pat. No. 5,912,700 discloses a camera and sensor based system for adding graphics and enhancing video images of a sporting event.
[0005] U.S. Pat. No. 6,141,060 discloses a method for improving the presentation of an American football game by adding a line to a video image indicating the first down position of the play. Field of view sensors are used in conjunction with cameras. This has been regarded as a useful addition to TV broadcasts.
[0006] U.S. Pat. Nos. 6,744,403 and 8,077,981 disclose a method of presenting motor racing video broadcasts which include collecting GPS data conducting statistical analysis and adding a graphic to a video image.
[0007] U.S. Pat. No. 7,116,342 discloses a method of inserting perspective correct content into an image sequence.
[0008] U.S. patent publication No. 2011/0013836 discloses a method of image analysis to assist in game strategy analysis of ice hockey games.
[0009] U.S. Pat. No. 8,249,254 discloses a system of collecting statistics by using a data logger on each player to transmit data to remote terminal for review by coaches.
[0010] U.S. Pat. No. 8,279,051 discloses a method of collecting game statistics using RF technology and a. base station to track players and enhance information to coaches.
[0011] U.S. Pat. No. 8,482,612 discloses a system using video camera clusters and a ball tracking technology for use with football games.
[0012] U.S. Pat. No. 8,477,046 discloses a system for collecting sports data using, sensors on participants and in the ball and using the information for analysis and camera positioning.
[0013] In spite of these developments there is still a need to provide additional analytical information and graphical displays for use by coaches and broadcasters.
[0014] It is an object of this invention to provide an improvement in the analysis and graphical presentation of American Football and the rugby codes.
SUMMARY OF THE INVENTION
[0015] To this end the present invention provides a system of collecting and displaying statistical performance data of football tactical plays which includes:
a) player data loggers worn by each player that include accelerometers and location sensors that provide data on duration of play, acceleration, speed, direction of movement, possession of ball, force of impacts b) a processor that collects the data from the sensors and from other sources and analyses the data for each tactical play to determine i) the initial line of scrimmage for each play, ii) the end of each play, iii) for each player one or more of start position and end position, duration of play, acceleration, speed, direction of movement, possession of ball, force of impacts, and iv) normalizing all the statistics for each tactical play relative to the initial scrimmage line or a players start point, so that all tactical plays and all individual player performances can be compared from the same start point c) display means to graphically display the statistics and combine the graphics with video images of the play and players.
[0019] This invention will be described in relation to American football as presented by the NFL but is also applicable to other territorial football games like rugby league and rugby ration. The insight of this invention for the NFL is to represent each play relative to the scrimmage line of that play so that each key player's movement and the movement of the ball is shown relative to the scrimmage line. This normalisation of the data from each play allows statistical analyses of all plays to be more meaningful no matter where the play took place on the playing field.
[0020] The plays may also be normalized with respect to the players starting position in direction ‘y’ (if x is the direction of play). Accordingly the players positions are normalised in the direction of play relative to the scrimmage line and also at right angles to the direction of play. So it doesn't matter where relative to the line of scrimmage a player (e.g. a wide receiver) started all his plays get normalised for his lateral position also.
[0021] Where the statistical data is used for broadcasting purposes some of the information used to determine the scrimmage line location at the start and end of each play may come from an external source such as the referee system used by the broadcaster.
[0022] The system may also incorporate ball tracking sensors in the ball to provide additional information on the movement of the ball and its possession by players.
[0023] The player data loggers used are preferably those described in U.S. Pat. Nos. 7,715,982 and 8,036,826. The position of the ball may be tracked using the ball tracking system disclosed in U.S. Pat. No. 8,353,791. The disclosure of those patents is incorporated into the disclosure of this specification.
[0024] It is preferred however to use a wireless triangulation system for the NFL as the hardware is usually in place in the major venues and given the accuracy required the triangulation method is preferred.
[0025] By using the time clock, and the GPS and accelerometer data, as well as the ball location data, the position of all players on each team and which quarterback has the ball, can be determined. Using this data at the start of the play, the position of the scrimmage line can be determined and then all subsequent movements of players are plotted relative to that scrimmage line.
[0026] The analyses that may be made are
1. tactical plots of quarterback and receiver movements and distances travelled as well as ball movement; the plots may be colour coded to show consequence of each play 2. line of scrimmage statistical analysis to analyse the performance of the scrimmage players on each team, including offensive line impact strengths for individual and multiple plays; individual line man stats 3. quarterback pass statistics per play, averaged over multiple plays for this game, or this opposition or all games 4. receiver run stats and running back rushing play stats 5. jamming stats for individual players or teams 6.0 heat maps showing time at a part of the field is interesting especially for players on the defensive side. These heat maps may be normalised with respect to the line of scrimmage (and normalised in the y direction). This allows linking several of heat or coverage maps of different players together, to display overlapping coverage of the field. Heat maps have been used in other sports, but again the key inventive step is normalising them with respect to the line of scrimmage. 7. Display the effective coverage area that a receiver can cover if the ball is passed in their direction from the quarterback. This allows the viewer or coach to see which receivers have the largest effective range to receive the ball and to evaluate where the passer of the ball (quarterback) has the best opportunity for passing the ball. 8. Pocket analysis—the pocket in American football is the area behind the line of scrimmage in which the quarterback can operate to pass the ball. The pocket is collapsed if a defender penetrates or passes around the scrimmage line or the quarterback runs out of the pocket. The analysis can report the size of the pocket and the time from the snap to when it collapses. 9. The effective coverage area and pocket analysis leads on to analysis of passing effectiveness and quality of quarter backs decision making.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Preferred embodiments will now be described with reference to the drawings in which:
[0037] FIG. 1 illustrates a graphical depiction of the position of players after each play relative to the line of scrimmage (LOS);
[0038] FIG. 2 illustrates tactical plots illustrating the movement of the ball from the quarter back to the receiver:
[0039] FIG. 3 shows a statistical breakdown of various aspects of a quarterbacks play;
[0040] FIG. 4 shows similar statistics for a wide receiver;
[0041] FIG. 5 illustrates tactical plots illustrating the movement of a wide receiver;
[0042] FIG. 6 illustrates the statistics of the defensive team on the receipt of the ball by a wide receiver;
[0043] FIG. 7 shows a statistical breakdown of various aspects of the rushing plays of a running back;
[0044] FIG. 8 shows a statistical breakdown of various aspects of the line man statistics of a Left Tackle player;
[0045] FIG. 9 shows a statistical breakdown of the hit strength of an offensive line;
[0046] FIG. 10 is a schematic view of a preferred embodiment of the system for broadcasting of games;
[0047] FIG. 11 illustrates the graphical representation of effective coverage area;
[0048] FIG. 12 illustrates the information to be obtained from the analysis of effective coverage area;
[0049] FIG. 13 illustrates a screen display for pocket analysis;
[0050] FIG. 14 illustrates a screen display of quarterback analysis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] The data provided for the graphical representations is collected using player data loggers described in U.S. Pat. Nos. 7,715,982 and 8,036,826 the ball tracking system disclosed in U.S. patent publication No. 2009/0048039.
[0052] With respect to FIGS. 1-9 the player data loggers record for each player their movements and actions such as passing the ball, receiving the ball, impacting or tackling another player or being blocked or tackled as well as acceleration, distance covered, and the route taken across the playing field. These statistics are partly processed in the data logger including signals received from the ball to show possession or contesting of the ball. The signals are transmitted to a central computer where the data is processed to provide raw statistics for each player. The data for the time period of each play is normalised by determining for each play the scrimmage line between the two teams prior to the play commencing and then relating position of each player along X and Y axes relative to the scrimmage line (where X is the direction of play) so that each subsequent play can he compared on the same basis.
[0053] The central computer will have access to statistical data for all teams and for all prior games so that competition averages can be obtained and players performances and team performances compared to previous games.
[0054] In FIG. 1 the LOS analysis allows spectators and coaches to see who is winning the LOS as the averages or individual play results show the net movement after collision for the so called unskilled positions in the game (like offensive and defensive linemen). In the graph shown the analysis is for all plays up to that point in the game.
[0055] FIG. 2 provides tactical plots for a particular quarterback in offensive plays for the previous 6 plays up to that point in the game. The lines show the movement of the ball while it is held by the quarterback, then in flight when it is passed and then in the possession of the receiver from when he receives the ball to when he touches down or is tackled or moves out of the field of play. Thus all plays can be shown in this way or just forward half plays, or back half plays, one or more rushing, plays and one or more passing plays.
[0056] FIG. 3 is a breakdown of statistics for a quarterback showing statistics for each play of pass length, ball speed, possession time and play length. These can be displayed as averages for a section of past plays or of all plays for that game or for all games for the season or the career of the quarterback. These statistics may also be compared to League averages for all quarterbacks.
[0057] FIG. 4 is similar to FIG. 3 except it is designed for a receiver and may be presented in as many variations as for FIG. 3 .
[0058] FIG. 5 is similar to FIG. 2 except that the plots are for a wide receiver showing as many runs and routes as desired. The runs may be colour coded showing velocity profile, outcome and on the screen the program can allow a mouse over function to highlight a list of statistics for each run. The wide receiver plots may be normalised to the scrimmage line or to the wide receivers start point at the beginning of each play so that the route distance and times may be more easily compared.
[0059] FIG. 6 looks at the Jamming statistics in the performance of a wide receiver showing, the delays to the receivers route caused by jamming by opposition defenders. The graphical display may also highlight successful receives or touchdowns and show the moment of impact from a tackler. This can be defined by looking at the velocity of the wide receiver just prior to impact from the defender (where impact is measured by the accelerometer etc.), and then waiting to see when the wide receiver regains this velocity after getting past the defender. This is then the lost time, during the jam which is a measure of how disruptive the defender has managed to be to the wide receiver getting to his designated position for the play.
[0060] FIG. 7 is similar to FIGS. 3 and 4 except it is designed for a running back to show acceleration, max speed, yards gained relative to the scrimmage line, yards run to reach that point, the number of collisions en route and the maximum collision force.
[0061] FIG. 8 is similar to FIGS. 3 , 4 and 7 except it is designed for a left tackle showing for a particular play the length of the play, the time in block, the maximum impact, stance to contact time, pull block acceleration and pull block speed.
[0062] FIG. 9 is similar to FIGS. 3 , 4 , 7 and 8 except it is designed to show the hit strength or impact per play statistics for an offensive line of players. For the linemen, measuring their displacement after contact is an interesting, statistic. Depending on the play, all the linesmen on both sides will move forward or backwards before they impact each other. But after that impact, they are each trying to push through their opposing player. So the distance and direction after impact is critical in understanding who is winning this battle. Again this can be accumulated over a number of plays.
[0063] FIGS. 11 and 12 illustrate the display of effective coverage area. The object is to measure and display the effective range that an athlete can cover if the ball were passed in their direction, based on the input parameters.
Input Parameters
[0000]
Current speed of the athlete
Distance from the ball
Acceleration ability of the athlete considering their current speed
Direction athlete is facing
Passing velocity of player with the ball
Output display
[0070] An area under the athlete is drawn to show the range that they can cover if the ball were thrown to them at that point in time. In FIG. 11 The Offense receivers areas are shown in hatching to display the areas of the field where the QB can throw the ball and only his receivers can get to the ball. The areas where the defenders can effectively cover are crosshatched.
[0071] The display of effective coverage provides the viewer with the ability to see which receivers have the largest effective range and also where the passer of the ball should be targeting for that receiver. This display combined with animation of opposition players gives the audience a real view of effective passing windows. It also allows the audience to see if athlete is able to reproduce their maximum performance potential. The display may be used on any player who can influence play downfield. (WR, CB, S. TE, LB, RB—if RB is out of the backfield)
[0072] In FIG. 13 the display for pocket analysis is shown. The definition of pocket is the area that is behind anyone who is lined up on the line of scrimmage and does not go more than 2 yrds in front of the line after the ball is snapped.
[0073] A pocket is considered collapsed once an opposition player gets on the QB side of the border of the offensive players,—this could be triggered by a defender pushing past their opponent or by the QB running outside the border of the pocket.
[0074] In the case of a defender penetrating the border of the pocket, the system will log where this penetration took place and how long the pocket was held.
[0075] The system may report the closest player to the point of penetration.
[0076] The system may report the size of the pocket at the positional sampling frequency.
[0077] These metrics will be logged historically and max/min/average may be recorded.
[0078] Quarter back effectiveness able to be displayed as shown in FIG. 14 . The objective is to valuate QB dropback effectiveness, time, efficiency and time in throwing position and pocket time, among other things, based on the input parameters.
Input Parameters
[0000]
Current speed of the QB
Possession status of the QB
Footfall patterns of the QB
Position of the QB relative to the tackles and tackle box
Facing direction of the QB
Peak Rotation of the QB
Position of the Linemen relative to each other
Output Parameters
[0000]
Time from possession to finish drop back
Steps taken in drop back
Time spent in pocket
Time pocket held
Pocket penetration point
Pocket size
Time from possession to scramble or throw
Peak Rotation
[0094] This analysis provides the coach and viewer with the ability to compare QB effectiveness. This makes highly technical, subjective concepts more measurable, relatable and comparable and gives the viewer the ability to clearly see and evaluate the performance of the Offensive line. This display also allows the viewer to physically see the relationship between offensive line performance and QB positioning, performance and opportunity to perform.
[0095] With reference to FIG. 10 the venue in which the sporting event is to take place is, in this preferred embodiment, fitted with four directional antennas carefully placed to provide optimal RF coverage of the field. Additionally GPS positions of key locations on the field [goal lines] are carefully measured and recorded.
[0096] All athletes at the event are equipped with data logger units described in U.S. Pat. Nos. 7,715,982 and 8,036,826 which have been calibrated for the location and ideally positioned on their person to receive the best possible GPS information.
[0097] During the event the data loggers gather GPS positional information which is continuously validated to create accurate snapshots of the athletes actions on the field. GPS can generate false movement events which the datalogger discards internally. The information is put into encrypted data packets broadcast over RF.
[0098] The venues antennas gather all the information in their field of view and relay it over cable to the systems Broadcaster software.
[0099] The Broadcaster rejects duplicate information and retransmits the relevant data over a TCP/IP connection on the venues local network.
[0100] The system Operator Console opens a port to this broadcast and transforms the GPS information into a field relative coordinate system which can then be used to display a live feed of every athlete's position on a virtualized field.
[0101] In parallel to the Operator Console the system Data Scribe also creates a connection to the broadcaster and transcribes the data to local and remote MySQL databases. Note that multiple scribes are run to reduce the risk of critical data loss should there be machine failure.
[0102] Finally the user of the Operator console is charged with tracking all game critical events: entering them into a MySQL database by way of a proprietary touch screen user interface which has been tailored for the given sport. Key of these events is timing information regarding the beginning and ending of plays or periods of play during the event.
[0103] Once an event has been marked in time by the user of the Operator Console the software is able to analyze the large volume of data recorded by the Data Scribe over this period. Hundreds of data points regarding athlete movement during a play are distilled down to a few dozen using a path reduction algorithm. The algorithm discards small movements in the same direction resulting in a route which conveys the needed information but using a web transfer friendly data size. The routes of each athlete are written in the MySQL database for use by the Media Portal.
[0104] The Media Portal is a system web service which allows the end user to request information from the event by specifying a variety of parameters including time period, athletes involved or team position (Running Backs, Forwards etc.) Routes from the request are pulled from the database for analysis.
[0105] Since the routes will have occurred in many different locations on the field the data must be normalized in order to be of use to the end user. The positional information stored at each route data point is transformed by subtracting the vector of the first point from each subsequent point in the route. Now all the routes from the request may be compared to one another allowing analysis regarding the frequency, speed, and shape of the routes.
[0106] From the above it can be seen that this invention provides a unique and significant improvement in the presentation of statistical information for coaches and spectators.
[0107] Those skilled in the art will realise that this invention may be implemented in embodiments other than those illustrated without departing from the core teachings of this invention. In particular the invention may be adapted to American football and rugby league or rugby union where an offside line is used and the normalisation of team and player positions can be used to display and compare multiple plays.
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A system of collecting and displaying statistical performance data of American football or rugby football tactical plays includes
a) Optional ball tracking sensors b) data loggers worn by each player that include accelerometers and location sensors that provide data on duration of play, acceleration, speed, direction of movement, possession of ball, force of impacts c) a processor that collects and analyzes the data for each tactical play to determine i) the initial fine of scrimmage for each play, ii) the end of each play, iii) for each player one or more of duration of play, acceleration, speed, direction of movement, possession of ball, force of impacts, and iv) normalizing all the statistics so that all tactical plays and all individual player performances can be compared from the same start point d) display means to graphically display the statistics and combine the graphics with video images of the play and players.
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Related Applications
This application is a nationalization under 35 U.S.C. 371 of PCT/CN2008/001658, filed Sep. 26, 2008, and published as WO 2009/049483 A1 on Apr. 23, 2009, which claims priority to Chinese Patent Application Serial No. 200710122597.7, filed Sep. 27, 2007; Chinese Patent Application Serial No. 200710122596.2, filed Sep. 27, 2007; Chinese Patent Application Serial No. 200710122577.X, filed September 27, 2007; Chinese Patent Application Serial No. 200710122599.6, filed Sep. 27, 2007; and Chinese Patent Application Serial No. 200710122600.5, filed Sep. 27, 2007, which applications and publication are incorporated herein by reference in their entirety and made a part hereof.
TECHNICAL FIELD
The present invention relates to a method of degumming jute fibres, in particular, relates to a method of degumming jute fibres with complex enzyme.
BACKGROUND
Bast fabrics have gained more and more popularity with people, due to better moisture absorption & breathing, low electrostatic susceptibility, and the antibacterial strength of bast fibres. For making the bast fabrics, the materials adopted can mainly be linen fibre, and ramie fibre, or the fibre combination of said fibres with other fibres, such as cotton fibres, wool fibres, chemical fibres, silk fibres after being blended spun. Linen or ramie is expensive, and this is also the reason why the bast-fabric clothing has not been applied widely. However, Jute, which is cheaper than linen and ramie, has better hygroscopicity and drapability than linen and ramie, and also has great antibiotic ability. Therefore, jute has huge potentiality and application value in clothing making industry. As the content of lignin within jute is relatively high, which is several times as much as that within linen, it is not effective to degum jute fibres and remove the lignin from jute by using the existing degumming technology. And this greatly restrains the application of jute in making clothing. <The Effect of Enzyme Treatment on Jute fibres> published in Journal of Tianjin Industrial University volume 24 of Aug. 2005 introduces the effect of cellulose, hemicellulase, ligninase and pectin depolymerise used in processing the jute fibres, but this article only introduces the method of processing jute fibres using single one of above mentioned enzymes. Although, there are some paragraphs in which the methods of complex enzyme treatment are mentioned, it only refers to the complex enzyme obtained via mixing laccase and cellulose enzyme or mixing hemicellulase enzyme and cellulose enzyme. However, it is testified in practice that it is not effective to remove lignin from jute fibres using the degumming method published in this article. Chinese Patent publication No CN 1232691C introduces a method of degumming jute using complex enzyme. In the method, pectinase and laccase are used to produce a complex enzyme for degumming jute fibres, and the degummed jute fibres, after blended spun or interlaced with other fibres such as cotton fibres and chemical fibres, can generally meet the requirements for clothing materials. However, the effect of removing lignin from jute fibres in such prior art, is still not good enough, as the removal rate is only about 76%. The content of lignin remaining in the jute fibres is still very high. Further more the intensity and the breaking elongation ratio of the jute fibres obtained are still not good enough. Therefore, there is a need of blended spinning or interlacing jute fibres with other fibres such as cotton fibres, and chemical fibres, when making the clothing materials. However, the quality of clothing materials made through blended spinning or interlacing jute fibres with other fibres such as cotton fibres, and chemical fibres still needs to be improved.
BRIEF DESCRIPTION OF INVENTION
The present invention introduces the first method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
In the first method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1; b. adjusting the PH value of said complex enzyme water solution to more than 5.5, but no more than 6.5, and adjusting the temperature of said complex enzyme water solution to 35° C.-65° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
The first method, wherein said jute fibres are accumulation stored before the step d.
The first method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
The first method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
The first method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
The first method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
The first method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
The first method, wherein said jute fibres is pre-processed before the step a.
The first method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
The first method, wherein the temperature of water bath ranges from 30° C. to 65° C.; said acid is sulphuric acid or acetic acid.
The present invention introduces the second method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
In the second method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1; b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to above 35° C., but below 55° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
The second method, wherein said jute fibres are accumulation stored before the step d.
The second method, wherein the duration for accumulation storing said jute fibres ranges from 6 to 24 hours.
The second method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
The second method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
The second method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
The second method, wherein the temperature of said hot water is above 75° C.; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
The second method, wherein said jute fibres is pre-processed before the step a.
The second method, wherein pre-processing said jute fibres is either through one of the means of water bath, acid bath, and soaking with Hydrogen Peroxide, or through at least two of the three means.
The second method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
The present invention introduces the third method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
In the third method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is equal to or larger than 12:1, but smaller than 15:1; b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55°-600°, then keeping said complex enzyme water solution with such temperature value for 25-50 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
The third method, wherein said jute fibres are accumulation stored before the step d.
The third method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
The third method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
The third method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
The third method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
The third method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
The third method, wherein said jute fibres is pre-processed before the step a.
The third method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
The third method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
The present invention introduces the fourth method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
In the fourth method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is larger than 15:1, but no more than 40:1; b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55° C.-60° C., then keeping said complex enzyme water solution with such temperature value for 25-50 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
The fourth method, wherein said jute fibres are accumulation stored before step d.
The fourth method, wherein the duration for accumulation storing said jute fibres ranges from 6 to 24 hours.
The fourth method, wherein the enzyme deactivation of jute fibres in step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
The fourth method, wherein that the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
The fourth method, wherein the weight proportion of said complex enzyme and jute fibres ranges from 0.5:100 to 5:100.
The fourth method, wherein that the temperature of said hot water is above 75° C.; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
The fourth method, wherein that said jute fibres is pre-processed before the step a.
The fourth method, wherein that pre-processing said jute fibres is either through one of the means of water bath, acid bath, and soaking with Hydrogen Peroxide, or through the combination of at least two of the three means.
The fourth method, wherein that the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
The present invention introduces the fifth method of degumming jute fibres with complex enzyme to effectively remove pectin and lignin from said jute fibres.
In the fifth method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of:
a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres is 15:1, and the weight proportion of said complex enzyme and jute fibres is equal to or larger than 0.5:100, but smaller than 1:100; b. adjusting the PH value of said complex enzyme water solution to 5.0-5.5, and adjusting the temperature of said complex enzyme water solution to 55°-60°, then keeping said complex enzyme water solution with such temperature value for 25-50 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-8.0, and adjusting the temperature of said complex enzyme water solution to 60° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 25-50 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
The fifth method, wherein said jute fibres are accumulation stored before the step d.
The fifth method, wherein the duration of accumulation storing said jute fibres ranges from 6 to 24 hours.
The fifth method, wherein the enzyme deactivation of jute fibres in the step d is through washing with hot water or adjusting the PH value of jute fibres, or through the combination of the two means.
The fifth method, wherein the weight percentage of pectinase in said complex enzyme ranges from 30% to 90%.
The fifth method, wherein the temperature of said hot water is above 75°; the PH value of jute fibres is adjusted to above 10.0 or below 4.0.
The fifth method, wherein said jute fibres is pre-processed before the step a.
The fifth method, wherein the pre-processing of said jute fibres is either through one of the means of water bath, acid bath, and soaking with hydrogen Peroxide, or through the combination of at least two of the three means.
The fifth method, wherein the temperature of water bath ranges from 30° C. to 100° C.; said acid is sulphuric acid or acetic acid.
In comparison with the prior art, the present invention has several advantages as follows:
(1) It is effective to remove pectinase and laccase from jute fibres through accumulation storing the jute fibre before conducting enzyme deactivation of said jute fibres via washing the jute fibres with hot water or adjusting its PH value, wherein the removal rate of pectinase from the jute fibres reaches about 90%, even up to 96% as its highest value; the removal rate of lignin from the jute fibres reaches about 78%, even up to 86% as its highest value. The jute fibres degummed through abovementioned method will have high spinnability. (2) The process parameters that match with each other are used in treatment of degumming jute fibres with complex enzyme. Via adjusting the PH value of enzyme water solution to more than 5.5 (pectinase is in its highest activity when the PH value is within 4.5-5.0, and the activity of pectinase declines gradually along with the rise of PH value from 5.0), or choose a relatively low holding temperature (lower than 55° C.) while the jute fibres are in the PH value interval in which the jute fibres are in its high activity, select a suitable liquor ratio (laccase is in its highest activity, when the liquor ratio is 15, and its activity declines along with the rise or decline of the liquor ratio), or reducing the use of complex enzyme and adjusting the other process parameters used, so as to ensure the effectiveness of removing lignin from jute fibres, and to further ensure that the jute fibres with high intensity and good breaking elongation ratio can be obtained through the method of degumming of this invention (there can be a rise of the intensity which is more than 2 times as much as it was before, reaching 6-9 dN/tex, and a rise of the breaking elongation ratio which is 1.5 times as much as it was before, reaching about 5-8%), thereby making the length of jute fibres match the its fineness, so as to improving the spinnability; (3) Pre-processing jute fibres before being degummed can swell the jute fibres, so as to better reduce the interacting force among the single fibres, facilitate the contact between enzyme water solution and jute fibres, and remove the pectin and lignin from the jute fibres.
DETAILED DESCRIPTION OF INVENTION
EXAMPLE 1
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65° C., and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.1 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 20 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating up the solution to 70° C., and keeping the solution with such temperature value for 20 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 2
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° C. and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.0 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 120 minutes; after that, adjusting the PH value of the heated solution to 9.5 with sodium bicarbonate, heating up the solution to 55° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 3
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.5 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 55° C. and keeping the solution with such temperature value for 40 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating up the solution to 50° C., and keeping the solution with such temperature value for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 4
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.2 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 40° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating up the solution to 60° C., and keeping the solution with such temperature value for 90 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 5
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 60° C., and the holding time is 3 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.3 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 60 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating up the solution to 40° C., and keeping the solution with such temperature value for 70 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 6
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 6.4 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 70 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating up the solution to 45° C., and keeping the solution with such temperature value for 80 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 7
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.7 with acetic acid and sodium bicarbonate; next, heating up the complex enzyme water solution to 60° C. and keeping the solution with such temperature value for 80 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating up the solution to 65° C., and keeping the solution with such temperature value for 100 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 8
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.8 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 65° C. and keeping the solution with such temperature value for 90 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 110 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 9
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.6 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 100 minutes; after that, adjusting the PH value of the heated solution to 9.3 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 120 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 10
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65° C., and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 20 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 20 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 11
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 54° C. and keeping the solution with such temperature value for 120 minutes; after that, adjusting the PH value of the heated solution to 9.5 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 12
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 45° C. and keeping the solution with such temperature value for 40 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating the solution to 50° C., and keeping the solution with such temperature value for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 13
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution with such temperature value for 90 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 14
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 52° C. and keeping the solution with such temperature value for 60 minutes; after that, adjusting the PH value of the heated solution to 8.5 with sodium bicarbonate, heating the solution to 45° C., and keeping the solution with such temperature value for 70 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 15
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 53° C. and keeping the solution with such temperature value for 70 minutes; after that, adjusting the PH value of the heated solution to 9.0 with sodium bicarbonate, heating the solution to 40° C., and keeping the solution with such temperature value for 80 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 16
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.1 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 50° C. and keeping the solution with such temperature value for 80 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 100 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 17
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 35° C. and keeping the solution with such temperature value for 90 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution with such temperature value for 110 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 18
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 52° C. and keeping the solution with such temperature value for 100 minutes; after that, adjusting the PH value of the heated solution to 9.3 with sodium bicarbonate, heating the solution to 55° C., and keeping the solution with such temperature value for 120 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 19
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram, and pre-processing the jute fibres via water bath, wherein the temperature of the water is 65° C., and the holding time is 2 hour; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution with such temperature value for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution with such temperature value for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 20
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, while the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution with such temperature value for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution with such temperature value for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 21
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, while the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 22
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 23
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 13 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 24
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 25
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 12 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the temperature of which is 3.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 26
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 27
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 14 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 28
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65°, and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 16 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 29
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, wherein the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 40 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1. Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 30
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through acid bath, wherein the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 35 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 31
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 30 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 32
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath at the temperature of 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 3:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 25 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 33
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 4:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 20 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 34
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 35 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 35
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 2:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 17 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 36
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 1:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 18 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.0 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 37
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath, while the temperature of water bath is 65 °, and the holding time is 2 hours; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:7, and the weight proportion of such complex enzyme and the jute fibres is 0.8:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.5 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 25 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 24 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 80° C.; finally, the degummed jute fibres are obtained. The removal rate of pectin and lignin from jute fibres is indicated in the table 1. The result of experiment shows that this is one of the most preferred embodiments of this invention.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 38
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath and water bath, wherein the acid used for acid bath is concentrated sulphuric acid with the concentration of above 90%. The temperature of water bath is 30° and the holding time is 1 hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 9:1, and the weight proportion of such complex enzyme and the jute fibres is 0.9:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.5 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 6 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 95° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1. Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 39
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through both acid bath, wherein the acid used for acid bath is acetic acid with the concentration of above 90%. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 1:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 40 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 60° C., and keeping the solution at such temperature for 50 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 10 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 85° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 40
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through soaking the jute fibres in hydrogen peroxide with the concentration of 5 g/L. then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as the jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.3 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 50 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 15 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 41
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, pre-processing the bits of jute fibres through water bath at the temperature of 100°, and the holding time is half an hour; then, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 5:1, and the weight proportion of such complex enzyme and the jute fibres is 0.5:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 55° C. and keeping the solution at such temperature for 30 minutes; after that, adjusting the PH value of the heated solution to 7.7 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 40 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 20 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 3.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 42
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 4:1, and the weight proportion of such complex enzyme and the jute fibres is 0.6:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 60° C. and keeping the solution at such temperature for 45 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 12 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with water solution, the PH value of which is 11.0; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 43
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:3, and the weight proportion of such complex enzyme and the jute fibres is 0.9:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.2 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 57° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 8.0 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 35 minutes; then, taking the jute fibres out of the solution, and accumulation storing the jute fibres for 8 hours; next, conducting enzyme deactivation of the accumulation stored jute fibres by washing the jute fibres with hot water at 90° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 44
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 3:1, and the weight proportion of such complex enzyme and the jute fibres is 0.8:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.0 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 58° C. and keeping the solution at such temperature for 35 minutes; after that, adjusting the PH value of the heated solution to 7.8 with sodium bicarbonate, heating the solution to 70° C., and keeping the solution at such temperature for 45 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 10.0 and the temperature of which is 75° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
EXAMPLE 45
An experiment is conducted through the following steps: firstly, dividing the jute fibres into several bits, wherein each bit of jute fibres weighs about 0.5 kilogram; secondly, mixing the pectinase and laccase into complex enzyme, wherein the weight proportion of pectinase and laccase is 2:1, and the weight proportion of such complex enzyme and the jute fibres is 0.7:100; next, diluting the complex enzyme with water, in order to produce complex enzyme water solution which is 15 times in weight as much as jute fibres; after that, soaking the jute fibres in the diluted complex enzyme water solution; then, adjusting the PH value of the diluted complex enzyme water solution to 5.4 with acetic acid and sodium bicarbonate; next, heating the complex enzyme water solution to 56° C. and keeping the solution at such temperature for 25 minutes; after that, adjusting the PH value of the heated solution to 7.6 with sodium bicarbonate, heating the solution to 65° C., and keeping the solution at such temperature for 30 minutes; then, taking the jute fibres out of the solution; next, conducting enzyme deactivation of the jute fibres by washing the jute fibres with hot water, the PH value of which is 3.5 and the temperature of which is 80° C.; finally, the degummed jute fibres are obtained. The removal of pectin and lignin from jute fibres is indicated in the table 1.
Said degummed jute fibres will be highly spinnable, after being bleached, stamped, washed, dehydrated, and dried via the prior art.
The pectinase (Bioprep) and the laccase (Denilite) mentioned in above examples are produced by the a Danish company called Novozymes. Table 1 illustrates the removal rates of pectinase and lignin from jute fibres of the different examples.
While this invention has been described as having several preferred embodiments, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from this present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
TABLE 1
Examples
1
2
3
4
5
6
7
8
9
Removal rate of pectinase
86%
96%
90%
92%
95%
96%
92%
91%
89%
Removal rate of lignin
79%
79%
80%
80%
84%
86%
82%
81%
78%
Examples
10
11
12
13
14
15
16
17
18
Removal rate of pectinase
86%
96%
90%
91%
95%
96%
91%
91%
89%
Removal rate of lignin
79%
80%
80%
82%
84%
86%
82%
81%
78%
Examples
19
20
21
22
23
24
25
26
27
Removal rate of pectinase
88%
94%
90%
91%
95%
96%
91%
90%
89%
Removal rate of lignin
79%
80%
79%
80%
84%
86%
82%
81%
78%
Examples
28
29
30
31
32
33
34
35
36
Removal rate of pectinase
88%
96%
88%
91%
95%
96%
91%
90%
89%
Removal rate of lignin
79%
80%
79%
80%
84%
86%
82%
81%
78%
Examples
37
38
39
40
41
42
43
44
45
Removal rate of pectinase
87%
91%
89%
91%
94%
92%
90%
91%
88%
Removal rate of lignin
82%
78%
79%
79%
82%
85%
81%
80%
81%
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A method of degumming jute fibres with complex enzyme, wherein said complex enzyme comprises pectinase and laccase, wherein comprising the steps of: a. soaking the jute fibres in the water solution of said complex enzyme made from pectinase and laccase, wherein the weight proportion of said complex enzyme water solution and jute fibres ranges from 12:1 to 40:1; b. adjusting the PH value of said complex enzyme water solution to more than 5.0, but no more than 6.5, and adjusting the temperature of said complex enzyme water solution to 35° C.-65° C., then keeping said complex enzyme water solution with such temperature value for 20-120 minutes; c. adjusting the PH value of said complex enzyme water solution to 7.5-9.5, and adjusting the temperature of said complex enzyme water solution to 40° C.-70° C.; then, keeping said complex enzyme water solution with such temperature value for 20-120 minutes; d. conducting enzyme deactivation of the jute fibres processed with said complex enzyme.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/560,615 filed Nov. 16, 2006, presently issued as U.S. Pat. No. 8,157,925 on Apr. 17, 2012 of like title and inventorship, the entire contents which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains generally to the cleaning of vessels, and more particularly to an improved siphon capable of dislodging residue and pumping the resulting liquid and residue mixture from the vessel. The teachings of the present invention are illustrated in a most specific and advantageous manifestation as a tool for cleaning recreational vehicle water heaters.
2. Description of the Related Art
Whenever a group of people gather and discuss the inventions that have had the most profound effect on the world, at least one old-timer that remembers the early days will suggest that indoor plumbing should be considered as one of the most profound. What we take for granted today was extremely important to the development of our modern society, bringing not only great convenience and time-savings, but also very greatly advancing the health and welfare of the population. With plumbing and the sanitation that was derived directly therefrom, densely populated cities have been able to develop and thrive, while remaining free of what used to be very common ailments and diseases. A large number of more specific improvements have continued to occur over time, further advancing the utility of plumbing. These advances have further improved health, welfare, convenience, aesthetic appearance, and other beneficial areas.
One such noteworthy improvement is the modern capability to transport a fully self-contained plumbing system, wherever modern man travels. Not only is fresh drinking water transported and provided through a safe and convenient faucet and pressurized line, but in many additional instances, such as within a recreational vehicle (RV) or the like, there will also be a waste storage system and a water heater. The water heater provides a limited amount of hot water on demand, often used by a person for various cleansing tasks, cooking and consumption.
Another noteworthy improvement in the plumbing industry has been the use of copper as the material for fresh-water pipes. Copper is advantageously used for the freshwater lines since it provides important biocidal activity, inhibiting the growth of bacteria, yeast, fungi and algae. Even when ion exchange occurs between impurities in the water and the copper, the copper will remain bio-active. The bio-activity will continue, so long as a sludge or film has not isolated copper ions from the water. Furthermore, even when leached into the water in the low quantities as occurs in such a plumbing system, copper is non-toxic. Consequently, water may be retained within copper pipes for reasonable durations within a plumbing system without becoming odorous or toxic.
Unfortunately, many of the portable systems described herein above, including those with water heaters, sit idle for many months at a time. A recreational vehicle may be used for only a few weeks or months out of a year, the rest of the time remaining parked. Even if the water within the pipes were to remain suitable, a water heater presents a very different environment.
The unique environment within a water heater, when compared to ordinary pipes and pumps, comes with elevated temperatures and the containment of a large relatively stagnant volume of water. Within the containment of the water heater vessel, it is quite common for sludge and particulate to precipitate. As the water heater ages, rust, scale and other impurities continue to deposit and accumulate on the walls and adjacent to the bottom. The minerals, rust flakes, and other contaminants can literally fill the bottom of the tank.
The deposits form both a thermal barrier to the introduction of heat, either through the vessel walls in the case of a gas heater, or from the element into the liquid in the case of an electric heater. The precipitate also forms a mass which is not biocidal and which can therefore sustain the growth of offensive and potentially toxic microbes. Any standing water which sits for durations measured in months within a water heater vessel will consequently tend to foul and produce an associated unpleasant odor. In some instances, it is also possible for the impurities to corrosively interact with the tank, and thereby accelerate local corrosion. Furthermore, as is known, as these sediments accumulate the water heat will lose operational efficiency and will also likely fail earlier.
The extended periods and the accumulation of sludge and other materials common to a water heater will lead to fouling of the water and generation of offensive odor, the contents which is not readily flushed from the plumbing system. Copper, which exhibits biocidal activity, is somewhat more expensive than other alternative materials, and not widely used in water heaters. Nor is this biocidal activity sufficient to overcome the sludge and precipitates. Other materials have been used within plumbing systems through time, and iron plumbing is also relatively commonplace, as are various iron alloys and coated or plated steel. Plated steel offers an excellent compromise between cost and corrosion resistance, and so is commonly used. None of the ferrous materials exhibit substantial biocidal activity. Polymers such as polyvinyl-chloride and others have been used within plumbing systems, but these polymers do not provide any biocidal activity, and instead are now known to be prone to the formation of harmful biofilms. Furthermore, the polymers also do not readily conduct thermal energy, and so are undesirable for use in combustion-type water heaters, such as gas water heaters. In addition, no reasonably-priced polymers exist which may be safely used as the containment vessel within a water heater. Consequently, most plumbing systems prefer to use polymer plumbing only for waste-conveyance. Finally, some of the most expensive systems rely on stainless-steel alloys. These are far less common, owing to the cost, and like the steel counterparts offer far less biocidal activity than copper. In the end, it is just not plausible or practical through materials science to provide a water heater vessel material which is reasonably priced, safe for potable water supplies, and also sufficiently biocidal to preserve the high-impurity content water found within a heater vessel for extended periods.
While copper pipes are more likely to preserve the water, and are readily easily flushed simply by running fresh water through for a brief time period, the same is not true for the tanks. When preparing such a tank for the next use, a person is forced to run a great deal of water to remove the residue from the tank. Consequently, a great deal of time and effort is spent not only with desirable draining, but in the flushing of the tank and associated preparation immediately before use. This time is in distinct contradiction to the primary benefit of a recreational vehicle, which is the “ready-for-travel” nature of such a fully-equipped vehicle.
To protect the water systems from damage due to freezing, or simply to prepare the plumbing system for extended storage, water lines and the water heater are commonly drained. This may at first blush appear to provide the solution to longer term storage. However, while water lines often may be fully drained, many water heaters will still retain a small amount of water adjacent to the bottom of the vessel. This remnant water adjacent the bottom of the tank is invariably the most highly contaminated water within the tank, where the most material has been deposited. With the prior art techniques for draining, these water heaters will foul even when drained. As may be apparent, no viable and effective solution exists to leaving an RV water heater idle for extended periods, even though this is typical for most recreational vehicles so equipped.
While portable plumbing systems such as found in recreational vehicles have been primarily discussed, many of the same issues arise with plumbing systems found in geographically static structures such as buildings and houses. In particular, it is quite common to accumulate a great deal of scale, precipitate and other deposits within a building or household water heater. Like the RV counterpart, many water heaters do not provide a ready way to fully and completely open and clean the interior of the water vessel. Instead, most commercially available water heaters, RV or otherwise, are fitted with some type of drain valve to which a hose may be coupled. The opening into the water heater is frequently quite small and restricted, preventing most persons from accessing the interior of the vessel. These openings are also most commonly slightly above the lowest point within the vessel. Once again then, cleaning is greatly inhibited, with the owner relying primarily upon flushes of smaller suspended particulate. The larger particulate and sludge remain within the tank. In the case of most home water heaters however, there are rarely times where water will remain stagnant for extended intervals. Consequently, it is much less common for there to be any issue with an accumulation of biofilms or microorganisms, or the development of offensive odor.
Potable water systems are not the only plumbing systems which could benefit from a more thorough cleaning than was heretofore possible. Consequently, a review of other systems is also appropriate, though other than the references made in the present disclosure these systems may share little or nothing in common, nor provide any teachings to those skilled in the art of water heaters. One feature which is important with respect to the present invention and the teachings found herein is the presence of a water vessel within which undesirable contaminants may be found, and for which there does not exist an optimum way to thoroughly clean and flush the system. Such systems are found not only in water heaters but in some cooling systems, aquariums, swimming pools and swimming pool filters, and many other systems.
To clean such systems, it is known to introduce fresh water into the system while simultaneously siphoning off water containing the undesirable contaminants, impurities or particulates. One example of known siphon-type cleaning systems is found in U.S. Pat. No. 6,517,320 by Reynolds, entitled “Hose siphon,” the contents and teachings which are incorporated herein by reference. The Reynolds invention is designed for cleaning a swimming pool sand filter, and illustrates a fresh water faucet inlet split between a cleaning line and a siphon priming line, the cleaning line and a siphon drain line entering into the swimming pool sand filter, and a junction between the siphon priming line and the drain line. The turbulence created within the filter is intended to entrain the sand or other debris, and permit the debris to then be carried through the siphon line to some discharge point. However, because the Reynolds invention uses separate lines for cleaning and siphoning, the size of these lines is undesirably limited to an undesirably small percentage of the cross-sectional area available for a given opening. Furthermore, the ability to manipulate these lines is quite limited, other than controlling the depth of insertion into the filter. For a sand filter, the depth may be the only factor of interest. However, in the case of other vessels where sediment, films and other deposits may accumulate at any level or elevation within the vessel, simply creating turbulence at the bottom will be inadequate.
The separation of control valves from adjacent the water vessel opening is also inconvenient in the Reynolds invention, requiring the operator somehow monitor the operation at a distance. Once again, this may be irrelevant in the case of a sand filter, where an overflow of the filter might be relatively inconsequential. However, in the case of a water heater with only limited space between drain outlet and the bottom of the heater, and the likelihood that leakage from the water heater could damage adjacent furnishings or finished surfaces such as floors, floor coverings, or other furniture or appliances, it would be very desirable to be able to simultaneously control both the operation of the siphon and also the fresh water inlet. The operator will also have to closely monitor the siphon hose, to ensure that within the turbulent water the siphon inlet does not wander into a surface within the vessel and then remain held there by the siphon vacuum.
Finally, the Reynolds patent illustrates a siphon-priming valve which is displaced from the convergence with the siphon line, and which evidently is only suitable for priming. This is due to the fact that water exiting from 17 a will be flow-limited by the valve, and then will accumulate within line 9 , consequently losing nearly all kinetic energy. In other words, the Reynolds siphon is only able to siphon liquid to a point lower than the level of water within the sand filter. Once again, in the case of a swimming pool sand filter, this may be generally adequate. Nevertheless, this undesirably limits the available application to above-ground sand filters or to sand filters with a readily accessible nearby drain into which the siphon hose may be inserted. In contrast to the sand filter, a water heater commonly is located such that the drain opening is only a few inches above the ground level. In such cases, it may be difficult or impossible to initiate and sustain a suitable siphon into a suitable receptacle or available drain.
A similar though somewhat more basic combination of a spray line and a siphon line entering into a swimming pool sand filter is illustrated in U.S. Pat. No. 4,943,211 by Boegh, entitled “Sand filter cleaning system,” the contents and teachings which are additionally incorporated herein by reference. Patents that illustrate other background siphon devices, the contents and teachings which are incorporated herein by reference, include U.S. Pat. No. 3,645,452 by Stoeckel et al, entitled “Tank Cleaner;” U.S. Pat. No. 5,133,484 by Globert et al, entitled “Suction tube device;” French patent 2,630,011 by Raigneau, entitled “Apparatus for introducing a clean washing liquid into a container and removing the used liquid by siphoning, in particular for washing the stomach of a patient;” and German patent 4,330,430 by Hini et al, entitled “Installation for the separation and extraction of liquid.” Other patents, the contents and teachings which are incorporated herein by reference, illustrate the use of various tools in combination with siphons: U.S. Pat. No. 4,722,670 by Zweifel, entitled “Aquarium pump and cleaning system;” and U.S. Pat. No. 5,152,026 by Scarpine, entitled “Cooling tower cleaning device.” Finally, a number of artisans in the heretofore unrelated field of fluid pumps have developed various jet pump technologies, the contents and teachings which are incorporated herein by reference, including: U.S. Pat. No. 5,167,046 by Benson, entitled “Induction vacuum;” U.S. Pat. No. 5,322,222 by Lott, entitled “Spiral jet fluid mixer;” U.S. Pat. No. 5,556,259 by Hlavenka, entitled “Vortex generating fluid injector assembly;” U.S. Pat. No. 6,261,067 by Popov, entitled “Liquid-gas jet apparatus having a predetermined ratio for a cross-section of an active liquid nozzle and a mixing chamber;” U.S. Pat. No. 6,269,800 by Fischerkeller et al, entitled “Device for feeding fuel;” U.S. Pat. No. 6,471,489 by Hua, entitled “Supersonic 4-way self-compensating fluid entrainment device;” U.S. Pat. No. 6,537,036 by Broerman et al, entitled “Flow amplifying pump apparatus;” U.S. Pat. No. 6,547,532 by Gonzalez et al, entitled “Annular suction valve;” U.S. Pat. No. 6,575,705 by Akiyama et al, entitled “Jet pump throat pipe having a bent discharge end;” U.S. Pat. No. 6,783,334 by Sanderson et al, entitled “Hydraulic pump reservoir having deaeration diffuser;” and U.S. Pat. No. 6,904,769 by Ogata et al, entitled “Ejector-type depressurizer for vapor compression refrigeration system.”
SUMMARY OF THE INVENTION
Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a water-line connected fresh water source, a divider which splits the fresh water between a siphon primer outlet and a tank flush source line, a spray nozzle terminating the tank flush source line, a siphon tank return line sharing an external wall with or alternatively concentrically arranged about the tank flush source line, a mixing chamber at the junction between the siphon primer outlet and the siphon tank return line, and a drain line. In addition to the basic siphon and jet pump components, flow control valves and various cleaning utensils may be added as desired or required.
In a first manifestation, the invention is a siphon adapted for thoroughly cleaning fluid vessels and containers. The inventive siphon is capable of elevating discharge waste fluid to water heads greater than present in the fluid vessels and containers, and derives the necessary motive power through fluid kinetic energy provided by a pressurized fluid source thereby obviating the need for undesirable electrical, chemical, or other mechanical power sources. In operation the siphon is both intuitive and without unexpected action required, such that persons of diverse experience, knowledge and skill may readily use the apparatus. The siphon has an inlet receiving pressurized fluid from a pressurized fluid source. A divider splits pressurized fluid between a jet port outlet and a tank flush source conduit. A siphon return conduit carries waste fluid from the fluid vessels and containers during operation to a drain conduit. A mixing chamber is provided at a junction between the jet port outlet and an outlet from the siphon return conduit. The jet port outlet is operative when no waste fluid is passing from the siphon return conduit into mixing chamber to induce a siphon-generating flow into the drain conduit. The jet port outlet is also operative when waste fluid is passing from the siphon return conduit into the mixing chamber to introduce a fluid flow of higher velocity than solely within the waste fluid, to thereby transfer kinetic energy into the waste fluid to accelerate the waste fluid into the drain conduit.
In a second manifestation, the invention is an apparatus for cleaning above and within an aqueous body. In this manifestation, a fluid inlet receives a pressurized fluid from a pressurized fluid source. A drain conduit is provided. A tank flush source conduit is coupled with the fluid inlet and is operative to conduct pressurized fluid from a tank flush source conduit inlet adjacent to the fluid inlet to a tank flush source conduit outlet adjacent to the aqueous body. A siphon return conduit is concentrically arranged about the tank flush source conduit for conducting waste fluid from a siphon return conduit inlet adjacent to the aqueous body to a siphon return conduit outlet adjacent to the drain conduit, the tank flush source conduit outlet protruding from the siphon return conduit inlet.
In a third manifestation, the invention is a recreational vehicle water heater cleaning apparatus adapted for thoroughly cleaning recreational vehicle water heaters which is capable of elevating discharge waste fluid to water heads greater than a water head present within the recreational vehicle water heater. The cleaning apparatus derives the necessary motive power through fluid kinetic energy provided by a fluid source and thereby obviates the need for undesirable electrical, chemical, or other mechanical power sources. Further, operation is both intuitive and without unexpected action required such that persons of diverse experience, knowledge and skill may readily use the apparatus. These benefits are made possible by several components. An inlet receives pressurized fluid from the pressurized fluid source. A divider splits the pressurized fluid between a jet port outlet and a tank flush source conduit. A cleaning attachment terminates the tank flush source conduit. A siphon return conduit is concentrically arranged about the tank flush source conduit and is operative to carry waste fluid from the recreational vehicle water heater, with the cleaning attachment originating from within an inlet to the siphon return conduit and protruding therefrom. The spray nozzle operatively blocks the siphon return conduit from being held by siphon vacuum against a surface of the fluid vessels and containers. A drain conduit is provided, as is a mixing chamber at a junction between the jet port outlet and an outlet from the siphon return conduit. The jet port outlet is operative when no waste fluid is passing from the siphon return conduit into the mixing chamber to induce a siphon-generating flow into the drain conduit. The jet port outlet is operative when waste fluid is passing from the siphon return conduit into the mixing chamber to introduce a fluid flow of higher velocity than that of the waste fluid, and thereby transfer kinetic energy into the waste fluid to accelerate the waste fluid into the drain conduit.
OBJECTS OF THE INVENTION
A first object of the invention is to provide an apparatus for thoroughly cleaning a water heater. A second object of the invention is to enable the preferred cleaning apparatus to discharge waste fluid at water heads greater than present in the vessel being cleaned. Another object of the present invention is to provide the necessary motive power to drive the cleaning apparatus through fluid kinetic energy provided by a water source, and thereby obviate the need for undesirable electrical, chemical, or other mechanical power sources. A further object of the invention is to ensure that the operation of the preferred embodiment is intuitive and without unexpected action required, such that persons of diverse experience, knowledge and skill may readily use the apparatus. Yet another object of the present invention is to enable ready customization and adaptation of the present invention for diverse needs or applications.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment siphon adapted for cleaning vessels in accord with the teachings of the present invention, in further combination with a water heater and a discharge receptacle, all from a projected generally isometric view. To facilitate a better understanding of the operation, the water heater vessel is shown by cross-section, with other features of the water heater removed for clarity.
FIG. 2 illustrates the preferred embodiment siphon of FIG. 1 by cross-sectional view taken along a plane approximately dividing the siphon into two symmetrical halves.
FIG. 3 illustrates a first alternative embodiment siphon adapted for cleaning vessels in accord with the teachings of the present invention by cross-sectional view taken along a plane approximately dividing the siphon into two symmetrical halves.
FIG. 4 illustrates a second alternative embodiment source water flow control by enlarged partial cross-sectional view taken along a plane approximately dividing the water flow control into two symmetrical halves.
FIG. 5 illustrates a third alternative embodiment siphon adapted for cleaning vessels in accord with the teachings of the present invention by cross-sectional view taken along a plane approximately dividing the siphon into two symmetrical halves.
FIG. 6 illustrates the third alternative embodiment siphon by a bottom view with the spray outlet and drain lines disconnected.
FIGS. 7 and 8 illustrate a preferred divider used in the third alternative embodiment siphon of FIGS. 5 and 6 by bottom and side elevational views, respectively.
FIGS. 9 and 10 illustrate an alternative embodiment divider by bottom and side elevational views, respectively.
FIG. 11 schematically illustrates a prior art cleaning system with the spray conduit retracted from the drain conduit.
FIG. 12 schematically illustrates an alternative embodiment siphon adapted for cleaning vessels with the spray conduit terminating adjacent with the drain conduit termination.
FIG. 13 schematically illustrates the preferred embodiment siphon adapted for cleaning vessels of FIGS. 1 and 2 with spray conduit protruding from drain conduit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Various embodiments of apparatus designed in accord with the present invention have been illustrated in the various figures. The embodiments are distinguished by the hundreds digit, and various components within each embodiment designated by the ones and tens digits. However, many of the components are alike or similar between embodiments, so numbering of the ones and tens digits have been maintained wherever possible, such that identical, like or similar functions may more readily be identified between the embodiments. If not otherwise expressed, those skilled in the art will readily recognize the similarities and understand that in many cases like numbered ones and tens digit components may be substituted from one embodiment to another in accord with the present teachings, except where such substitution would otherwise destroy operation of the embodiment. Consequently, those skilled in the art will readily determine the function and operation of many of the components illustrated herein without unnecessary additional description.
A preferred embodiment siphon 100 , adapted for cleaning vessels and designed in accord with the teachings of the present invention, is illustrated in FIG. 1 . Siphon 100 is illustrated in a preferred further combination operatively cleaning a prior art water heater vessel 10 resting upon floor 30 , with siphon 100 drawing from vessel 10 and discharging waste water into a prior art discharge receptacle 20 also resting upon floor 30 . Discharge receptacle 20 may, for exemplary purposes only and certainly not limited thereto, take the form of an ordinary pail having a top opening 22 . Many other suitable fluid sinks are contemplated herein and known in the art, and again without limiting solely thereto may alternatively or additionally comprise such devices as sinks, plumbing drains, the earthen ground or other ground surface, and other suitable liquid receivers, sinks or receptacles. In some instances, it may further be desirable to filter or otherwise purify the waste water and recycle the water back into inlet 110 .
The illustration in FIG. 1 shows water heater vessel 10 containing water therein at an upper level 12 which is just below the level of drain hole 16 . The level illustrated may be obtained by ordinary use of drain hole 16 , such that a balance of water filling water heater vessel 10 would have been drained by gravity out of vessel 10 , either directly spilling therefrom or through some secondary discharge hose or conduit, the likes of which are known and not illustrated herein. In the case of prior art recreational vehicle water heaters, this drain hole 16 may only be approximately one-half inch in diameter, which is too small to permit or facilitate further prior art cleaning or inspection. Rust, scale, and other impurities and matter 14 will ordinarily be suspended within the water, and will also commonly include a substantial amount of sediment.
Siphon hose 130 has been inserted through opening 16 . Passing inside of siphon hose 130 is spray hose 140 . Most preferably, spray hose 140 extends into vessel 10 just farther than siphon hose 130 , such that spray hose 140 protrudes slightly therefrom. By so arranging hoses 130 , 140 , the inlet to siphon hose 130 cannot be blocked by accidental contact with a surface, which could in the prior art be followed by being held in this blocked position by the vacuum force created by the siphoning liquid. Instead, in the preferred embodiment siphon 100 , when hoses 130 , 140 approach a wall or floor of vessel 10 , the discharge of water from hose 140 will repel hoses 130 , 140 away. Consequently, the combination of siphon hose 130 and spray hose 140 with spray hose 140 protruding will facilitate proper movement and use of preferred embodiment siphon 100 .
Clean water or other suitable fluid is introduced into siphon 100 at inlet 110 , where it is metered and divided between outlet 120 and spray hose 140 , as will be explained in greater detail with respect to FIG. 2 . Desirably, fluid sprayed from spray hose 140 will interact with matter 14 to entrain and withdraw this matter from vessel 10 . Contaminating matter 14 and liquid are drawn into siphon hose 130 , pass through junction 150 to outlet 120 , and then pass into receptacle top opening 22 to be collected within discharge receptacle 20 .
FIG. 2 illustrates preferred embodiment siphon 100 of FIG. 1 in much greater detail. Most preferably fluid inlet 110 comprises a means for coupling to a pressurized water inlet. The coupling means in the simplest embodiment is inlet wall 112 , which forms a tight friction fit with a suitable tube from a water source. Any of a myriad of other couplings are contemplated herein, which might commonly include such devices as a garden hose terminating in either hose threads or quick release couplings, or any other fluid couplings known in the couplings art. Fluid passing into inlet 110 might commonly include ordinary tap or household water, at typical pressure levels of approximately thirty to sixty pounds per square inch (PSI). While water is described as the preferred fluid of choice, those skilled in the art will recognize that the fluid might alternatively include or be solely composed of other compounds, ranging from RV antifreeze to storage or cleaning solutions, such as but not limited to vinegar and water solutions, phosphoric acid solutions, chlorinated solutions, soap solutions, alcohol solutions, or others of the many known solutions which are suitable for use in cleaning or otherwise treating potable water supplies.
From adjacent to inlet wall 112 , the fluid will divide through two outlet ports. Spray outlet port 114 is of appropriate diameter to couple with inlet 142 in an interior conduit 146 of spray hose 140 . Jet port 116 will typically be of smaller diameter, and is used in two ways. The water passing through jet port 116 will serve as an initial primer to initiate a vacuum within outlet 120 . In other words, as water or fluid passes through jet port 116 and into the entrance 127 into interior passage 123 of outlet 120 , air will naturally be carried therewith. This flow of matter and mass out of passage 123 , which is greater than the fluid input through jet port 116 , will serve to build a vacuum which will extend into chamber 158 . The outlet 134 of siphon hose 130 is directly coupled into chamber 158 . Consequently, vacuum will also begin to build within the interior passage 136 of siphon hose 130 . Eventually, sufficient vacuum forces will be generated therein to draw fluid into siphon hose 130 through siphon inlet 132 , and this fluid will in many cases fill the entire space of interior passage 136 .
As this occurs, and chamber 158 similarly fills, the movement of fluid through jet port 116 will begin to interact directly with the fluid passing from interior passage 136 into chamber 158 . As a result, this same fluid will be accelerated by kinetic energy transferred from the fluid jet into siphon flow. Consequently, fluid passing through jet port 116 will not only serve to initiate a priming of siphon 100 , but this same fluid stream will act as a jet pump through the transfer of kinetic energy. Consequently, once operational, siphon 100 is not only able to act through siphon to transfer fluid from a container of higher surface or head to a container of lower surface or head, as is known in the siphon art, but the present invention is able to transfer from a container of lower surface or head to one of higher surface or head. This is of particular benefit in the case of a water heater that rests immediately adjacent to the ground or other surface, and which has a drain hole only a few inches higher. Rather than only being able to fill a discharge receptacle with a small quantity of the fluid within the water heater, preferred embodiment siphon 100 may fully discharge fluid until siphon hose inlet 132 no longer remains fully submerged, and so instead begins to draw air into siphon hose interior passage 136 . If siphon hose inlet 132 is subsequently re-submerged, then the priming and jet pumping process will restart.
Proper selection of the diameter of jet port 116 is important to the successful operation of preferred embodiment siphon 100 . The size is a function of the inlet pressure, the available cross-section of siphon hose interior passage 136 and outlet passage 123 , and the temperature and associated viscosity of the fluids being used. In the case of water, temperatures above freezing will result in no consequential changes in viscosity, and the preferred apparatus is quite tolerant of pressure variations. Consequently, those skilled in the art, without undue experimentation, will be able to select an appropriate jet port size for use within a siphon designed in accord with the present teachings. Another important factor is the material from which jet port 116 is fabricated. Since size is important to proper operation, it is desirable for a higher quality siphon 100 to include a jet port 116 which is fabricated from a material or alloy which is both reasonably hard or durable and which also exhibits excellent corrosion resistance. The extent of durability and corrosion resistance chosen will depend upon how long a designer wishes the present invention to last, cost considerations, and the expected operating pressures.
Proper orientation of jet port 116 with respect to outlet 120 and chamber 158 is also very important. While not specifically illustrated, a number of means are contemplated herein and known in the industry for obtaining this alignment. The particular means selected may further depend in part upon the methods of fabrication and coupling of each of the components. For exemplary purposes, and not solely limited thereto, inlet 110 may be threaded into junction 150 , in which case an alignment mark or the like will preferably be provide on the exposed side of inlet 110 distal to port 114 . As another exemplary means, a keyway and associated key may be provided to force alignment between inlet 110 and junction 150 , such as the formation of a small slot partially penetrating inlet 110 and a small protrusion extending from junction 150 into this slot. With such arrangement, inlet 110 may only be placed in alignment where the slot and protrusion align, thereby ensuring proper alignment. In this type of arrangement, inlet 110 might for exemplary purposes be press-fit into junction 150 adjacent to junction inlet 152 , or may be soldered, welded, adhesively bonded or otherwise rigidly affixed. Just as inlet 110 may be coupled through a myriad of appropriate methods, so exist a myriad of possibilities for the other couplings and junctions illustrated in the present invention. Furthermore, it is contemplated herein that ones of the various components illustrated herein may either be consolidated into a single unitary device, or they may be fabricated from a plurality of discrete components. In either case, the component assembly and methods of affixing are not critical, so long as the finished siphon remains functional. As aforementioned, there are a myriad of other suitable keying or alignment techniques that are known and applicable to the present invention.
An additional coupler 125 is illustrated in the preferred embodiment siphon 100 . This is so because it is anticipated that the spatial orientation of siphon 100 may be changed during use to help redirect spray outlet 144 about the interior surfaces of vessels to be cleaned. Nevertheless, outlet 120 will be expected to remain within discharge receptacle 20 or other discharge receptacle. Consequently, to best accommodate this movement, outlet 120 will most preferably include a conduit 121 which is flexible and pliant, such as one fabricated from pliable polymers, elastomers, rubbers, or rubber-like compounds. In such case, coupling may be readily achieved through many techniques, but the flared barbed end 126 of coupler 125 will in most cases serve to hold the end 124 of conduit 121 distal to outlet 120 termination 122 in place. Likewise, coupler 125 may be securely coupled to junction 150 adjacent junction outlet 156 using a threaded coupling 128 or by any other suitable means.
A first alternative embodiment siphon 200 adapted for cleaning vessels in accord with the teachings of the present invention is illustrated in FIG. 3 . For sake of brevity, components which are like in geometry and function to those illustrated in the preferred embodiment siphon 100 will not be numbered or separately discussed. Nevertheless, for this and the subsequent alternatives, it will be understood that these components are in fact present and function as already described herein above.
In siphon 200 , two noteworthy changes have been made. The first change is to inlet 210 , which differs from inlet 110 by the placement and orientation of jet port 216 relative to outlet entrance 127 . More particularly, jet port 216 will direct high pressure fluid directly into and parallel with outlet passage 123 , thereby fully preserving the kinetic energy of the fluid flowing through jet port 216 . Whether such kinetic energy remains primarily with that fluid and adjacent entrained air, or whether the kinetic energy is transferred into a siphon flow originating at siphon inlet 132 depends upon whether siphon 200 has been primed, and fluid is being conveyed from siphon inlet through to adjacent jet port 216 . Nevertheless, less kinetic energy is lost in siphon 200 than in siphon 100 .
The second noteworthy change illustrated in FIG. 3 is in the arrangement and geometry of the spray outlet. In contrast to simple tubular spray outlet 144 , spray tip 246 is held within a termination 244 of spray hose 240 by barbs or similar suitable means. Termination 244 is within the confines of siphon hose 130 , but spray tip 246 most preferably extends beyond inlet 132 of siphon hose 130 , for the same reasons as did spray outlet 144 . Rather than a single tubular stream or jet, spray tip 246 is configured for at least three jets, emanating from jet outlets 247 - 249 . While three smaller jet outlets are shown, it will be recognized that any suitable geometry may be provided within spray tip 246 , and that a plurality of tips may be designed for different functions or capabilities. Further, one or more of a variety of cleaning attachments such as brushes, squeegees or the like may be coupled within termination 244 or formed in association with spray tip 246 , the specific geometries which are taught for example by the Scarpine patent and others incorporated herein above by reference.
FIG. 4 illustrates a second alternative embodiment source water flow control by enlarged partial cross-sectional view, such that siphon hose 330 and spray hose 340 are only visible in small part adjacent to inlet 310 , and the entrance 327 to outlet 120 is visible, while outlet 120 is not. In this second alternative embodiment, fluid inlet 310 is divided between ports 314 and 316 , but neither of these ports is limited to a small enough diameter to generate a jet therefrom. Instead, port 314 passes valve body 311 and valve seat 313 into spray hose inlet 342 of spray hose 340 . Fluid entering port 316 will similarly pass valve body 315 and valve seat 317 , before being expelled from jet port 318 . Most preferably, jet port 318 is sufficiently small relative to the opening defined by valve seat 317 that, when desired, the pressure developed on the side of jet port 318 adjacent to seat 317 will build to nearly the pressure at fluid inlet 310 . In this way, valve seat 317 will not act as a detrimental flow restriction. Otherwise, valve seat 317 will reduce the kinetic energy being transferred by fluid passing through jet port 318 . From jet port 318 , fluid will pass into inlet 327 , from where it will most preferably couple co-axially with outlet 120 for discharge therefrom. Valve bodies 311 , 315 may each separately be adjusted, allowing a person to control both the amount and pressure of spray fluid emanating from a spray house outlet such as spray outlet 144 and also to control the priming and extent of jet pumping from jet port 318 . As but one example, when valve body 311 is closed, fluid will cease to be delivered into the fluid vessel. Nevertheless, the siphoning action persists, and any fluid within the vessel such as 12 illustrated in FIG. 1 may be drained. Particularly in those vessels where the bottom is lightly bowl-shaped or concave, remaining fluid will collect in the center of the bottom. In such case, it may be possible to remove almost all of the fluid from within the vessel. The vessel may be left in this state, or, if the operator so elects, valve 311 may once more be opened to run through another cleaning cycle.
An alternative embodiment arrangement of spray and siphon hoses is also illustrated in FIG. 4 . More particularly, while the previous embodiment hoses 130 , 140 were illustrated as being generally co-axial, with spray hose 140 of smaller cross-sectional area than siphon hose 130 , the co-axial arrangement is not necessary to the operation or functioning of the present invention. Nevertheless, it is most preferable to incorporate a smaller spray hose 140 within the cross-section of a larger siphon hose 130 , or to at least share a common exterior wall with at least a portion of the exterior of spray hose 140 serving as a portion of the interior surface defining siphon hose interior passage 136 . In this way, the limited cross-sectional area which is available in RV water heaters and in other applications will be most efficiently utilized by apparatus designed in accord with the teachings of the present invention. In the case of this figure, it is also conceived herein that spray outlets may be provided at any point and in any suitable pattern and size along the length of spray hose 340 as may be desired.
FIG. 5 illustrates a third alternative embodiment siphon 400 adapted for cleaning vessels in accord with the teachings of the present invention. In siphon 400 , several changes have been made. One change is to inlet 410 , which differs from inlet 210 by the incorporation of two ball valves 411 and 415 therein. While ball valves are illustrated herein as exemplary valves, those skilled in the art of fluid valves will recognize that a myriad of other valve types may be substituted herein, and such substitution is contemplated and incorporated herein. Valve 411 is used to solely control the amount and pressure of fluid emanating from spray outlet 448 , independent of flow through outlet 420 and siphon hose 430 . Valve 415 is used to control all water input, both to spray outlet 448 and to jet port 416 . While manufacture is somewhat more difficult than previous embodiments illustrated herein, the addition of these valves with the placement shown provides an operator with more convenient control over the operation of siphon 400 . As may be apparent, in the siphon 400 embodiment, inlet wall 412 in combination with valve 411 , spray outlet port 414 , and jet port 416 together form the divider that splits the incoming pressurized cleaning fluid into the two streams. Valve 411 when open ensures that the two streams are simultaneously flowing, and, if closed, blocks the spray outlet stream. In contrast, in the siphon 100 embodiment, inlet wall 112 in combination with spray outlet port 114 , and jet port 116 together form the divider that splits the incoming cleaning fluid into the two streams, and the two streams are always simultaneously flowing.
Another noteworthy change illustrated in FIG. 5 is in the arrangement and geometry of the spray outlet. While a simple tubular spray outlet is shown that ends adjacent to siphon inlet 432 , a protruding blocking member 460 of any suitable geometry serves to block siphon hose 430 from direct contact with aqueous vessel wall 18 . For exemplary purposes only, and not solely limiting thereto, protruding blocking member 460 may simply be one or more protrusions about siphon inlet 432 , or may alternatively take the form of one or more hemispherical arches. While it is less preferable to terminate spray outlet 448 adjacent to siphon inlet 432 , as will be further described herein below, protruding blocking member 460 will at least ensure that siphon 400 remains operational even when pressed against vessel wall 18 inadvertently.
FIG. 6 illustrates the third alternative embodiment siphon, focusing on junction 450 , by a bottom view with the spray outlet and drain lines disconnected. As visible therein, inlet wall 412 may be sloped or tapered from the inlet side towards ports 414 , 416 . This is also illustrated in FIGS. 7 and 8 . This taper, which forms a wedge that subtends less than 180 degrees, and in this preferred embodiment only ninety degrees, keeps junction outlet 456 as open as possible. Inlet wall 412 thereby forms only a minimal obstruction to the outflow of fluid from tank 10 . Additionally, in this embodiment jet port 416 is relatively centered with respect to junction outlet 456 , and thereby, with respect to outlet 420 .
FIG. 8 additionally illustrates an optional jet port extension 417 which may be used to reduce turbulence within the output jet flow. While not critical to the operation of the invention, there may be times where the incorporation of this extension 417 are beneficial and preferred.
FIGS. 9 and 10 illustrate an alternative embodiment inlet wall 512 by bottom and side elevational views, respectively. Rather than the wedge of inlet wall 412 , these figures illustrate a beveled face 519 that similarly helps to reduce the impact of the protrusion of inlet wall 512 into the outlet fluid stream flow. As may be apparent, other geometries which through ordinary technical evaluation optimize the flow of the outlet fluid stream are contemplated herein, and considered to be incorporated herein.
FIG. 11 illustrates a prior art cleaning system with the spray conduit retracted from the drain conduit. As illustrated therein, since return conduit 630 has a suction therein, fluid passing out of spray outlet 644 will tend to be drawn directly back into return conduit 630 . Fluid will follow flow path 645 from spray outlet 644 into return conduit 630 without even exiting return conduit inlet 632 . All fluid that flows directly from spray outlet 644 into return conduit 630 is wasted, since this spray outlet fluid never has an opportunity to contact vessel wall 18 , or interact with the water within vessel 10 or matter 14 which is to be removed. While some fluid from spray outlet 644 may ultimately contact vessel wall 18 , any fluid that does must first flow counter to fluid from vessel 10 flowing into return conduit 630 . This will lead to turbulence, and substantially reduced flow either from vessel 10 into return conduit 630 or from spray outlet 644 into vessel 10 .
FIG. 12 illustrates alternative embodiment siphon 400 with spray conduit 440 terminating adjacent with siphon hose conduit termination 432 . In this embodiment, fluid flowing from spray outlet 444 will follow flow path 445 , and at least pass outside of siphon hose conduit 630 inlet. As a result, there will be some interaction between the cleaning fluid, vessel wall 18 , and matter 14 , which is a significant improvement over flow path 645 of FIG. 11 .
FIG. 13 schematically illustrates preferred embodiment siphon 100 adapted for cleaning vessels with spray hose 140 protruding from siphon hose 130 . With sufficient separation between spray outlet 144 and siphon inlet 132 , cleaning fluid exiting spray outlet 144 will mix into vessel fluid while traversing fluid flow path 145 , and thereby entrain matter 114 therein. Further, the flow will form an eddy current as shown by the arrow for flow 145 that reinforces the entrainment and removal of matter 114 from vessel 10 . As might be apparent from a comparison of the three FIGS. 11-13 , the protruding spray hose 140 of FIG. 13 is vastly more effective at cleaning vessel wall 18 and removing matter 14 than either of the alternatives of FIGS. 11-12 .
The specific materials used in the fabrication of the various components within siphon 100 are generally not critical to the invention. Where importance has been given to the selection of materials, some suitable materials have been identified. Nevertheless, it will be obvious to one skilled in the art, upon a review of the present disclosure, to substitute other materials. Furthermore, the components as identified herein do not have to be fabricated in as few or as great a count as shown. Instead, several components may be fabricated as a single integral unit, or one component illustrated may be fabricated from several, as the needs of manufacturing become known for a particular design. Such substitutions are contemplated herein, in consideration with the functions which are outlined herein above.
As aforementioned, a number of different chemical compositions are contemplated for use herein. Exemplary of these, but not solely limited thereto, are RV antifreeze, other storage solutions, and cleaning and treatment solutions such as vinegar and water solutions, phosphoric acid solutions, chlorinated solutions, alcohol solutions, and soap or surfactant solutions. Rather than supply such cleaning solutions to both inlet 142 and jet port 116 , in some instances it may be desirable to introduce this solution solely to inlet 142 . In such case, a separate injector, metering device, venturi, or other suitable means may be provided subsequent to the division of pressurized fluid and adjacent to or even within spray hose 140 , through which additional ingredients may be introduced.
While the most preferred application for the present apparatus is the cleaning of potable water vessels such as RV water heaters, the invention is not limited solely thereto. In the case of a pair of aquariums, with a first one elevated with respect to a second one, and with the inlet of a typical aquarium pump and filter combination inserted into the lower second aquarium, the present invention can be used to assist with circulation between the two aquariums, permitting the single aquarium pump and filter combination to service both tanks. This is accomplished by connecting the outlet from the aquarium pump and filter to fluid inlet 310 of FIG. 4 . The spray outlet 344 is placed into the first elevated aquarium with siphon hose 330 , and must protrude therefrom such as illustrated in FIG. 13 . Next, outlet 320 is placed into the second lower aquarium. Valves 311 and 315 may then be controlled to adjust the amount of filtered water that passes into each tank. The height of siphon inlet 332 is what sets the top level of the first elevated tank. Should the elevated first tank receive an excess of water, this water will rise to the siphon inlet 332 , and from there siphon through siphon hose 330 into the second lower tank without consequence.
Similarly, the present apparatus may be used to clean aquariums, use the fluid stream to clean hard surfaces such as floors and counter-tops, and drain liquid from clogged plumbing fixtures. In one particularly diverse application, a spray outlet may be used to loosen and entrain earth and remove the earth through the siphon hose. As long as the spray outlet is advanced into the earth, this technique can be used to drill small diameter holes in the ground while continuously extracting the earth in the process.
Consequently, while the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. The scope of the invention is set forth and particularly described in the claims herein below.
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A siphon is adapted for thoroughly cleaning fluid vessels. The siphon is capable of elevating discharge waste fluid through a transfer of kinetic energy provided by a pressurized fluid source, thereby obviating any need for undesirable electrical, chemical, or other mechanical power sources. An inlet couples pressurized fluid to a divider that splits the pressurized fluid between a jet port outlet and a tank flush source conduit. A siphon return conduit is operative to carry waste fluid from the fluid vessel, with the cleaning attachment protruding from the siphon return conduit. By slightly protruding, the cleaning attachment operatively blocks the siphon return conduit from being held by siphon vacuum against a surface of the fluid vessel while developing a beneficial eddy current flow path. A drain conduit is provided, as is a mixing chamber at a junction between the jet port outlet and an outlet from the siphon return conduit.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present invention claims the benefit of U.S. provisional application Ser. No. 60/923,413, filed Apr. 13, 2007, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to frozen confection serving devices, and, more particularly, to ice cream scoops.
BACKGROUND OF THE INVENTION
[0003] Ice cream and other frozen confections are enjoyed around the world, and are often eaten with sprinkled candy or nuts on top. Traditionally, ice cream is stored in large refrigerated receptacles and scooped into smaller portions for individual servings. Traditionally, to serve a portion of ice cream with candy or nuts on top, a portion of ice cream is first scooped into an individual serving with a scoop, and then candy and/or nuts are sprinkled over the ice cream using a spoon, an open bag, or other dispensing device.
SUMMARY OF THE INVENTION
[0004] The present invention provides a dual function ice cream scoop that is used to perform the scooping of ice cream and is also used to perform the dispensing of candy confections, nuts, or other toppings. In one form of the present invention, the dual function scoop is provided with a hollow handle that is adapted to store candies, ground nuts, or the like. The scoop allows a user to scoop a portion of frozen confection, such as ice cream, and then sprinkle or otherwise dispense the candy out of the handle and onto the frozen confection before serving.
[0005] According to another form of the present invention, an ice cream scoop includes a scooping bowl and a handle. The handle defines a substantially hollow section to receive a topping such as a candy confection or nuts. The handle has a first end, a second end, a gripping surface, and at least one aperture. The aperture permits dispensing of the confection, and a cover is provided for covering the aperture. In one aspect of the invention, the handle is substantially clear to permit viewing of the confection inside the handle. Alternatively, the confection storing region of the device includes a viewing zone that is transparent and provides for viewing of the confection stored therein. That viewing zone or zones may be decoratively configured to increase the aesthetic appeal of the device. Still alternatively, the viewing zone or handle are translucent to allow viewing of the stored confection, and may impart other attributes such as a tinting or distortion of light reflected by the stored confections.
[0006] According to another form of the present invention, a method of serving ice cream is provided. The method includes providing an ice cream scoop having a handle defining a hollow section with a topping such as a candy confection contained inside the handle. The handle defines an aperture for dispensing the candy confection. Next, a portion of the frozen confection is scooped with the scoop, and the candy confection is dispensed through the aperture and onto the frozen confection.
[0007] These and other objects, advantages, purposes, and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a first embodiment of the ice cream scoop of the present invention;
[0009] FIG. 2 is another perspective view of the ice cream scoop;
[0010] FIG. 3 is a side elevation view of the ice cream scoop;
[0011] FIG. 4 is a top plan view of the ice cream scoop; and
[0012] FIG. 5 is a perspective view of the ice cream scoop, taken towards the second end as viewed from above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring now to the drawings, an ice cream scoop, one preferred form of which is referenced by the numeral 10 , is provided for serving frozen confections, such as ice cream, frozen yoghurt, frozen custard, or the like, and also allows a user to store and dispense candy confections onto the frozen confection. The scoop 10 has a bowl portion 12 and a handle portion 14 . Handle 14 is substantially hollow and has a first end 14 a and a second end 14 b . Bowl portion 12 is attached to handle 14 at first end 14 a . An end cap 16 is provided at second end 14 b of handle 14 ( FIGS. 1-5 ). End cap 16 includes an aperture 18 for dispensing a topping such as a candy confection 20 .
[0014] Handle 14 is a tapered hollow cylinder sized to comfortably fit in a user's hand. Handle 14 is open at second end 14 b , through which candy confection may be added to handle 14 . Handle 14 may incorporate dispensing holes (not shown) through the cylindrical wall, such as proximate first end 14 a , proximate second end 14 b , or between first end 14 a and second end 14 b . Handle 14 is made of clear plastic, and may be made of any suitably strong material resistant to embrittlement in low temperatures. Alternatively, for example, the handle may comprise an inner cylinder rotatably or slidably mounted within an outer cylinder, each cylinder having one or more dispensing holes that may be aligned to dispense candy, and un-aligned to prevent spillage of candy. Handle 14 may be opaque or translucent, for example, and may have a light filter to create color, reflection, refraction, and/or distortion effects on the light reflected by candy 20 . Alternatively, handle 14 may have one or more viewing regions (not shown), where the viewing regions may be one or more of a plurality of shapes, for example, stars, strips, circles, triangles, lines, etc.
[0015] End cap 16 is removable and fits snugly into second end 14 b of handle 14 , substantially closing off the opening in handle 14 at second end 14 b . End cap 16 defines aperture 18 . End cap 16 may be made of plastic, rubber, or other resilient material, and may be retained in handle 14 such as with screw threads, friction fit, snap-fit, or the like. Alternatively, end cap 16 may be fixed in second end 14 b of handle 14 .
[0016] Aperture 18 in end cap 16 ( FIGS. 2 and 5 ) has a diameter between approximately 2 millimeters to 10 millimeters, and may be larger or smaller depending on whether aperture 18 is to be used for filling or dispensing, or both filling and dispensing, candy 20 . Although shown as a single round hole, aperture 18 may comprise a plurality of smaller holes or slots such as when used only for dispensing candy 20 . A removable cover or plug 22 covers aperture 18 , to prevent undesired spillage or contamination of candy 20 in handle 14 . The plug may be made of rubber, for example, and may be hingedly attached or otherwise tethered to end cap 16 of handle 14 . Alternatively, the plug may comprise a sliding or rotating member to block aperture 18 when aperture 18 is not in use. Still alternatively, end cap 16 may be on a side of handle 14 , may be near bowl portion 12 , or may be inside bowl portion 12 , for example.
[0017] Examples of candy confections that may be used in conjunction with the dual function ice cream scoop of the present invention include, but are not limited to: M&M's® brand MINIS®, available from Mars Inc.; JOLLY RANCHER ROCKS®, available from Hershey Foods Corp.; and WONKA® brand NERDS®, available from Nestlé USA, Inc. However, it will be appreciated that any suitably small and clumping-resistant candy, or nuts, or other desired food item may be used with the invention.
[0018] Accordingly, the ice cream scoop 10 may be used to scoop a serving of frozen confection and then dispense candy 20 onto the frozen confection, such as by orienting the ice cream scoop such that aperture 18 is aimed downward, or by shaking or tapping scoop 10 to dispense candy 20 . Handle 14 may be filled with candy 20 by removing end cap 16 and filling handle 14 at second end 14 b , or by removing plug 22 from aperture 18 and filling handle 14 through aperture 18 .
[0019] As will be appreciated by those skilled in the art, alternative embodiments of dual function ice cream scoops are contemplated without departing from the spirit and scope of the present invention. The alternative embodiments described herein are intended to be exemplary and are not limiting in any way. For example, a first alternative embodiment of a dual function ice cream scoop includes a handle portion, a bowl portion, and a separate candy storage and dispensing chamber for storing and dispensing candy through one or more apertures in a wall of the chamber. In a second alternative embodiment, a dual function ice cream scoop incorporates a candy storage and dispensing chamber that is internally illuminated, and which may include one or more batteries and a switch to supply electrical energy to a light. In a third alternative embodiment, a dual function ice cream scoop incorporates a candy storage and dispensing chamber that is at least partially opaque and has one or more translucent or transparent regions or zones through which an interior portion of the candy storage and dispensing chamber may be viewed. The transparent region or zone may distort light reflected by candy in the candy storage and dispensing chamber, such as to create a distorted, colored, or textured view of the candy. The opaque regions and the translucent or transparent regions may be arranged in a decorative pattern and may, for example, create an aesthetically-pleasing visual effect when the storage and dispensing chamber is at least partially filled with candy. For example, the storage and dispensing chamber may be a hollow cylindrical handle with a spiral pattern of white opaque regions alternating with colorless transparent regions that, when the storage and dispensing chamber is at least partly filled with colored candy, creates a “candy cane” visual effect.
[0020] In a fourth alternative embodiment, a dual function ice cream scoop incorporates a candy storage and dispensing chamber and an agitator or vibrating device to facilitate the dispensing of candy through one or more apertures in a wall of the storage and dispensing chamber, and may include one or more batteries and a switch to supply electrical energy to the agitator or vibrating device. In a fifth alternative embodiment, a dual function ice cream scoop incorporates a candy storage and dispensing chamber, and an ejector device that is similar to ejector or firing devices commonly used in conjunction with spring-loaded BB guns or pinball machines. A small portion of candy, such as an individual candy piece, is received in an ejection chamber, whereupon a spring-loaded member is drawn back and released to impact the candy piece and eject it through a barrel or tube in the candy storage and dispensing chamber, and out through an aperture in an outer wall of the candy storage and dispensing chamber. The loading and ejecting functions may be automated such that individual candy pieces may be sequentially ejected in rapid succession by depressing and holding a switch, for example.
[0021] These and other changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.
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An ice cream scoop includes a scooping bowl and a handle coupled to the scooping bowl. The scoop defines a confection retention enclosure for receiving a candy confection therein. An aperture is provided for dispensing the confection out of the enclosure. A removable plug is used to cover the aperture to selectively permit and prevent the confection from being dispensed out of the enclosure. The retention enclosure may be transparent or translucent to permit viewing of the confection located therein.
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CROSS-REFERENCE TO OTHER APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/189,305 filed by Shilin Chen on Jul. 2, 2002, which is a continuation of U.S. patent application Ser. No. 09/629,344 filed by Shilin Chen on Aug. 1, 2000, now U.S. Pat. No. 6,412,577, which is a continuation of U.S. patent application Ser. No. 09/387,304 filed by Shilin Chen on Aug. 31, 1999, now U.S. Pat. No. 6,095,262, which claims the benefit of U.S. Provisional Application Serial No. 60/098,422 filed on Aug. 31, 1998, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates generally to the drilling of oil and gas wells, or similar drilling operations, and in particular to orientation of tooth angles on a roller cone drill bit.
[0003] Background: Rotary Drilling
[0004] Oil wells and gas wells are drilled by a process of rotary drilling, using a drill rig such as is shown in FIG. 10. In conventional vertical drilling, a drill bit 10 is mounted on the end of a drill string 12 (drill pipe plus drill collars), which may be more than a mile long, while at the surface a rotary drive (not shown) turns the drill string, including the bit at the bottom of the hole.
[0005] Two main types of drill bits are in use, one being the roller cone bit, an example of which is seen in FIG. 11. In this bit a set of cones 16 (two are visible) having teeth or cutting inserts 18 are arranged on rugged bearings on the arms of the bit. As the drill string is rotated, the cones will roll on the bottom of the hole, and the teeth or cutting inserts will crush the formation beneath them. (The broken fragments of rock are swept uphole by the flow of drilling fluid.) The second type of drill bit is a drag bit, having no moving parts, seen in FIG. 12.
[0006] Drag bits are becoming increasingly popular for drilling soft and medium formations, but roller cone bits are still very popular, especially for drilling medium and medium-hard rock. There are various types of roller cone bits: insert-type bits, which are normally used for drilling harder formations, will have teeth of tungsten carbide or some other hard material mounted on their cones. As the drill string rotates, and the cones roll along the bottom of the hole, the individual hard teeth will induce compressive failure in the formation.
[0007] The bit's teeth must crush or cut rock, with the necessary forces supplied by the “weight on bit” (WOB) which presses the bit down into the rock, and by the torque applied at the rotary drive. While the WOB may in some cases be 100,000 pounds or more, the forces actually seen at the drill bit are not constant: the rock being cut may have harder and softer portions (and may break unevenly), and the drill string itself can oscillate in many different modes. Thus the drill bit must be able to operate for long periods under high stresses in a remote environment.
[0008] When the bit wears out or breaks during drilling, it must be brought up out of the hole. This requires a process called “tripping”: a heavy hoist pulls the entire drill string out of the hole, in stages of (for example) about ninety feet at a time. After each stage of lifting, one “stand” of pipe is unscrewed and laid aside for reassembly (while the weight of the drill string is temporarily supported by another mechanism). Since the total weight of the drill string may be hundreds of tons, and the length of the drill string may be tens of thousands of feet, this is not a trivial job. One trip can require tens of hours and is a significant expense in the drilling budget. To resume drilling the entire process must be reversed. Thus the bit's durability is very important, to minimize round trips for bit replacement during drilling.
[0009] Background: Drill String Oscillation
[0010] The individual elements of a drill string appear heavy and rigid. However, in the complete drill string (which can be more than a mile long), the individual elements are quite flexible enough to allow oscillation at frequencies near the rotary speed. In fact, many different modes of oscillation are possible. (A simple demonstration of modes of oscillation can be done by twirling a piece of rope or chain: the rope can be twirled in a flat slow circle, or, at faster speeds, so that it appears to cross itself one or more times.) The drill string is actually a much more complex system than a hanging rope, and can oscillate in many different ways; see WAVE P ROPAGATION IN P ETROLEUM E NGINEERING , Wilson C. Chin, (1994).
[0011] The oscillations are damped somewhat by the drilling mud, or by friction where the drill pipe rubs against the walls, or by the energy absorbed in fracturing the formation: but often these sources of damping are not enough to prevent oscillation. Since these oscillations occur down in the wellbore, they can be hard to detect, but they are generally undesirable. Drill string oscillations change the instantaneous force on the bit, and that means that the bit will not operate as designed. For example, the bit may drill oversize, or off-center, or may wear out much sooner than expected. Oscillations are hard to predict, since different mechanical forces can combine to produce “coupled modes”; the problems of gyration and whirl are an example of this.
[0012] Background: Roller Cone Bit Design
[0013] The “cones” in a roller cone bit need not be perfectly conical (nor perfectly frustroconical), but often have a slightly swollen axial profile. Moreover, the axes of the cones do not have to intersect the centerline of the borehole. (The angular difference is referred to as the “offset” angle.) Another variable is the angle by which the centerline of the bearings intersects the horizontal plane of the bottom of the hole, and this angle is known as the journal angle. Thus as the drill bit is rotated, the cones typically do not roll true, and a certain amount of gouging and scraping takes place. The gouging and scraping action is complex in nature, and varies in magnitude and direction depending on a number of variables.
[0014] Conventional roller cone bits can be divided into two broad categories: Insert bits and steel-tooth bits. Steel tooth bits are utilized most frequently in softer formation drilling, whereas insert bits are utilized most frequently in medium and hard formation drilling.
[0015] Steel-tooth bits have steel teeth formed integral to the cone. (A hardmetal is typically applied to the surface of the teeth to improve the wear resistance of the structure.) Insert bits have very hard inserts (e.g. specially selected grades of tungsten carbide) pressed into holes drilled into the cone surfaces. The inserts extend outwardly beyond the surface of the cones to form the “teeth” that comprise the cutting structures of the drill bit.
[0016] The design of the component elements in a rock bit are interrelated (together with the size limitations imposed by the overall diameter of the bit), and some of the design parameters are driven by the intended use of the product. For example, cone angle and offset can be modified to increase or decrease the amount of bottom hole scraping. Many other design parameters are limited in that an increase in one parameter may necessarily result in a decrease of another. For example, increases in tooth length may cause interference with the adjacent cones.
[0017] Background: Tooth Design
[0018] The teeth of steel tooth bits are predominantly of the inverted “V” shape. The included angle (i.e. the sharpness of the tip) and the length of the tooth will vary with the design of the bit. In bits designed for harder formations the teeth will be shorter and the included angle will be greater. Gage row teeth (i.e. the teeth in the outermost row of the cone, next to the outer diameter of the borehole) may have a “T” shaped crest for additional wear resistance.
[0019] The most common shapes of inserts are spherical, conical, and chisel. Spherical inserts have a very small protrusion and are used for drilling the hardest formations. Conical inserts have a greater protrusion and a natural resistance to breakage, and are often used for drilling medium hard formations.
[0020] Chisel shaped inserts have opposing flats and a broad elongated crest, resembling the teeth of a steel tooth bit. Chisel shaped inserts are used for drilling soft to medium formations. The elongated crest of the chisel insert is normally oriented in alignment with the axis of cone rotation. Thus, unlike spherical and conical inserts, the chisel insert may be directionally oriented about its center axis. (This is true of any tooth which is not axially symmetric.) The axial angle of orientation is measured from the plane intersecting the center of the cone and the center of the tooth.
[0021] Background: Rock Mechanics and Formations
[0022] There are many factors that determine the drillability of a formation. These include, for example, compressive strength, hardness and/or abrasivity, elasticity, mineral content (stickiness), permeability, porosity, fluid content and interstitial pressure, and state of under-ground stress.
[0023] Soft formations were originally drilled with “fish-tail” drag bits, which sheared the formation away. Roller cone bits designed for drilling soft formations are designed to maximize the gouging and scraping action. To accomplish this, cones are offset to induce the largest allowable deviation from rolling on their true centers. Journal angles are small and cone-profile angles will have relatively large variations. Teeth are long, sharp, and widely-spaced to allow for the greatest possible penetration. Drilling in soft formations is characterized by low weight and high rotary speeds.
[0024] Hard formations are drilled by applying high weights on the drill bits and crushing the formation in compressive failure. The rock will fail when the applied load exceeds the strength of the rock. Roller cone bits designed for drilling hard formations are designed to roll as close as possible to a true roll, with little gouging or scraping action. Offset will be zero and journal angles will be higher. Teeth are short and closely spaced to prevent breakage under the high loads. Drilling in hard formations is characterized by high weight and low rotary speeds.
[0025] Medium formations are drilled by combining the features of soft and hard formation bits. The rock breaks away (is failed) by combining compressive forces with limited shearing and gouging action that is achieved by designing drill bits with a moderate amount of offset. Tooth length is designed for medium extensions as well. Drilling in medium formations is most often done with weights and rotary speeds between that of the hard and soft formations. Area drilling practices are evaluated to determine the optimum combinations.
[0026] Background: Roller Cone Bit Interaction with the Formation
[0027] In addition to improving drilling efficiency, the study of bottom hole patterns has allowed engineers to prevent detrimental phenomena such as those known as tracking, and gyration. The impressions a tooth makes into the formation depend largely on the design of the tooth, the tangential and radial scraping motions of the tooth, the force and speed with which the tooth impacts the formation, and the characteristics of the formation. Tracking occurs when the teeth of a drill bit fall into the impressions in the formation formed by other teeth at a preceding moment in time during the revolution of the drill bit. Gyration occurs when a drill bit fails to drill on-center. Both phenomena result in slow rates of penetration, detrimental wear of the cutting structures and premature failure of bits. Other detrimental conditions include excessive uncut rings in the bottom hole pattern. This condition can cause gyration, result in slow rates of penetration, detrimental wear of the cutting structures and premature failure of the bits. Another detrimental phenomenon is bit lateral vibration, which can be caused by radial force imbalances, bit mass imbalance, and bit/formation interaction among other things. This condition includes directional reversals and gyration about the hole center often known as whirl. Lateral vibration results in poor bit performance, overgage hole drilling, out-of-round, or “lobed” wellbores, and premature failure of both the cutting structures and bearing systems of bits. (Kenner and Isbell, DYNAMIC ANALYSIS REVEALS STABILITY OF ROLLER CONE ROCK BITS, SPE 28314, 1994).
[0028] Background: Bit Design
[0029] Currently, roller cone bit designs remain the result of generations of modifications made to original designs. The modifications are based on years of experience in evaluating bit records, dull bit conditions, and bottom hole patterns.
[0030] One method commonly used to discourage bit tracking is known as a staggered tooth design. In this design the teeth are located at unequal intervals along the circumference of the cone. This is intended to interrupt the recurrent pattern of impressions on the bottom of the hole. Examples of this are shown in U.S. Pat. No. 4,187,922 and UK application 2,241,266.
[0031] Background: Shortcomings of Existing Bit Designs
[0032] The economics of drilling a well are strongly reliant on rate of penetration. Since the design of the cutting structure of a drill bit controls the bit's ability to achieve a high rate of penetration, cutting structure design plays a significant role in the overall economics of drilling a well. Current bit designs have not solved the issue of tracking. Complex mathematical models can simulate bottom hole patterns to a limited extent, but they do not suggest a solution to the ever-present problem of tracking. The known angular orientations of teeth designed to improve tooth impact strength leave excessive uncut bottom hole patterns and do not solve the problem of tracking. The known angular orientations of teeth designed to increase bottom hole coverage, fail to optimize tooth orientation and do not solve the problem of tracking. Staggered tooth designs do not prevent tracking of the outermost rows of teeth. On the outermost rows of each cone, the teeth are encountering impressions in the formation left by teeth on other cones. The staggered teeth are just as likely to track an impression as any other tooth. Another disadvantage to staggered designs is that they may cause fluctuations in cone rotational speed, resulting in fluctuations in tooth impact force and increased bit vibration. Bit vibration is very harmful to the life of the bit and the life of the entire drill string.
[0033] Background: Cutting Structure Design
[0034] In the publication A NEW WAY TO CHARACTERIZE THE GOUGING-SCRAPING ACTION OF ROLLER CONE BITS (Ma, Society of Petroleum Engineers No. 19448, 1989), the author determines that a tooth in the first (heel or gage) row of the drill bit evaluated contacts the formation at −22 degrees (measured with respect to rotation of the cone about its journal) and begins to separate at an angle of −6 degrees. The author determines that the contacting range for the second row of the same cone is from −26 degrees to 6 degrees. The author states that “because the crest of the chisel inserts are always in the parallel direction with the generatrix of the roller cone radial scraping will affect the sweep area only slightly.” The author concludes that scraping distance is a more important than the velocity of the cutter in determining performance.
[0035] In U.S. Pat. No. 5,197,555, Estes discloses a roller cone bit having opposite angular axial orientation of chisel shaped inserts in the first and second rows of a cone. This invention is premised on the determination that inserts scrape diagonally inboard and either to the leading side (facing in the direction of rotation) or to the trailing side (facing opposite to the direction of rotation). It is noted that the heel row inserts engage the formation to the leading side, while the second row inserts engage the formation to the trailing edge. In one embodiment, the inserts in the heel row are axially oriented at an angle between 30 degrees and 60 degrees, while the inserts in the second row are axially oriented between 300 degrees and 330 degrees. This orientation is designed to provide the inserts with a higher resistance to breakage. In an alternative embodiment, the inserts in the heel row are oriented at an axial angle between 300 degrees and 330 degrees, while the inserts in the second row are axially oriented between 30 degrees and 60 degrees. This orientation is designed to provide the inserts with a broader contact area with the formation for increased formation removal, and thereby an increased rate of penetration of the drill bit into the formation.
[0036] Summary: Roller-Cone Bits, Systems, Drilling Methods, and Design Methods with Optimization of Tooth Orientation
[0037] The present application describes bit design methods (and corresponding bits, drilling methods, and systems) in which tooth orientation is optimized jointly with other parameters, using software which graphically displays the linearized trajectory of each tooth row, as translated onto the surface of the cone. Preferably the speed ratio of each cone is precisely calculated, as is the curved trajectory of each tooth through the formation. However, for quick feedback to a design engineer, linear approximations to the tooth trajectory are preferably displayed.
[0038] The disclosed innovations, in various embodiments, provide one or more of at least the following advantages:
[0039] The disclosed methods provide a very convenient way for designers to take full advantage of the precision of a computer-implemented calculation of geometries. (The motion over hole bottom of roller cone bit teeth is so complex that only a complex mathematical model and associated computer program can provide accurate design support.)
[0040] The disclosed methods provide convenient calculation of tooth trajectory over the hole bottom during the period when the tooth engages into and disengages from the formation.
[0041] The disclosed methods permit the orientation angle of teeth in all rows to be accurately determined based on the tooth trajectory.
[0042] The disclosed methods permit the influence of tooth orientation changes on bit coverage ratio over the hole bottom to be accurately estimated and compensated.
[0043] The disclosed methods also permit designers to optimally select different types of teeth for different rows, based on the tooth trajectory.
[0044] The following patent application describes roller cone drill bit design methods and optimizations which can be used separately from or in synergistic combination with the methods disclosed in the present application. That application, which has common ownership, inventorship, and effective filing date with the present application, is:
[0045] Application Ser. No. 09/387,737, filed 31 Aug. 1999, entitled “Force-Balanced Roller-Cone Bits, Systems, Drilling Methods, and Design Methods” (atty. docket no. SC-9825), claiming priority from U.S. provisional application No. 60/098,466 filed 31 Aug. 1998.
[0046] That nonprovisional application, and its provisional priority application, are both hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0048] FIGS. 1 A- 1 C shows a sample embodiment of a bit design process, using the teachings of the present application.
[0049] [0049]FIG. 2 shows the tangential and radial velocity components of tooth trajectory, viewed through the cutting face (i.e. looking up).
[0050] [0050]FIGS. 3A, 3B, 3 C, and 3 D show plots of planar tooth trajectories for teeth in four rows of a single cone, referenced to the XY coordinates of FIG. 2.
[0051] [0051]FIGS. 4A and 4B show tangential and radial distances, respectively, for the four tooth trajectories shown in FIGS. 3 A- 3 D.
[0052] [0052]FIG. 5 is a sectional view of a cone (normal to its axis), showing how the tooth orientation is defined.
[0053] [0053]FIG. 6 shows time-domain plots of tooth tangential speed, for the five rows of a sample cone, over the duration of the trajectory for each row.
[0054] [0054]FIGS. 7A and 7B show how optimization of tooth orientation can perturb the width of uncut rings on the hole bottom.
[0055] [0055]FIGS. 8A and 8B show how optimization of tooth orientation can disturb the tooth clearances.
[0056] [0056]FIGS. 9A, 9B and 9 C show the screen views which a skilled bit designer would see, according to some embodiments of the invention, while working on a bit optimization which included optimization of tooth orientation.
[0057] [0057]FIG. 10 shows a drill rig in which bits optimized by the teachings of the present application can be advantageously employed.
[0058] [0058]FIG. 11 shows a conventional roller cone bit, and FIG. 12 shows a conventional drag bit.
[0059] [0059]FIG. 13 shows a sample XYZ plot of a non-axisymmetric tooth tip.
[0060] [0060]FIG. 14 shows axial and sectional views of the i-th cone, and illustrates the enumeration of rows and teeth.
[0061] FIGS. 15 A- 15 D show how the planarized tooth trajectories vary as the offset is increased.
[0062] FIGS. 16 A- 16 D show how the ERSD and ETSD values vary for all rows of a given cone as offset is increased.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
[0064] Overview of Sample Design Process
[0065] FIGS. 1 A- 1 C show a sample embodiment of a bit design process, using the teachings of the present application. Specifically, FIG. 1A shows an overview of the design process, and FIGS. 1B and 1C expand specific parts of the process.
[0066] First, the bit geometry, rock properties, and bit operational parameters are input (step 102 ). Then the 3D tooth shape, cone profile, cone layout, 3D cone, 3D bit, and 2D hole profile are displayed (step 104 ).
[0067] Since there are two types of rotation relevant to the calculation of the hole bottom (cone rotation and bit rotation), transformation matrices from cone to bit coordinates must be calculated (step 106 ). (See FIG. 1B.) The number of bit revolutions is input (step 108 ), and each cone is counted (step 110 ), followed by each row of teeth for each cone (step 112 ). Next, the type of teeth of each row is identified (step 114 ), and the teeth are counted (step 116 ). Next, a time interval delta is set (step 118 ), and the position of each tooth is calculated at this time interval (step 120 ). If a given tooth is not “cutting” (i.e., in contact with the hole bottom), then the algorithm continues counting until a cutting tooth is reached (step 122 ). The tooth trajectory, speed, scraping distance, crater distribution, coverage ratio and tracking ratios for all rows, cones, and the bit are calculated (step 124 ). This section of the process (depicted in FIG. 1B) gives the teeth motion over the hole bottom, and displays the results (step 126 ).
[0068] Next the bit mechanics are calculated. (See FIG. 1C.) Again transformation matrices from cone to bit coordinates are calculated (step 128 ), and the number of bit revolutions and maximum time steps, delta, are input (step 130 ). The cones are then counted (step 132 ), the bit and cone rotation angles are calculated at the given time step (step 134 ), and the rows are counted (step 136 ). Next, the 3D tooth surface matrices for the teeth on a given row are calculated (step 138 ). The teeth are then counted (step 140 ), and the 3D position of the tooth on the hole bottom is calculated at the given time interval (step 142 ). If a tooth is not cutting, counting continues until a cutting tooth is reached (step 144 ). The cutting depth, area, volume and forces for each tooth are calculated, and the hole bottom model is updated (based on the crater model for the type of rock being drilled). Next the number of teeth cutting at any given time step is counted. The tooth force is projected into cone and bit coordinates, yielding the total cone and bit forces and moments. Finally the specific energy of the bit is calculated (step 146 ).
[0069] Finally, all results are outputted (step 148 ). The process can then be reiterated if needed.
[0070] Four Coordinate Systems
[0071] Four coordinate systems are used, in the presently preferred embodiment, to define the crest point of a tooth in three dimensional space. All the coordinate system obey the “Right Hand Rule”. These coordinate systems—tooth, cone, bit, and hole—are described below.
[0072] Local Tooth Coordinates
[0073] [0073]FIG. 13 shows a sample XYZ plot of a tooth tip (in tooth local coordinates). Tooth coordinates will be indicated here by the subscript t. (Of course, each tooth has its own tooth coordinate system.) The center of the X t Y t Z t coordinate system, in the presently preferred embodiment, is located at the tooth center. The coordinate of a tooth's crest point P t will be defined by parameters of the tooth profile (e.g. tooth diameter, extension, etc.).
[0074] Cone Coordinates
[0075] [0075]FIG. 14 shows axial and sectional views of the i-th cone, and illustrates the enumeration of rows and teeth. Cone coordinates will be indicated here by the subscript c. The center of the cone coordinates is located in the center of backface of the cone. The cone body is fixed with respect to these coordinates, and hence THESE COORDINATES ROTATE WITH THE CONE. (Of course, each cone has its own cone coordinate system.) The axis Z c coincides with the cone axis, and is oriented towards to the bit center. Cone axes Y c and X c , together with axis Z c , follow the right hand rule. As shown in FIG. 13, four parameters are enough to completely define the coordinate of the crest point of a tooth on cone profile. These four parameters are H c , R c , φ c and θ c . For all the teeth on the same row, H c , R c , and φ c are the same.
[0076] Bit Coordinates
[0077] Similarly, a set of bit axes X b Y b Z b , indicated by the subscript b, is aligned to the bit. The bit is fixed with respect to these coordinates, and hence THESE COORDINATES ROTATE WITH THE BIT. Axis Z b preferably points toward the cutting face, and axes X b and Y b are normal to Z b (and follow the right-hand rule).
[0078] Hole Coordinates
[0079] The simplest coordinate system is defined by the hole axes X h Y h Z h , which are fixed in space. Note however that axes Z b and Z h may not be coincident if the bit is tilted. FIG. 2 shows the tangential and radial velocity components of tooth trajectory, viewed through the cutting face (i.e. looking up). Illustrated is a small portion of a tooth trajectory, wherein a tooth's crest (projected into an X h Y h plane which approximates the bottom of the hole) moves from point A to point B, over an arc distance ds and a radial distance dr.
[0080] Transformations
[0081] Since all of these coordinate systems are xyz systems, they can be interrelated by simple matrix transformations.
[0082] Both the bit and the cones are rotating with time. In order to calculate the position on hole bottom where the crest point of a tooth engages into formation, and the position that the crest point of a tooth disengages from formation, all the teeth positions at any time must be described in hole coordinate system XhYhZh.
[0083] The transformation from tooth coordinates X t Y t Z t to cone coordinates X c Y c Z c can be defined by a matrix Rtc, which is a matrix function of teeth parameters:
Rtc=f ( H c , R c , θ c , φ c ),
[0084] so that any point P t in X t Y t Z t can be transformed into local cone coordinates X c Y c Z c by:
P c =R tc *P t .
[0085] At time t=0, it is assumed that the plane X c O c Z c is parallel to the bit axis. At time t, the cone has a rotation angle λ around its negative axis (−Z c ). Any point on the cone moves to a new position due to this rotation. The new position of P c in X c Y c Z c can be determined by combining linear transforms.
[0086] The transform matrix due to cone rotation is R cone :
R cone =cos(λ) I +(1−cos(λ)) NcNc ′+sin(λ) Mc,
[0087] where N c is the rotation vector and M c is a 3*3 matrix defined by N c .
[0088] Therefore, the new position P crot of P c due to cone rotation is:
P
crot
=R
cone
*P
c
[0089] Let R cb1 , R cb2 , and R cb3 be respective transformation matrices (for cones 1, 2, and 3) from cone coordinate to bit coordinates. (These matrices will be functions of bit parameters such as pin angle, offset, and back face length.) Any point P ci in cone coordinates can then be transformed into bit coordinates by:
P b =R cbi *P ci +P c0i for i= 1, 2, or 3,
[0090] where P c0i is the origin of cone coordinates in the bit coordinate system.
[0091] The bit is rotating around its own axis. Let us assume that the bit axes and hole axes are coincident at time t=0. At time t, the bit has a rotation angle β. The transform matrix due to bit rotation is:
Rbh =cos(β) I +(1−cos(β)) NbNb ′+sin(β) Mb
[0092] where Nb is the rotation vector and Mb is a 3*3 matrix defined by Nb.
[0093] Therefore, any point Pb in bit coordinate system can be transformed into the hole coordinate system X h Y h Z h by:
Ph=Rbh*Pb.
[0094] Therefore, the position of the crest point of any tooth at any time in three dimensional space has been fully defined by the foregoing seven equations. In order to further determine the engage and disengage point the formation is modeled, in the presently preferred embodiment, by multiple stepped horizontal planes. (The number of horizontal planes depends on the total number of rows in the bit.) In this way, the trajectory of any tooth on hole bottom can be determined.
[0095] Calculation of Trajectories in Bottomhole Plane
[0096] With the foregoing transformations, the trajectory of the tooth crest across the bottom of the hole can be calculated. FIGS. 3A, 3B, 3 C, and 3 D show plots of planar tooth trajectories, referenced to the hole coordinates X h Y h , for teeth on four different rows of a particular roller cone bit. The teeth on the outermost row (first row) scrapes toward the leading side of the cone. Its radial and tangential scraping distances are similar, as can be seen by comparing the first bar in FIG. 4A with the first bar in FIG. 4B. However for teeth on the second row the radial scraping motion is much larger than the tangent motion. The teeth on the third row scrape toward the trailing side of the cone, and the teeth on the forth row scrape toward the leading side of the cone.
[0097] [0097]FIGS. 4A and 4B show per-bit-revolution tangential and radial distances, respectively, for the four tooth trajectories shown in FIGS. 3 A- 3 D. Note that, in this example, the motion of the second row is almost entirely radial, and not tangential.
[0098] Projection of Trajectories into Cone Coordinates
[0099] The tooth trajectories described above are projected on the hole bottom which is fixed in space. In this way it is clearly seen how the tooth scrapes over the bottom. However for the bit manufacturer or bit designer it is necessary to know the teeth orientation angle on the cone coordinate, in order either to keep the elongate side of the tooth perpendicular to the scraping direction (for maximum cutting rate in softer formations) or to keep the elongate side of the tooth in line with the scraping direction (for durability in harder formations). To this end the tooth trajectories are projected to the cone coordinate system. Let P 1 ={x 1 , y 1 , z 1 } c and P 2 ={x 2 , y 2 , Z 2 } c be the engage and disengage points on cone coordinate system, respectively, and approximate the tooth trajectory P 1 -P 2 as a straight line. Then the scraping angle in cone coordinates is:
R s ={square root}{square root over (( x 2 −x 1 ) 2 +( y 1 +y 2 ) 2 )}
[0100] and
γ s = tan - 1 ( R s z 2 - z 1 )
[0101] The teeth can then be oriented appropriately with respect to this angle gamma. For example, for soft formation drilling the tooth would preferably be oriented so that its broad side is perpendicular to the scraping direction, in order to increase its rate of rock removal. In this case, the direction γ c of the elongate crest of the tooth, in cone coordinates, is normal to γ s , i.e. γ c =γ s +π/2. Conversely, for drilling harder formations with a chisel-shaped tooth it might be preferable to orient the tooth with minimum frontal area in the direction of scraping, i.e. with γ c =γ s .
[0102] Derivation of Equivalent Radial and Tangential Scraping
[0103] There are numerous parameters in roller cone design, and experienced designers already know, qualitatively, that changes in cone shape (cone angle, heel angle, third angle, and oversize angle) as well as offset and journal angle will affect the scraping pattern of teeth in order to get a desired action-on-bottom. One problem is that it is not easy to describe a desired action-on-bottom quantitatively. The present application provides techniques for addressing this need.
[0104] Two new parameters have been defined in order to quantitatively evaluate the cone shape and offset effects on tooth scraping motion. Both of these parameters can be applied either to a bit or to individual cones.
[0105] (1) Equivalent Tangent Scraping Distance (ETSD) is equal to the total tangent scraping distance of all teeth on a cone (or bit) divided by the total number of the teeth on the cone (or bit).
[0106] (2) Equivalent Radial Scraping Distance (ERSD) is equal to the total radial scraping distance of all teeth on a cone (or bit) divided by the total number of the teeth on the cone (or bit).
[0107] Both of these two parameters they have much more clear physical meaning than the offset value and cone shape.
[0108] Surprisingly, the arcuate (or bulged) shape of the cone primarily affects the ETSD value, and the offset determines the ERSD value. Also surprisingly, the ERSD is not equal to zero even at zero offset. In other words, the teeth on a bit without offset may still have some small
[0109] radial scraping effects.
[0110] The radial scraping direction for all teeth is always toward to the hole center (positive).
[0111] However, the tangential scraping direction is usually different from row to row.
[0112] In order to use the scraping effects fully and effectively, the leading side of the elongated teeth crest should be orientated at an angle to the plane of the cone's axis, which is calculated as described above for any given row.
[0113] [0113]FIG. 2 shows the procedure in which a tooth cuts into (point A) and out (point B) the formation. Due to bit offset, arcuate cone shape and bit and cone rotations, the motion from A to B can be divided into two parts: tangent motion ds and radial motion dr. Notice the tangent and radial motions are defined in hole coordinate system XhYh. Because ds and dr vary from row to row and from cone to cone, we derive an equivalent tangent scraping distance (ETSD) and an equivalent radial scraping distance (ERSD) for a whole cone (or for an entire bit).
[0114] For a cone, we have
ETSD = ∑ j Nr ds j Nt j Nc and ERSD = ∑ j Nr dr j Nt j Nc
[0115] where Nc is the total tooth count of a cone and Nr is the number of rows of a cone.
[0116] Similarly for a bit, we have
ETSD = ∑ i 3 ∑ j Nr ds ij Nt ij Nb and ERSD = ∑ i 3 ∑ j Nr dr ij Nt ij Nb
[0117] where Nb is the total tooth count of the bit.
[0118] FIGS. 15 A- 15 D show how the planarized tooth trajectories vary as the offset is increased. These figures clearly show that with the increase of the offset value, the radial scraping distance is increased. Surprisingly, the radial scraping distance is not equal to zero even if the offset is zero. This is due to the arcuate shape of the cone.
[0119] FIGS. 16 A- 16 D show how the ERSD and ETSD values vary for all rows of a given cone as offset is increased. From these Figures, it can be seen that the tangent scraping distance of the gage row, while very small compared to other rows but is not equal to zero. It means that there is a sliding even for the teeth on the driving row. This fact may be explained by looking at the tangent speed during the entry and exit of teeth into and out of the rock. (FIG. 6 shows time-domain plots of tooth tangential speed, for the five rows of a sample cone, over the duration of the trajectory for each row.) During the cutting procedure the tangent speed is not equal to zero except for one instant. Because the sliding speed changes with time, the instantaneous speed is not the best way to describe the teeth/rock interaction.
[0120] Note that the tangent scraping directions are different from row to row for the same cone. FIG. 5 is a sectional view of a cone (normal to its axis), showing how the tooth orientation is defined in the present application: the positive direction is defined as the same direction as the bit rotation. This means that the leading side of tooth on one row may be different from that on another row.
[0121] The ERSD increases almost proportionally with the increase of the bit offset. However, ERSD is not zero even if the bit offset is zero. This is because the radial sliding speed is not always zero during the procedure of tooth cutting into and cutting out the rock.
[0122] Calculation of Uncut Rings, and Row Position Adjustment
[0123] [0123]FIGS. 7A and 7B show how optimization of tooth orientation can perturb the width of uncut rings on the hole bottom. The width of uncut rings is one of the design constraints: a sufficiently narrow uncut ring will be easily fractured by adjacent cutter action and mud flows, but too large an uncut ring will slow rate of penetration. Thus one of the significant teachings of the present application is that tooth orientation should not be adjusted in isolation, but preferably should be optimized jointly with the width of uncut rings.
[0124] Interference Check
[0125] Another constraint is tooth interference. In the crowded geometries of an optimized roller cone design, it is easy for an adjustment to row position to cause interference between cones. FIGS. 8A and 8B graphically show how optimization of tooth orientation can disturb the tooth clearances. Thus optimization of tooth orientation is preferably followed by an interference check (especially if row positions are changed).
[0126] Iteration
[0127] Preferably multiple iterations of the various optimizations are used, to ensure that the various constraints and/or requirements are all jointly satisfied according to an optimal tradeoff.
[0128] Graphic Display
[0129] The scraping motion of any tooth on any row is visualized on the designer's computer screen. The bit designer has a chance to see quantitatively how large the motion is and in which direction if bit geometric parameters like cone shape and offset are changed.
[0130] [0130]FIGS. 9A, 9B and 9 C show the screen views which a skilled bit designer would see, according to some embodiments of the invention, while working on a bit optimization which included optimization of tooth orientation. These three views show representations of tooth orientation and scraping direction for each tooth row on each of the three cones. This simple display allows the designer to get a feel for the effect of various parameter variations
[0131] Calculation of Cone/Bit Rotation Ratio
[0132] The present application also teaches that the ratio between the rotational speeds of cone and bit can be easily checked, in the context of the detailed force calculations described above, simply by calculating the torques about the cone axis. If these torques sum to zero (at a given ratio of cone and bit speed), then the given ratio is correct. If not, an iterative calculation can be performed to find the value of this ratio.
[0133] However, it should be noted that the exact calculation of the torque on the cones is dependent on use of a solid-body tooth model, as described above, rather than a mere point approximation.
[0134] Previous simulations of roller cone bits have assumed that the gage row is the “driving” row, which has no tangential slippage against the cutting face. However, this is a simplification which is not completely accurate. Accurate calculation of the ratio of cone speed to bit speed shows that it is almost never correct, if multiple rows of teeth are present, to assume that the gage row is the driver.
[0135] Changes in the tooth orientation angle will not themselves have a large immediate effect on the cone speed ratio. However, the tooth orientation affects the width of uncut rings, and excessive uncut ring width can require the spacing of tooth rows to be changed. Any changes in the spacing of tooth rows will probably affect the cone speed ratio.
[0136] Definitions:
[0137] Following are short definitions of the usual meanings of some of the technical terms which are used in the present application. (However, those of ordinary skill will recognize whether the context requires a different meaning.) Additional definitions can be found in the standard technical dictionaries and journals.
[0138] Drag bit: a drill bit with no moving parts that drills by intrusion and drag.
[0139] Mud: the liquid circulated through the wellbore during rotary drilling operations, also referred to as drilling fluid. Originally a suspension of earth solids (especially clays) in water, modem “mud” is a three-phase mixture of liquids, reactive solids, and inert solids.
[0140] Nozzle: in a passageway through which the drilling fluid exits a drill bit, the portion of that passageway which restricts the cross-section to control the flow of fluid.
[0141] Orientation: the angle of rotation with which a non-axisymmetric tooth is inserted into a cone. Note that a tooth which is axisymmetric (e.g. one having a hemispherical tip) cannot have an orientation.
[0142] Roller cone bit: a drilling bit made of two, three, or four cones, or cutters, that are mounted on extremely rugged bearings. Also called rock bits. The surface of each cone is made up of rows of steel teeth (generally for softer formations) or rows of hard inserts (typically of tungsten carbide) for harder formations.
[0143] According to a disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: adjusting the orientation of at least one tooth on a cone, in dependence on an expected trajectory of said tooth through formation material at the cutting face, in dependence on an estimated ratio of cone rotation to bit rotation; recalculating said ratio, if the location of any row of teeth on said cone changes during optimization; recalculating the trajectory of said tooth in accordance with a recalculated value of said cone speed; and adjusting the orientation of said tooth again, in accordance with a recalculated value of said tooth trajectory.
[0144] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of calculating the trajectory of at least one tooth on each cone through formation material at the cutting face; and jointly optimizing both the orientations of said teeth and the width of uncut rings on said cutting face, in dependence on said trajectory.
[0145] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit comprising the steps of: a) adjusting the orientation of at least one row of teeth on a cone, in dependence on an expected trajectory of said tooth through formation material at the cutting face; b) calculating the width of uncut rings of formation material, in dependence on the orientation of said row of teeth, and adjusting the position of said row of teeth in dependence on said calculated width; and c) recalculating the rotational speed of said cone, if the position of said row is changed, and accordingly recalculating said trajectory of teeth in said row.
[0146] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: calculating the respective trajectories, of at least two non-axisymmetric teeth in different rows of a roller cone bit, through formation material at the cutting face; and graphically displaying, to a design engineer, both said trajectories and also respective orientation vectors of said teeth, as the engineer adjusts design parameters.
[0147] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: calculating the curved trajectory of a non-axisymmetric tooth through formation material at the cutting face, as the bit and cones rotate; calculating a straight line approximation to said curved trajectory; and orienting said tooth with respect to said approximation, and not with respect to said curved trajectory.
[0148] According to another disclosed class of innovative embodiments, there is provided: A roller cone drill bit designed by any of the methods described above, singly or in combination.
[0149] According to another disclosed class of innovative embodiments, there is provided: A rotary drilling system, comprising: a roller cone drill bit designed by any of the methods described above, singly or in combination a drill string which is mechanically connected to said bit; and a rotary drive which rotates at least part of said drill string together with said bit.
[0150] According to another disclosed class of innovative embodiments, there is provided: A method for rotary drilling, comprising the actions of: applying weight-on-bit and rotary torque, through a drill string, to a drill bit designed in accordance with any of the methods described above, singly or in combination.
[0151] Modifications and Variations
[0152] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0153] For example, the various teachings can optionally be adapted to two-cone or four-cone bits.
[0154] In the example of FIGS. 9 A- 9 C the crest profiles of all rows except the gage rows are shown as identical (and their crest orientations are indicated by simple ellipses). However, this is not necessary: optionally the designer can be allowed to plug in different tooth profiles for different rows, and the optimization routines can easily substitute various tooth profiles as desired. In particular, various tooth shapes can be selected from a library of profiles, to fit the scraping motion of each row.
[0155] In one contemplated class of alternative embodiments, the orientations of teeth can be perturbed about the optimal value, to induce variation between the gage rows of different cones (or within an inner row of a single cone), to provide some additional resistance to tracking.
[0156] Of course the bit will also normally contain many other features besides those emphasized here, such as gage buttons, wear pads, lubrication reservoirs, etc. etc.
[0157] Additional general background, which helps to show the knowledge of those skilled in the art regarding implementations and the predictability of variations, may be found in the following publications, all of which are hereby incorporated by reference: A PPLIED D RILLING E NGINEERING , Adam T. Bourgoyne Jr. et al., Society of Petroleum Engineers Textbook series (1991), O IL AND G AS F IELD D EVELOPMENT T ECHNIQUES : D RILLING , J.-P. Nguyen (translation 1996, from French original 1993), M AKING H OLE (1983) and D RILLING M UD (1984), both part of the Rotary Drilling Series, edited by Charles Kirkley.
[0158] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
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A novel and improved roller cone drill bit and method of design are disclosed. A roller cone drill bit for drilling through subterranean formations having an upper connection for attachment to a drill string, and a plurality cutting structures rotatably mounted on arms extending downward from the connection. A number of teeth are located in generally concentric rows on each cutting structure. The actual trajectory by which the teeth engage the formation is mathematically determined. A straight-line trajectory is calculated based on the actual trajectory. The teeth are positioned in the cutting structures such each tooth having a designed engagement surface is oriented perpendicular to the calculated straight-line trajectory.
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In producing chemical pulp according to the Kraft chemical pulp process, waste liquor is produced that is being evaporated prior to burning. During the evaporation process, liquor vapor is stripped off, which in addition to water vapor, also contains certain volatile contaminants. Such contaminants are hydrogen sulfide, methylmercaptan, dimethylsulfide, methanol, terpenes etc. At the evaporation which takes place as a so called multiple effect evaporation with a number of stages, effects (normally 4-7), the liquor vapor is also condensed in multiple stages, whereby also large amounts of the volatile contaminants will condense. The condensation takes place in at least as many stages there are effects. This means that the quality of the condensate varies significantly from the different stages of the evaporation. Normally 2-3 different condensate qualities are being separated, where each one is a mixture of condensates from a number of effects. The dirtiest condensate, (foul condensate), is normally treated in a steam stripper where the volatile components are flashed off. This foul condensate is typically a small amount of the total condensate flow and therefore the steam economy is not affected to any higher degree of the fact that steam is used as the stripper gas. The investment cost can also be kept at a minimum.
The purity of the other condensate qualities is highly dependent on the amount of foul condensate. If the amount of foul condensate is increased the contaminated condensates will be cleaner. A too high amount of foul condensate however the operating and investment cost for the steam stripper system will increase.
The other, less contaminated condensates can to a limited extent be used as process water in dependency of their cleanliness. However if the condensate is too contaminated it can not be re-used but must instead be discharged to the recipient subsequent to some form of treatment
The primary limiting factor for the use of the contaminated condensate as process water is the content of sulfides, as these can give an unpleasant small and taste to the pulp. It also creates a significant problem for the working environment. Also terpenes give a smell. The terpenes however are normally present at very low amounts in the less contaminated condensates.
The technology available to clean these condensates is predominately steam stripping. Since the various condensate flows are very large, the size of the stripper will be significant and a large amount of steam will be required for stripping. The steam volumes will be so large that it will definitely not be economical to use fresh steam. On the other hand it is possible to use flash steam driven off from the evaporation of the waste liquor, in multiple effect evaporation for the stripping. The steam leaving the stripper then can be regained as heat in the next evaporation effect. The cleaning efficiency of such a stripper is however limited since the flash steam from the preceding effect is already contaminated with sulfides, which limits the degree of purity of the output condensate. Primarily the cleanliness is limited regarding sulphides, as the waste liquor can have a considerable content of sulphides. This sulphide content is dependent on that steam is normally taken from the first effect, where the temperature is rather high, which gives an increased sulphide content.
Another drawback is that when the steam passes through the stripper, it loses pressure and volatile components are enriched. These two things will reduce the condensation temperature, which means that the temperature difference available at the evaporation is reduced. The energy and capital cost are both negatively impacted thereby. Furthermore the evaporation plant and the stripper are completely integrated, whereby these two parts can not be independently operated.
The dimensions of the stripper also will become large, which means significant costs for the equipment.
In a conventional steam stripper also other volatile components, such as methanol, are stripped off.
Air can be used to in lieu of steam to strip the condensates. A big drawback with this method is that air is being contaminated and must be cleaned in some way. The air volumes can also be very large. Additionally the condensate is being cooled down by the air, which has a lower wet bulb temperature as compared to the temperature of the condensate. For these reasons pure air stripping is not a realistic alternative for a modern and environmentally friendly pulp mill.
The present invention provides a possibility to strip off primarily sulfides at a very high efficiency from liquor-steam condensates from a pulp manufacturing process, and simultaneously to take care of the sulphur, thus that it will not contaminate the environment. This is being done in a closed loop concept that is comprised of three process steps, where the sulfides are stripped off from the condensate, the stripped off sulfides are being oxidized to sulphur dioxide, and to absorb the sulphur dioxide formed.
The three process steps are consequently:
1. Stripping off sulphides from liquor-steam condensate
2. Oxidation of combustible components such as sulphides and hydro carbons.
3. Absorption of sulphur dioxide.
By integrating these three process steps (1, 2, and 3) in a closed loop cycle, the cleaning of condensates can be done with a high efficiency, good heat economy, and minimal impact on the environment
BRIEF DESCRIPTION OF THE DRAWING
The drawing schematically shows the various process steps in accordance with the invention.
DETAILED DESCRIPTION
The invention will in the following text be exemplified with reference to a scheme show in the attached drawing.
In the present invention a gas is used as a medium for stripping off the sulphides from the condensate. This gas is substantially and preferably composed of air. This process step is normally designed as a scrubber column 1 , where the gas 4 is introduced in the lower section and the condensate 5 in the upper section, thus that the gas and the condensate meet in counterflow contact. The contact means in the scrubber can be trays or packing material. The gas 6 leaving the scrubber will contain sulphides in form i.a of hydrogen sulphide and methyl mercaptan, but also organic compounds such as methanol and terpenes. This contaminated gas 6 is led to an oxidization process 2 , where the gas is treated counterflow in a regenerative beat exchanger. The gas 7 from the oxidization step contains partly sulphur dioxide These gases are then fed to a contact device, in form of a SO 2 scrubber 3 , where the sulphur dioxide is absorbed in a preferably alkaline solution 8 . The gas is then returned to the condensate scrubber to be used again as a stripping medium. In this manner is formed a closed the loop. Since oxidation in the closed loop consumes oxygen is necessary to add fresh oxygen. Additional oxygen can be added by supply 9 preferably of air or some other oxygen containing gas. The system does not allow for gas accumulation in the loop and therefore a minor portion of the gas 10 must be bled off. The gas circulation through the three process steps is accomplished by the use preferably of a fan.
Since the gas in the closed loop is primarily being circulated, an elevated level of various gas components can accumulate to rather high levels. However, since only a minor portion of the gas is bled off, the discharge of components harmful to the environment, will be limited, in spite of high concentrations in the system.
A method of improving the cleaning of the condensate in the stripper is to increase the level of SO 2 after the SO 2 scrubber ( 3 ). Such a method will result in that the condensate in the stripper ( 1 ) will get a lower pH value. A lower pH value in turn gives a better stripping of sulphides and makes possible an almost complete stripping of sulphides. This would otherwise be difficult to achieve since the condensate contains a smaller amount of alkali components, i.e. ammonia, which would increase the pH value of the condensate when the acidic sulfides are stripped off. An alkali component such as ammonia will remain in the condensate at a lowered pH. Thereby is avoided discharge of ammonia, which should otherwise be transformed to Nox, after the oxidation process.
An increase of the SO 2 concentration after the SO 2 scrubber ( 3 ) can be obtained by adjusting the supply of alkali to this stage thus that the te absorption medium will get a comparatively lower pH. The lower the pH the higher the SO 2 concentration in the gas leaving the scrubber ( 3 ). The higher the SO 2 -level in the gas, which constitutes the stripper media, the better the efficiency of stripping off sulfides from the condensate. In turn this effect can be utilized in such a way that the ratio between the condensate flow and stripper gas flow can be increased with continuos good sulphide stripping. This in turn implies an elevated level of sulphides in the stripper off gases, which in turn means an increased SO 2 level after the oxidization step. In this way the SO 2 level in the entire system can be significantly increased. This gives the following benefits the SO 2 concentration after the SO 2 scrubber can be:
1. Production of a sodiumbisulfite solution with a relative low pH is made possible.
2. The size of the plant can be reduced
3. NO x emission is reduced (see above)
The first benefit is accomplished since an increased SO 2 level in a gas, from an equilibrium point of view, gives a lower pH in the absorption medium. Since the addition of alkali is reduced a bisulfite solution is formed. This acid can be utilized as acidification in e.g. the bleach plant or the tall oil plant. An increased SO 2 -level in the recirculated gas results however in an increased SO 2 discharge from the system via the bleed off to the atmosphere ( 10 ). Connecting a scrubber in this point, to absorb SO2 can cure this. A scrubber in this position is preferably designed with multiple absorption steps, e.g. of the same design as the stripper. It could be so that only SO 2 is permitted to be absorbed in this position. In that way the SO 2 scrubber ( 3 ) can be eliminated from the system.
The second benefit follows the fact that the circulating gas volume substantially determines the size of the equipment Since an increased SO 2 content facilitates a higher ratio of condensate/stripper gas flow, the gas flow in the system can be reduced.
The cleaned condensate will contain very low levels of sulphides and also any terpenes will be stripped off. This will give a condensate which is rather free from nasty-smelling contaminants. Methanol is another significant contaminant in black liquor condensate.
Some of the methanol will be stripped off in the stripper and some will stay in the condensate. The amount stripped off methanol is dependent on the ratio of supplied condensate to gas and the volume of the circulated gas.
The heat economy in the system is excellent since no external heat energy must be added. In the oxidation stage, heat is furthermore generated. This energy can compensate for various energy losses in the system, and any surplus can be absorbed as heat in the outgoing condensate. In other systems, where for example air is used as stripper gas, a significant amount of heat is absorbed in the air since the warm condensate transfers water vapor in contact with air. This cools down the condensate, which is avoided in the present invention, where any possible evaporated water vapor is returned to the system. It might also be possible to recover heat from the system by implementing a heat exchanger in the system. With such a heat exchanger, which cools the system, the temperature can be controlled.
There might also be a need to supply heat to the system. One reason could be to avoid oversaturated gas in certain parts of the system. As the recirculated gas, for instance after the stripper, is saturated with water vapor there is a risk that water droplets will fall out as moisture in the gas. By heating the gas, it would be possible to eliminate that moisture.
The investment costs and the size of equipment is mainly directly proportional to the amount of recirculated gas. For that reason it is important to minimize the gas recirculation. This will consequently have an impact on the methanol removal. It is therefore reasonable to count with a certain amount of methanol still remaining in the condensate. Methanol, as a pollutant in the condensate can be a drawback if the condensate is discharged to the recipient. If the condensate is being recirculated back into the process, e.g. as process water in the bleach plant, brown stock washing or limewashing, then the condensate is excellent in spite of the methanol content.
Methanol has a positive impact on bleaching, it acts as a radical scavenger and it also increases the solubility of lignin. Furthermore, this condensate is metal free. Normal process water prepared from nearby water streams always contains a certain amount of metals, such as i.a. transition metals. These transition metals can be very harmful for the bleaching process since they decompose the bleaching agents such as hydrogen peroxide. Since the methanol act as a radical scavenger, the degradation of cellulose molecules will decrease. A metal free condensate used in the bleach plant therefore has significant benefits in spite of a certain methanol content. By recirculating the condensate to the process a discharge of oxygen consuming matters is avoided. The methanol enrichment in the process is very marginal, since the discharge of methanol from the process is relatively large for each process cycle.
The stripping of condensate can be performed in several different ways. The type of equipment chosen shall be an equipment having a very high stripper efficiency. Such type of equipment ought to have several equilibrium steps, where the condensate meets a counterflow of gas. Examples on such equipment are columns with trays or packing material. This is well defined in the technical literature, such as i.e. “Perry's Chemical Engineers' Handbook”, MacGraw-Hill Book Company, 1984.
The oxidization process can be done in different ways, but the relatively low concentrations of combustible components require certain prerequisites for this type of process. A relatively high temperature is needed in order to oxidize the combustible components. A regenerative thermal oxidization process (RTO) is preferred where the gas is treated in a heat exchanger under such temperature conditions that almost a complete oxidization takes place. Example on such a process is described in the patent application PCT/SE85/00257.
Scrubbing of the SO 2 gas can be done with an alkaline solution At a pulp mill there is a surplus of alkaline process fluids. One such fluid is oxidized white liquor. In the oxidized white liquor the sulfides have been removed by oxidization. White liquor is such a strong alkali that SO 2 easily can be absorbed. One equilibrium stage is sufficient. A venturi scrubber is a piece of equipment wherein one equilibrium stage is almost achieved. A relatively high gas velocity can be maintained in a venturi scrubber, which makes it compact. The scrubber medium is circulated through the venturi.
The pH of the scrubber medium shall be controlled in order to control the SO 2 level in the gases leaving the scrubber. The venturi scrubber has also a significant benefit in that the circulating liquid can have a relatively short residence time. This implies a fast control of the pH in the scrubber. As the scrubber has only almost one equilibrium stage instead of several, a rapid response time is also achieved.
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A method to remove sulfides and other volatile contaminants from liquor vapor condensate in a pulp manufacturing process, where the mentioned liquor vapor condensate is fed into a stripper, which is part of a closed loop system including the stripper, a regenerative thermal oxidization process (RTO) and a SO 2 scrubber, in which loop a gas is circulated, preferably air, and such components formed or stripped off, in this loop whereafter the circulating gas is stripped off sulfides and other volatile components from the liquor vapor condensate, whereafter the gas stream is fed into a RTO process, where the stripped off contaminants are combusted are under formation of SO 2 and thereafter the SO 2 enriched gas is led to a SO 2 scrubber, where preferably alkali is used as absorption medium, and thereafter the circulating gas is returned back into the stripper.
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CROSS-REFERENCE TO A RELATED APPLICATION
This application claims priority under 35 U.S.C. §119 based on U.S. Provisional Patent Application No. 61/718,785, which was filed on Oct. 26, 2012, the subject matter of each of which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to the field of rotary filling machines for dispensing dry products and, more particularly, to a rotary filling machine fitted with magnetic funnel attachments for easy funnel removal and attachment.
2. Discussion of the Related Art
Rotary filling machines, sometimes referred to as rotary fillers, are routinely used for dispensing dry products into receiving containers. They can be used to fill both free-flowing and non-free-flowing products into rigid containers at rates of 100 to 400 containers per minute. Exemplary products commonly dispensed by rotary filling machines include infant formula, non-dairy creamer, spices, baking soda, drink mixes, and other products with similar characteristics. A rotary filling machine can have multiple funnels that attach to a main turret that is rotated to move the funnels around a path over the receiving container, which can be a ridged container or a pouch. A product is dispensed into the funnels and is allowed to flow into the receiving container.
Typical attachments for mounting the funnels to the turret include fasteners that bolt the funnel directly to a fill plate on the turret, spring loaded plungers that hold the funnel to the fill plate, and/or toggle clamps that hold the funnel to the fill plate. In these instances, all of these attachments have also been used in combination with tongue and groove receivers on one or more edges of the funnel.
The current attachment methods, however, suffer from drawbacks. For example, the requirements for complex mechanical fasteners render the funnels difficult to install and to remove. There are many instances in which funnels need to be removed or reinstalled in the process of using a rotary filling machine. For example, a funnel may need to be removed for cleaning, changing the size of the funnel, inspecting, or replacing a damaged funnel. However, the current methods make removing and reinstalling a funnel time-consuming and burdensome. The present invention provides an improvement over current rotary funnel attachments.
SUMMARY OF THE INVENTION
By way of summary, the present invention relates to a magnetic funnel attachment for a rotary filling machine. A primary aspect of the invention is to provide an improvement in the way funnels are attached to the turret. The present invention utilizes a magnetic system which allows the funnel to be installed and removed faster and more easily for the purposes of cleaning, changing over in sizes, inspection, or replacement.
In accordance with a first aspect of the invention, a magnetic funnel attachment is provided that includes a funnel and a fill plate. Installation of the funnel onto the fill plate may involve a two-step process. First, an interaction of alignment pins and receptacles or other alignment mechanisms on the funnel and fill plate allows for correct positioning of the funnel with respect to the fill plate. Second, magnetic forces secure the funnel to the fill plate.
In one example, two alignment pins guide the funnel into place as the magnets engage. The two alignment pins are provided on the front and hack of the fill plate to allow the funnel to be situated in the correct position during installation. The back pin aligns with a back slot of the funnel, and the front pin aligns with a front hole of the funnel so that, during installation, the back pin starts the alignment process and the front pin provides exact axial location. Other mechanical alignment locating mechanisms or features can be used instead of or in addition to the alignment pins and the corresponding hole and notch.
The magnets are mounted to the funnel and the fill plate with the poles oriented in opposite directions to allow for a pulling action by the magnets when they are in close proximity. The magnets of the funnel and fill plate may be located in pockets created in the funnel and fill plate, respectively. The pockets for the magnets can be made in several different ways. However, it is preferred that the pockets are made blind, i.e., they do not extend all the way through the funnel or fill plate, allowing for an easily cleanable surface above the magnet that is typically near the product contact zone. Alternately, a magnet may align with a ferrous material blind or surface mounted in the pockets.
A handle may be formed into or attached to the funnel to facilitate in installation and removal of the funnel from the full plate.
These and other features and aspects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
FIGS. 1A-1B are a side elevation and top plan view, respectively, showing a rotary filling machine with which a magnetic funnel attachment constructed in accordance with the invention is usable;
FIG. 2 is a perspective view of a magnetic funnel attachment assembly usable with the rotary filling machine of FIGS. 1A and 1B and constructed according to an embodiment of the present invention;
FIG. 3 is a top plan view of a fill plate segment of the magnetic funnel attachment assembly of FIG. 2 ;
FIG. 4 is a side elevation view of the fill plate segment of FIG. 2 ;
FIG. 5 is a bottom plan view of the fill plate segment of FIGS. 2 and 3 ;
FIG. 6 is a top elevation view of one embodiment of a funnel of the funnel attachment assembly of FIG. 2 ;
FIG. 7 is a side elevation view of the funnel of FIG. 6 ;
FIG. 8 is a bottom plan view of the funnel of FIGS. 6 and 7 ;
FIG. 9 is a front elevation view of the funnel of FIGS. 6-8 ;
FIG. 10 is a fragmentary perspective view of the fill plate segment of FIGS. 4-6
FIG. 11 is a fragmentary perspective view showing an intermediate position of the mounting of a funnel of FIGS. 6-9 on a corresponding fill plate segment of FIGS. 4-6 ;
FIG. 12 is a fragmentary perspective view of a funnel of FIGS. 6-9 , showing the funnel fully mounted to a corresponding fill plate segment of FIGS. 4-6 ;
FIG. 13 is a perspective view of a portion of the rotary filling machine of FIGS. 1 and 2 with all of the funnels installed thereon using the funnel attachment assemblies of FIGS. 2-12 ;
FIG. 14 is a perspective view of an alternative magnetic funnel assembly; and
FIG. 15 is a top elevation view of the magnet funnel assembly of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments described in detail in the following description.
Referring first to FIGS. 1A , 1 B, and 13 , a rotary filling machine 20 for dispensing flowable or non flowable dry products is illustrated and may include magnetic funnel attachments 22 ( FIGS. 2-13 ) constructed in accordance with the present invention. The rotary filling machine has multiple funnels 26 that are attached to a main turret 100 . The main turret 100 is rotated to move the funnels 26 around a path under a dispensing funnel 102 or other dispensing mechanism and over a receiving container 104 ( FIG. 13 ), which can be a ridged container or a pouch. Each funnel 26 dispenses a controlled amount of materials into the associated receiving container 104 . The receiving containers 104 feed into a series of rotating star wheels 106 and/or timing screws and then into the main turret 100 .
In operation, the containers 104 are timed via an initial star that syncs and transfers the containers to the main turret 100 , which transports the containers 104 and corresponding funnels 26 . The containers 104 and their associated funnels 26 are then transported beneath the dispensing funnel 102 , where a controlled amount of dry product is dispensed into the funnels 26 . Products can be dispensed to the dispensing funnel 102 using, for example an auger filler, a volumetric cup filler, a combination or linear scale, or any other filling mechanism that can continuously feed dry product or time the drop of the product into a funnel. The product then flows through the funnel 26 and into the container 104 being transported around the main turret 100 , thus allowing the product to settle into the container 104 as the main turret 100 continues to rotate. At the discharge of the main turret 100 , containers 104 are received by another timing star wheel 108 ( FIG. 13 ) to transfer the containers 104 from the main turret 100 to the discharge conveyor 110 .
A plurality of magnetic funnel attachments 22 may be attached to the turret 100 of the rotary filling machine 20 to provide for the mounting of funnels 26 in an annular pattern circumferentially around the main turret 100 of machine 20 , as seen from above in FIGS. 2 and 10 - 13 .
Referring now to FIGS. 2-5 , each magnetic funnel attachment 22 includes 1) a segment 24 of a fill plate and 2) one or more funnels 26 attached to a bottom surface of each fill plate segment 24 . The circumferentially arranged fill plate segments 24 may be formed on a unitary or segmented ring attached to and moving with the main turret 100 . In the illustrated embodiment, each fill plate segment 24 receives three funnels 26 at three evenly spaced mounting locations as best seen in FIGS. 2 , 3 , and 5 . Each counting location has a central opening that opens into a respective funnel 26 . Each fill plate segment 24 may be formed from a rigid, durable material such as aluminum or steel.
Each mounting location of each fill plate segment 24 has a front aligning pin 28 and a back aligning pin 30 that each penetrate the fill plate 24 and protrude outwardly from the top and bottom surfaces of the fill plate 24 , as seen from the side view in FIG. 4 . The front aligning pin 28 and rear aligning pin 30 assist to couple the fill plate 24 to the rotary filling machine 20 and to properly align the funnel 26 with an associated fill opening 48 in the fill plate segment 24 through which product flows during a filling operation. Moreover, a back notch 46 may be formed in the fill plate segment 24 to help locate the fill plate segment 24 at the appropriate location on rotary filling machine 20 by, for instance, mating with a pin or similar protuberances (not shown) on the main turret 100 .
Referring briefly to FIGS. 10-12 , each fill plate segment 24 is coupled to the rotary filling machine 20 via the upwardly extending front aligning pin 28 and back aligning pin 30 . Specifically, these pins 28 and 30 extend upwardly through apertures in an annual shoulder on the main turret 100 and receive fasteners such as nuts.
At least one magnet is provided on at least one of the fill plate segment 24 and the base plate 36 for securing the base plate 36 to the corresponding mounting location on the fill plate segment 24 . If one or both of the fill plate segment 24 and the base plate 36 are formed from stainless steel or another magnetizable material, a magnet conceivably could be provided in only one of the fill plate segment 24 and the base plate 36 . It is presently preferred, however, that magnets be provided in both the fill plate segment 24 and the base plate. Hence, referring to FIGS. 2 , 3 , and 5 each fill plate segment 24 has a plurality of fill plate pockets 32 on the front end and the back end thereof. The fill plate pockets 32 carry a plurality of first magnets 34 . The fill plate pockets 32 preferably are made “blind” so that the pockets 32 do not go all the way through the fill plate segment 24 so that, while the face of the magnets 34 may be exposed from the bottom of the plate, as seen in FIG. 5 , they are not exposed from the top of the fill plate segment 24 , as seen in FIG. 3 . This provides for a smooth surface on the top of the fill plate segment 24 , which contacts the rotary filling machine 20 . Each magnet 34 may be mounted in the corresponding pocket 32 by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener.
Referring now to FIGS. 6-9 , each funnel 26 has a horizontal base plate 36 and a hollow generally frusto-conical funnel body 37 extending downwardly from the bottom surface of the base pate 36 . Suitable materials for each funnel 26 include, but are not limited to, stainless steel, mild steel, aluminium other metals, plastic, fiberglass, urethane and other synthetic materials that can be molded. The funnel 26 may also be created on a 3D printer. A central aperture 39 is formed through the base plate 36 . Aperture 39 is surrounded by the funnel body 37 and has a size and shape that at least generally correspond to those of the corresponding opening 48 in the fill plate segment 24 .
First and second alignment mechanisms are provided on the base plate 36 and the fill plate segment 24 for assuring proper positioning of the funnel 26 on the machine. The base plate 36 of this embodiment carries one or more receptacles for mating with one or more alignment devices on the fill plate segment 24 . In the illustrated embodiment, the base plate 36 carries two pin receptacles for mating with the corresponding pins 28 and 30 in the fill plate segment 24 . The pin receptacles take the form of a front hole 38 and a back notch 40 located in front of and behind the funnel body 37 , respectively. The hole 38 and notch 40 mate with the front and rear pins 28 and 30 respectively, of the corresponding fill plate segment 24 .
It should be noted that the pins 28 and 30 on the base plate segment 24 and the hole 38 and notch 40 on the funnel base plate 36 could be replaced with other alignment mechanisms or features that assure the desired alignment of the funnel 26 with the corresponding receiving area of the base plate segment 24 . For example, upwardly facing pins or other protuberances could be provided on the funnel base plate 36 for mating with corresponding holes, notches, or other receptacles in the base plate segment 24 .
Referring to FIGS. 6 and 8 , the base plate 36 has a plurality of pockets 42 in front of and behind the opening 39 that are alignable with the fill plate pockets 32 of the fill plate segment 24 . The base pockets 42 carry a plurality of second magnets 44 with opposite polarity as the first magnets 34 . In one embodiment as shown in FIGS. 14-15 , the base pockets 42 will be “blind pockets” that stop short of the top surface of the base plate 36 . This allows the top surface of the base plate 36 to be free of uneven surfaces, which allows the base plate 36 to easily be cleaned after use. Each second magnet 44 may be mounted in the corresponding pocket 42 by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener. In this embodiment, the second magnets 44 will be sufficiently strong to attract the first magnets 34 through the base plate 36 . A handle opening 50 may be formed in or through the front end of the base plate 36 to assist the user in attachment and removal of the funnel 26 . The handle opening 50 could be supplemented with or replaced by a knob, if desired.
Alternatively, the base pockets 42 may extend through the base plate 36 so that the faces of the second magnets 44 are exposed from the top and bottom of the base plate 36 , as seen in FIGS. 6 and 8 . In another embodiment, the pockets 42 may be “blind pockets” that stop short of the bottom surface of the base plate 36 . In either case, each magnet 44 preferably is mounted in the corresponding pocket 42 so that its upper face is exposed and thus capable of direct contact with the mating magnet 34 in the fill plate segment 24 . Each magnet 44 may be mounted in the corresponding pocket 42 by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener. A handle opening 50 may be formed in or through the front end of the base plate 36 to assist the user in attachment and removal of the funnel 26 . The handle opening 50 could be supplemented with or replaced by a knob, if desired.
Referring now to FIGS. 10-12 and initially to FIG. 10 , the funnel 26 is mounted on the fill plate segment 24 using only one hand by grasping the funnel 26 using the handle opening 50 and inserting the back aligning pin 30 of the fill plate 24 with the back notch 40 of the base plate 36 . Referring now to FIG. 11 , the funnel 26 is then pivoted upwardly so that the front aligning pin 28 is inserted into the front hole 38 of the base 36 . As the second magnets 44 approach the first magnets 34 , the magnetic force attracts the funnel 26 to the fill plate segment 24 to create a strong attachment, as seen in FIG. 12 . Alternately, the magnet may be attracted to a metal plate.
To remove a funnel 26 , all one needs to do is to grasp the handle opening 50 and pull the funnel 26 down against the resistance of the magnets 34 , 44 to a position in which the hole 38 in the base plate 36 clears the bottom end of the front aligning pin 28 in the base plate segment 24 , whereupon the funnel 26 can then be pulled forwardly and downwardly with the notch 40 in the base plate 36 moving away from the rear aligning pin 30 in the base plate segment 24 .
Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes and modifications will become apparent from the appended claims.
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A rotary filling machine includes a magnetic funnel attachment that can be easily installed, removed, and reinstalled into the machine for cleaning, changing the size of the funnel, inspecting, or replacing a damaged funnel. The magnetic funnel attachment includes a fill plate segment for receiving one or more funnels, and a funnel for attachment to the fill plate. The fill plate and funnel have mating alignment mechanisms to assist in the correct positioning of the funnel on the fill plate segment, and magnets to assist in the coupling of the funnel to the fill plate segment. This is especially helpful in creating a quick and easy method for funnel installation and removal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid quantity detecting device for detecting the quantity of liquid stored in a predetermined tank.
2. Description of the Prior Art
Previously, as a conventional liquid quantity detecting device, a device having a float which floats on the liquid has usually been used. In this device, the quantity of liquid is detected on the basis of the change of resistance between one end of a resistor and a movable contact sliding thereon. The contact is fixed to the float and moves on the resistor in accordance with the movement of the float. However, in this device, the quantity of liquid is detected on the basis of the liquid level, and, therefore, the quantity of liquid cannot be detected precisely because of the difference between the form of the tank in which the liquid is stored and the form of the surface of the resistor, and because of the difference of the resistance value due to the contact area between the contact and the surface of the resistor. Particularly when the liquid decreases to a small quantity the measurement error is large. Therefore, the present invention is proposed in order to improve the above-mentioned inaccuracy in measurement.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a liquid quantity detecting device in which, when the quantity of liquid is large, the prior art liquid quantity detecting device is used, and when the liquid is less than a predetermined amount, a device for detecting and displaying the quantity of liquid on the basis of the weight of the liquid to be measured is used, whereby when the liquid decreases to a small quantity, the quantity can be detected and displayed precisely.
Another object of the present invention is to provide a liquid quantity detecting device in which, when the quantity of the liquid is large, the prior art liquid quantity detecting device, which detects the quantity of liquid by a combination of the sliding contact fixed to the float and the resistor and displays the quantity of liquid with a needle, is used, and when the liquid decreases to a small quantity, torsion is generated between a housing and torsion bars due to the weight of the tank in which the liquid to be measured is stored The tank is directly linked to the housing, a twisted angle detector is located on the housing and the stationary portion of the torsion bars is fixed. The twisted angle of the torsion bars is detected, and the weight of the liquid to be measured, namely the quantity of liquid, is precisely detected and is accurately displayed.
Still another object of the present invention is to provide a liquid quantity detecting device in which the twisted angle detector comprises a first coil in a housing supplied with a pulse voltage signal and a second coil located perpendicular to the first coil at a certain distance, said second coil being electrically linked to the first coil by inductance and mechanically linked to the first coil by the torsion bars. The positional relationship between the first coil and the second coil is changed by the mechanical linkage and, the degree of magnetic flux to the second coil is thereby changed. The position of the second coil (i.e., the twisted angle of the torsion bars) is determined by determining the change of the flux, and the weight of the liquid, (i.e., the quantity of liquid) can be detected precisely and displayed accurately even when the liquid decreases to a small quantity.
Still another object of the present invention is to provide a liquid quantity detecting device in which the twisted angle detector comprises a first and a second electrode, whereby the twisted angle of the torsion bars is determined according to change of electrostatic capacities between the first and second electrodes and the quantity of liquid can be detected precisely and displayed accurately even when the liquid decreases to a small quantity.
Still another object of the present invention is to provide a liquid quantity detecting device in which the quantity of liquid is detected on the basis of weight instead of volume so that it is more precisely detected and more accurately displayed due to the fact that the effect of the coefficient of volume expansion is eliminated when the liquid decreases to a small quantity.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing,
FIG. 1A shows a perspective view of a liquid quantity detecting device according to an embodiment of the present invention;
FIG. 1B shows an elevational view of a display in the device in FIG. 1A;
FIG. 1C shows a partial sectional view of the device in FIG. 1A;
FIG. 2 shows a partial sectional view of the device in FIG. 1A;
FIG. 3 shows a partial sectional view of a side of the device in FIG. 2;
FIG. 4 shows a sectional view taken along line IV--IV in the device of FIG. 3;
FIG. 5, A and B, shows an electrical circuit diagram of the device according to the embodiment of the present invention;
FIG. 6 shows a waveform diagram illustrating the operation of the circuit in FIG. 5;
FIGS. 7A and 7B show explanatory views of the operation of the coils in FIG. 5;
FIG. 8 shows a partial sectional view of the device according to another embodiment of the present invention;
FIG. 9, A and B, shows an electrical circuit diagram of the device in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A liquid quantity detecting device according to an embodiment of the present invention will be explained below with reference to FIGS. 1A through 7. In FIG. 1A, a liquid meter 1, which detects the twisted angle of the torsion bars due to the weight of a tank, which stores the liquid to be measured, and includes electrical circuits which generate a pulse width signal proportional to the twisted angle (i.e., the quantity of liquid to be measured), is fixed to the tank 2 at both ends with stays 3 and 4 and is attached to a supporting member (not shown) by an arm 5. In addition, FIG. 1A shows a mouth 6, through which liquid flows in and out, and a conventional float-type liquid-quantity meter 7. In FIG. 1B is shown a display 8 consisting of a conventional pointer-type indicator 8a and an indicator 8b which displays the quantity of liquid precisely and digitally when the quantity of liquid is less than a predetermined quantity. The indicator 8a is a known bimetal-type meter having a pointer 81, and the indicator 8b is a digital display meter using, for example, a liquid crystal display, a fluorescent display tube, or the like. The float-type liquid-quantity meter 7 consists of a float 73, a float arm 72, and a potentiometer 71 as shown in FIG. 1C.
In FIG. 2, one end of the arm 5 is fixed to a stationary portin 11 of torsion bars 10 with a nut 12, and at the other end of the arm 5 a tapped hole (not shown) is provided so that the arm can be attached to the supporting member. The torsion bars 10 are pressed into housings 14 and 15, respectively, with two bearings 13 and are fixed to the housings with two knock pins 16.
In FIG. 3, the housing 15 is fixed to the housing 14 with four bolts 17, and the housings each have three tapped holes 18 so that they can be attached to the stays 3 and 4 in FIG. 1A, respectively. Stands 19 and 20 are fixed to housings 14 and 15 with four bolts 21, respectively. A first bobbin 23 is fixed to the stands with two bolts 22, an electric processor 25 is fixed to the stands with two bolts 24, and a cover 27 is fixed to the stands with two bolts 26. In addition to the above-mentioned elements, FIG. 3 shows a first coil 28 which is wound around the first bobbin 23, a coilstand 29 which will be explained later, and a cord bushing 30 which is attached to a cover 27 to protect outgoing electric lines 31.
In FIG. 4, the above-mentioned coilstand 29 is fixed to the stationary portion 11 of the torsion bars 10 with two bolts 32, and a second bobbin 33, which has a ferrite core (not shown), is attached to and fixed to the coilstand 29. A second coil 34 is wound around the second bobbin 33. The first coil 28 is wound around the first bobbin 23. If the housings 14 and 15 are twisted with reference to the stationary portion of the torsion bars (i.e., the arm 5) more than a predetermined angle through the torsion bars 10, the housings 14 and 15 contact the arm 5, and after such contact the housings 14 and 15 are no longer twisted. Thus, the opening through which arm 5 engages meter 1 (FIG. 1A) provides a physical limit to the twisting action of the torsion bars. The quantity of liquid at that time (i.e., point of maximum twist) is determined so as to be a predetermined quantity. The conventional pointer-type indicator 8a is not explained in detail since it is publicly known.
Reference symbols (A) to (G) in FIG. 5 correspond to those of the waveform diagram in FIG. 6. In FIG. 5, a battery 51 supplies electric power to the indicator 8b and the electric processor 25. The electric current-detecting resistor 52 is located in the indicator 8b. The indicator 8b includes an electric current-detection circuit 54 for generating pulses having a pulse width corresponding to the voltage of a point 53(G), a pulse width measurement circuit 55 for converting the pulse width to the binary signal, a decoder 56 for decoding the binary signal, and a liquid display unit 57 for displaying the digital value in response to the signal from the decoder 57. The decoder 56 is a known device which makes the display of the display unit blank if the binary signal from the pulse width measurement circuit 55 overflows a predetermined value, for example, if the fifth column changes from "0" to "1". Accordingly, if the liquid exceeds the predetermined quantity, the display unit 57 changes the display thereof to blank. A power source terminal 101 is connected to the battery 51 through the electric current-detecting resistor 52, and a ground terminal 102 is connected to a ground terminal of the battery 51.
A terminal 103 is connected to one terminal of the second coil 34 wound around the second bobbin 33 in FIG. 4, and the other terminal of the second coil 34 is connected to a terminal 105. A terminal 104 is connected to one terminal of the first coil 28 wound around the first bobbin 23 in FIG. 4, and the other terminal of the first coil 28 is connected to the terminal 105.
A regulator circuit 110 consists of a regulator 111 (for example, Model No. NC 7806 made by Motorola) and capacitors 112 and 113 and supplies a constant output voltage.
An oscillation circuit 200 consists of an oscillator, a binary counter 211 (for example, Model No. TC 4020 made by Toshiba), an inverse gate 212, a transistor 213, resistors 214, 215, and 216, capacitors 217 and 218, and a diode 219. The oscillator consists of inverse gates 201 and 202, a ceramic vibrator 203, a resistor 204, and capacitors 205 and 206. The oscillation circuit 200 supplies a square wave to the first coil 28 through the terminal 104.
An amplifier circuit 300 includes an operational amplifier 301, resistors 302, 303, 304, 305, 306, 307, and 308, and capacitors 309, 310, and 311 and amplifies a signal generated across the second coil 34. A peak-hold circuit 350 includes an operational amplifier 351, resistors 352, 353, and 354, a capacitor 355, and a diode 356. The peak-hold circuit 350 holds the negative peak voltage of the output signal from an amplifier circuit 300.
A triangular wave-generating circuit 400 includes an operational amplifier 401, resistors 402, 403, 404, and 405, and capacitors 406 and 407 and generates a trianglar wave.
A pulse width conversion circuit 500 consists of an operational amplifier 501 and resistors 502, 503, and 504 and generates a pulse width signal having a pulse width proportional to the voltage generated by the peak-hold circuit 350.
An electric current value conversion circuit 550 consists of a transistor 551 and resistors 552 and 553 and converts the output signal of the pulse width conversion circuit 500 to the amplitude of the electric current. Thus, the displacement of the second coil 34 with reference to the first coil 28 is transmitted to the terminal 101 as the change of electric current value and is detected at a terminal 53 of the electric current-detecting resistor 52 in the indicator 8b as a voltage change.
The operation of the above-mentioned device is explained below. If the liquid to be measured in the tank 2 of FIG. 1A is more than a predetermined quantity, the housings 14 and 15 fixed to the stays 3 and 4 contact the arm 5 attached to the supporting member (not shown) and the torsion bars 10 are in a maximal twisted state. In this state, the quantity of liquid is detected and displayed by the conventional float-type liquid-quantity meter 7 and the conventional pointer-type indicator 8a. Since a conventional device is used, a detailed explanation of this state is not given.
When the quantity of liquid is large, the approximate quantity is preferably determined, and when the quantity of liquid is small, the exact quantity is preferably determined. Therefore, in order not to enlarge the displacement of the torsion bars and in order to measure the quantity of liquid more precisely, when there is only a small quantity of liquid, it is preferred that the torsion bars be used to precisely measure the quantity of liquid, and when the quantity of liquid is large, it is preferred that the float-type liquid-quantity meter be used to measure the quantity of liquid. However, it is preferable that both types of liquid meters be used together.
A detailed explanation is given below of a case in which the liquid to be measured in the tank 2 of FIG. 1A is less than a predetermined quantity and the amount of torsion between the housings 14 and 14 fixed to the stays 3 and 4 and the arm 5 attached to the supporting member (not shown) by the torson bars 10 is small. At first, a pulse signal from the inverse gate 202 of the oscillation circuit 200 is supplied to the clock (CL) terminal of the binary counter 211. At an output terminal Q1 of the first stage of the binary counter 211, the pulse signal shown in FIG. 6(A) is generated. The pulse signal drives the transistor 213 through the inverse gate 212 and is supplied to the first coil 28 through the terminal 104. Since torsion occurs at the torsion bars 10, if the second coil 34 moves with reference to the first coil 28 as shown in FIG. 7A, the number of magnetic fluxes which are generated from the first coil 28 and are linked to the second coil 34 increases, a voltage signal which corresponds to the twisted angle of the torsion bar is generated across the second coil 34 as shown in FIG. 6(B), and the generated voltage signal is supplied to one terminal of the capacitor 309 of the amplifier circuit 300. On the other hand, the other terminal of the capacitor 309 is supplied with a reference voltage divided by the resistors 302 and 303 through the resistor 304. This other terminal of the capacitor 309 is connected to the non-inverting input terminal of the operational amplifier 301, and the inverting input terminal thereof is supplied with the reference voltage divided by the resistors 302 and 303. Therefore, the signal shown in FIG. 6(B) supplied to the capacitor 309 is amplified by the operational amplifier 301. The output waveform of the operational amplifier 301 is shown in FIG. 6(C).
The signal shown in FIG. 6(C) is supplied to the non-inverting input terminal of the operational amplifier 351 in the peak-hold circuit 350. The output signal is held at the negative peak voltage of the input signal shown in FIG. 6(C) and generates the waveform shown in FIG. 6(D) since the negative peak voltage of the input signal shown in FIG. 6(C) is lower than the reference voltage divided by resistors 302 and 303.
The pulse signal generated at the output terminal Q10 of the tenth stage of the binary counter 211 in the oscillation circuit 200 is supplied to the inverting input terminal of the operational amplifier 401 through the resistor 402 in the triangular wave-generating circuit 400. The output signal of the operational amplifier 401 forms a triangular wave determined by the time constant due to the resistor 402 and the capacitor 407, as shown in FIG. 6(E). The output signal is supplied to the non-inverting input terminal of the operational amplifier 501 in the pulse width conversion circuit 500, the signal shown in FIG. 6(D) is supplied to the inverting input terminal of the operational amplifier 501, the signal shown in FIG. 6(E) is compared with the signal shown in FIG. 6(D), and the signal shown in FIG. 6(F) is generated by the output terminal of the operational amplifier.
The signal shown in FIG. 6(F) is supplied to the electric current value conversion circuit 550, the transistor 551 is switched on and off, and the battery supplies electric current to the transistor 551 through the regulator circuit 110. As a result, the signal shown in FIG. 6(G) is generated at the terminal 53 of the electric current detection resistor 52 in the indicator 8b, namely, superposed on the power source line, the width of the signal corresponding to the twisted angle of the torsion bar 10 and the polarity being from a certain voltage to the level of logic "0". The pulse width is converted to the digital value in the indicator 8b, and the indicator 8b precisely indicates the quantity of liquid digitally.
If there is no liquid to be measured in the tank 2 of FIG. 1A, the housings 14 and 15 fixed to the stays 3 and 4 are not twisted with reference to the arm 5 attached to the supporting member (not shown) and the second coil 34 is positioned at the center of the first coil 28 as shown in FIG. 7B. Accordingly, in the case of the magnetic flux which is generated by the first coil 28 and is linked to the second coil 34, the portion of the flux which is perpendicularly linked to the second coil 34 does not exist, and the output of the second coil 34 is logic "0" as shown in the right portion of FIG. 6(B). Thus the output of the amplifier circuit 300 becomes the same level as the reference voltage divided by the resistors 302 and 303 as shown in FIG. 6(C). The output voltage of the peak-hold circuit 350 becomes the same as the voltage shown in FIG. 6(C) (this voltage is shown in FIG. 6(D)) and the output of the pulse width conversion circuit 500 becomes logic "0" as shown in FIG. 6(F). The signal shown in FIG. 6(F) is supplied to the electric current value conversion circuit 550, as mentioned above, a certain voltage is generated at the terminal 53 of the electric current detection resistor 52 as shown in FIG. 6(G), a signal which indicates that no torsion exists in the torsion bars is obtained from the above-mentioned certain voltage and is operated in the indicator 8b, and the quantity of liquid to be measured is digitally displayed as zero.
In the above-mentioned embodiment, a ceramic vibrator is used as the oscillator in the oscillation circuit 200. However, instead of a ceramic vibrator, an RC oscillation circuit or a quartz crystal oscillator may be used. At a peak-hold circuit 350, a negative peak voltage is detected. However, a positive peak voltage may be detected instead. A pulse width signal proportional to the output voltage of the peak-hold circuit 350 is obtained by using the triangular wave from the triangular wave-generating circuit 400. Instead of the triangular wave, a sawtooth wave may be used. Although a pulse signal is supplied to the first coil 28, a sinusoidal wave may be supplied instead.
Another embodiment of the present invention will be explained below with reference to FIG. 8. A plate 41 having a first (a) electrode 42 and a first (b) electrode 43 is fixed to the stands 19 and 20 with the two bolts 22. An electrode stand 44 having a second electrode 45 is fixed to the stationary portion 11 of the torsion bars 10 with the two bolts 32, and an electrostatic capacity between the first (a) electrode 42 and the second electrode 45 and another electrostatic capacity between the first (b) electrode 43 and the second electrode 45 are created. The elements in FIG. 8 which are identical to those in FIG. 4 are referred to by the same reference numerals as in FIG. 4. An electrical circuit diagram of the device according to the embodiment in FIG. 8 is shown in FIG. 9. In FIG. 9, the output of the inverse gate 212 in the oscillation circuit 200 is supplied to the first (a) electrode 42 through a terminal 106 and the inverted output of an inverse gate 221 is supplied to the first (b) electrode 43 through a terminal 107. The second electrode 45 is connected to one terminal of the capacitor 309 through a terminal 108. The constitution of the circuit of FIG. 9, except for the above-mentioned portion, is the same as that of the circuit of FIG. 5.
The operation of the circuit in FIG. 9 will be explained below. If the torsion bars 10 are not twisted, the second electrode 45 is positioned the same distance from the first (a) electrode 42 as from the first (b) electrode 43. Therefore, the electrostatic capacity between the first (a) electrode 42 and the second electrode 45 is the same as the electrostatic capacity between the first (b) electrode 43 and the second electrode 45. Further, since a pulse voltage signal having an inverted phase with reference to the phase of the pulse voltage signal supplied to the first (a) electrode 42 is supplied to the first (b) electrode 43, the signal generated at the second electrode 45 is in an intermediate potential and is supplied to the capacitor 309 through the terminal 108. Except for these operations, a detailed explanation of the embodiment is not given here. If the torsion bars 10 are twisted and the second electrode 45 approaches the first (a) electrode 42, the electrostatic capacity between the first (a) electrode 42 and the second electrode 45 is greater than the electrostatic capacity between the first (b) electrode 43 and the second electrode 45, and the pulse voltage signal from the inverse gate 212, which pulse voltage signal is proportional to the difference of the above-mentioned capacities, is conducted to the second electrode 45 and is supplied to one terminal of the capacitor 309 through the terminal 108. Except for these operations, a detailed explanation of the embodiment is not given here.
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A liquid quantity detecting device includes a float-type liquid-quantity meter and a torsion bar-type liquid meter. In the float-type liquid-quantity meter, the liquid quantity is detected by a float in a tank and the position of the float is converted to an electric signal by a variable resistor. The torsion bar-type liquid meter includes housings fixed to the tank, torsion bars, one end of each being fixed to the tank by the housings and the other end of each being fixed to a supporting member so that the torsion bars are twisted by weight of the tank, twisted angle detection means for detecting the twisted angle of the torsion bars, and an electrical processor for supplying a signal corresponding to the quantity of liquid in the tank after receiving a signal from the twisted angle detector. When the liquid quantity in the tank is larger than a predetermined quantity, the liquid quantity, for example, the quantity of gasoline in a gasoline tank, is measured by the floating-type liquid-quantity meter. When the liquid quantity in the tank is smaller than a predetermined quantity, the liquid quantity is displayed precisely and accurately by the torsion bar-type liquid meter.
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BACKGROUND OF THE INVENTION
[0001] This invention relates in general to drilling a wellbore and, in particular, to drilling an intersecting wellbore through a drill string including well casing or liner and a downhole drilling apparatus interconnected therein.
[0002] Without limiting the scope of the invention, its background is described in connection with drilling a wellbore for hydrocarbon production, as an example.
[0003] Heretofore, in this field, a typical drilling operation has involved attaching a drill bit on the lower end of a drill string and rotating the drill bit along with the drill string to create a wellbore through which subsurface formation fluids may be produced. As the drill bit penetrates the various earth strata to form the wellbore, additional joints of drill pipe are coupled to the drill string. During drilling, drilling fluid is circulated through the drill string and the drill bit to force cuttings out of the wellbore to the surface, and to cool the drill bit.
[0004] Periodically as the drilling of the wellbore progresses, the drill bit and drill string are removed from the wellbore and tubular steel casing is inserted into the wellbore to prevent the wall of the wellbore from caving in during subsequent drilling. Typically, after casing is inserted into the wellbore, the annulus between the casing and wellbore is filled with a cement slurry that hardens to support the casing in the wellbore. Thereafter, deeper sections of wellbore with progressively smaller diameters than the previously installed casing may be drilled.
[0005] Once a predetermined depth is reached for each subsequent section of wellbore, the drill bit and drill string are again removed from the wellbore and that section of the wellbore may be cased. Alternatively, however, a liner may be used to case an open section of wellbore instead of a full casing string. The liner, which is a string of connected lengths of tubular steel pipe joints, is lowered through the casing and into the open wellbore. At its upper end, the liner is attached to a setting tool and liner hanger. The liner hanger attaches the liner to the previous casing such that the casing will support the weight of the liner.
[0006] The length of the liner is predetermined such that its lower end will be proximate the bottom of the open wellbore, with its upper end, including the liner hanger, overlapping the lower end of the casing above. As with the casing, after the liner is inserted into the wellbore, the annulus between the liner and the wellbore may be filled with a cement slurry that hardens to support the liner in the wellbore.
[0007] It has been found, however, that in many well drilling operations it is desirable to minimize rig time by utilizing the casing or liner string as the drill string for rotating a drill bit, which may be left in the wellbore upon the completion of drilling a section of the wellbore. As such, this procedure does not require the use of a separate liner or casing upon the withdrawal of the drill bit and drill string as in conventional drilling operations, and thereby reduces the time needed to drill, case and cement a section of wellbore.
[0008] For example, attempts have been made to utilize the casing or liner string as the drill string along with a drill bit that is rotatable relative to the casing or liner string. The drill bit is rotated by a downhole drill motor that is driven by drilling fluid. Upon completion of drilling operations, the motor and the retrievable portions of the drill bit may be removed from the wellbore so that further wellbore operations, such as cementing, may be carried out and further wellbore extending or drilling operations may be conducted. This system, however, requires the use of expensive and sometimes unreliable downhole drill motors and a specially designed drill bit.
[0009] Alternatively, other attempts have been made to utilize the casing or liner string as the drill string using conventional rotary techniques wherein the drill bit is rotated by rotating the entire casing or liner string. This approach, however, requires the use of a drill bit with minimal cutting structure, since a drill out could not be performed through a typical drill bit having a full cutting structure, such as a tricone bit.
[0010] Therefore, a need has arisen for a drill string which may be used as a well casing or liner, which includes a drill bit on its lower end, and which, upon completion of drilling operations, may be retained within the wellbore without the need to retrieve the drill bit or the drill string. A need has also arisen for such a well casing or liner string that may be left in the wellbore along with a drill bit, and which does not require the use of expensive, unreliable or specialty equipment. Further, a need has arisen for such a well casing or liner string which may be cemented in place along with a drill bit having a full cutting structure.
SUMMARY OF THE INVENTION
[0011] The present invention, as exemplified by an embodiment disclosed herein, comprises a downhole drilling apparatus that is interconnectable in a casing or liner drill string and includes a drill bit connected thereto which, upon completion of drilling operations, may be retained within the wellbore without the need to retrieve the drill bit or the drill string. The apparatus allows the well casing or liner to be left in the wellbore along with the drill bit and does not require the use of expensive, unreliable or specialty equipment. The apparatus also allows for the well casing or liner to be cemented in place along with a drill bit having a full cutting structure.
[0012] The downhole drilling apparatus includes a housing that is interconnectable in a casing string. The housing has a window cut therein to allow a subsequent drill bit and pipe string to pass therethrough during a drill out operation. To facilitate the deflection of the drill bit and pipe string through the window, a whipstock is disposed within the housing. A filler material is also disposed within the housing between the whipstock and the window to prevent the flow of drilling fluids or cement through the window prior to the drill out. The filler and the whipstock have a central bore that permits the passage of fluids through the center of the downhole drilling apparatus. One or more valves may be disposed within the central bore to control the flow of fluids therethrough. The valves may be, for example, back pressure or float valves that allow one-way flow of fluids downwardly through the apparatus.
[0013] A drill bit having a full cutting structure, such as a tricone bit, may be operably coupled to the downhole drilling apparatus. The casing or liner string may be used to rotate the drill bit. Alternatively, a downhole motor may be coupled between the downhole drilling apparatus and the drill bit to facilitate rotation of the drill bit, without the need for rotating the casing string.
[0014] In another embodiment, a downhole drilling apparatus includes a housing having a window, an alignment member disposed within the housing and a back pressure valve assembly. The back pressure valve assembly includes a central bore that permits the passage of fluids therethrough. Once downhole, a whipstock may be run into the apparatus such that the whipstock operably engages the alignment member. The alignment member orients the whipstock within the housing relative to the window, so that the drill bit may subsequently be deflected through the window.
[0015] In operation, either embodiment of the downhole drilling apparatus may be interconnected in a casing or liner string having a drill bit disposed on its lower end. A first wellbore is drilled. Following the drilling of the first wellbore, the casing or liner string may be cemented within the wellbore. A pipe string having another drill bit on its lower end is passed through the casing or liner string, such that a drill out through the downhole drilling apparatus is performed to drill a second wellbore. The pipe string and drill bit that are used to create the second wellbore are deflected through the window in the housing of the downhole drilling apparatus by the whipstock disposed within the apparatus.
[0016] Thus, with the use of the downhole drilling apparatus, a casing or liner string including a drill bit having a full cutting structure may be used as a drill string to create a wellbore. The drill string may be cemented in place within the wellbore, and thereafter have a drill out performed therethrough to create an intersecting wellbore.
[0017] These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings of which:
[0019] [0019]FIG. 1 is a schematic illustration of an offshore oil and gas platform during a drilling operating wherein a downhole drilling apparatus embodying principles of the present invention is utilized;
[0020] [0020]FIG. 2 is a schematic illustration of a first downhole drilling apparatus embodying principles of the present invention;
[0021] [0021]FIG. 3 is a cross sectional view of the downhole drilling apparatus of FIG. 2, taken along line 3 - 3 ;
[0022] [0022]FIG. 4 is a cross sectional view of the downhole drilling apparatus of FIG. 2, taken along line 4 - 4 ;
[0023] [0023]FIG. 5 is a schematic illustration of an offshore oil and gas platform during a drilling operating wherein a downhole drilling apparatus embodying principles of the present invention is being utilized in conjunction with a downhole motor;
[0024] [0024]FIG. 6 is a cross sectional view of a second downhole drilling apparatus embodying principles of the present invention before insertion of a whipstock therein; and
[0025] [0025]FIG. 7 is a cross sectional view of the second downhole drilling apparatus after insertion of a whipstock therein.
DETAILED DESCRIPTION
[0026] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not limit the scope of the invention.
[0027] Referring to FIG. 1, an offshore oil and gas platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over a subterranean oil and gas formation 14 located below sea floor 16 . A well 18 extends through the sea 20 , penetrating sea floor 16 to form wellbore 22 , which traverses various earth strata. A wellbore extension is formed by wellbore 24 , which extends from wellbore 22 through additional earth strata, including formation 14 .
[0028] Platform 12 has a hoisting apparatus 26 and a derrick 28 for raising and lowering pipe strings, such as drill string 30 , including drill bit 32 located in wellbore 24 , and casing string 34 , including drill bit 36 , crossover subassembly 38 and downhole drilling apparatus 40 located in wellbore 22 . As used herein, the term “casing string” is used to refer to a tubular string which includes sections of casing or liner.
[0029] As in a typical drilling operation, wellbore 22 is formed by rotating drill bit 36 while adding additional sections of pipe to casing string 34 . When drill bit 36 reaches total depth, however, casing string 34 and drill bit 36 are not retrieved from wellbore 22 . Rather, casing string 34 and drill bit 36 are cemented in place by cement 42 which fills the annular area between casing string 34 and wellbore 22 .
[0030] Cementing casing string 34 and drill bit 36 in place within wellbore 22 is a cost effective alternative to conventional drilling, in that significant rig time is saved by minimizing the number of trips into and out of wellbore 22 . At least one trip out of wellbore 22 and one trip into wellbore 22 are saved by using downhole drilling apparatus 40 . Additionally, the use of downhole drilling apparatus 40 avoids the possibility of collapse of wellbore 22 , particularly in unconsolidated or weakly consolidated formations.
[0031] Alternatively, downhole drilling apparatus 40 may be used in conjunction with conventional drilling operations once a conventional drill string and bit have been tripped out of wellbore 22 . For example, if wellbore 22 has traversed an unconsolidated or weakly consolidated formation and it is likely that a collapse has occurred within wellbore 22 , it may be necessary to reopen that portion of wellbore 22 . In this case, wellbore 22 may be reopened using casing string 34 with downhole drilling apparatus 40 and drill bit 36 .
[0032] Once cementing of wellbore 22 has been completed, wellbore 24 may be drilled. Drill bit 32 creates wellbore 24 by traveling through window 44 of downhole drilling apparatus 40 , as will be more fully discussed with reference to FIGS. 2 - 4 below. As drill bit 32 and drill string 30 continue to form wellbore 24 , formation 14 is traversed. Note that the drill string 30 may include another apparatus 40 , if desired.
[0033] Even though FIG. 1 depicts wellbore 22 as a vertical wellbore, it should be understood by those skilled in the art that wellbore 22 may be vertical, substantially vertical, inclined or even horizontal. It should also be understood by those skilled in the art that wellbore 22 may include multilateral completions wherein wellbore 22 may be the primary wellbore having one or more branch wellbore extending laterally therefrom, or wellbore 22 may be a branch wellbore. Additionally, while FIG. 1 depicts an offshore environment, it should be understood by one skilled in the art that the use of downhole drilling apparatus 40 is equally well suited for operation in an onshore environment.
[0034] Schematically illustrated in FIG. 2 is a downhole drilling apparatus 50 embodying principles of the present invention. Apparatus 50 has a pin end 52 , so that the apparatus 50 is interconnectable in a drill string, such as casing string 34 of FIG. 1. Downhole drilling apparatus 50 also has a box end 54 that may be threadedly connected to crossover subassembly 38 as depicted in FIG. 1.
[0035] Apparatus 50 has a generally tubular housing 56 with a window 58 cut through a sidewall thereof. Window 58 is generally elliptically shaped and is sized such that a drill bit, such as drill bit 32 of FIG. 1, may pass therethrough during a drill out operation.
[0036] Now referring to FIG. 3, a cross sectional view of downhole drilling apparatus 50 taken along line 3 - 3 of FIG. 2 is depicted. Disposed within housing 56 of apparatus 50 is a whipstock 60 . A central bore 62 extends through whipstock 60 to provide fluid passage for drilling mud and cement through apparatus 50 during drilling and cementing operations. Valves 64 , 66 are disposed within central bore 62 of the downhole drilling apparatus 50 . Valves 64 , 66 may be back pressure or float valves that allow one-way flow of drilling mud or cement through the apparatus 50 . As an example, valves 64 , 66 may be SuperSeal II back pressure valves, available from Halliburton Energy Services, Inc. of Duncan, Okla.
[0037] Whipstock 60 has an inclined upper surface, so that it directs a drill bit, such as drill bit 32 of FIG. 1, through window 58 of downhole drilling apparatus 50 . Whipstock 60 may be constructed of any material, such as steel, having sufficient strength to deflect a drill bit through window 58 . Whipstock 60 may also provide additional torsional strength to the downhole drilling apparatus 50 .
[0038] A filler 68 occupies the volume between whipstock 60 and window 58 of downhole drilling apparatus 50 . Filler 68 prevents the flow of drilling mud or cement through window 58 of apparatus 50 . Filler 68 may be, for example, concrete that has been poured into downhole drilling apparatus 50 . Window 58 may also be filled with filler 68 to provide protection to window 58 . Other suitable solid materials, such as resins, may be used for filler 68 , so long as they set sufficiently and permit the directional passage of a drill bit through window 58 of apparatus 50 .
[0039] In operation, when a drill bit, such as drill bit 32 of FIG. 1, encounters whipstock 60 , the drill bit cuts through filler 68 and is deflected laterally by whipstock 60 toward window 58 in housing 56 . Window 58 is wider that the outer diameter of the drill bit, permitting the drill bit to laterally exit the apparatus 50 .
[0040] Referring now to FIG. 4, a cross sectional view of downhole drilling apparatus 50 is depicted that is taken along line 4 - 4 of FIG. 2. Apparatus 50 includes housing 56 , whipstock 60 , filler 68 and window 58 . As with typical drill down shoes, downhole drilling apparatus 50 may have sufficient torsional strength to rotate a drill bit, such as drill bit 36 of FIG. 1. The wall thickness of housing 56 and the size of window 58 will affect the torsional strength of downhole drilling apparatus 50 . Of course, the window 58 should be dimensioned to permit a drill bit to pass therethrough.
[0041] The shape of whipstock 60 can be varied to maximize its deflecting capability. For example, whipstock 60 may be made concave or convex to direct a drill bit, such as drill bit 32 , through window 58 of downhole drilling apparatus 50 . If whipstock 60 is made concave, drill bit 32 will encounter window 58 at a position slightly below that where a straight whipstock 60 would direct the bit. Conversely, a convex whipstock 60 will force the encounter of drill bit 32 with window 58 at a position above that of the flat-surfaced whipstock 60 .
[0042] Referring now to FIG. 5, an offshore oil and gas platform is schematically illustrated and generally designated 70 . A semi-submersible platform 72 is centered over a subterranean oil and gas formation 74 located below sea floor 76 . A well 78 extends through the sea 80 , penetrating sea floor 76 to form wellbore 82 , which traverses various earth strata. Wellbore 82 has a wellbore extension that is formed by wellbore 84 , which extends from wellbore 82 through additional earth strata, including formation 74 .
[0043] Platform 72 has a hoisting apparatus 86 and a derrick 88 for raising and lowering pipe strings, such as drill string 90 , including drill bit 92 located in wellbore 84 , and casing string 94 , including drill bit 96 , downhole motor 98 , crossover subassembly 100 and downhole drilling apparatus 102 located in wellbore 82 . Using downhole motor 98 , it is not necessary to rotate casing string 94 , including downhole drilling apparatus 102 , in order to rotate drill bit 96 .
[0044] Drilling mud, used to cool drill bit 96 and carry cuttings to the surface, also provides the power to operate downhole motor 98 . As the drilling mud travels through downhole motor 98 , downhole motor 98 imparts rotation to drill bit 96 , so that wellbore 82 is drilled. Using downhole motor 98 in conjunction with downhole drilling apparatus 102 reduces the torsional stress typically encountered by downhole drilling apparatus 102 when casing string 94 is used to rotate drill bit 96 . This reduction in torsional stress allows for the use of a maximum width window 106 in downhole drilling apparatus 102 .
[0045] When drill bit 96 reaches total depth, casing string 94 , including drill bit 96 , downhole motor 98 , crossover subassembly 100 and downhole drilling apparatus 102 , is not retrieved from wellbore 82 . Rather, casing string 94 is cemented in place by cement 104 , which fills the annular area between casing string 94 and wellbore 82 .
[0046] Once cementing of wellbore 82 has been completed, wellbore 84 may be drilled using downhole drilling apparatus 102 . Drill bit 92 creates wellbore 84 by traveling through window 106 of downhole drilling apparatus 102 in the manner discussed above with reference to FIGS. 2 - 4 .
[0047] Referring next to FIG. 6, a cross sectional view of another downhole drilling apparatus 120 embodying principles of the present invention is depicted. Downhole drilling apparatus 120 has a pin end 122 , so that downhole drilling apparatus 12 is interconnectable in a drill string, such as casing string 94 of FIG. 5, or to other downhole tools. Downhole drilling apparatus 120 also has a box end 123 which may be threadedly connected to crossover subassembly 100 as depicted in FIG. 5.
[0048] Apparatus 120 has a generally tubular housing 124 with a window 126 cut through a sidewall thereof. Window 126 is generally elliptically shaped and is sized such that a drill bit, such as drill bit 92 of FIG. 5, may pass therethrough during a drill out operation. Surrounding window 126 is a cover or shield 128 that prevents the flow of drilling mud or cement through window 126 . Apparatus 120 also has at least one alignment member 130 , such as a track, within housing 124 .
[0049] Disposed within housing 124 is a back pressure valve assembly 132 . A central bore 134 extends through back pressure valve assembly 132 to provide fluid passage for drilling mud and cement used during drilling and cementing operations. Valves 136 , 138 are disposed within central bore 134 of back pressure valve assembly 132 . Valves 136 , 138 may be back pressure valves or float valves that allow one-way flow of drilling mud or cement therethrough.
[0050] As best seen in FIG. 7, a whipstock 140 may be run into downhole drilling apparatus 120 to direct a drill bit, such as drill bit 92 of FIG. 5, through window 126 of apparatus 120 . Whipstock 140 may be installed within downhole drilling apparatus 120 following a cementing operation and subsequent use of a conventional cementing plug 142 . Whipstock 140 includes one or more alignment lugs 144 that cooperate with track 130 of downhole drilling apparatus 120 to radially orient whipstock 140 with respect to window 126 .
[0051] After cementing the casing string 94 within wellbore 82 , including installing the plug 142 in the drilling apparatus 120 , the whipstock 140 is conveyed into the drilling apparatus. The alignment track 130 and lugs 144 cooperatively engage and thereby radially orient the whipstock 140 to face toward the window 126 . A drill bit may then be deflected off of the whipstock 140 to cut through the shield 128 , or the shield may be previously displaced to open the window 126 , for example, by using a conventional shifting tool.
[0052] In the embodiments described above, the present invention provides the ability to drill a wellbore using a well casing or liner string as the drill string, and using a drill bit having a full cutting structure. The use of a downhole drilling apparatus embodying principles of the present invention as part of the drill string allows a well extension to be drilled from the existing wellbore, without having to bore through a drill bit on the end of the casing or liner string. Thus, trips into and out of the wellbore may be eliminated and a drill bit having a full cutting structure may be used.
[0053] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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A downhole drilling apparatus for interconnection in a casing or liner string having a drill bit disposed thereon for enabling the drilling of intersecting wellbores without removal of the drill bit is disclosed. In a disclosed embodiment, the apparatus comprises a housing having a window. A whipstock is disposed within the housing. Between the window and the whipstock is a filler. The whipstock and the filler define a central bore providing a fluid path through the apparatus. A back pressure valve may be disposed within the central bore to prevent back flow of fluids through the apparatus. Once the total depth of an initial wellbore is reached, the casing or liner string, including the apparatus, may be cemented in place. Thereafter, an intersecting wellbore may be drilled by laterally deflecting a second drill bit with the whipstock through the window of the housing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of application Ser. No. 13/957,546, filed Aug. 2, 2013, which is a continuation of International application No. PCT/JP2012/054466, filed Feb. 23, 2012, which claims priority to Japanese Patent Application No. 2011-046315, filed Mar. 3, 2011, the entire contents of each of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a laminated ceramic capacitor, and relates to a laminated ceramic capacitor in which a dielectric layer contains, as its main constituent, a perovskite compound such as barium titanate (BaTiO 3 ).
BACKGROUND OF THE INVENTION
[0003] Conventionally, laminated ceramic capacitors have been advancing with reduction in thickness for dielectric layers containing, as their main constituent, barium titanate (BaTiO 3 ) or the like, in order to achieve the reduction in size and the increase in capacitance.
[0004] However, there is a possibility that the reduction in thickness for the dielectric layers will increase the electric field intensity applied to the dielectric layers, thereby leading to a decrease in withstanding voltage or in reliability against high-temperature and high-electric-field loading tests.
[0005] When the resistance distribution is broad in the dielectric, an electric field is concentrated on higher-resistance points to decrease the insulation resistance as an element in a short period of time. In order to avoid this decrease, a dielectric ceramic which has excellent reliability against high-temperature and high-electric-field load is achieved by adding V to a barium titanate or a barium titanate partially substituted with Ca as a main constituent for dielectric layers (for example, see Patent Document 1).
[0006] Patent Document 1: JP 2000-311828 A
SUMMARY OF THE INVENTION
[0007] The environments for the use of laminated ceramic capacitors have been also increasingly severe, and these days, laminated ceramic capacitors have been also used in environments reaching temperatures exceeding 125° C. in some cases. In such cases, mounting onto substrates with solder, which has been common to date, has the problem of deterioration in joint strength and connection resistance with time.
[0008] In order to solve this problem, conductive adhesives containing Ag as a filler are increasingly used for mounting onto substrates when laminated ceramic capacitors are used at high temperatures exceeding 125° C. In addition, as laminated ceramic capacitors, the surfaces of external electrodes are changed from plating to sintered metal containing Ag to ensure the joint strengths with the conductive adhesives.
[0009] However, the Ag contained in the external electrodes and the conductive adhesives turns into silver compounds such as a silver oxide (Ag 2 O), a silver chloride (AgCl), and a silver sulfide (Ag 2 S). This silver compound is brought into contact with the ceramic in dielectric layers, which is obtained by adding V to barium titanate or barium titanate partially substituted with Ca as a main constituent, and when an electric field is applied in a high-temperature environment, the silver will penetrate into the dielectric layers to alter the ceramic.
[0010] The present invention is, in view of the circumstances, intended to provide a laminated ceramic capacitor capable of suppressing alterations of a ceramic even when V is added to a dielectric layer.
[0011] The present invention provides, in order to solve the problems described above, a laminated ceramic capacitor configured as follows.
[0012] The laminated ceramic capacitor includes: (a) dielectric layers stacked adjacent one another to form a laminated body; (b) internal electrodes arranged between the dielectric layers of the laminated body; (c) external electrodes formed along surfaces of the laminated body and connected to the internal electrodes, which include a silver-containing layer containing at least Ag as its main constituent; and (d) a covering layer for covering at least portions of sections covered with the external electrodes, among the surfaces of the laminated body along which edges of the external electrodes lie. The dielectric layers and the covering layer contain, as their main constituent, a perovskite compound represented by a chemical formula “ABO 3 ” when at least one of Ba, Sr, and Ca is denoted by “A”, at least one of Ti, Zr, and Hf is denoted by “B”, and oxygen is denoted by “O”. Among the dielectric layers and the covering layer, V is added to only the dielectric layers.
[0013] It is to be noted that the main constituent ABO 3 may deviate from the stoichiometric composition in some cases. Specifically, the ratio A/B in terms of mol between A and B preferably falls within the range of 0.98 to 1.05.
[0014] In addition, the dielectric layers and the covering layer may be identical or different in terms of composition other than V.
[0015] In the configuration described above, V is added to the dielectric layers, and the withstanding voltage and the reliability against high-temperature and high-electric-field loading tests can be ensured even when the dielectric layers are reduced in thickness.
[0016] According to the configuration described above, the laminated body of the laminated ceramic capacitor is covered with the covering layer to which V is not added, and silver is thus less likely to penetrate into the covering layer even under high temperature and electric field in an environment in contact with a silver compound through the alteration of silver contained in the silver-containing layers of the external electrodes. Therefore, even when the laminated ceramic capacitor is placed under high-temperature and electric field in an environment in contact with the silver compound, no silver penetrates into the ceramic of the laminated body, and the ceramic is less likely to be altered by high-temperature and high-electric-field load.
[0017] Preferably, the silver-containing layer is a conductive resin containing Ag metal particles.
[0018] In this case, external electrodes of electronic components can be easily mounted on circuit boards, etc.
[0019] Preferably, the difference in material composition between the dielectric layers and the covering layer is only that V is added to the dielectric layers whereas V is not added to the covering layer.
[0020] In this case, it is easy to prepare respective materials for the dielectric layers and the covering layer.
[0021] Preferably, the laminated body has a cuboid shape. The internal electrodes are exposed at a pair of mutually opposed end surfaces of the laminated body. The covering layer covers the four surfaces of the laminated body, other than the end surfaces.
[0022] In this case, the laminated body is simply covered with the covering layer.
[0023] According to the present invention, alterations of the ceramic can be suppressed even when V is added to the dielectric layers.
BRIEF EXPLANATION OF THE DRAWINGS
[0024] FIGS. 1( a ) and 1 ( b ) are cross-sectional views of a laminated ceramic capacitor. (Experimental Example)
[0025] FIG. 2 is an exploded perspective view of a main body of the laminated ceramic capacitor. (Experimental Example)
DETAILED DESCRIPTION OF THE INVENTION
[0026] An experimental example will be described below as an embodiment of the present invention.
Experimental Example
[0027] A laminated ceramic capacitor 10 according to an experimental example of the present invention will be described with reference to FIGS. 1( a ), 1 ( b ) and 2 .
[0028] FIG. 1( a ) is a cross-sectional view of the laminated ceramic capacitor 10 . FIG. 1( b ) is a cross-sectional view of FIG. 1( a ) along the line A-A. As shown in FIGS. 1( a ) and 1 ( b ), the laminated ceramic capacitor 10 has external electrodes 16 a , 16 b formed on a pair of end surfaces 12 a , 12 b of a main body 12 . Internal electrodes 14 are formed within the main body 12 . The internal electrodes 14 are exposed alternately at the end surfaces 12 a , 12 b , and connected to the external electrodes 16 a , 16 b . The main body 12 is provided with a covering layer 30 exposed on four surfaces 12 s , 12 t , 12 u , and 12 v other than the end surfaces 12 a , 12 b . More specifically, the covering layer 30 entirely covers, among the surfaces 20 a , 20 b , 20 s , 20 t , 20 u , 20 v of the laminated body 20 , the respective surfaces 20 s , 20 t , 20 u , 20 v along which edges 16 p , 16 q of the external electrodes 16 a , 16 b lie.
[0029] The external electrodes 16 a , 16 b include a silver-containing layer containing at least Ag as its main constituent. For example, the silver-containing layer, which is a conductive resin containing Ag metal particles, is formed by applying and drying the conductive resin containing Ag metal particles.
[0030] FIG. 2 is an exploded perspective view schematically illustrating the configuration of the main body 12 . As shown in FIG. 2 , the main body 12 includes the laminated body 20 which have dielectric layers 22 , 24 , 26 , 28 stacked, and the covering layer 30 covering the four surfaces of the laminated body 20 . The internal electrodes 14 are formed on principal surfaces of the certain dielectric layers 24 , 26 of the laminated body 20 .
[0031] The dielectric layers 22 , 24 , 26 , 28 of the laminated body 20 are dielectric ceramic layers containing, as their constituent, a perovskite compound such as barium titanate (BaTiO 3 ).
[0032] The perovskite compound is represented by a chemical formula “ABO 3 ” when at least one of Ba, Sr, and Ca is denoted by “A”, at least one of Ti, Zr, and Hf is denoted by “B”, and oxygen is denoted by “O”.
[0033] V is added to the dielectric layers 22 , 24 , 26 , 28 of the laminated body 20 .
[0034] The covering layer 30 has, except that V is not added thereto, the same composition as the dielectric layers 22 , 24 , 26 , 28 of the laminated body 20 . More specifically, the covering layer 30 is a dielectric ceramic layer without V present therein. When V is 0.01 parts by mol or less with respect to 100 parts by mol of the B component in the ceramic constituent of the covering layer 30 herein, it is considered that “V is not added” or that “V is present only in.”
[0035] Even when the laminated ceramic capacitor 10 thus including the main body 12 with the laminated body 20 covered with the covering layer 30 is placed under high temperature and electric field in an environment where the covering layer 30 of the main body 12 of the laminated ceramic capacitor 10 is brought into contact with a silver compound, no silver penetrates into the ceramic of the laminated body 20 of the main body 12 , and the ceramic is less likely to be altered by high-temperature and high-electric-field load. Thus, the reliability of the laminated ceramic capacitor 10 can be ensured because the electrical characteristics are less likely to be changed.
[0036] Next, a laminated ceramic capacitor made as a prototype will be described.
[0037] In order to prepare a dielectric raw material, BaCO 3 and TiO 2 powders were prepared, weighed in predetermined amounts so that the molar ratio of Ba to Ti was 1, and then, with addition of pure water and a dispersant, subjected to a grinding and crushing treatment by using a forced-circulation type wet grinder (with use of PSZ media). The treated slurry was dried in an oven, and then subjected to a heat treatment at a temperature of 950° C. or higher, thereby providing a first powder with an average grain size of 0.15 to 0.25 μm.
[0038] Subsequently, in addition to the first powder, BaCO 3 , Dy 2 O 3 , MgCO 3 , MnCO 3 , SiO 2 , and V 2 O 5 powders were prepared, weighed in predetermined amounts so as to provide the additional additive amounts of Ba, Dy, Mg, Mn, Si, and V in terms of parts by mol as shown in Table 1 with respect to 100 parts by mol of the Ti in the first powder, and then, with addition of pure water and a dispersant, subjected to a grinding and crushing treatment by using a forced-circulation type wet grinder (with use of PSZ media). The treated slurry was dried in an oven to obtain a dielectric raw material.
[0039] Further, it has been confirmed by an ICP emission spectrometric analysis that the obtained raw material powder is nearly identical to the prepared compositions shown in Table 1 below.
[0000]
TABLE 1
Ba
Dy
Mg
Amount
Amount
Amount
Mn Amount
Si Amount
V Amount
(parts by
(parts by
(parts by
(parts by
(parts by
(parts by
mol)
mol)
mol)
mol)
mol)
mol)
1.8
2.0
1.0
0.3
1.5
0.14
[0040] The prepared dielectric raw material powder was, with the addition of a polyvinyl butyral binder and an organic solvent such as ethanol thereto, subjected to wet mixing in a ball mill to prepare ceramic slurry. This ceramic slurry was subjected to sheet forming by a doctor blade method or the like so that fired dielectric layers were 7.0 μm in thickness, thereby providing rectangular green sheets. Next, a conductive paste containing Ni was applied by screen printing onto the green sheets, thereby forming conductive layers to serve as internal electrodes.
[0041] In order to form a laminated body, 10 of the green sheets before applying the conductive paste by printing were stacked first, and 100 of the green sheets with the conductive paste printed were stacked thereon so as to alternate the sides to which the conductive paste was drawn. Thereafter, 10 of the green sheets before applying the conductive paste by printing were stacked again, and the stacked body was cut into individual pieces to obtain laminated bodies. These are samples of experimental run numbers 1, 5, 10, and 15 in Table 2 shown later.
[0042] On the other hand, a raw material with only the V 2 O 5 eliminated from the dielectric raw material was prepared by the same method as described above, and with addition of a polyvinyl butyral binder and an organic solvent such as ethanol thereto, subjected to wet mixing in a ball mill to prepare ceramic slurry. This ceramic slurry was subjected to sheet forming by a doctor blade method or the like, thereby providing rectangular green sheets of 15 μm in thickness.
[0043] Among the green sheets formed from the raw material with only the V 2 O 5 eliminated, a desired number of sheets were subjected to pressure bonding onto four surfaces of the laminated bodies other than end surfaces thereof, thereby providing main bodies without V present on the surfaces other than the end surfaces. These are samples of experimental run numbers 2 to 4, 6 to 8, 11 to 13, and 16 to 18 in Table 2 shown later.
[0044] Furthermore, a raw material with the additional additive amount of V adjusted to 0.01 parts by mol with respect to 100 parts by mol of the Ti in the first powder as compared with the dielectric raw material was prepared by the same method as described above, and with addition of a polyvinyl butyral binder and an organic solvent such as ethanol thereto, subjected to wet mixing in a ball mill to prepare ceramic slurry. This ceramic slurry was subjected to sheet forming by a doctor blade method or the like, thereby providing rectangular green sheets of 15 μm in thickness.
[0045] Among the green sheets formed from the raw material containing 0.01 parts by mol of V, a desired number of sheets were subjected to pressure bonding onto four surfaces of the laminated bodies other than end surfaces thereof, thereby providing main bodies without V present on the surfaces other than the end surfaces. These are samples of experimental run numbers 9, 14, and 19 in Table 2 shown later.
[0046] The laminated bodies provided, by pressure bonding, with the green sheets formed from the raw material with only the V 2 O 5 eliminated, and for comparison, a laminated body provided, by pressure bonding, with none of the green sheets formed from the raw material with only the V 2 O 5 eliminated (that is, the laminated body itself) were each subjected to a binder removal treatment by heating to 250° C. in a N 2 atmosphere, and to firing at a maximum temperature of 1200 to 1300° C. and an oxygen partial pressure of 10 −9 to 10 −10 MPa in a reducing atmosphere composed of H 2 —N 2 —H 2 O gases, thereby providing sintered ceramic laminated bodies.
[0047] A Cu paste containing B 2 O 3 —Li 2 O 3 —SiO 2 —BaO based glass frit was applied to both end surfaces of the sintered ceramic laminated bodies obtained, and baked at a temperature of 850° C. in a N 2 atmosphere to form external electrodes electrically connected to the internal electrodes, thereby providing laminated ceramic capacitors according to the experimental examples and the comparative examples.
[0048] The laminated ceramic capacitors obtained in the way described above were about 1.2 mm in width, 2.0 mm in length, and about 1.1 mm in thickness, and the dielectric ceramic layers sandwiched between the internal electrodes of the capacitor were 7.0 μm in thickness.
[0049] It is to be noted that while laminated ceramic capacitors as products are formed so that external electrodes include a silver-containing layer containing at least Ag as its main constituent, the external electrodes of the laminated ceramic capacitors made as prototypes according to the experimental examples and the comparative examples have no silver-containing layer formed therein, because the prototypes are used in a simulation test for which the external electrodes have silver-containing layers protruding and adhering to the laminated ceramic capacitors.
[0050] The test using the laminated ceramic capacitors made as prototypes according to the experimental examples and the comparative examples was carried out as follows.
[0051] A silver compound powder of Ag 2 O, AgCl, or Ag 2 S, or a metal silver powder of Ag mixed with 40 vol % of epoxy resin was applied onto one of the external electrodes so as to come into contact with both the ceramic body and the Cu external electrode, but so as not to cover a portion of the Cu external electrode on the end surface, which was connected to a connection terminal, for being able to ensure an electrical connection, and cured at a temperature of 175° C. to obtain a test sample.
[0052] While using, as an anode, the external electrode with the applied epoxy mixed with the silver compound powder or the metal silver powder, a voltage of DC 100 V was applied and held for 150 hours under an environment at 175° C. In order to keep the silver compound and silver powder contained in the epoxy resin from being affected by the atmosphere gas during this test, the test was carried out with the sample and connection terminal covered with a silicone resin after connecting to a power source.
[0053] After completion of the test, the portion in contact with the epoxy resin mixed with the silver compound powder or the silver powder and 50 μm away from the Cu external electrode was cut in the stacking direction to expose a vertical cross section (WT cross section) of the ceramic body (main body), and the exposed cross section was subjected to an ICP analysis using a laser abrasion method to detect Ag and V. When there was a point at which Ag was detected somewhere in the exposed cross section 10 μm or more inside from the body surface layer (the surface of the main body), it was determined that the penetration of Ag was observed. In addition, among the points at which more than 0.01 parts by mol of V was detected with respect to 100 parts by mol of Ti, the shortest distance from the body surface layer was regarded as a thickness without V present.
[0054] The test results are shown in Table 2 below.
[0000]
TABLE 2
Sheet without V
Type of Mixed
(15 μm thickness)
Sheet with V
Thickness
Silver
Sheet without V
The Number of
V Additive
of Layer
Penetration
Compound
V Content
Sheet Stacked
Amount
without V
of Silver
1 *
Ag
0 mol %
0
0.14 mol %
0 μm
No
2
Ag
0 mol %
3
0.14 mol %
43 μm
No
3
Ag
0 mol %
6
0.14 mol %
86 μm
No
4
Ag
0 mol %
9
0.14 mol %
130 μm
No
5 *
Ag2O
0 mol %
0
0.14 mol %
0 μm
Yes
6
Ag2O
0 mol %
3
0.14 mol %
40 μm
No
7
Ag2O
0 mol %
6
0.14 mol %
84 μm
No
8
Ag2O
0 mol %
9
0.14 mol %
127 μm
No
9
Ag2O
0.01 mol %
3
0.14 mol %
44 μm
No
10 *
AgCl
0 mol %
0
0.14 mol %
0 μm
Yes
11
AgCl
0 mol %
3
0.14 mol %
41 μm
No
12
AgCl
0 mol %
6
0.14 mol %
85 μm
No
13
AgCl
0 mol %
9
0.14 mol %
124 μm
No
14
AgCl
0.01 mol %
3
0.14 mol %
44 μm
No
15 *
Ag2S
0 mol %
0
0.14 mol %
0 μm
Yes
16
Ag2S
0 mol %
3
0.14 mol %
38 μm
No
17
Ag2S
0 mol %
6
0.14 mol %
84 μm
No
18
Ag2S
0 mol %
9
0.14 mol %
128 μm
No
19
Ag2S
0.01 mol %
3
0.14 mol %
41 μm
No
Mark * outside the scope of the present invention
[0055] In Table 2, the “Type of Mixed Silver Compound” refers to the type of the silver compound powder or metal silver powder contained in the epoxy brought into contact with both the ceramic body and the Cu external electrode. The “Sheet without V” refers to the green sheet formed from the raw material with only the V 2 O 5 eliminated, or the green sheet formed from the raw material containing 0.01 parts by mol of V with respect to 100 parts by mol of Ti, which was subjected to pressure bonding onto the four surfaces of the laminated body. The “Thickness of Layer without V” is almost equal to the thickness of the fired green sheet formed from the raw material with only the V 2 O 5 eliminated, or the fired green sheet formed from the raw material containing 0.01 parts by mol of V with respect to 100 parts by mol of Ti, which was subjected to pressure bonding onto the four surfaces of the laminated body (the thickness of the covering layer). The experimental run numbers 1, 5, 10, and 15 with the mark * represent comparative examples.
[0056] The following is determined from Table 2.
[0057] From the experimental run numbers 1, 2, 3, and 4, it is determined that in the case of the metal silver powder mixed, the penetration of Ag is not caused regardless of the presence or absence of the layer without V (covering layer). This is a simulation without corrosion of Ag, from which it is determined migration is not caused.
[0058] From the experimental run numbers 5, 10, and 15, it is determined that in the case of the silver compound powder mixed, the penetration of Ag is caused in all of the samples without the layer without V (covering layer), regardless of the type of the silver compound mixed.
[0059] From the experimental run numbers 6, 7, 8, 9, 11, 12, 13, 14, 16, 17, 18, and 19, it is determined that in the case of the silver compound powder mixed, the penetration of Ag is not caused in all of the samples with the layer without V (covering layer), regardless of the type of the silver compound mixed.
[0060] More specifically, in the case of the silver compound in contact with the surface of the main body of the laminated ceramic capacitor, Ag penetrates into the ceramic of the main body in a high-temperature and high-electric-field environment when V is present in the surface layer of the main body of the laminated ceramic capacitor, whereas no Ag penetrates into the ceramic of the main body even in a high-temperature and high-electric-field environment when no V is present in the surface layer of the main body of the laminated ceramic capacitor.
[0061] Therefore, even when the configuration with no V present in the surface layer of the main body is placed under high temperature and electric field in an environment in contact with a silver compound, no silver penetrates into the ceramic of the main body, thereby achieving a laminated ceramic capacitor which is less likely to be altered by high-temperature and high-electric-field load.
CONCLUSION
[0062] As described above, in the laminated body of the dielectrics stacked, which is covered with the covering layer with no V added thereto, alterations of the ceramic can be suppressed even when V is added to the dielectric layers.
[0063] It is to be noted that the present invention is not to be considered limited to the embodiment described above, and various modifications can be made in the practice of the present invention.
[0064] For example, there is a great effect preferably in the case where the sections covered with the external electrodes 16 a , 16 b are entirely covered with the covering layer 30 , among the surfaces 20 s , 20 t , 20 u , 20 v of the laminated body 20 along which the edges 16 p , 16 q of the external electrodes 16 a , 16 b lie as shown in FIG. 1 , but the present invention is not to be considered limited to this case. The covering layer 30 only has to cover at least portions of the sections covered with the external electrodes 16 a , 16 b , among the surfaces 20 s , 20 t , 20 u , 20 v of the laminated body 20 along which the edges 16 p , 16 q of the external electrodes 16 a , 16 b lie, and may be formed on only some of the surfaces 20 s , 20 t , 20 u , 20 v of the laminated body 20 along which the edges 16 p , 16 q of the external electrodes 16 a , 16 b lie.
DESCRIPTION OF REFERENCE SYMBOLS
[0000]
10 laminated ceramic capacitor
12 main body
14 internal electrode
16 a , 16 b external electrode
16 p , 16 q edge
20 laminated body
20 a , 20 b , 20 s , 20 t , 20 u , 20 v surface
22 , 24 , 26 , 28 dielectric layer
30 covering layer
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A method of manufacturing a ceramic capacitor component that includes preparing a laminate body including first to third green sheets by stacking the first green sheets before applying conductive paste, stacking the second green sheets with conductive paste applied thereon on the first green sheets, and stacking the third green sheets before applying conductive paste on the second green sheets; preparing fourth green sheets from a raw material that does not contain V 2 O 5 ; providing the fourth green sheets onto four surfaces of the laminate body other than end surfaces of the laminate body to form a main body; firing the main body; and applying and baking a Cu paste onto the four surfaces of the main body and the end surfaces of the main body.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a vehicle four-wheel-drive transfer case, and in particular to a four-wheel-drive transfer case which provides automatic torque balancing, differentiation, and traction enhancement in the event of wheel slip.
Four-wheel-drive systems for vehicles are being utilized to a greater extent, providing increased traction and safety of operation for the vehicle. Recently, "full time" four-wheel-drive systems have been developed for vehicles, wherein a transfer case is typically provided with an interaxle differential for dividing torque between the vehicle front and rear differentials. The torque transfer mechanisms to supply drive power to the four wheels of a vehicle are usually connected to the vehicle transmission which is driven by the vehicle engine.
In a vehicle provided with a "full time" two-wheel-drive system, to prevent excess slippage between the front and rear wheels, the transfer case has included a selectively engageable clutch, which is operative to lock the interaxle differential upon sensing predetermined slippage between the front and rear output shafts of the transfer case. As an example, a transfer case has been designed to utilize electronic control, and includes a planetary interaxle differential for proportional torque split. An electromagnetic clutch is locks the differential to enhance mobility when road coefficients cause single wheel or single axle traction loss. The actuation of the clutch system is monitored by an electronic module and sensor system, which can detect abnormal amounts of differentiation in the interaxle unit and correct for this differentiation. This type of system does improve vehicle handling and stability, but may not adequately balance torque between the front and rear axles, nor adequately account for differentiation in the full time four-wheel-drive system.
There has thus been found a need to provide improved torque balancing and differentiation along with the ability to provide extra torque in the event of single-wheel or single-axle traction loss for improved mobility and stability in a full time four-wheel-drive system associated with a vehicle.
SUMMARY OF THE INVENTION
The invention is therefore directed to a full time four-wheel-drive system for a vehicle having front and rear drive wheels, and an engine and transmission assembly providing output torque to the front and rear wheels of the vehicle. The four-wheel-drive system a unique torque-transfer case assembly, including a torque input shaft for receiving output torque from the transmission assembly of the vehicle, and front- and rear-output shafts connected to front and rear differentials of the vehicle. The transfer case assembly inches means for connecting the input shaft to the front and rear output shafts, transferring a predetermined amount of torque to each output shaft, comprising a continuously variable belt drive. The continuously variable drive arrangement will include at least a primary pulley on the input shaft and a secondary pulley on the front output shaft, the pulleys carrying a therebetween. Each pulley comprises a pair of sheaves, which are axially moveable, in relation to one another. The pair of sheaves of each pulley are shifted axially relative to one another by means which are responsive to divide torque between the front and rear output shafts in a predetermined relationship. The system operates to substantially maintain this predetermined relationship during normal operation of the vehicle, and balance torque between the front and rear output shafts to yield improved vehicle handling, stability anti feel.
The means to shift the pulley sheaves may comprise a ball ramp mechanism which drivingly connects the rear output shaft to the input shaft, with the magnitude of the torque transferred to the rear output shaft from the input shaft depending upon the angles established in the ball ramp assembly. As an alternative to the ball ramp assembly, desired torque distribution is provided by an electronic control system which monitors the torque to both the front and rear output shafts and controls a mechanism to cause shifting of the moveable sheaves to vary the ratio and division of torque to the front and rear output shafts. Alternatively, the transfer case assembly may include an additional drive in association with the continuously variable drive system in a dual path torque transmission arrangement.
A main advantage of the transfer case assembly of the invention is therefore to provide differentiation between front and rear output shafts in a full time four-wheel-drive system, and enable torque balancing and transfer to each of the output shafts in a predetermined relationship. The system provides traction enhancement by increasing torque transfer in the event of a predetermined amount of wheel slip, and therefore yield improved vehicle handling, stability, and mobility in an all-wheel-drive vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the present invention will become readily apparent one skilled in the art from a reading of the following detailed description in conjunction with the attached drawings, wherein:
FIG. 1 is a top plan view of a four-wheel-drive system which utilizes the transfer case of the invention:
FIG. 2 is a sectional view through the transfer case assembly of the invention, illustrating a first embodiment of the invention;
FIG. 3 is an enlarged partial sectional view through the ball ramp mechanism in the embodiment of FIG. 2;
FIG. 4 is an enlarged partial sectional view taken of the transfer case assembly, illustrating the transfer of additional torque to the front output shaft;
FIG. 5 is an enlarged partial sectional view through the transfer case assembly, illustrating the transfer of additional torque to the rear output shaft;
FIG. 6 is a sectional view through the transfer case assembly, illustrating an alternative embodiment of the invention; and
FIG. 7 is a sectional view through the transfer case assembly, illustrating yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a vehicle four-wheel-drive system which utilizes the transfer case of the invention. As shown in FIG. 1, a vehicle includes a drive engine (10), which is coupled with a transmission unit (12) of conventional configuration. The transmission unit (12) is secured to a transfer case (14) in accordance with the invention, which includes a rear output shaft or yoke (16) as well as a front output shaft or yoke (18). The rear output shaft (16) is connected to a rear drive shaft (20) by means of a universal joint connection, and drive shaft (20) is in turn connected to an input shaft or yoke (22) of a rear differential unit (24) by means of a universal joint coupling (26). The rear differential (24) is adapted to divide torque from the drive shaft (20) between the rear wheels (28) of the vehicle. Similarly, the front output shaft (18) of transfer case (14) is connected to the rearward end of a front drive shaft (30) by means of a universal joint coupling (32). The front drive shaft (30) has the forward end thereof connected to an input shaft or yoke (34) of a front differential unit (36) by means of a universal joint coupling (38). The front differential unit (36) is adapted to divide torque received from the front drive shaft (30) between the front wheels (40) of the vehicle.
Referring now to FIGS. 2 and 3, the specific construction of a first embodiment of the transfer case (14) of the invention will be discussed in more detail. As seen in FIG. 2, the transfer case (14) includes a torque input shaft (42) which receives output torque from the vehicle transmission. The transfer case (14) includes an outer housing (46), which generally will include sections secured together by a plurality of bolts or the like. The transfer case input shaft (42) has a forward end connected to the rearward end of the transmission output shaft (44), by means of a spline connection at (48), which prevents relative rotation between output shaft (44) and input shaft (42). The forward end of the input shaft (42) is rotatably supported in the housing (46) by means of a ball bearing assembly (50). Further, the input shaft (42) is sealed within all opening provided in the front face of the housing (46) by annular seal means in a known manner. The input shaft (42) extends into the transfer case housing (46) and has a rearward end positioned within an annular recess (52) of a rear output shaft (54) of the transfer case assembly (14). An annular bushing (72) is mounted within the annular cavity (52) of the rear output shaft (54) to rotatably support the rear end of the input shaft (42) therein. The rear output shaft (54) comprises a slidable splined sleeve or collar section (62) coupled to a rear output yoke (66). The rearward end of sleeve (62) is provided with internal splines (64) which receive an external splined section (65) of rear output yoke (66). The rear output yoke (66) is a fixed yoke, and the collar (62) provides a slip spline in association with the rear output yoke (66) to allow relative axial movement between the slidable splined collar (62) and rear output yoke (66). In this configuration, the rear output yoke (66) is restrained from axial movement, with the slip spline enabling relative axial movement of section (62) in association with the ball-ramp mechanism (100) which will be hereinafter described. The slip spline may be formed in a known manner, and may use a ball-type spline or a Glidecote® plastic having a low coefficient of friction. As an alternative, a slip yoke could be provided to allow axial movement of the rear output a slip spline in association with the rear output yoke (66) to allow relative axial movement between the slidable splined collar (62) and rear output yoke (66). In this configuration, the rear output yoke (66) is restrained from axial movement, with the slip spline enabling relative axial movement of section (62) in association with the ball-ramp mechanism (100) which will be hereinafter described. The slip spline may be formed in a known manner, and may use a ball-type spline or a Glidecote ® plastic having a low coefficient of friction. As an alternative, a slip yoke could be provided to allow axial movement of the rear output shaft (54). The rear output yoke (66) associated with rear output shaft (54) is rotatably supported within the rear of transfer case housing (46), by means of a bushing (55) and ball bearing assembly (56), which is secured relative to the yoke (66) by means of a snap ring (58) and relative to the housing (46) by means of a snap ring (60). The rear output shaft (54) is provided with external splines (64), and is adapted to receive a splined section of a rear output yoke (66). The rear output shaft (54), and particularly rear output yoke (66) is sealed with respect to a rear opening provided in the housing (46) by annular sealing means (68).
Also as seen in FIG. 2, there is proivded a continuously variable v-belt drive which is supported on the torque input shaft (42) of the transfer case assembly (14). The continuously variable belt drive is generally indicated at (75), and includes a primary or drive pulley (76) mounted in association with the input shaft (42), and a secondary pulley (78) mounted in association with a front output shaft (80). The front output shaft (80) is rotatably supported in the transfer case housing (46) by means of ball bearing assemblies (82) and (84) or other types of bearing assemblies in a known manner. The ball bearing assemblies (82) and (84) is secured relative to the housing (46) by means of snap rings (86) and (88), while being secured relative to tje front output shaft (80) by means of snap rings (90) and (92). The forward end of the front output shaft (80) is provided with external splines (94) for receiving internal splines provided on a sleeve portion of a front output yoke (96) to prevent relative rotation therebetween. An annular seal assembly (98) is provided within a front opening in transfer case housings (46), to seal about the front output shaft (80) and corresponding front output yoke (96).
The continuously variable drive (75), including primary pulley (76) and secondary pulley (78), provides torque transfer from the torque input shaft (42) to the front output shaft (80). Driving torque is transferred to the rear output shaft (54) from input shaft (42) assembly through a ball ramp assembly generally indicated at (100). In the ball ramp system (100), the torque input shaft (42) carries a first ball ramp portion (102) extending radially from the shaft and acting upon a plurality of ball bearings (104) in a dual ball ramp configuration. As seen in FIG. 3, the ball ramp portion (102) of input shaft (42) includes two ramp bearing surfaces (106) and (108) acting on a pair of balls (104). Corresponding to this structure, the primary pulley (76) comprises a moveable sheave (110) and a fixed sheave (112), which are relatively slidable in relation to one another in an axial direction. The hub portion (114) of the moveable sheave (110) is adapted to extend through an annular opening (116) in the fixed sheave (112) as shown in FIG. 2. The hub portion (118) of the fixed sheave (112) is rotatably mounted on the torque input shaft (42) by means of a ball bearing assembly (120). The hub portion (118) of the fixed sheave (112) also carries a bias spring member (122), which is fixed in position by means of a snap ring (124). The bias spring member (122) is adapted to act on the moveable sheave (110), such that the spring member (122) actuates and biases the moveable sheave (110), imparting a force which acts to squeeze sheaves (110) and (112) together. In association with hub portion (114) of the moveable sheave (110), an extension generally indicated at (126) includes a ball ramp portion (128), which together with ball ramp portion (102) of the input shaft (42), forms a load camming mechanism for torque transfer through the continuously variable drive (75) to the front output shaft (80) of transfer case (14). Similarly, rear output shaft (54) includes a ball ramp portion (130) which together with ball ramp portion (106)of the input shaft (42) form a load cam mechanism for actuating torque transfer from the input shaft (42) to rear output shaft (54). The extension (126) of hub portion (114) associated with the moveable sheave (110) also extends beyond the ramp portion (130) associated with output shaft (54), and is rotatably coupled thereto by means of a ball bearing assembly (132). The rear output shaft (54), and particularly splined sleeve section (62), is free to move axially relative to the torque input shaft (42). The slip spline provided between the input shaft (42) and splined sleeve (62) enables sleeve (62) to move in association with the ball ramp mechanism (100), with axial movement limited by the degree of movement of the moveable sheave (110) associated with primary pulley (76) and the extension of moveable sheave (110).
The ball ramp assembly (100) of the invention transfers torque from the input shaft (42) to the rear output shaft (54) via the rear ball ramp mechanism consisting of ramp portions (106) and (130) and the associated ball (104) disposed therebetween. The amount of torque transferred to the rear output shaft will depend upon the angle established on the ramp portions (106) and (130). Similarly, transfer of torque from the input shaft (42) to the front output shaft (80) of transfer case (14) is provided by means of the continuously variable drive (75). Transfer of torque to the front output shaft (80) via the continuously variable belt drive (75) will depend upon the position of the moveable sheave (110) relative to the fixed sheave (112) of the primary pulley (76). It should be recognized, that the angles of the ball ramp systems will determine the distribution of torque transferred to both the rear output shaft (54) and front output shaft (80), to allow any desired torque split between the front and rear output shafts. Although the ramps shown in FIGS. 2 and 3 are symmetrical, indicating an even torque split between front and rear output shafts under normal operating conditions, it is contemplated that an uneven torque split is achieved by merely varying the angles of the ramps acting on the respective front or rear output shafts if desired. For example, if a vehicle is desired to maintain a rear drive/reel a two-thirds to one-third distribution is chosen, with the high torque side driving the rear output shaft (54), while at the same time achieving the front wheel drive's front traction advantage in a four-wheel-drive system.
The ball ramp configuration of the invention also achieves balancing of torque in the desired and predetermined ratio between the rear output shaft (54) and front output shaft (80) driven by the continuously variable belt drive (75). This balancing of torque distribution between the front and the rear output shafts of the transfer case will be seen more distinctly in FIGS. 4 and 5. As seen in FIG. 4, the primary pulley (76) is shown, and reflects the torque balancing effect of the ball ramp mechanism associated with this embodiment of the invention. Although the secondary pulley of the continuously variable drive (75) is not shown, it should be understood that it corresponds to actuation of the primary pulley (76) to effect variable drive of the front output shaft (80) as previously described. In operation, the transfer case of the invention will distribute torque from the input shaft (42) to the front and rear output shafts in a predetermined relationship, and the ball ramp mechanism will continuously act to balance torque between the output shafts according to this predetermined relationship. In FIG. 4, there is illustrated the ability to transfer additional torque to the front output shaft (54) to compensate for an increased torque on the rear output shaft. In operation, if an increased torque is applied to the rear output shaft due to cornering or other operational characteristic of the vehicle, additional torque will be transferred through the ball ramp system including ramps (106) and (130) and the associated ball (104). This increased torque will result in the ball (104) traveling on ramps (106) and (130) in a manner such that the moveable sheave (110) would be urged toward the fixed sheave (112) by movement of the sheave extension (126) toward rear output shaft (54) in association with axial movement of shaft (54). The bias spring member (122) will facilitate actuation of the moveable sheave (110) resulting in a configuration of the primary pulley (76) as seen in FIG. 4. As the moveable sheave (110) is urged toward the fixed sheave (112), the belt (t 13) will be urged upwardly within sheaves (110) and (112), such that the system will try to overdrive the front output shaft. In this configuration of the continuously variable drive {,75), if the front output shaft is restricted by the pavement on which the wheels of the vehicle travel, then torque transfer from the input shaft (42) to the front output shaft will be increased, and torque between the front and rear output shafts will be balanced.
Conversely, as seen in FIG. 5, if more torque is experienced on the front output shaft, the additional torque would operate on the ball ramp assembly comprising ramps (108) and (128) and the associated ball (104). As the ball (104) travels on ramps (108) and (128), this would urge the sheave extension (126) associated with moveable sheave (110) away from the rear output shaft (54), resulting in shifting of the moveable sheave (110) away from the fixed sheave (112) as seen in FIG. 5. In this condition, the torque transfer to the front output shaft via the continuously variable drive (75) is reduced, tending to overdrive the rear output shaft (54). Again, if the speed of the rear output shaft is restricted by the pavement, then the torque transferred to the rear output shaft (54) will be increased to effect balancing of torque between the front and rear output shafts.
The continuously variable drive (75) provides differentiation between the front and rear output shafts as desired. Normal vehicle cornering produces a certain amount of required differentiation, which is suitably provided by the continuously variable drive (75). The differentiation required for normal vehicle cornering also must be distinguished from wheel slip or spin, and the continuously variable drive (75) is configured such that its limits correspond to parameters associated with normal differentiation due to cornering. Normal differentiation is defined as that which can occur in a corner of a given radius before a "skid-out" speed is reached. The control of the ratio of torque transfer from the torque input shaft to the front and rear output shafts allows for normal differentiation due to steer angle and wheel or tire radius variations, and the dual ball ramp assembly will effectively balance torque transfer to substantially maintain the predetermined ratio between the front and rear ts.
In addition to providing normal interaxle differentiation, the transfer case assembly of the invention also provides traction enhancement. When a front or rear wheel spins out due to a low coefficient surface, more torque will be delivered to the opposite axle which is on a less slippery surface. This traction enhancement increases the ability of the vehicle to move itself and to improve vehicle handling and stability. In the present invention, traction enhancement is obtained upon the occurrence of a predetermined amount of wheel slip, which correlates to the maximum speed of the continuously variable belt drive (75). As the continuously variable torque transfer arrangement inherently has limits in the amount of torque which can be transferred, this limit is utilized to provide additional torque transfer upon the occurrence of a single wheel or single axle traction loss, to provide additional traction to the output shaft where no traction loss has occurred and enhance mobility of the vehicle. This traction enhancement is provided by the dual ball ramp assembly, and occurs after a predetermined amount of wheel slip correlating to the maximum speed of the continuously variable drive. Upon the occurrence of a wheel slip, the torque applied to the corresponding output shaft associated with that wheel will drop off, and the balancing function of the ball ramp mechanism (100) as previously described will be actuated. It should be recognized that upon actuation of the torque balancing function, it is possible that the maximum speed of the continuously variable belt drive (75) will be reached, wherein the balancing function will no longer restrict in additional torque being transferred to the output shaft associated with the wheel slip. When the limits of the continuously variable drive are exceeded, additional torque will then be delivered to the opposite output shaft and axle which is on a less slippery surface.
Turning now to FIG. 6, an alternative embodiment of the invention is shown to include an electronic control system adapted to monitor the torque of both the front and the rear output shafts of the transfer case assembly, and to control operation of the continuously variable drive (75) associated with the interaxle transfer case. In this embodiment, only distinctions between this and the embodiment of FIGS. 2-5 will be referred to, and common reference numerals will be used for common components of the transfer case assembly.
Electronic control of torque distribution may provide better mobility and handling characteristics in that the limits of the continuously variable drive system would not need to be exceeded in order to transfer additional torque in the event of traction loss. In accordance with this embodiment, the input shaft (42) extends into the transfer case housing (46) and has its rearward end coupled to rear output yoke (66). The input shaft (42) rotatably supported within housing (46) by ball bearing assemblies (50) adjacent the front end, and ball bearing assemblies (150) positioned adjacent the rear end of input shaft (42). The input shaft (42) is coupled to the rear output yoke (66) by means of a spline connection, to prevent relative rotation therebetween. Similarly, the front output shaft (80) is drivingly engaged to the input shaft (42) by means of the continuously variable belt drive (75) as previously described. The torque of the rear output shaft (54) is monitored by means of a torque sensor (166) which may be any conventional means to sense the torque of shaft (54). Similarly, the torque of the front output shaft (80) is monitored by means of a torque sensor (168) as part of an electronic control system. The outputs of the torque sensors (166) and (168) are connected to an electronic control system, generally indicated at (170) which includes processing means to determine the torque on the output shafts. The electronic control system (170) in turn controls an adjustable mechanism generally indicated at (172). The adjustable mechanism (172) is adapted to act upon the hub extension (114) of moveable sheave (110), to effect shifting of moveable sheave (110) relative to fixed sheave (112) associated with primary pulley (76) of the continuously variable drive (75). In this manner, distribution of torque from the input shaft (42) can be effectively controlled in response to the detected torques of both the front output shaft (80) and rear output shaft (54) in the system. Shifting of moveable sheave (110) by means of adjustable mechanism (172) is performed in response to the detected torques sensed form the front and rear output shafts to properly distribute torque in the desired manner.
As shown in FIG. 6, the adjustable mechanism (172) may comprise an electric motor device positioned around the input shaft (42), being controlled by the electronic control system (170). The adjustable mechanism (172) may thus comprise a motor housing (152) supported within transfer case housing (46). The motor housing (152) includes field windings or stator windings (154) positioned relative to an armature or rotor (156) which is supported relative to motor housing (152) by means of ball bearing assemblies (158) or the like. The electronic control system (170) will provide actuating power to the stator windings (154) of the motor assembly to produce rotation of the armature (156) relative to stator (154) and motor housing (152). The motor housing (152) further includes an extension (160) which is splined or tanged onto a rotatable sleeve (162) which cooperates with hub extension (114) of moveable sheave (I 10). The armature (156) is also provided with external threads which mate with the threaded portion of shift collar or sleeve (162). Upon actuation of the motor, the armature (156) will be made to rotate, which will in turn cause axial movement of the shift collar (162). The shift collar (162) is restrained from rotation by means of the housing extension (160), but the spline connection will allow axial movement of collar (162). In this configuration, it should be recognized that the armature (156) may be rotated in alternative directions to effect axial movement of shift collar (162) and resulting movement of movable sheave (110) by means of hub extension (114). The hub portion (114) of movable sheave (110) may be connected to shift collar (162) by means of a washer and snapping assembly shown at (164).
Although the adjustable mechanism (172) is described as an electric motor device to perform shifting of moveable sheave (110) in the variable drive (75), the adjustable mechanism (172) may be of any suitable type, including electronic, hydraulic, or pneumatic mechanisms to effect shifting of moveable sheave (110) relative to fixed sheave (112) of pulley (70. In this manner, torque distribution to the front and rear output shafts is regulated as a function of the measured torque, which may result in an improved control system as the limits of the continuously variable drive (75) would not need to be exceeded in order to transfer additional torque when necessary.
Turning now to FIG. 7, an alternate embodiment of the invention is shown to include a dual-path torque transmission arrangement. In this embodiment, only distinctions between the previous embodiments will be referred to, and common reference numerals will be used to common components. As previously mentioned, it is possible in some vehicles that using the continuously variable drive to effect torque transfer in a predetermined relationship between front and rear output shafts may result in the limits of the continuously variable drive being exceeded under abnormal operating conditions of the vehicle. Due to the limitations of continuously variable drive technology, it may therefore be desirable to provide a fixed drive mechanism which is used in parallel with the continuously variable drive to transmit a fixed amount of torque from the input shaft to the front and rear output shafts of the transfer case. The continuously variable drive is used to transmit a varying amount of additional torque in the dual path torque transfer arrangement, to achieve an increase in torque of several times or the reduction in the size of continuously variable drive required. The torque transferred by the constant drive can be set to eliminate the possibility that the limits of the continuously variable drive will be exceeded, even under conditions of wheel slip or the like. In this embodiment, the input shaft (42) carries a conventional chain-belt drive generally indicated at (180) for rotation therewith. The chain-belt drive (180) is in turn coupled to a planet-gear set (182) mounted in association with the front output shaft (80) in the transfer case. The planetary gear set (182) includes a planet carrier (184) formed integrally with front output shaft (80) or coupled thereto by means of spline connection to prevent relative rotation between the planet carrier (184) and front output shaft (80). The planet carrier (184) carries a plurality of circumferentially spaced apart planet gears (186), each of which are rotatably mounted about a separate shaft (188). The planetary gear set (182) further includes a ring gear (189) which will include internal ring gear teeth which engage the gear teeth of each of the planet gears (186). The planet gear set (182) further includes a sun gear (190) rotatably mounted on the front output shaft (80). In this embodiment, the chain belt of drive (180) is connected to the ring gear of the planetary gear set (182) to transfer torque from the input shaft (42) to ring gear (189) via the sprocket set (192) mounted on input shaft (42) which carries the chain belt (194) thereon. Torque from the input shaft (42) will therefore be transferred in a predetermined relationship through the ting gear (189) and planetary gears (186) ill the planetary gear set to transfer torque to the carrier (184) and to front output shaft (180) in predetermined relationship. Further, the sun ring gear (190) of the planetary gear set (182) has supported thereon the pulley (78) associated with the continuously variable belt drive (75). The continuously variable belt drive mechanism (75) is therefore connected to the sun gear (190) of the planetary gear set to transfer the desired amount of torque from the input shaft (42) to the rear output of the transfer case assembly. In this embodiment, the input shaft (42) has a rear output yoke (66) mounted thereon, and is rotatably supported within transfer case housing (46) by means of ball bearings (56). The torque transferred to the rear output yoke (66) will vary depending upon the continuously variable drive (75) in the transfer case assembly. As described in previous embodiments, the continuously variable belt drive (75) may be controlled by the ball ramp mechanism or alternatively by the electronic control system as desired. In the embodiment of FIG. 7, the means to shift moveable sheave (110) of the continuously variable drive (75) is shown in block form and generally indicated at (200), and may comprise each of the embodiments previously described.
In the preferred embodiment, more torque will be transferred through the chain drive (180) to the ring gear (189), than through sun gear (190). For example, two-thirds of the input torque will be transferred through the ring gear, while one-third of the input torque transferred through the sun gear so as to reduce the requirements of the continuously variable drive in the system. In this embodiment, control or torque transfer to both the front and rear output shafts is maintained in a manner similar to the embodiments previously described. Input torque can be divided in a predetermined relationship between the front and the rear outputs, while the chain drive yields the ability to transfer increased torque without the limits of the continuously variable drive being exceeded. Thus, the arrangement again provides differentiation, torque balance, and traction enhancement in the event of a predetermined amount of wheel slip.
The transfer case for the full time four-wheel-drive system of the invention has been illustrated and described by what are considered to represent preferred embodiments thereof. Although described in terms of preferred embodiments, it should be appreciated that various modifications could be made without departing from the spirit or scope of the invention as defined by the attached claims.
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A full time four-wheel-drive system for a vehicle is described which uses a unique torque-transfer case assembly. The transfer case includes a torque input shaft for receiving output torque from the transmission assembly of the vehicle, and front- and rear-output shafts connected to front and rear differentials of the vehicle. The transfer case assembly includes continuously variable belt drive connecting the input shaft to the front and rear output shafts, transferring a predetermined amount of torque to each output shaft. The continuously variable drive arrangement will include at least a primary pulley on the input shaft and a secondary pulley on the front output shaft, the pulleys carrying a belt therebetween. Each pulley comprises a pair of sheaves, which are axially moveable in relation to one another. The pair of sheaves of each pulley are shifted axially relative to one another by an assembly which is responsive to divide torque between the front and rear output shafts in a predetermined relationship. The system operates to substantially maintain this predetermined relationship during normal operation of the vehicle, and balance torque between the front and rear output shafts to yield improved vehicle handling, stability and feel.
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This is a continuation of copending application Ser. No. 595,274 filed Mar. 30, 1984, now abandoned.
TECHNICAL FIELD
This invention relates to pumps, and more particularly, to hydraulic injection pumps. One aspect of the invention relates to pneumatically actuated pumps adapted to inject fluids into a pressurized line or vessel at a controlled rate. Another aspect of the invention relates to an injection pumping apparatus comprising a unique and superior relay valve. Still another aspect of the invention relates to an improved method for controlling air flow through a fluid actuated hydraulic pumping apparatus.
BACKGROUND ART
Pneumatically driven injection pumps are well known. Such pumps are particularly useful for injecting small amounts of liquids into vessels or flow lines at relatively high pressures. These pumps typically employ a low pressure air supply to drive a large diameter piston that coacts with a small diameter plunger to multiply the pressure delivered through the high pressure injection cylinder. The required supply gas pressure is determined by dividing the desired injection pressure by the published pump ratio. The flow of supply gas to the large diameter piston is controlled by a relay valve adapted to cycle the pump frequently enough so as to achieve the desired flow rate. Different relay valve configurations have been utilized by the manufacturers of the various conventional, commercially available pumps. These include valves employing mechanical switches, pressure shifted spool valves, and mechanical shifted spool valves. However, injection pumps employing each of these types of relay valves have experienced undesirably high failure rates. Such failures usually occur at the bottom end of the power stroke where the relay doesn't quite reset.
With the relays actuated by mechanical switches, problems have been encountered with spring failure. With the pressure shifted spool valve relays, O-ring problems sometimes cause the spool not to shift properly or completely in response to light pressure loads, resulting in stall. Stall occurs because the miniature bleeder valves that operate the spool partially exhaust. Similarly, with the mechanically shifted spool valve relays, stalling may occur as a result of mechanical failure or by a partial bleeding through the relay, thereby robbing the air piston of its driving force.
Conventional air driven injection pumps are commercially available from suppliers such as Arrow Specialty Company of Tulsa, Oklahoma, Haskell, Inc., of Burbank, California, and Sprague Engineering of Gardena, California.
SUMMARY OF THE INVENTION
In accordance with the present invention, a hydraulically actuated pumping apparatus is provided that exhibits superior reliability and control capabilities when compared to conventional injection pumps.
According to one embodiment of the invention, an air driven hydraulic injection pump is provided that is adapted to inject fluid into a vessel or flow line at high pressure at a controlled rate with superior performance and reliability.
According to another embodiment of the invention, a fluid actuated, piston driven injection pump is provided that is adapted to pump liquids at controlled rates and at high pressures without stalling.
According to another embodiment of the invention, a pneumatically driven pumping apparatus is provided that further comprises a three-way normally closed pilot operated relay valve adapted to provide improved control over the air flow through the apparatus without the partial bleeding experienced with conventional air driven injection pumps.
According to yet another embodiment of the invention, a hydraulically actuated positive displacement injection pumping apparatus is provided that comprises a three-way normally closed relay valve controlled by means of a multiported hollow plunger.
According to yet another embodiment of the invention, a fluid actuated, piston driven injection pump is provided that employs a multiported hollow plunger to exhaust pilot pressure past an exhaust seal in the top of the pump, thereby permitting the relay valve to recycle and to exhaust the supply fluid exerting pressure on the driving piston.
According to another embodiment of the invention, a fluid actuated pumping apparatus is provided that employs a supply fluid at a relatively low gauge pressure to drive a large diameter piston which in turn drives a small diameter piston that pumps another fluid at a relatively higher pressure.
According to another embodiment of the invention, a method is provided for operating a gas actuated, piston-driven injection pump in combination with a three-way normally closed relay valve whereby pilot pressure is supplied to the pilot port of the relay valve through an adjustable orifice in fluid communication with the supply port of the relay valve, causing a piston within the relay valve to force a plunger downward, permitting fluid communication between the supply port and the gas-driven piston within the injection pump. The force exerted by the supply gas on the gas-driven piston of the injection pump is thereafter transmitted to the pumping cylinder through a smaller diameter plunger which coacts with the gas-driven piston to produce the desired pumping pressure. At the bottom of the pumping stroke, pilot pressure to the relay valve is exhausted through ports disposed in the end of the pump plunger opposite the pumping cylinder, thereby permitting the piston within the relay valve to recycle, and in turn causing the plunger within the relay valve to block fluid communication between the supply port and the gas-driven piston of the injection pump, and permitting the supply gas within the driving cylinder to be exhausted through the exhaust port of the relay valve.
BRIEF DESCRIPTION OF THE DRAWINGS
The apparatus and method of the invention are further described and explained in relation to the following drawings wherein:
FIG. 1 depicts a perspective view of a preferred embodiment of the pumping apparatus of the invention;
FIG. 2 depicts an elevation view, partially in section, of the three-way normally closed relay valve of FIG. 1; and
FIG. 3 depicts a cross sectional elevation view of the gas operated injection pump shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, pumping apparatus 10 preferably comprises injection pump 12, relay valve 14, and adjustable orifice 16. Supply gas is introduced into relay valve 14 through supply port 18 which also communicates interiorly of relay valve 14 with pilot pressure supply line 20. Although the configuration shown is preferred for use in the apparatus of the invention, it will be apparent to one reading this disclosure that supply port 18 of relay valve 14 and pilot pressure supply line 20 can also be independently connected to the source of supply gas or can be separately supplied from a tee to a common supply line. Supply gas then flows through pilot pressure supply line 20 and adjustable orifice 16 to pilot port 22 of relay valve 14 through upper housing 24 of injection pump 12.
When sufficient supply gas has entered relay valve 14 through pilot port 22 to actuate the valve, fluid communication is also established between supply port 18 and pump supply line 26. Supply gas then enters upper housing 24 of injection pump 12 through pump supply port 28. The supply gas exerts pressure on a piston disposed inside cylinder 30, which in turn coacts with a smaller diameter plunger to pump fluid through a pumping cylinder disposed within lower housing 32, as will be further described in relation to FIG. 3 below. Upper housing 24 and lower housing 32 of injection pump 12 are preferably connected by means of hex bolts 34.
During pumping, the pumped fluid enters lower housing 32 through fluid inlet port 36 and is discharged through fluid outlet port 38.
According to a preferred embodiment of the invention, injection pump 12 and relay valve 14 are both constructed from chemically resistant materials such as stainless steel. Relay valve 14, adjustable orifice 16, pilot pressure supply line 20, pump supply line 26 and the fittings employed therewith are preferably rated for use at supply pressures ranging from about 20 to about 150 psig. Fittings employed on the discharge side of injection pump 12 are preferably rated at pressures up to about 10,000 psi. Although the throughput of pumping apparatus 10 will necessarily vary according to the size of injection pump 12, the pump ratio and the flow of supply gas through adjustable orifice 16 to pilot port 22 of relay valve 14, pumping rates ranging from about one pint up to about 110 gallons per day are achieved with a pump having dimensions of about seven inches by about five and three quarters inches. The pumping apparatus of the invention can be employed for pumping a variety of liquids including, by way of example and without limitation, chemicals, hydrocarbons, water, and the like. The apparatus of the invention provides superior performance when installed in any position. It can also be used with or without an airline lubricator, although an airline lubricator is recommended for extreme pumping for long periods. The weight of the pumping apparatus as described herein is about 17 pounds. The construction and method of operation of pumping apparatus 10 is further described and explained in relation to FIGS. 1 and 2 below.
FIG. 2 is an elevation view, partially in section, of relay valve 14 of pumping apparatus 10. Relay valve 14 is preferably a three-way normally closed pilot operated valve. As shown in FIG. 2, relay valve 14 is adapted for use at working pressures up to about 150 psi. Relay valve 14 further comprises body 40 and piston housing 42, which are preferably made of stainless steel and are interconnected by threads 44. Body 40 further comprises a centrally disposed, stepped longitudinal bore 46 and a plurality of radially extending ports that provide fluid communication through longitudinal bore 46. These ports include supply port 18, pilot pressure supply port 48, valve port 50 and exhaust port 52. Ports 18, 48, 50 and 52 are preferably threaded to facilitate connection with appropriate fittings as desired.
Supply port 18 provides fluid communication between a source of supply fluid and longitudinal bore 46 of body 40. A preferred supply fluid for use with the subject apparatus is a gas such as compressed air, although other gasses, such as natural gas or nitrogen can also be used effectively if desired. The pressure of the supply gas is preferably controlled by a pressure regulator (not shown) disposed between supply port 18 and the supply gas source. The pressure regulator is desirably set at a pressure approximately 10 to 15 psig above the pressure needed to operate the gas-driven piston within injection pump 12. In order for pumping apparatus 10 to function properly, the supply gas pressure should be at least about 20 psi.
Pilot pressure supply port 48 provides fluid communication between supply port 18 and pilot pressure supply line 20, as previously discussed in relation to FIG. 1. Valve port 50 alternately provides fluid communication between pump supply line 26 and either supply port 18 or exhaust port 52, depending upon the position of plunger 54 and spool valve 56 within longitudinal bore 46, as discussed below.
Piston housing 42 further comprises pilot port 22, which is adapted to provide fluid communication with pilot pressure supply line 20 through adjustable orifice 16 and upper housing 24 of injection pump 12. As shown in FIG. 1, adjustable orifice 16 further comprises a manually operated adjustment knob 58 that permits the operator to control the rate of flow of supply gas through pilot pressure supply line 20 to pilot port 22. It is of course understood that an automatic controller with appropriate instrumentation can be substituted for adjustment knob 58 if desired. Likewise, adjustment knob 58 can be calibrated by correlating appropriate indexing marks on the adjustment knob with the corresponding resultant flow rates. When adjustable orifice 16 is opened, supply gas flows inwardly through pilot port 22 into the cylindrical space 60 defined by interior walls 62, 64 of piston housing 42. The pilot pressure then forces piston 68 downward against the counteractive force of compression spring 70, also causing plunger 54 to move downward. Piston 68 is further adapted by means of U-cup seal or O-ring 72 in annular groove 74 to prevent the supply gas from leaking out of cylindrical space 60 between piston 68 and interior wall 64.
When piston 68 and plunger 54 are in the position shown in FIG. 2, supply pressure to valve port 50 is blocked by O-ring 76 and pressure in valve port 50 is opened through the passage between plunger 54 and O-ring 55 to exhaust port 52. However, when pilot pressure forces piston 68 and plunger 54 downward, fluid communication is provided between supply port 18 and valve port 50 around O-ring 76 and fluid communication between valve port 50 and exhaust port 52 is blocked when plunger 54 engages O-ring 55.
When plunger 54 of relay valve 14 has been depressed sufficiently by piston 68 to permit supply gas to flow from supply port 18 through valve port 50 and to block the escape of supply gas from valve port 50 through exhaust port 52, the supply gas is permitted to flow through pump supply line 26 and pump supply port 28 into upper housing 24 of injection pump 12 as shown in FIG. 3. Referring to FIG. 3, supply gas entering upper housing 24 of injection pump 12 through pump supply port 28 is directed through radial bore 78 and axial bore 80 into the cavity 82 defined by bottom 84 of upper housing 24, interior wall 86 of cylinder 30, and face 88 of drive piston 90. As supply gas fills cavity 82, drive piston 90 is forced downward against compression spring 92. O-rings 94, 96 prevent the escape of supply gas along interior wall 86 of cylinder 30.
Injection pump 12 further comprises plunger 98, which extends coaxially through longitudinal bore 100 of upper housing 24, longitudinal bore 102 of drive piston 90, and longitudinal bore 104 of lower housing 32. Shoulder 106 of drive piston 90 is disposed in contacting and abutting relation to shoulder 108 of plunger 98, thereby causing plunger 98 to move downward as drive piston 90 moves downward under the force of the supply gas in cavity 82. O-ring 110 in annular groove 112 of plunger 98 prevents the escape of supply gas downwardly through bore 102 of drive piston 90. The interior of cylinder 30 is vented through passageway 114 of lower housing 32 to prevent pressure buildup in the event of fluid leakage past the O-ring seals within injection pump 12.
The pumping cylinder of injection pump 12 is disposed within longitudinal bore 104 of lower housing 32 and is preferably maintained in coaxial and concentric alignment with upper housing 24 and cylinder 30 by a plurality of hex bolts 34.
Retainer 116 threadedly engages lower housing 32 and further comprises a centrally disposed, stepped longitudinal bore 118 that provides containment for pumping cavity 120, bearing 122, nonextrusion ring 124, Teflon sealing ring 126, packing 128, cylindrical packing guide 130, compression spring 132, spring guide 134 and check valve seat assembly 136. Check valve seat assembly 136 is adapted to seat ball 138, which is also contacted by spring 140. O-rings 142, 144 further assist in preventing fluid leakage around retainer 116.
Retainer 116 preferably further comprises radial passageways 146 that provide fluid communication between pumping cavity 120 and fluid outlet port 38 through annular space 148 and radial bore 150 of lower housing 32. Fluid outlet port 38 is also provided with outlet retainer 152 that threadedly engages lower housing 32. O-ring 154 provides sealing engagement between outlet retainer 152 and lower housing 32. Outlet retainer 152 further comprises stepped radial bore 156 containing a check valve assembly including check valve seat assembly 158, ball 160 and spring 162.
As supply gas forces drive piston 90 downward, plunger 98 is also forced downward inside pumping cavity 120. When this occurs, ball 138 seats itself against check valve seat assembly 136, and fluid disposed in pumping cavity 120 is forced outwardly through radial passageways 146, annular space 148, radial bore 150, outlet retainer 152 and fluid outlet port 38. The construction of lower housing 32, including the threaded engagement between lower housing 32 and retainer 116 and outlet retainer 152 must be sufficient to withstand the discharge pressure of injection pump 12.
Plunger 98 is desirably constructed in such manner that whenever bottom face 164 of plunger 98 reaches the bottom of its stroke, the radially extending passageways 166 at the opposite end of plunger 98 move downward past O-ring 168 so as to establish fluid communication from upper housing pilot inlet port 170 through stepped radial pilot bore 172, annular space 174, radial passageway 176 in plunger guide 178, radial passageways 166 and longitudinal passageway 180 of plunger 98 to plunger cavity 182 and pilot pressure exhaust vents 184 through upper housing 24. When this occurs, the pilot pressure acting on piston 68 of relay valve 14 is exhausted through upper housing 24 of injection pump 12, and compression spring 70 of relay valve 14 forces piston 68 upward within piston housing 42. As piston 68 moves upward, spring guide 186 as shown in FIG. 2 contacts dowel pin 188 which passes through plunger 54, thereby causing plunger 54 to also move in an upward direction. Fluid communication is then blocked between supply port 18 and valve port 50 and is established between valve port 50 and exhaust port 52. Because the back pressure through exhaust port 52 is less than the spring pressure exerted by spring 92 against the underside of drive piston 90 within injection pump 12, drive piston 90 is also forced upward, forcing the supply gas outward through axial bore 80 and radial bore 78 of upper housing 24, outwardly through pump supply port 28 and pump supply line 26, inwardly through valve port 50, and outwardly through exhaust port 52.
As drive piston 90 of injection pump 12 is moved upward by compression spring 92, spiral ring 190 also raises plunger 98, causing fluid to be drawn inwardly through fluid inlet port 36 past ball 138 into pumping cavity 120 in preparation for the next downward stroke.
As plunger 98 moves upward, sealing contact is established between plunger 98 and O-ring 168, preventing further escape of pilot supply gas until the subsequent operation of relay valve 14. O-rings 161, 163 seal inside and outside of plunger guide 178 to prevent commingling of supply gas in cavity 174 and supply gas in cavity 82. Pumping apparatus 10 will then continue to cyclically function in this manner for so long as supply pressure is maintained to supply port 18.
Although the apparatus and method of the invention are described herein in relation to the preferred embodiment shown in FIGS. 1-3, certain design alterations and modifications will become apparent to those of ordinary skill in the art upon reading this disclosure in connection with the accompanying drawings. For example, the design and/or arrangement of the check valves can be altered to permit the use of other well known, commercially available components without departing from the spirit and scope of the invention. Similar variations may also apply to the plunger configuration, sealing means, piston design, mounting methods and procedures, orifice adjustment for rate control, choice of materials, and weather protection. It is intended, however, that the scope of the invention be limited only by the appended claims.
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A hydraulically actuated pumping apparatus including a piston-driven, plunger-type injection pump in combination with a three-way normally closed pilot-operated relay valve, and a variable restrictor adjustable during operation of the pumping apparatus for controlling the flow of a pilot fluid to the relay valve. Pilot fluid is vented from the relay valve through passageways in the plunger of the injection pump at the completion of each pumping stroke.
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This application is a Divisional of Ser. No. 09/192,457 filed Nov. 16, 1998, now U.S. Pat. No. 6,344,392.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to capacitors for DRAMs and more particularly to lower electrodes of crown capacitors with fins or to lower electrodes of stack capacitors.
2. Description of Related Art
U.S. Pat. No. 5,208,180 of Gonzalez shows a “Method of Forming a Capacitor” using a oxide etching process.
U.S. Pat. No. 5,532,182 of Woo for a “Method for Fabricating Stacked Capacitor of a DRAM Cell” shows a fin type capacitor using doped and undoped amorphous Si layers.
U.S. Pat. No. 5,573,967 of Tseng describes a “Method for Making Dynamic Random Access Memory with Fin-type Stacked Capacitor”.
U.S. Pat. No, 5,631,184 of Ikemasu et al. describes a “Method of Producing a Semiconductor Device Having a Fin-type Capacitor.”
U.S. Pat. No. 5,637,523 of Fazan describes a “Method for Forming a Capacitor and a Capacitor Structure” shows a in type capacitor formed by etching doped and undoped polysilicon layers.
U.S. Pat. No. 5,656,536 of Wu describes a “Method of Manufacturing a Crown Shaped Capacitor with Horizontal Fins for High Density DRAMS.”
SUMMARY OF THE INVENTION
A fin structure can be made by alternately depositing silicon nitride (Si 3 N 4 ) and silicon dioxide (SiO 2 ) and dipping back and then filling with a polysilicon layer which is a complicated process.
A crown or stack capacitor with a fin structure is made with a different silicon dioxide etching rate in a vapor of hydrogen fluoride HF acid environment.
This invention teaches a method of forming a fin structure using a combination of both doped and undoped silicon dioxide layers with a bulk or a thin film second conductive layer formed into a capacitor core. The core can be composed of a monolithic body of conductive material.
In accordance with this invention, a process of forming an electrode comprises the steps of formation of a capacitor core formed on a semiconductor device which contains doped regions in the surface thereof blanketed with a dielectric layer which contains a conductive plug extending therethrough which contacts one of the doped regions in the semiconductor substrate.
First, form a sublayer comprising a first conductive layer in contact with a plug which contacts one of the doped regions in the semiconductor substrate. Form a mold from a stack of silicon dioxide layers which are alternatingly an undoped layer covered with a doped layer on the sublayer comprising the first conductive layer with the stack comprising a bottom layer formed on top of the sublayer and each additional layer in the stack formed on a previous one of the layers in the stack. Pattern the silicon dioxide layers in the mold which are alternatingly doped and undoped to form an intercore, capacitor-core-shaping cavity in the stack of silicon dioxide layers reaching down through the stack to be bottom of the stack. Perform differential etching of the silicon dioxide layers in the mold. Form undercut edges in the doped silicon dioxide layers with the undoped silicon dioxide layers having cantilevered ribs projecting from the stacks into the cavity to complete the mold. Deposit a layer of polysilicon into the cavity forming a capacitor core with counterpart ribs cantilevered (projecting) with a complementary pattern to the mold and the capacitor core having a top surface. Polish the capacitor core to remove the top surface of the core, and remove the mold.
Preferably, the mold is etched with a combination of hydrogen fluoride vapor and water vapor.
In one embodiment, the core is formed of a solid deposit of a second conductive layer which fills the cavity. The dopant comprises boron and phosphorus and the mold is etched with a combination of hydrogen fluoride vapor and water vapor.
Preferably, the dopant comprises boron and phosphorus, and the mold is etched with a combination of hydrogen fluoride vapor and water vapor.
The core is planarized by a CMP process which removes a top undoped layer of the mold whereby the core has a flat upper surface with a rib located on top of the core, and etch back the sublayer comprising a first thin conductive layer to separate the core from adjacent cores.
Alternatively one can deposit a thin layer of a second conductive layer such as polysilicon into the cavity. Then, form a thin capacitor core with an array of counterpart cantilevered (projecting) ribs with a pattern which is complementary to the pattern of the mold. The capacitor core has a top surface.
In the case of the thin layer of the second conductive layer, next deposit a photoresist layer into the inner cavity filling the inner cavity. Then polish the capacitor core to remove the top surface of the core, and remove the photoresist and remove the mold.
Then etch back the sublayer comprising a first thin conductive layer to separate the core from adjacent cores.
Preferably, the core is a monolithic core.
In accordance with another aspect of this invention, a monolithic capacitor core is formed on a semiconductor device. A sublayer comprising a first conductive layer is formed in contact with a plug which contacts a doped first conductive region in the semiconductor substrate. A second conductive layer is formed into a monolithic capacitor core having cantilevered ribs projecting from exterior sidewalls of the monolithic core. The monolithic capacitor core has a cantilevered top surface projecting from the exterior sidewall of the monolithic core.
Preferably the second conductive layer is formed into a hollow monolithic capacitor core having cantilevered ribs projecting from exterior sidewalls of the monolithic core and a base covering the first conductive layer. It that case it is preferred that the second conductive layer formed into a monolithic core is composed of a material selected from the group consisting of aluminum, copper, tungsten, doped polysilicon, and titanium nitride, and said second conductive layer has a thickness from about 500 Å to about 1,000 Å.
Alternatively, the second conductive layer is formed as a solid monolithic capacitor core having cantilevered ribs projecting from exterior sidewalls of the monolithic core and the core covering the first conductive layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects and advantages of this invention are explained and described below with reference to the accompanying drawings, in which:
FIG. 1 shows a sectional vertical elevation of a fragment of a semiconductor device with a first conductive layer formed on the top surface in an intermediate stage of fabrication of a device in accordance with this invention.
FIG. 2 shows the device of FIG. 1 after formation of sacrificial structures which are to serve as molds with monolithic capacitor core cavities formed of stacks of laminated, blanket layers formed over the first conductive layer.
FIG. 3 shows a first embodiment of the device of FIG. 2 after thin film monolithic crown capacitor cores have been formed in the cavities on the sidewalls of the stacks of laminated, blanket layers formed over the first conductive layer. Photoresis fills the hollow spaces within the monolithic capacitor cores.
FIG. 4 shows the device of FIG. 3 after the monolithic capacitor cores have been polished down, the molds have been removed, and the first conductive layer has been etched in a self-aligned etch.
FIG. 5 shows a second embodiment of the device of FIG. 2 after solid stack monolithic capacitor cores have been formed in the cavities over the first conductive layer.
FIG. 6 shows the device of FIG. 5 after the monolithic capacitor cores have been polished down, the molds have been removed, and the first conductive layer has been etched in a self-aligned etch.
DESCRIPTION OF STRUCTURE ANCILLARY TO THE PREFERRED EMBODIMENT
FIG. 1 shows a sectional vertical elevation of a fragment of a semiconductor device 10 in an intermediate stage of fabrication of a device in accordance with this invention. A P-doped silicon semiconductor substrate 12 is shown with N+ doped regions 14 and 14 ′ formed in the surface of the substrate 12 and spaced on opposite ends of the portion of substrate 12 shown in FIG. 1 . Four gate electrode/conductor stacks 21 A- 21 D are shown on the surface of substrate 12 with the stack 21 A formed on the surface of an N+ doped region 14 and stack 21 D formed on the surface of an N+ doped region 14 ′.
The stacks 21 A- 21 D include gate oxide regions GOX on which polysilicon conductor/gate electrode layers 16 are formed on the surface of substrate 12 . On each of the gate oxide regions GOX is a refractory metal silicide layer 19 such as tungsten silicide (WSi 2 ), a cap layer usually composed of silicon dioxide (SiO 2 ) layer 20 and a silicon nitride (Si 3 N 4 ) layer 22 which can be implemented, as is well understood by those skilled in the art and as is described in the U.S. Pat. No. 5,792,689 of Fu-Lian Yang and Erik S. Jeng for “Method for Manufacturing Double Crown Capacitors Self-Aligned to Node Contacts on Dynamic Random Access Memory”.
Silicon dioxide sidewall spacers SP are formed on the sidewalls of the layers 16 , 19 , 20 and 22 of stacks 21 A- 21 D as described in Liaw et al U.S. Pat. No. 5,712,202.
Layers 20 , 22 and spacers SP insulate the layers 16 / 19 from the polysilicon plugs PL which are formed between stacks 21 A/ 21 B and 21 C/ 21 D which reach the capacitor node contacts where plugs PL are formed on the surface of P-substrate 12 .
There are doped regions 14 and 14 ′ in the surface of the substrate 12 having top surfaces to which the plugs PL 1 and PL 2 respectively make electrical and mechanical contact, as in Liaw et al U.S. Pat. No. 5,712,202 and in Yang et al U.S. Pat. No. 5,792,689.
A planarizing insulating layer 24 composed of BPSG has been formed as described in Liaw et al U.S. Pat. No. 5,712,202 covering the stacks 21 A- 21 D and the substrate 12 , but capacitor node contact openings have been formed between the sidewall spacers SP of stacks 21 A and 21 B on the left and between the sidewall spacers SP of stacks 21 C and 21 D on the right and those openings have been filled with metal, conductive plugs PL 1 /PL 2 extending from contact with the N+ doped regions 14 / 14 ′ respectfully on the surface of the substrate 12 between the stacks 21 A/ 21 B and between the stacks 21 C/ 21 D to the top surface of the BPSG layer 24 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Step 1
Above the BPSG layer 24 and plugs PL 1 /PL 2 a doped, thin first conductive layer/sublayer SL composed of doped polysilicon is formed on the surface of the device 10 of FIG. 1 . In step 1, after the capacitor node contact and poly-silicon plugs PL 1 /PL 2 are formed a thin polysilicon sublayer comprising a first conductive layer SL is deposited which can be implanted with arsenic with a dose in the range from about 1E20 to 1E22 ions/cm 2 and an energy between 30 keV and 45 keV thus giving the first conductive layer SL a dopant concentration from about 1E20 ions/cm 3 to 1E22 ions/cm 3 . Preferably, the first conductive layer SL has a thickness from about 5000 Å to about 10,000 Å with a preferable thickness of about 8,000 Å.
Step 2
Referring to FIG. 2, the device of FIG. 1 is shown after formation of molds (sacrificial structures) SS 1 , SS 2 and SS 3 formed of a stack of laminated, blanket layers formed over first conductive layer SL SL. The molds SS 1 , SS 2 and SS 3 comprise undoped silicon dioxide (SiO 2 ) layer 28 A- 28 D alternating with SiO 2 layers 30 A- 30 C which are doped with Boron/Phosphorus (B/P) dopant to form a doped glass dielectric, i.e. BPSG. The sequence is to form an undoped SiO 2 layer 28 A on the bottom, then form a BPSG layer 30 A, covered in turn with an undoped SiO 2 layer 28 B, followed by BPSG layer 30 B and topped with undoped SiO 2 layer 28 C. The alternating laminated layers 28 A- 28 D and 30 A- 30 C are formed in situ in a CVD chamber alternately, by depositing one of the undoped oxide layers 28 A- 28 D, followed by depositing one of the BSPG layers 30 A- 30 C in the same chamber of the CVD equipment in a continuous, uninterrupted process by periodically opening and closing the B/P dopant source in a CVD chamber as is described below, and as will be well understood by those skilled in the art.
Step 2 involves depositing undoped oxide blanket layers 28 A/ 28 B/ 28 C/ 28 D and boron/phosphorous doped silicon oxide blanket layers 30 A/ 30 B/ 30 C alternately in the same chamber of the CVD equipment by opening and closing the B/P dopant source in a periodic way to form SiO 2 layers 28 A/ 28 B/ 28 C/ 28 D alternating with BPSG glass layers 30 A/ 30 B/ 30 C.
Step 3
Then patterning mask sections PR 1 /PR 2 /PR 3 with windows W 1 and W 2 therebetween are formed over the layer 28 D on top of the blanket laminated layers 28 A/ 30 A/ 28 B/ 30 B/ 28 C/ 30 C/ 28 D of SiO 2 alternating with BPSG glass layers. The layers 28 A/ 30 A/ 28 B/ 30 B/ 28 C/ 30 C/ 28 D are then patterned into sacrificial molds SS 1 -SS 3 and etched using the mask sections PR 1 /PR 2 /PR 3 . The mask sections PR 1 /PR 2 /PR 3 were used to form molds to shape the cores of capacitor crowns that are patterned by etching in step 4 below to produce the result shown in FIG. 2 with a set of intercore, capacitor-core-shaping cavities CC 1 /CC 2 formed below windows W 1 and W 2 respectively (to serve as molds for capacitor cores) in FIG. 2, by plasma dry etching between sacrificial structures SS 1 , SS 2 and SS 3 .
The laminated, sacrificial molds SS 1 , SS 2 and SS 3 are shown protected by patterning photoresist mask sections PR 1 /PR 2 /PR 3 which were formed for the purpose of protecting the molds SS 1 , SS 2 and SS 3 during patterning of the alternating laminated layers 28 A- 28 D and 30 A- 30 C by etching of those laminated layers to form intercore, capacitor-core-shaping cavities CC 1 and CC 2 above the plugs PL 1 and PL 2 respectively in complementary patterns to the capacitor crowns which are to be formed subsequently as indicated by FIGS. 3 and 4 for the first embodiment and by FIGS. 5 and 6 for the second embodiment.
Then the intercore cavities CC 1 /CC 2 (which are to be used as sacrificial molds for shaping capacitor cores seen in FIGS. 4 and 6) are formed in the shape of the photoresist mask elements PR 1 , PR 2 , and PR 3 by plasma dry etching between molds (sacrificial structures) SS 1 -SS 3 as described in step 3 below.
Next, the device is etched again in step 4 to produce the undercuts UC seen in FIG. 2 .
Step 4
A differential rate of etching back the undoped silicon dioxide layers 28 A/ 28 B/ 28 C/ 28 D (slowly) and the doped BPSG layers 30 A/ 30 B/ 30 C (more rapidly) is performed to enlarge the intercore, capacitor-core-shaping CC 1 /CC 2 with a vapor solution of hydrogen fluoride (HF). The silicon dioxide and BPSG are etched in an atmosphere of water vapor and hydrogen fluoride (HF) which provides a vapor etchant. The BPSG layers 30 A/ 30 B/ 30 C are etched back at a greater rate than the undoped silicon dioxide layer providing an undercut UC in BPSG glass layers 30 A/ 30 B/ 30 C leaving cantilevered ribs CR of SiO 2 layers 28 A/ 28 B/ 28 C/ 28 D which now project into the intercore cavities CC 1 /CC 2 .
One can tune doped/undoped selectivity by varying the concentration of hydrogen fluoride HF and water vapor.
First Embodiment
The first embodiment of the process continues after step 4 comprising the following steps:
Step 5A
FIG. 3 shows the device of FIG. 2 after thin film crown capacitor cores 42 A/ 42 B have been formed in the cavities CC 1 and CC 2 on the sidewalls of stacks SS 1 -SS 3 . The cores 42 A/ 42 B are preferably monolithic in the sense that they are formed of a single homogeneous, conductive, core layer 40 .
Then a filler layer 41 of a material such as photoresist fills the hollow spaces within the capacitor cores 42 A/ 42 B.
In the case of the crown capacitor cores 42 A/ 42 B in FIGS. 3, deposit a conformal, thin polysilicon, second conductive, core layer 40 into cavity blanketing the top of first conductive layer SL and coating the walls of the molds SS 1 , SS 2 and SS 3 , as shown in FIG. 3 to form crown capacitor cores 42 A/ 42 B from conductive core layer 40 , leaving the openings 44 only partially filled by the thin layer of conductive material 40 . Conductive core layer 40 can be composed of an electrically conductive material selected from the group consisting of aluminum, copper, tungsten, doped polysilicon, and titanium nitride. Conductive material 40 has a thickness from about 500 Å to about 1,000 Å.
Step 6A
FIG. 4 shows the device of FIG. 3 after the capacitor cores 42 A/ 42 B have been polished down and the molds have been removed.
As can be seen in FIG. 4 counterpart cantilevered ribs 40 A, 40 B, 40 C have been formed where the cores extend out into the space where the undercut regions UC had been located in the molds SS 1 , SS 2 and SS 3 .
The crown capacitor cores 42 A/ 42 B in FIG. 4 are shown after the openings 44 which were filled with filler (photoresist) layer 41 have been polished by a CMP (Chemical Mechanical Planarization) process to remove polysilicon layer 28 D and a portion of the core layer 40 above the rib 40 C.
Thus, the cores have been planarized by the CMP process which removes a top undoped layer 28 D of the molds SS 1 -SS 3 whereby the cores 42 A/ 42 B have a flat upper surface with a rib 40 C located on top of each of the cores 42 A/ 42 B.
Step 7A
The first part of Step 7A is to remove the filler layer 41 in the conventional manner.
Then, remove the mold formed by silicon dioxide/BPSG layers 28 A/ 30 A/ 28 B/ 30 B/ 28 C/ 30 C/ 28 D from the inside and the outside of the crown capacitor cores 42 A/ 42 B subtractively in a process which removes the SiO 2 layers 28 A/ 28 B/ 28 C/ 28 D and the BPSG glass layers 30 A/ 30 B/ 30 C by a step with a Buffered Oxide Etching (BOE) solution which leaves the crown shape with the horizontal fins which consists of the first conductive layer SL and the second conductive, core layer 40 .
Then dry etch back the polysilicon first conductive layer SL in a self-aligned etch using the crown capacitor cores 42 A/ 42 B as masks to isolate the individual capacitor cores 42 A/ 42 B forming a separate conductive pad SL′ below each of the capacitor cores 42 A/ 42 B.
Second Embodiment
The process continues after step 4 comprising the following steps:
Step 5B
FIG. 5 shows a second embodiment of the device of FIG. 2 after solid stack capacitor cores 52 A/ 52 B have been formed in the cavities over the first conductive layer SL. The cores 52 A/ 52 B are preferably monolithic in the sense that they are formed of a single homogeneous material. The capacitor cores 52 A/ 52 B of FIGS. 5 are formed from a thick polysilicon layer 50 blanketing the top of device 10 as shown in FIGS. 5 and 6 to form a set of solid stack conductive capacitor cores 52 A/ 52 B formed by of a core layer 50 of conductive material. Layer 50 can be composed of an electrically conductive material selected from the group consisting of aluminum, copper, tungsten, doped polysilicon, and titanium nitride.
As can be seen in FIG. 5 counterpart cantilevered ribs 50 R have been formed where the cores extend out into the space where the undercut regions UC had been located in the molds SS 1 , SS 2 and SS 3 .
Step 6B
FIG. 6 shows the device of FIG. 5 after the capacitor cores have been polished down, the molds have been removed, and the first conductive layer has been etched in a self-aligned etch.
In the case of the thick core layer 50 of FIG. 6 the CMP can be applied directly to the top of the cores 50 of stack capacitor cores 52 A/ 52 B to produce the planarized structures 52 A/ 52 B, as shown in FIG. 6 to remove the portion of core layer 50 above the top rib 50 R.
Thus, the cores 52 A/ 52 B have been planarized by the CMP process which removes a top undoped layer 28 D of the molds SS 1 -SS 3 whereby the cores 52 A/ 52 B have a flat upper surface with a rib 5 OR located on top of each of the cores 52 A/ 52 B.
Step 7B
Next, remove the mold comprising the layers 28 A/ 30 A/ 28 B/ 30 B/ 28 C/ 30 C/ 28 D of silicon dioxide and BPSG from the inside and the outside of the capacitor structures 52 A/ 52 B by a subtractive process which removes the SiO 2 layers 28 A/ 28 B/ 28 C/ 28 D by the steps of a BOE process and the BPSG glass layers 30 A/ 30 B/ 30 C with by the steps of a BOE process.
Then dry etch back polysilicon first conductive layer SL in a dry etching such as an RIE process using the capacitor structures 52 A/ 52 B as self-aligned masks to isolate the individual capacitor structures 52 A/ 52 B forming a separate conductive pad SL″ below each of the capacitor structures 52 A/ 52 B.
While this invention has been described in terms of the above specific embodiment(s), those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims, i.e. that changes can be made in form and detail, without departing from the spirit and scope of the invention. Accordingly all such changes come within the purview of the present invention and the invention encompasses the subject matter of the claims which follow.
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A capacitor core is formed on a semiconductor device with a first conductive layer in contact with a plug. A mold is formed from a stack of alternately doped and undoped silicon dioxide layers on the sublayer with the stack comprising a bottom layer formed on top of the sublayer and each additional layer in the stack formed on a previous one of the layers in the stack. Pattern the silicon dioxide layers in the mold which are alternatingly doped and undoped to form an intercore, capacitor-core-shaping cavity in the stack of silicon dioxide layers reaching down through the stack to be bottom of the stack. Then perform differential etching of the silicon dioxide layers in the mold. Form undercut edges in the doped silicon dioxide layers with the undoped silicon dioxide layers having cantilevered ribs projecting from the stacks into the cavity to complete the mold. Deposit a bulk or a thin film second monolithic conductive layer into the cavity to form a monolithic capacitor core with counterpart cantilevered ribs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to papermaking fabrics, in general, and to dryer felts having a soft, bulky top surface, in particular.
2. Description of the Prior Art
A conventional dryer felt consists of an endless conveyor belt made from a one-, two-, or three-plane fabric, wherein the various planes can be defined either by different groups of cross machine direction yarns, machine direction yarns or both. During the drying process, the upper plane, or top surface of the felt is in contact with the paper web being processed. Accordingly, it is desirable for the upper plane of the felt to have a smooth and soft surface to avoid undue marking of the finished paper. Various methods have been tried to produce a dryer felt having an upper surface which exhibits the desired smoothness and softness. While a close weave of the upper or top plane produces the desired smoothness, this advantage is offset by the comparatively high resistance of the dryer felt to the passage of water and water vapor therethrough; the material costs of a close weave felt are also quite high.
The use of soft spun yarns to replace the basic cross machine direction or filling yarns of the top plane has been tried. However, it was found that the resulting dryer felt was too unstable. Later, stuffer or center picks were added in an effort to increase the stability of dryer felts using soft yarns in the top plane. Although stability improved, the cost of producing such dryer felts was greatly increased.
Using cross machine direction or filling yarns made from a stiff core filament or fiber surrounded by a plurality of twisted filaments or fibers to replace the filling yarns of the top plane has also been tried. It has been found that, in use, the stiff core filament or fiber tends to protrude through the twisted-filament or fiber wrap and thereby causes paper marking problems.
There is, thus, a need for an economical, stable dryer felt which overcomes the paper marking problem noted above.
SUMMARY OF THE INVENTION
In general, the subject invention consists of a dryer felt having a soft, bulky top surface or face. A plurality of machine direction yarns and a plurality of cross machine direction yarns are interwoven according to a desired weave pattern to produce the top surface. A preselected number of the yarns of the top surface are encapsulated yarns having a core fiber encapsulated in a sheath or sleeve made from a material producing a soft, bulky texture. A sufficient number of encapsulated yarns are used to ensure that a major portion of the top surface is soft and bulky.
In one embodiment of the subject invention, a single-layer dryer felt having a soft, bulky top surface is provided by using encapsulated cross machine direction yarns.
In another embodiment of the subject invention, there is provided a duplex weave dryer felt having a base plane or surface and a top plane or surface. The base plane is defined by a plurality of cross machine direction yarns. The top plane, which is soft and bulky, is defined by a plurality of encapsulated cross machine direction yarns.
In a further embodiment of the subject invention, a triplex weave dryer felt is provided, having a base plane, a top plane and an intermediate plane. The base plane and the intermediate plane are each defined by a plurality of cross machine direction yarns. The top plane, which is soft and bulky, is defined by a plurality of encapsulated cross machine direction yarns.
By using the encapsulated yarns to replace the filling yarns in the top plane of both the duplex and triplex weave dryer felts, the problem of paper marking is diminished by the soft, bulky surface of the dryer felts. Other advantages of using the encapsulated yarns to replace the filling yarns are that yarn migration is eliminated, while at the sametime fabric stability is greatly increased.
It is, thus, an object of the present invention to provide an economical and stable dryer felt which is not plagued by paper marking problems.
It is another object of the present invention to provide a dryer felt having encapsulated filling yarns to define a soft, bulky top surface.
It is a further object of the present invention to provide a dryer felt having encapsulated machine direction yarns to define a soft, bulky surface.
It is yet another object of the present invention to provide a dryer felt having encapsulated machine direction and cross machine direction yarns to define a soft, bulky top surface.
It is yet a further object of the present invention to provide an economical and stable dryer felt which is not plagued by yarn migration.
Other objects and advantages of this invention will further become apparent hereinafter and in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show, in perspective, two embodiments of encapsulated yarns in various stages of assembly.
FIG. 2 is a longitudinal section of a single-layer dryer felt employing the subject invention.
FIG. 3 is a longitudinal section of a duplex weave employing the subject invention.
FIG. 4 is a longitudinal section of another duplex weave employing the subject invention.
FIG. 5 is a longitudinal section of a triplex weave employing the subject invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it should be understood that the invention is not to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
The subject invention will now be described with reference to the figures, in which FIGS. 1A and 1B illustrate two types of encapsulated yarns. At the heart of the encapsulated yarn is a monofilament core, designated as 2 in FIG. 1A and 4 in FIG. 1B. The monofilament core 2 is a monofilament of a single fiber, whereas the monofilament core 4 is composed of a bundle of synthetic fibers 6, treated with a high temperature resistent resin such as phenolic resin, to cause the bundle to act as a monofilament fiber in the woven fabric.
The fibers constituting the monofilament cores 2 and 4 are preferably made from polyester. However, the fibers can also be made from polyamides, aramids, acrylics and polyolefins. It is also possible to employ fine wire and/or rubber-type resin treated glass yarns as core materials.
Each of the monofilament cores 2 and 4 is encapsulated in a sheath or sleeve 8 made from a material producing a soft, bulky texture. Sleeve 8 may be of mineral fibers such as asbestos, natural fibers such as cotton or wool, or synthetic fibers such as polyamides, polyesters, acrylics or aramids. In one embodiment, the sleeve is produced by spun staple fibers in sliver, roving or yarn form. In another embodiment, the sleeve is produced by employing a yarn texturising process. In such a process, a yarn comprising a plurality of filaments made from man-made materials which are not originally or inherently crinkled are rendered bulky by causing the filaments to become crinkled. The plurality of filaments of the yarn is made up of a group of more than one substantially continuous filament, or a plurality of such groups of filaments. Such yarns are sometimes referred to in the textile arts as "textured" yarns. In yet another embodiment, the sleeve is produced by employing natural yarns which are originally or inherently crinkled, such as cotton or wool, and which are not inherently crinkled, such as bast fibers.
One embodiment of the subject invention is illustrated in FIG. 2. A single-layer fabric, generally designated as 10, contains a top plane or surface 12. The top surface, which provides the face of the dryer felt, is defined by a plurality of encapsulated cross machine direction yarns 14, which are made from a synthetic monofilament or a synthetic multifilament core encapsulated in a sheath or sleeve made from a material producing a soft, bulky texture, such as a roving of acrylic fiber. The cross machine direction yarns 14 are interwoven in a binding relationship with a plurality of machine direction yarns, 15-18, in accordance with a desired weave pattern. The machine direction yarns, 15-18, are made from a synthetic monofilament, a synthetic multifilament, or spun staple fibers.
Another embodiment of the subject invention is illustrated in FIG. 3. A duplex weave, generally designated as 20, contains a top plane or surface 22 and a bottom plane or surface 24. The top plane 22, which provides the face of the dryer felt, is defined by a plurality of encapsulated cross machine direction yarns 28, which are made from a synthetic monofilament or a synthetic multifilament core encapsulated in a roving or acrylic fiber. The bottom plane or surface 24, which provides the back of the dryer felt, is defined by a plurality of filling yarns 30, which are made from a synthetic monofilament, a synthetic multifilament or spun staple fibers. The yarn made from the multifilament, or the spun staple fibers is preferably stabilized by a resin treatment using for example phenolic resin; but this is not essential, and it would not be done with every type of dryer felt. The various yarns defining the planes are united or bound in place by a plurality of machine direction yarns 33 through 36. These yarns are also made from a synthetic monofilament, a synthetic multifilament, or spum staple fibers.
It is to be understood that other duplex weave dryer felts can benefit greatly from employing the encapsulated yarns of the subject invention. As an example, another duplex weave dryer felt, generally designated as 21, is illustrated in FIG. 4, wherein like numbers denote like elements.
Yet another embodiment of the subject invention is illustrated in FIG. 5, wherein a triplex weave dryer felt is disclosed. The dryer felt, generally designated as 40, contains a top plane or surface 42, a bottom plane or surface 44, and an intermediate plane 43. The bottom plane 44, which provides the back of the dryer felt, is defined by a plurality of cross machine direction yarns 48, which are made from a synthetic monofilament, a synthetic multifilament or spun staple fibers. The intermediate plane is defined by a plurality of cross machine direction yarns 50, which are also made from a synthetic monfilament, a synthetic multifilament or spun staple fibers. The top plane, which defines the face of the dryer felt, is defined by a plurality of encapsulated cross machine direction filling yarns 46. The yarns used to define the various planes are united or bound in place by a plurality of machine direction yarns 52 through 57. These yarns are also made from a synthetic monofilament, a synthetic multifilament or spun staple fibers.
It is also contemplated that encapsulated yarns may be used to provide a dryer felt having a soft, bulky top surface in other ways. Encapsulated yarns may replace some or all of the machine direction yarns, the filling yarns of the top surface being synthetic monofilament or synthetic multifilament yarns which may or may not be encapsulated in a sheath or sleeve made frodm a material producing a soft, bulky texture.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings, and it is contemplated that the encapsulated yarns of the subject invention may not replace all of the top surface filling yarns in the various dryer felt embodiments. It is further contemplated that the diameter of the core fibers 2 and 4, as well as the diameter of the synthetic monofilament or the synthetic multifilament, used for the remaining yarns in the dryer felt, are in the range of about 5 to 50 mils, with a range of about 15 to 25 mils being preferred. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A dryer felt having a soft, bulky top surface and comprising at least a top surface, which is defined by a plurality of machine direction yarns and a plurality of cross machine direction yarns interwoven according to a desired weave pattern. A preselected number of the yarns of the top surface are encapsulated yarns, the number being chosen to ensure that a major portion of the top surface is soft and bulky.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to laminated multi-ply thermoplastic film. Specifically, the invention relates to multi-ply film where one film layer is substantially un-pigmented and the other film layer is substantially pigmented. In one embodiment, the invention relates to trash bags of thermoplastic films having both an outer bag and an inner bag that are laminated together to form a multi-ply trash bag.
2. Description of the Related Art
A multitude of consumer and packaging products are made from low-cost, pliable thermoplastic films. Multi-ply films can provide improved physical properties over single ply films, however they may have higher material and processing costs that may outweigh the additional benefit in physical properties. Creating films with a metallic appearance may add additional cost because of the high cost of metallic pigments. There is a clear need to provide thermoplastic multi-ply films with an improved metallic appearance and improved performance at costs appropriate for a wide range of uses.
BRIEF SUMMARY OF THE INVENTION
Implementations of the present invention solve one or more problems in the art with apparatus and methods for creating trash bags with an outer bag and an inner bag with increased strength, decrease total amount of materials, and unique appearance. In particular, one or more implementations provide for bags having a unique metallic looking appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings, in which:
FIG. 1A illustrates a schematic diagram of a film ply being cold stretched by MD intermeshing rollers in accordance with one or more implementations of the present invention;
FIG. 1B illustrates an enlarged view of a thermoplastic film passing together through the intermeshing rollers of FIG. 1A taken along the circle 1 B of FIG. 1 to form a cold stretched film ply;
FIG. 2 illustrates a view of a cold stretched thermoplastic film created by the intermeshing rollers of FIG. 1A ;
FIG. 3A illustrates a schematic diagram of a thermoplastic film ply being cold stretched by TD intermeshing rollers in accordance with one or more implementations of the present invention;
FIG. 3B illustrates an enlarged view of a thermoplastic film passing through the transverse direction intermeshing rollers of FIG. 3A taken along the circle 3 B of FIG. 3A to form a cold stretched film ply;
FIG. 4 illustrates a view a cold stretched thermoplastic film ply created by the intermeshing rollers of FIG. 3A ;
FIG. 5A illustrates a view of a multi-ply laminated thermoplastic film created by the intermeshing rollers of FIG. 1A ;
FIG. 5B illustrates a view of another multi-ply laminated thermoplastic film created by the intermeshing rollers of FIG. 1A ;
FIG. 6 illustrates a schematic diagram of a set of intermeshing rollers used to form a structural elastic like film (SELF) by imparting cold stretched strainable networks into the film in accordance with one or more implementations of the present invention;
FIG. 7 illustrates a view of a multi-ply, cold stretched, laminated thermoplastic film created by the intermeshing rollers of FIG. 6 ;
FIG. 8 illustrates a view of a thermoplastic film including cold stretched strainable networks in accordance with one or more implementations of the present invention;
FIG. 9 illustrates a view of another thermoplastic film including cold stretched strainable networks in accordance with one or more implementations of the present invention;
FIG. 10 illustrates a view of a multi-ply film created by the intermeshing rollers of both FIGS. 1A and 3A ;
FIG. 11 illustrates a view of a cold stretched and laminated multi-ply trash bag;
FIG. 12 illustrates a view of a cold stretched and laminated multi-ply trash bag having a draw tape; FIGS. 1A-1F are perspective views of a thermoplastic bag having a draw tape;
FIG. 13 illustrates a cross-sectional view of a laminated multi-ply film;
FIG. 14A illustrates a cross-sectional view of a laminated multi-ply film;
FIG. 14B illustrates a cross-sectional view of a laminated multi-ply film;
FIG. 14C illustrates a perspective view of the laminated multi-ply film of 14 B with a linear bonding pattern; and
FIG. 14D illustrates a perspective view of the laminated multi-ply film of 14 B with a spot bonding pattern.
DETAILED DESCRIPTION
Reference will now be made to the drawings wherein like numerals refer to like parts throughout. For ease of description, the components of this invention are described in the normal (upright) operating position, and terms such as upper, lower, horizontal, top, bottom, etc., are used with reference to this position. It will be understood, however, that the components embodying this invention may be manufactured, stored, transported, used, and sold in an orientation other than the position described.
Figures illustrating the components of this invention show some conventional mechanical elements that are known and that will be recognized by one skilled in the art. The detailed descriptions of such elements are not necessary to an understanding of the invention, and accordingly, are herein presented only to the degree necessary to facilitate an understanding of the novel features of the present invention.
All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.
As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps. Accordingly, the term “comprising” encompasses the more restrictive terms “consisting essentially of” and “consisting of”.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
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 to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.
As used herein, the term “orientation” refers to the molecular organization within a polymer film, i.e., the orientation of molecules relative to each other. Similarly, the process by which “orientation” or directionality of the molecular arrangement is imparted to the film refers to processes whereas the polymer is molten and not in the solid state. An example where process of orientation is employed to impart desirable properties to films, includes making cast films where higher MD tensile properties are realized. Depending on whether the film is made by casting as a flat film or by blowing as a tubular film, the orientation process employs substantially different procedures. This is related to the different physical characteristics possessed by films made by the two conventional film-making processes; casting and blowing. Generally, blown films tend to have greater stiffness and toughness. By contrast, cast films usually have the advantages of greater film clarity and uniformity of thickness and flatness, generally permitting use of a wider range of polymers and producing a higher quality film. When a film has been oriented in a single direction (monoaxial orientation), the resulting film exhibits great strength and stiffness along the direction of orientation, but it is weak in the other direction, i.e., orthogonal to the direction of the primary orientation, often splitting or tearing when flexed or pulled.
As used herein, the phrase “machine direction”, herein abbreviated “MD”, or “longitudinal direction”, refers to a direction “along the length” of the film, i.e., in the direction of the film as the film is formed during extrusion and/or coating. As used herein, the phrase “transverse direction”, herein abbreviated “TD”, refers to a direction across the film, perpendicular to the machine or longitudinal direction.
As used herein, the phrase “thermoplastic” refers to a synthetic plastic becoming soft when heated and rehardening on cooling without appreciable change of properties. As used herein, the term “polyolefin” refers to any polymerized olefin, which can be linear, branched, cyclic, aliphatic, aromatic, substituted, or unsubstituted. More specifically, included in the term polyolefin are homopolymers of olefin, copolymers of olefin, copolymers of an olefin and a non-olefinic comonomer copolymerizable with the olefin, such as vinyl monomers, modified polymers thereof, and the like. Specific examples include polyethylene homopolymer, polypropylene homopolymer, polybutene, ethylene/alpha-olefin copolymer, propylene/alpha-olefin copolymer, butene/alpha-olefin copolymer, ethylene/unsaturated ester copolymer, ethylene/unsaturated acid copolymer, (especially ethyl acrylate copolymer, ethylene/butyl acrylate copolymer, ethylene/methyl acrylate copolymer, ethylene/acrylic acid copolymer, ethylene/methacrylic acid copolymer), modified polyolefin resin, ionomer resin, polymethylpentene, etc. Modified polyolefin resin is inclusive of modified polymer prepared by copolymerizing the homopolymer of the olefin or copolymer thereof with an unsaturated carboxylic acid, e.g., maleic acid, fumaric acid or the like, or a derivative thereof such as the anhydride, ester or metal salt or the like. It could also be obtained by incorporating into the olefin homopolymer or copolymer, an unsaturated carboxylic acid, e.g., maleic acid, fumaric acid or the like, or a derivative thereof such as the anhydride, ester or metal salt or the like.
Useful materials in the inventive films include but are not limited to thermoplastic polyolefins, including polyethylene and copolymers thereof and polypropylene and copolymers thereof. The olefin based polymers include the most common ethylene or propylene based polymers such as polyethylene (including HDPE, LDPE, LLDPE, and VLDPE), polypropylene, and copolymers such as ethylene vinylacetate (EVA), ethylene methyl acrylate (EMA) and ethylene acrylic acid (EAA), or blends of such polyolefins. Other examples of polymers suitable for use as films include elastomeric polymers. Suitable elastomeric polymers may also be biodegradable or environmentally degradable. Suitable elastomeric polymers for the film include poly(ethylene-butene), poly(ethylene-hexene), poly(ethylene-octene), poly(ethylene-propylene), poly(styrene-butadiene-styrene), poly(styrene-isoprene-styrene), poly(styrene-ethylene-butylene-styrene), poly(ester-ether), poly(ether-amide), poly(ethylene-vinylacetate), poly(ethylene-methylacrylate), poly(ethylene-acrylic acid), poly(ethylene butylacrylate), polyurethane, poly(ethylene-propylene-diene), ethylene-propylene rubber. This new class of rubber-like polymers may also be employed and they are generally referred to herein as metallocene polymers or polyolefins produced from single-cite catalysts. The most preferred catalysts are known in the art as metallocene catalysts whereby ethylene, propylene, styrene and other olefins may be polymerized with butene, hexene, octene, etc., to provide elastomers suitable for use in accordance with the principles of this invention, such as poly(ethylene-butene), poly(ethylene-hexene), poly(ethylene-octene), poly(ethylene-propylene), and/or polyolefin terpolymers thereof. It can be suitable to blend into the resin a suitable amount of a cling agent, such as polyisobutylene, to control the level of lamination during the lamination process.
As the term “high density polyethylene” (HDPE) is used herein, it is defined to mean an ethylene-containing polymer having a density of 0.940 or higher. (Density (d) is expressed as g/cm 3 ) One particularly suitable HDPE for use with the methods of the present invention is the resin sold as M6211 (d=0.958) by Equistar. Another particularly suitable HDPE is the resin sold as HD 7845.30 (d=0.958) by Exxon. Other suitable HDPE resins include, for example, BDM 94-25 (d=0.961) and 6573×HC (d=0.959) which are both available from Fina Oil and Chemical Co., Dallas, Tex. and Sclair 19C (d=0.951) and 19F (d=0.961) which are both available from Nova Corporation, Sarnia, Ontario, Canada.
The Melt Index (MI) of the HDPE useful according to the prevention is in the range of from about 0.01 to about 10. (Melt Index is expressed as g/10 min.) Melt index is generally understood to be inversely related to viscosity, and decreases as molecular weight increases. Accordingly, higher molecular weight HDPE generally has a lower melt index. Methods for determining melt index are known in the art, e.g., ASTM D 1238.
The term “low density polyethylene” (LDPE) as used herein is defined to mean an ethylene-containing polymer having a density of about 0.926 or lower and a MI of about 7. LDPE is readily available, e.g., PE 1017 (MI=7; d=0.917) from Chevron, San Francisco, Calif., SLP 9045 (MI=7.5; d=0.908) from Exxon, Houston, Tex., and ZCE 200 (MI=3; d=0.918) from Mobil Chemical Corporation, Fairfax, Va.
The term “very low density polyethylene” (VLDPE) as used herein is defined to mean an ethylene-based hexane copolymer having a density of from about 0.890 to about 0.915 and a MI of from about 3 to about 17. VLDPE is readily available from Exxon, e.g., Exact Plastomer SLP-9087 (MI=7.5; d=0.900) and Exact Plastomer SLP-9088 (MI=16.5; d=0.900). Other suitable VLDPE resins include, for example, product No. XPR 0545-33260 46L (MI=3.3; d=0.908) from Dow Chemical Company, Midland, Mich.
The term “linear low density polyethylene” (LLDPE) as used herein is defined to mean a copolymer of ethylene and a minor amount of an olefin containing 4 to 10 carbon atoms, having a density of from about 0.910 to about 0.926 and a MI of from about 0.5 to about 10. LLDPE is readily available, e.g., Dowlex® 2045.03 (MI=1.1; d=0.920) from Dow Chemical Company, Midland, Mich.
Materials such as HDPE, when used alone or in combinations with other thermoplastics in the substantially un-pigmented and cold stretched ply, may give a greater degree of metallic appearance to a laminate with a substantially pigmented ply than lower density materials, such as LDPE. In addition, adding a voiding agent, even to materials such as LDPE or LLDPE, may give a greater degree of metallic appearance to a laminate with a substantially pigmented ply than lower density materials, such as LDPE. Some examples of voiding agents suitable for use in the present invention include calcium carbonate, magnesium carbonate, barium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, calcium oxide, magnesium oxide, titanium oxide, zinc oxide, aluminum hydroxide, magnesium hydroxide, talc, clay, silica, alumina, mica, glass powder, starch, incompatible polymers, etc. In one or more implementations, the voiding agent any be any inorganic or organic material with a relatively lower elasticity than the thermoplastic material of the film. One will appreciate in light of the disclosure herein that the foregoing list of voiding agents are examples of some of the voiding agents that may be suitable for use with the present invention.
As used herein, the term “cold stretched” refers to the process of cold stretching of the polymer film between geared or non-geared rollers under conditions where the polymer film is stretched at substantially ambient conditions. Examples of processes for “cold stretching” include MD ring rolling, TD ring rolling, and strainable network formation. Such process as heated extrusion using casting and blown film extrusion or heated embossing are not processes for stretching. Extruded film may be extruded completely flat or extruded with ribs or other designs. These extruded films are not cold stretched unless processed further by a cold stretching process.
As used herein, the term “substantially un-pigmented” refers to a thermoplastic ply or plies that are substantially free of a significant amount of pigment such that the ply is substantially transparent or translucent. As used herein, the term “substantially pigmented” refers to a thermoplastic ply or plies that are pigmented such that the ply is substantially opaque. As used herein, the term “pigment or pigments” are solids of an organic and inorganic nature which are defined as such when they are used within a system and incorporated into the thermoplastic, absorbing part of the light and reflecting the complementary part thereof which forms the color of the thermoplastic ply. As used herein, the term “pigment or pigments” does not include white opacifying agents such as titanium dioxide. Representative, but not limiting, examples of suitable pigments include inorganic colored pigments such as such as iron oxide, in all their shades of yellow, brown, red and black; and in all their physical forms and particle-size categories, chromium oxide pigments, also co-precipitated with nickel and nickel titanates, blue and green pigments derived from copper phthalocyanine, also chlorinated and brominated in the various alpha, beta and epsilon crystalline forms, yellow pigments derived from lead sulphochromate, yellow pigments derived from lead bismuth vanadate, orange pigments derived from lead sulphochromate molybdate lead oxide, cadmium sulfide, cadmium selenide, lead chromate, zinc chromate, nickel titanate, and the like. For the purposes of the present invention, the term “organic pigment” comprises also black pigments resulting from organic combustion (so-called “carbon black”). Organic colored pigments include yellow pigments of an organic nature based on arylamides, orange pigments of an organic nature based on naphthol, orange pigments of an organic nature based on diketo-pyrrolo-pyrole, red pigments based on manganese salts of azo dyes, red pigments based on manganese salts of beta-oxynaphthoic acid, red organic quinacridone pigments, and red organic anthraquinone pigments. Organic colored pigments include azo and diazo pigments, phthalocyanines, quinacridone pigments, perylene pigments, isoindolinone, anthraquinones, thioindigo, solvent dyes and the like.
As used herein, the terms “lamination,” “laminate,” and “laminated film,” refer to the process and resulting product made by bonding together two or more plies of film or other material. The term “bonding”, when used in reference to bonding of multiple plies of a multi-ply film, may be used interchangeably with “lamination” of the plies. According to methods of the present invention, adjacent plies of a multi-ply film are laminated or bonded to one another. In some embodiments, the bonding purposely results in a relatively weak bond between the plies that has a bond strength that is less than the strength of the weakest ply of the film. This allows the lamination bonds to fail before the film ply, and thus the film, fails.
The term laminate does not include heated coextruded multilayer films comprising one or more tie layers. As a verb, “laminate” means to affix or adhere (by means of, for example, adhesive bonding, pressure bonding (e.g., ring rolling, embossing, strainable network formation or SELFing), ultrasonic bonding, corona lamination, and the like) two or more separately made film articles to one another so as to form a multi-ply structure. As a noun, “laminate” means a product produced by the affixing or adhering just described.
In one or more implementations, the lamination or bonding between plies of a multi-ply film may be non-continuous (i.e., discontinuous or partial discontinuous). As used herein the terms “discontinuous bonding” or “discontinuous lamination” refers to lamination of two or more plies where the lamination is not continuous in the machine direction and not continuous in the transverse direction. More particularly, discontinuous lamination refers to lamination of two or more plies with repeating bonded patterns broken up by repeating un-bonded areas in both the machine direction and the transverse direction of the film.
As used herein the terms “partially discontinuous bonding” or “partially discontinuous lamination” refers to lamination of two or more layers where the lamination is substantially continuous in the machine direction or in the transverse direction, but not continuous in the other of the machine direction or the transverse direction. Alternately, partially discontinuous lamination refers to lamination of two or more layers where the lamination is substantially continuous in the width of the article but not continuous in the height of the article, or substantially continuous in the height of the article but not continuous in the width of the article. More particularly, partially discontinuous lamination refers to lamination of two or more layers with repeating bonded patterns broken up by repeating unbounded areas in either the machine direction or the transverse direction.
As used herein the terms “grided discontinuous bonding” or “grided discontinuous lamination” refers to lamination of two or more layers where the lamination is substantially continuous in the machine direction and in the transverse direction, but the lamination is broken up by a regular pattern of discrete un-bonded areas surrounded by continuous bonded regions in both the machine direction or the transverse direction. Alternately, partially discontinuous lamination refers to lamination of two or more layers where the lamination is substantially continuous in the width of the article but not continuous in the height of the article, or substantially continuous in the height of the article but not continuous in the width of the article. More particularly, partially discontinuous lamination refers to lamination of two or more layers with repeating bonded patterns broken up by repeating unbounded areas in either the machine direction or the transverse direction.
Lamination may also be either stretched lamination or un-stretched lamination. Continuous lamination, for example by flat plate heated lamination or continuous adhesive lamination, is generally un-stretched. Discontinuous or partially discontinuous lamination can be stretched or un-stretched. Examples of un-stretched discontinuous lamination include discontinuous adhesive lamination or discontinuous heated embossing. Examples of stretched discontinuous lamination include MD ring rolling, TD ring rolling, and strainable network formation.
As used herein, the term “flexible” refers to materials that are capable of being flexed or bent, especially repeatedly, such that they are pliant and yieldable in response to externally applied forces. Accordingly, “flexible” is substantially opposite in meaning to the terms inflexible, rigid, or unyielding. Materials and structures that are flexible, therefore, may be altered in shape and structure to accommodate external forces and to conform to the shape of objects brought into contact with them without losing their integrity. In accordance with further prior art materials, web materials are provided which exhibit an “elastic-like” behavior in the direction of applied strain without the use of added traditional elastic. As used herein, the term “elastic-like” describes the behavior of web materials which when subjected to an applied strain, the web materials extend in the direction of applied strain, and when the applied strain is released the web materials return, to a degree, to their pre-strained condition.
In one embodiment, the invention comprises a laminated multi-ply thermoplastic film comprising a first film ply being substantially un-pigmented and cold stretched; and a second film ply being substantially pigmented; wherein the first film ply and the second film ply are discontinuously laminated or partially discontinuously laminated together.
In another embodiment, the invention comprises a laminated multi-ply thermoplastic film comprising a first film ply being substantially un-pigmented; and a second film ply being substantially pigmented; wherein the first film ply and the second film ply are discontinuously laminated or partially discontinuously laminated together by a process that results in cold stretching of at least one of the film plies.
In another embodiment, the invention comprises bag having an interior and an exterior and comprising an outer bag having a first sidewall made of flexible thermoplastic web material and a second sidewall of flexible thermoplastic web material, overlaid and joined to the first sidewall to provide an outer bag interior volume, the first and second sidewalls joined along a first sealed side edge, an opposite second sealed side edge, and a closed bottom edge, the first and second sidewalls un-joined along their respective top edges to define an opening opposite the bottom edge; and an inner bag separated from and within the interior volume of the outer bag and having a first sidewall made of flexible thermoplastic web material and a second sidewall of flexible thermoplastic web material, overlaid and joined to the first sidewall to provide an inner bag interior volume, the first and second sidewalls of the inner bag joined along the first sealed side edge and the second sealed side edge of the outer bag, and a closed bottom edge of the inner bag, the first and second sidewalls un-joined along their respective top edges to define an opening opposite the bottom edge for accessing the inner bag interior volume; wherein the outer bag web material is substantially un-pigmented and has been stretched by a cold stretch formation process selected from the group consisting of MD ring rolling, TD ring rolling, and strainable network formation, and wherein the inner bag web material is substantially pigmented.
Referring now to the Figures, FIGS. 1A and 1B illustrate one exemplary process of incrementally stretching a thermoplastic film. In particular, FIGS. 1A and 1B illustrate an MD ring rolling process that incrementally stretches a thermoplastic film 10 by passing the film 10 through a pair of MD intermeshing rollers 12 , 14 . The MD ring rolling process cold stretches the film 10 in the machine direction.
As shown by FIGS. 1A and 1B , the first roller 12 and the second roller 14 can each have a generally cylindrical shape. The rollers 12 , 14 may be made of cast and/or machined metal, such as, steel, aluminum, or any other suitable material. The rollers 12 , 14 can rotate in opposite directions about parallel axes of rotation. For example, FIG. 1A illustrates that the first roller 12 can rotate about a first axis 16 of rotation in a counterclockwise direction 18 . FIG. 1A also illustrates that the second roller 14 can rotate about a second axis 20 of rotation in a clockwise direction 22 . The axes of rotation 16 , 20 can be parallel to the transverse direction and perpendicular to the machine direction.
The intermeshing rollers 12 , 14 can closely resemble fine pitch spur gears. In particular, the rollers 12 , 14 can include a plurality of protruding ridges 24 , 26 . The ridges 24 , 26 can extend along the rollers 12 , 14 in a direction generally parallel to axes of rotation 16 , 20 . Furthermore, the ridges 24 , 26 can extend generally radially outward from the axes of rotation 16 , 20 . The tips of ridges 24 , 26 can have a variety of different shapes and configurations. For example, the tips of the ridges 24 , 26 can have a rounded shape as shown in FIG. 1B . In alternative implementations, the tips of the ridges 24 , 26 can have sharp angled corners. FIGS. 1A and 1B also illustrate that grooves 28 , 30 can separate adjacent ridges 24 , 26 . The configuration of the ridges 24 , 26 and grooves 28 , 30 can dictate the amount stretching that a film passing through the MD intermeshing rollers 12 , 14 undergoes.
Referring specifically to FIG. 1B , various features of the ridges 24 , 26 and grooves 28 , 30 are shown in greater detail. The pitch and depth of engagement of the ridges 24 , 26 can determine, at least in part, the amount of incremental stretching created by the intermeshing rollers 12 , 14 . As shown by FIG. 1B , the pitch 32 is the distance between the tips of two adjacent ridges on the same roller. The “depth of engagement” (DOE) 34 is the amount of overlap between ridges 24 , 26 of the different rollers 12 , 14 during intermeshing. The ratio of DOE 34 to pitch 32 can determine, at least in part, the amount of stretch imparted by a pair of intermeshing rollers 12 , 14 .
As the thermoplastic film 10 passes between the intermeshing rollers 12 , 14 , the ridges 24 , 26 can incrementally cold stretch the film 10 in the machine direction. Additionally, the rollers 12 , 14 can impart or form a generally striped pattern 36 into the film 10 . As used herein, the terms “impart” and “form” refer to the creation of a desired structure or geometry in a film upon stretching the film that will at least partially retain the desired structure or geometry when the film is no longer subject to any strains or externally applied forces.
FIGS. 1A and 1B illustrate that the film 10 a comprises a single ply film. In any event, FIGS. 1A and 1B illustrate the intermeshing rollers 12 , 14 can process the film 10 a into a MD incrementally, cold stretched film 10 b . As previously mentioned, the MD incrementally, cold stretched film 10 b can include a striped pattern 36 . The striped pattern 36 can include alternating series of “un-stretched” regions or thicker ribs 44 and stretched regions or thinner ribs 46 . Because of the cold stretching process between rollers 12 , 14 , the thicker ribs 44 are generally symmetrical about the plane of the film 10 and thinner ribs 46 are generally symmetrical about the plane of the film 10 , when the film 10 is symmetrical about the plane of the film prior to stretching. In one or more implementations, the “un-stretched” regions of the incrementally-stretched films may be stretched to a small degree. In any event, the “un-stretched” regions can be stretched significantly less compared to the stretched regions.
The thicker ribs or un-stretched regions 44 can have a first average thickness or gauge 48 . The first average gauge 48 can be approximately equal to the starting gauge 42 . In one or more implementations, the first average gauge 48 can be less than the starting gauge 42 . The thinner ribs or stretched regions 46 can have a second average thickness or gauge 50 . In one or more implementations, the second average gauge 50 can be less than both the starting gauge 42 and the first average gauge 48 . In one or more implementations, the thicker ribs or un-stretched regions 44 and the thinner ribs or stretched regions 46 are not corrugated and lie in the same plane to give a ribbed flat film. One will appreciate in light of the disclosure herein that the striped pattern 36 may vary depending on the method used to incrementally cold stretch the film 10 . To the extent that MD ring rolling is used to incrementally cold stretch the film 10 , the striped pattern 36 on the film 10 can depend on the pitch 32 of the ridges 24 , 26 , the DOE 34 , and other factors.
FIG. 2 illustrates a top view of the MD incrementally, cold stretched film 10 b . The thicker ribs 44 and thinner ribs 46 can extend across the film 10 b in a direction transverse (i.e., transverse direction) to a direction in which the film was extruded (i.e., machine direction). The pitch 32 and the DOE 34 of the ridges 24 , 26 of the MD intermeshing rollers 12 , 14 can determine the width and spacing of the ribs 44 , 46 . Thus, as explained in greater detail below, by varying the pitch 32 and/or DOE 34 , the width and/or spacing of the ribs 44 , 46 , the amount of stretching the film undergoes, and the effects of the stretching on the physical properties can be varied.
The ribs 44 , 46 or ribbed pattern 36 , can provide a pleasing appearance and connote strength to a consumer. For example, the stripped pattern 36 can signify that the MD incrementally, cold stretched film 10 b has undergone a physical transformation to modify one or more characteristics of the MD incrementally, cold stretched film 10 b . For example, MD ring rolling the film 10 can increase or otherwise modify one or more of the tensile strength, tear resistance, impact resistance, or elasticity of the MD incrementally, cold stretched film 10 b . The ribbed pattern 36 can signify the physical transformation to a consumer. In one or more embodiments of the invention, cold stretching of a substantially un-pigmented ply or plies can surprisingly modify the appearance of a multi-ply film when the un-pigmented ply or plies is discontinuously laminated to a substantially pigmented ply or plies.
As mentioned previously, MD ring rolling is one exemplary method of incrementally cold stretching a thermoplastic film to create visually-distinct stretched regions in accordance with an implementation of the present invention. TD ring rolling is another suitable method of incrementally cold stretching a film to create visually-distinct stretched regions. For example, FIGS. 3A and 3B illustrate a TD ring rolling process that incrementally stretches a thermoplastic film 10 by passing the film 10 through a pair of TD intermeshing rollers 52 , 54 . A TD ring rolling processes (and associated TD intermeshing rollers 52 , 54 ) can be similar to the MD ring rolling process (and associated MD intermeshing rollers 12 , 14 ) described herein above, albeit that the ridges 56 , 58 and grooves 60 , 62 of the TD intermeshing rollers 52 , 54 can extend generally orthogonally to the axes of rotation 18 , 22 .
Thus, as shown by FIG. 3A , as the thermoplastic film 10 passes between the intermeshing rollers 52 , 54 , the ridges 56 , 58 can incrementally cold stretch the film 10 in the transverse direction. In particular, as the film 10 proceeds between the intermeshing rollers 52 , 54 , the ridges 56 , 58 can impart or form a striped pattern 36 a into the film 10 to form a TD incrementally, cold stretched film 10 c.
Referring specifically to FIG. 3B , various features of the ridges 56 , 58 and grooves 60 , 62 are shown in greater detail. The pitch and depth of engagement of the ridges 56 , 58 can determine, at least in part, the amount of incremental cold stretching created by the intermeshing rollers 52 , 54 . As shown by FIG. 3B , the pitch 32 is the distance between the tips of two adjacent ridges on the same roller. The “depth of engagement” (DOE) 34 is the amount of overlap between ridges 56 , 58 of the different rollers 52 , 54 during intermeshing. The ratio of DOE 34 to pitch 32 can determine, at least in part, the amount of stretch imparted by a pair of intermeshing rollers 52 , 54 .
As the thermoplastic film 10 passes between the intermeshing rollers 52 , 54 , the ridges 56 , 58 can incrementally cold stretch the film 10 in the transverse direction. Additionally, the rollers 52 , 54 can impart or form a generally striped pattern 36 a into the film 10 . As used herein, the terms “impart” and “form” refer to the creation of a desired structure or geometry in a film upon stretching the film that will at least partially retain the desired structure or geometry when the film is no longer subject to any strains or externally applied forces.
FIGS. 3A and 3B illustrate that the film 10 a comprises a single ply film. In any event, FIGS. 3A and 3B illustrate the intermeshing rollers 52 , 54 can process the film 10 a into a TD incrementally, cold stretched film 10 c . As previously mentioned, the TD incrementally, cold stretched film 10 c can include a striped pattern 36 a . The striped pattern 36 a can include alternating series of “un-stretched” regions 64 formed between ridges 56 , 58 , “unstretched” regions 66 at the ridges 56 , 58 and stretched regions or thinner ribs 68 . Because of the cold stretching process between rollers 52 , 54 , the thicker ribs 64 . 66 are symmetrical about the plane of the film 10 and thinner ribs 68 are symmetrical about the plane of the film 10 . In one or more implementations, the “un-stretched” regions 66 of the incrementally-stretched films may be stretched to a small degree. The “un-stretched” regions 66 can be stretched significantly less compared to the stretched regions 68 . The “un-stretched” regions 66 can be stretched slightly more compared to the “un-stretched” regions 64 . The “un-stretched” regions 66 can have a smooth transition to the stretched regions 68 . The “un-stretched” regions 64 can have a sharp transition to the stretched regions 68 . The “un-stretched” regions 64 can have a greater length and greater thickness or gauge 70 compared the thickness or gauge 72 of the “un-stretched” regions 66 . The “un-stretched” regions 64 can have a greater thickness or gauge 70 compared the thickness or gauge 74 of the stretched regions 68 . The “un-stretched” regions 66 can have a greater thickness or gauge 72 compared the thickness or gauge 74 of the stretched regions 68 . In one or more implementations, the thicker ribs or un-stretched regions 64 , 66 and the thinner ribs or stretched regions 68 are not corrugated and lie in the same plane to give a ribbed flat film.
One will appreciate in light of the disclosure herein that the striped pattern 36 a may vary depending on the method used to incrementally stretch the film 10 . To the extent that TD ring rolling is used to incrementally cold stretch the film 10 , the striped pattern 36 a on the film 10 can depend on the pitch 32 of the ridges 56 , 58 , the DOE 34 , and other factors.
FIG. 4 illustrates a top view of the TD incrementally-stretched film 10 c . The thicker ribs 64 , 66 and thinner ribs 68 can extend across the film 10 c in a direction transverse (i.e., transverse direction) to a direction in which the film was extruded (i.e., machine direction). The pitch 32 and the DOE 34 of the ridges 56 , 58 of the TD intermeshing rollers 52 , 54 can determine the width and spacing of the ribs 64 , 66 , 68 . Thus, as explained in greater detail below, by varying the pitch 32 and/or DOE 34 , the width and/or spacing of the ribs 64 , 66 , 68 , the amount of stretching the film undergoes, and the effects of the stretching on the physical properties can be varied.
The ribs 64 , 66 , 68 or ribbed pattern 36 a , can provide a pleasing appearance and connote strength to a consumer. For example, the stripped pattern 36 a can signify that the TD incrementally, cold stretched film 10 c has undergone a physical transformation to modify one or more characteristics of the TD incrementally, cold stretched film 10 c . For example, TD ring rolling the film 10 can increase or otherwise modify one or more of the tensile strength, tear resistance, impact resistance, or elasticity of the TD incrementally, cold stretched film 10 c . The ribbed pattern 36 a can signify the physical transformation to a consumer. In one or more embodiments of the invention, cold stretching of a substantially un-pigmented ply or plies can surprisingly modify the appearance of a multi-ply film when the un-pigmented ply or plies is discontinuously laminated to a substantially pigmented ply or plies.
FIG. 5A illustrates an MD ring rolling process that partially discontinuously laminates the individual adjacent plies 10 d , 10 e of thermoplastic film by passing the plies 10 d , 10 e through a pair of MD intermeshing rollers 12 , 14 , as illustrated in FIG. 1A . As a result of MD ring rolling, the multi-ply, partially discontinuously laminated film 10 f is also intermittently, cold stretched in the machine direction MD. In particular, the rollers 12 , 14 can include a plurality of protruding ridges 24 , 26 . For example, the tips of the ridges 24 , 26 can have a rounded shape as shown in FIG. 5A . In alternative implementations, the tips of the ridges 24 , 26 can have sharp angled corners. FIG. 5A also illustrates that grooves 28 , 30 can separate adjacent ridges 24 , 26 . Additionally, the configuration of the ridges 24 , 26 and grooves 28 , 30 can affect the amount of stretching and the bond strength resulting from partially discontinuous lamination as the two plies pass through intermeshing rollers 12 , 14 .
Referring specifically to FIG. 5A , various features of the ridges 24 , 26 and grooves 28 , 30 are shown in greater detail. The pitch and depth of engagement of the ridges 24 , 26 can determine, at least in part, the amount of incremental stretching and partially discontinuous lamination caused by the intermeshing rollers 12 , 14 . As shown by FIG. 5A , the pitch 32 is the distance between the tips of two adjacent ridges on the same roller. The “depth of engagement” (“DOE”) 34 is the amount of overlap between ridges 24 , 26 of the different rollers 12 , 14 during intermeshing. The ratio of DOE 34 to pitch 32 can determine, at least in part, the bond strength provided by the partially discontinuous bonding. According to one embodiment, the ratio of DOE to pitch provided by any ring rolling operation is less than about 1.2:1, suitably less than about 1.0:1, suitably between about 0.5:1 and about 1.0:1, or suitably between about 0.8:1 and about 0.9:1.
In particular, as the film plies 10 d , 10 e proceed between the intermeshing rollers 12 , 14 , the ridges 24 of the first roller 12 can push the film plies 10 d , 10 e into the grooves 30 of the second roller 14 and vice versa. The pulling of the film plies 10 d , 10 e by the ridges 24 , 26 can cold stretch the film plies 10 d , 10 e . The rollers 12 , 14 may not stretch the film plies 10 d , 10 e evenly along its length. Specifically, the rollers 12 , 14 can stretch the portions of the film plies 10 d , 10 e between the ridges 24 , 26 more than the portions of the film plies 10 d , 10 e that contact the ridges 24 , 26 . Thus, the rollers 12 , 14 can impart or form a generally striped pattern 36 b into the multi-ply film 10 f . As used herein, the terms “impart” and “form” refer to the creation of a desired structure or geometry in a film upon stretching the film that will at least partially retain the desired structure or geometry when the film is no longer subject to any strains or externally applied forces.
FIG. 5A illustrates that the film plies 10 d , 10 e (i.e., the film plies that are yet to pass through the intermeshing rollers 12 , 14 ) can have a substantially flat top surface 38 and substantially flat bottom surface 40 . The film plies 10 d , 10 e can have an initial total thickness or starting gauge 42 (i.e., the sum of 42 a and 42 b ) extending between its major surfaces (i.e., the top surface 38 and the bottom surface 40 ). In at least one implementation, the starting gauge 42 , as well as the gauge 42 a , 42 b of individual layers 10 d and 10 e can be substantially uniform along the length of the plies 10 d , 10 e . Because the inner surfaces of each layer 10 d and 10 e are somewhat tacky, the layers become lightly bonded together as they are pulled through and cold stretched by intermeshing rollers 12 , 14 . Those areas that are compressed on the ridges become lightly bonded together.
In one or more implementations, the film plies 10 d , 10 e need not have an entirely flat top surface 38 , but may be rough or uneven, or even have extruded ribs. Similarly, bottom surface 40 or the inner oriented surfaces of plies 10 d and 10 e can also be rough or uneven, or even have extruded ribs. Further, the starting gauge 42 , 42 a , and 42 b need not be consistent or uniform throughout the entirety of plies 10 d , 10 e . Thus, the starting gauge 42 , 42 a , and 42 b can vary due to product design, manufacturing defects, tolerances, or other processing issues. According to one embodiment, the individual plies 10 d and 10 e may already be cold stretched (e.g., through MD ring rolling, TD ring rolling, etc.) before being positioned adjacent to the other layer ( 10 d or 10 e , respectively). Such cold stretching of individual plies can result in a striped surface exhibiting an uneven top and bottom surface similar to that seen in FIGS. 1B and 3B .
FIG. 5A illustrates that films 10 f , can include two initially separate film plies 10 d - 10 e . FIG. 5B illustrates an alternative implementation where the incrementally cold stretched film 10 i can be produced from three initially separate film plies: a middle film ply 10 g , and two outer film plies 10 h , 10 k . In other embodiments, more than 3 plies may be provided (four, five, six, or more partially discontinuously or discontinuously laminated plies). In one or more embodiments of the invention in a similar manner as in FIG. 5B , cold stretching of substantially un-pigmented outer plies, such as 10 h and 10 k can surprisingly modify the appearance of a multi-ply film 10 i when the un-pigmented plies 10 h , 10 k are discontinuously laminated to a substantially pigmented inner ply 10 g or plies.
As seen in FIGS. 5A and 5B , upon cold stretching and partially discontinuous lamination of the adjacent plies, the multi-ply laminated film 10 f of FIG. 5A , 10 i of FIG. 5B , can include a striped pattern 36 b . The striped pattern 36 b can include alternating series of un-bonded and un-stretched regions 74 adjacent to bonded and stretched regions 76 . FIGS. 5A and 5B illustrate that the intermeshing rollers 12 , 14 can incrementally stretch and partially discontinuously bond films plies 10 d , 10 e or 10 g , 10 h , 10 k to create multi-ply laminated films 10 f , 10 i including bonded regions 76 , 76 a and un-bonded regions 74 , 74 a.
For example, FIG. 5A illustrates that the film plies 10 d , 10 e of the multi-ply laminated film 10 f can be laminated together at the un-stretched regions 76 , while the stretched regions 74 may not be laminated together. Similarly, FIG. 5B illustrates that the film layers 10 g , 10 h , 10 k of the multi-ply laminated film 10 i can be laminated together at the un-stretched regions 76 , while the stretched regions 74 may not be laminated together.
In addition to any compositional differences between plies 10 c , 10 d , 10 f , 10 g , or 10 h of a given multi-ply film, the different film plies can have differing gauges or thicknesses. In one or more implementations, the film plies may be substantially equal to one another in thickness. For example, the inventors have found that the MD or TD tear resistance of the composite, multi-ply film is typically approximately equal to the lowest MD or TD tear value of the individual plies, absent any increase in tear resistance provided by light bonding between the plies. In other words, the weakest ply often determines the strength of the multi-ply film structure.
In other embodiments, in a manner similar to FIGS. 5A and 5B , two or more film plies may be partially discontinuously laminated and cold stretched together using the TD ring rolling process of FIGS. 3A and 3B to give a multi-ply cold stretched film. In a manner similar to FIGS. 5A and 5B , one or more plies may be substantially un-pigmented and one or more plies may be substantially pigmented.
In accordance with another implementation, a structural elastic like film (SELF) process may be used to create a thermoplastic film with strainable networks, which similarly results in discontinuous bonding of adjacent layers within a multi-layer film. As explained in greater detail below, the strainable networks can include adjacent bonded and un-bonded regions. U.S. Pat. Nos. 5,518,801; 6,139,185; 6,150,647; 6,394,651; 6,394,652; 6,513,975; 6,695,476; U.S. Patent Application Publication No. 2004/0134923; and U.S. Patent Application Publication No. 2006/0093766 each disclose processes for forming strainable networks or patterns of strainable networks suitable for use with implementations of the present invention. The contents of each of the aforementioned patents and publications are incorporated in their entirety by reference herein.
FIG. 6 illustrates a pair of SELF'ing intermeshing rollers 82 , 84 for creating cold stretched, strainable networks of a single ply or of lightly bonded multiple plies of film. The first SELF'ing intermeshing roller 82 can include a plurality of ridges 86 and grooves 88 extending generally radially outward in a direction orthogonal to an axis of rotation 16 . Thus, the first SELF'ing intermeshing roller 82 can be similar to a TD intermeshing roller 52 , 54 of FIG. 3A . The second SELF'ing intermeshing roller 84 can also include a plurality of ridges 90 and grooves 92 extending generally radially outward in a direction orthogonal to an axis of rotation 20 . As shown by FIG. 6 , however, the ridges 90 of the second SELF'ing intermeshing roller 84 can include a plurality of notches 94 that define a plurality of spaced teeth 96 .
Referring now to FIG. 7 , a multi-ply cold stretched and discontinuously laminated film 10 m with bonded regions dispersed about un-bonded regions created using the SELF'ing intermeshing rollers 82 , 84 of FIG. 6 is shown. In particular, as the film passes through the SELF'ing intermeshing rollers 82 , 84 , the teeth 96 can press a portion of the multi-ply web or film out of plane to cause permanent deformation and stretching of a portion of the film in the Z-direction. The portions of the film that pass between the notched regions 94 of the teeth 96 will be substantially unformed in the Z-direction, resulting in a plurality of deformed, raised, rib-like elements 98 . The length and width of rib-like elements 98 depends on the length and width of teeth 96 .
As shown by FIG. 7 , the strainable network of the multi-ply lightly-laminated film 10 m can include first un-bonded regions 100 d , second un-bonded regions 100 e , and bonded transitional regions 102 e connecting the first and second un-bonded regions 100 d , 100 e . The second un-bonded regions 100 e and the bonded regions 102 e can form the raised rib-like elements 98 of the strainable network. The bonded regions 102 e can be discontinuous or separated as they extend across the multi-layered film 10 m in both transverse and machine directions. This is in contrast to stripes that extend continuously across a film in one of the machine or transverse directions.
The rib-like elements 98 can allow the multi-ply lightly-laminated film 10 m to undergo a substantially “geometric deformation” prior to a “molecular-level deformation” or a “macro-level deformation.” As used herein, the term “molecular-level deformation” refers to deformation which occurs on a molecular level and is not discernible to the normal naked eye. That is, even though one may be able to discern the effect of molecular-level deformation, e.g., macro-level deformation of the film, one is not able to discern the deformation which allows or causes it to happen. As used herein, the term “macro-level deformation” refers to the effects of “molecular-level deformation,” such as stretching, tearing, puncturing, etc. In contrast, the term “geometric deformation,” which refers to deformations of multi-ply lightly-laminated film 10 m which are generally discernible to the normal naked eye, but do not cause the molecular-level deformation when the multi-ply film 10 m or articles embodying the multi-ply lightly-laminated film 10 m are subjected to an applied strain. Types of geometric deformation include, but are not limited to bending, unfolding, and rotating.
Thus, upon application of strain, the rib-like elements 98 can undergo geometric deformation before either the rib-like elements 98 or the flat regions undergo molecular-level deformation. For example, an applied strain can pull the rib-like elements 98 back into plane with the flat regions prior to any molecular-level deformation of the multi-layered film 10 m . Geometric deformation can result in significantly less resistive forces to an applied strain than that exhibited by molecular-level deformation.
In addition to improved properties thus provided by the ability to geometrically deform, the SELF'ing process also discontinuously and lightly laminates adjacent plies of the multi-ply film together, providing the benefits noted above. In particularly, the film plies 11 f , 11 g can be lightly laminated at stretched regions 102 e , but un-bonded at the un-stretched regions 100 d and 100 e . The strength of the lamination bond is relatively weak, so as to be less than the weakest tear resistance of the individual plies of the multi-ply film. Thus, the lamination bond is broken rather than the individual ply tearing upon application of a force. Typically, tearing in the MD direction requires less applied force than tearing in the TD direction, thus in one embodiment, the lamination bond strength is less than the MD tear resistance of each individual ply of the multi-ply film.
FIG. 8 illustrates a multi-ply lightly-laminated film 10 n with a strainable network of rib-like elements 98 a arranged in diamond patterns. The strainable network of the multi-ply lightly-laminated film 10 n can include first un-bonded regions 100 d , second un-bonded regions 100 e , and bonded transitional regions 102 e connecting the first and second un-bonded regions 100 d , 100 e.
One or more implementations of the present invention can include strainable network patterns other than those shown by FIGS. 7 and 8 , or combinations of various patterns. It should be understood that the term “pattern” is intended to include continuous or discontinuous sections of patterns, such as may result, for example, from the intersection of first and second patterns with each other. Furthermore, the patterns can be aligned in columns and rows aligned in the machine direction, the transverse direction, or neither the machine direction nor the transverse direction. FIG. 9 illustrates a top view of the SELF incrementally, cold stretched film 10 m . The SELF'ing process can be used to cold stretch a single ply or multi-ply film. The cold stretched single ply or multi-ply film can then be discontinuously laminated to another film ply. In one or more embodiments of the invention in a similar manner as in FIGS. 6 and 7 , cold stretching of a substantially un-pigmented ply, such as 11 f , can surprisingly modify the appearance of a multi-ply film 10 m when the un-pigmented ply 11 f is discontinuously laminated to a substantially pigmented inner ply 11 g or plies.
In still further implementations, a multi-ply film can undergo both an MD ring rolling process and a TD ring rolling process to cold stretch the individual plies and to lightly bond the individual plies together. For example, FIG. 10 illustrates a top view of a multi-ply lightly-laminated film 10 p with bonded regions separated by un-bonded regions created by MD and TD ring rolling. The multi-ply lightly-laminated film 10 p can have a grid pattern 36 d including alternating series of un-bonded, stretched regions 104 b and bonded regions 106 b , 106 c . In particular, un-bonded regions 104 b may comprise a plurality of discrete squares or rectangles while the remainder of the surface comprises a grid of horizontal and vertical bonded regions that are connected together to form a grided discontinuous lamination. The bonded regions 106 b , 106 c can include stripes 106 b that extend along the multi-ply lightly-laminated film 10 p in the machine direction, and stripes 106 c that extend along the film in the transverse direction, which cross each other. As shown by FIG. 10 , in one or more implementations, the aspect ratio of the rows and columns of the bonded regions 106 b , 106 c can be approximately 1 to 1. In alternative implementations, such as the multi-ply trash bag 110 of FIG. 11 created by MD and TD ring rolling, the aspect ratio of the rows and columns of bonded regions 106 f , 106 g can be greater or less than 1 to 1. Where one ply is substantially pigmented and the other ply is substantially un-pigmented and stretched either prior to or during lamination, the laminated multi-ply film may give a metallic appearance.
FIG. 12 illustrates a multi-ply lightly-laminated trash bag 120 , having an interior 107 and an exterior 108 . The trash bag 120 is formed with an outer bag 102 having a first sidewall 103 made of flexible thermoplastic web material and a second sidewall 105 of flexible thermoplastic web material, overlaid and joined to the first sidewall 103 to provide an interior 107 , the first and second sidewalls 103 , 105 joined along a first sealed side edge 111 , an opposite second sealed side edge 112 , and a closed bottom edge 114 , the first and second sidewalls 103 , 105 un-joined along their respective top edges 113 , 115 to define an opening 116 opposite the bottom edge 114 for accessing the interior 107 .
The thrash bag 120 is also formed with an inner bag 122 within the interior 107 of the outer bag 102 , the inner bag 122 joined along the first sealed side edge 111 and the second sealed side edge 112 of the outer bag 102 . The outer bag 102 and the inner bag 122 are folded over and attached to the inner bag 122 forming a hem 132 having a hem seal 134 , the hem 132 including one or more draw tape notches 136 and a draw tape 126 within the hem 132 .
In a suitable example, the outer bag web material is substantially un-pigmented and has been stretched by a cold stretch formation process selected from the group consisting of MD ring rolling, TD ring rolling, and strainable network formation and the inner bag web material is substantially pigmented. The other bag may be cold stretched prior to or during lamination to the inner bag, or both. In this example, the outer bag may have a metallic appearance.
The thrash bag 120 is also formed with an inner bag 122 within the interior 107 of the outer bag 102 , the inner bag 122 joined along the first sealed side edge 111 and the second sealed side edge 112 of the outer bag 102 . The outer bag 102 and the inner bag 122 are folded over and attached to the inner bag 122 forming a hem 132 extending along the open top end 116 disposed opposite the bottom edge 114 of the outer bag 102 . The hem 132 has a hem seal 134 , the hem 132 including one or more draw tape notches 136 and a draw tape 126 within the hem 132 .
FIG. 13 illustrates a cross-sectional view of incrementally-stretched adhesively-laminated multi-ply film 10 q . The incrementally stretched, adhesively laminated multi-ply film 10 q includes an MD incrementally stretched film ply 10 r adhesively laminated to a TD incrementally stretched film ply 10 s . In particular, FIG. 13 illustrates that the MD incrementally stretched film ply 10 r is adhesively laminated to the TD incrementally stretched film ply 10 s by bonds or bond areas 152 . The bond areas 152 can be separated in one or more implementations by un-bonded areas 154 .
The bond areas 152 shown in FIG. 13 bond the film plies 10 r , 10 s together at the intersections of the thicker TD extending ribs 156 of MD stretched film ply 10 r and the thicker MD extending ribs 156 a of TD stretched film ply 10 s . The bond areas 152 are discontinuous in both the machine direction and the transverse direction, and thus, form a discontinuous lamination. Where one of the film plies 10 r or 10 s is substantially un-pigmented and the other of the film plies 10 s or 10 r is substantially pigmented, then the multi-ply film 10 q will have a metallic appearance when viewed from the side of the substantially un-pigmented film ply.
FIG. 14A illustrates a cross-sectional view of a multi-ply film 160 with a flat ply 162 bonded to a incrementally cold stretched ply 164 where the incrementally cold stretched ply 164 is under tension when the bonds 166 between the flat ply 162 and the incrementally cold stretched ply 164 have been made and where the incrementally cold stretched ply 164 has a higher rebound ratio than the flat ply 162 . FIG. 14B shows a cross-sectional view of the multi-ply film 160 where the plies 162 , 164 of the multi-ply film 160 are not under tension and the multi-ply film 160 has contracted to give puckers 168 in the flat ply 162 . FIG. 14C shows a perspective view of FIG. 14B where the bonding shows laminated stripes 170 , giving a partially discontinuous lamination pattern. The lamination process can be any lamination process including, but not limited to, adhesive lamination, embossing lamination, and cold stretching lamination. Where, for example, the ply 162 is substantially pigmented and the cold stretched ply 164 is substantially un-pigmented, the multi-ply film 160 may have a metallic appearance when viewed from the bottom side 172 . FIG. 14D shows a perspective view of FIG. 14B where the bonding shows laminated points 174 , giving a discontinuous lamination pattern. The lamination process can be any lamination process including, but not limited to, adhesive lamination, embossing lamination, and cold stretching lamination. Where, for example, the ply 162 is substantially pigmented and the cold stretched ply 164 is substantially un-pigmented, the multi-ply film 174 may have a metallic appearance when viewed from the bottom side 176 .
EXAMPLES
Example A
Control. A continuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film with 2.5 mil tall ribs spaced approximately 400 mils apart (formed by extruding the film in a ribbed pattern) and continuously laminating the films together by coextrusion. The laminated film A had a black appearance as shown in Table I.
Example B
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film and laminating the films together discontinuous adhesive lamination. The laminated film B had a slightly silver metallic appearance as shown in Table I.
Example C
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film and laminating the films together by MD ring rolling at 430 DOE with a 400 pitch tool. The laminated film C had a more silver metallic appearance as shown in Table I.
Example D
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film with 2.5 mil tall ribs spaced approximately 0.40 inches apart (formed by extruding the film in a stretched ribbed pattern) and laminating the films together by MD ring rolling at 430 DOE with a 400 pitch tool. The laminated film D had a more silver metallic appearance and shown in Table I.
Example E
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film with 2.5 mil tall ribs spaced approximately 0.40 inches apart (formed by extruding the film in a ribbed pattern) and laminating the films together by TD ring rolling at 20 DOE with a 40 pitch tool. The laminated film E had a more silver metallic appearance and shown in Table I.
Example F
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film with 2.5 mil tall ribs spaced approximately 0.40 inches apart (formed by extruding the film in a ribbed pattern), the un-pigmented film then stretched by MD ring rolling at 430 DOE with a 400 pitch tool and laminating the films together by TD ring rolling at 20 DOE with a 40 pitch tool. The laminated film F had a silvery appearance and shown in Table I.
Example G
A discontinuously laminated two ply film was created by overlaying a 0.5 mil, 0.920 density LLDPE, un-stretched, black film containing 4.8% carbon black with a 0.5 mil, 0.920 density LLDPE, un-stretched, un-pigmented film with 2.5 mil tall ribs spaced approximately 0.40 inches apart (formed by extruding the film in a ribbed pattern), the un-pigmented film then stretched by MD ring rolling at 430 DOE with a 400 pitch tool and laminating the films together the discontinuous application of adhesive. The laminated film F had a silvery appearance and shown in Table I.
TABLE I
Multi-ply Film
Appearance
Unpigmented on
Black = 0
Pigmented
Description
Silver Metallic = 4
Example A - Control
Pigmented - Unstretched
0
Un-Pigmented -
Unstretched
Continuous lamination
Example B
Pigmented - Unstretched
1
Un-Pigmented -
Unstretched
Discontinuous Un-Stretched
lamination
Example C
Pigmented - Unstretched
2
Un-Pigmented -
Unstretched
Discontinuous Stretched
lamination
Example D
Pigmented - Unstretched
3
Un-Pigmented -
Unstretched, non-Flat
Discontinuous Stretched
lamination
Example E
Pigmented - Unstretched
3
Un-Pigmented -
Unstretched, non-Flat
Discontinuous Stretched
lamination
Example F
Pigmented - Unstretched
4
Un-Pigmented - Stretched
Discontinuous Stretched
lamination
Example G
Pigmented - Unstretched
4
Un-Pigmented - Stretched
Discontinuous Un-Stretched
lamination
The Examples in Table I show that a multi-ply film resulting from the discontinuous lamination of an un-pigmented ply to a pigmented ply, where the un-pigmented ply has been cold stretched by prior to or during lamination, will have a noticeably metallic appearance.
Exemplary embodiments are described herein. Variations of those embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor(s) expect skilled artisans to employ such variations as appropriate, and the inventor(s) intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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Laminated multi-ply films where one film layer is substantially unpigmented and the other film layer is substantially pigmented can provide a metallic appearance when the substantially unpigmented film layer is cold stretched either prior to lamination or during the lamination step. This surprising result provides an inexpensive way to produce films with a metallic appearance. Trash bags having an inner bag and an outer bag laminated together may be formed according to this process.
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[0001] Applicant claims priority to U.S. Provisional Application for A Portable Table, Application No. 60/524,259, filed Jan. 5, 2004.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method and device for a collapsible table preferably constructed from and contained in a thin portable cardboard box.
[0003] There are a variety of foldable paperboard tables. Some of these include U.S. Pat. No. 6,267,065 issued to Lin for a foldable paperboard table comprising a number of sections to form the base, and an additional center section support is required because the structure of the table top is insufficiently suitable on its own. Additionally, the structure on the periphery must be folded over and attached to base to provide adequate peripheral support.
[0004] Another paperboard table patent is shown in U.S. Pat. No. 6,206,473 issued to Kondratiev. This device has no transporting means and it requires a separate attaching means to connect the base to the top.
[0005] A transportable box is provided in U.S. Pat. No. 6,135,033 for a triangulated shelf display unit. The transportable box contains a number of internally transported paperboard members that serve as shelves and the box itselfconverts to a column support.
[0006] Foldable furniture is provided in U.S. Pat. No. 5,394,810 issued to Howard et al. Although the various members may be inserted into a package for shipping, no shipping container (box) is provided or utilized in the design.
[0007] A knock down semi-rigid table assembly is shown in U.S. Pat. No. 5,018,454 issued to Negus. The box shown in FIG. 1 is not utilized as part of the configured table. U.S. Pat. No. 4,078,502 issued to Barna relates to similar furniture construction.
[0008] The principal disadvantage of such devices is their bulky, difficult to transport configurations and lack of structural integrity.
[0009] To alleviate these inherent problems, and others which will become apparent from the disclosure which follows, the present invention conveniently provides an easily transportable table which includes substantial structural integrity and can withstand considerable more loading than existing foldable tables. Furthermore, the embodiments of this invention provide a collapsible paperboard table assembly which is easily assembled on site that is inexpensive, lightweight, and which can be either disposable or reusable.
[0010] The citation of the foregoing publications is not an admission that any particular publication constitutes prior art, or that any publication alone or in conjunction with others, renders unpatentable any pending claim of the present application. None of the cited publications is believed to detract from the patentability of the claimed invention.
ADVANTAGES OF THIS INVENTION
[0011] The transportable box of the instant invention which also serves as a table top has sufficient independent structure to provide the necessary support without all of the additional elements and attachments that are required by the foregoing references. Nonetheless, this transportable table can be made out of lightweight corrugated paper board or cardboard and coated to reduce the effects of water on corrugated material protecting it against water from drinks in glasses or bottles that may be placed on the table top. It can be used inside or outdoors on a clean, dry, and level surface. Footings have been provided for more effective stabilization on uneven surfaces. Waterproof footings have been added to allow it to be used on surfaces that are not entirely dry.
[0012] The base and table top snap and lock together when the unit is assembled without the need of separate attachment elements. The units can be made in a variety of sizes, each of which can support about 100 pounds of evenly distributed weight.
[0013] Moreover, the instant invention provides methods and devices for building a collapsible table from a thin lightweight cardboard box having a bottom surface, a top surface, an end flap for sealing an end opening and an interior space, a collapsible base that can be stored in the interior space of the box, and preferably a fold back stabilizer and a pair of interlocking flat cardboard sheets. In one embodiment of the collapsible table, the bottom surface has a pair of transverse perforated cuts forming four opposing wedges which can be displaced to form an aperture for receiving a base. The base can be removed from storage in the interior space and inserted into the aperture of the outer thin box to form a lightweight easily transported table.
[0014] Each of the pair of interlocking flat cardboard sheets, the collapsed open-ended base, and the fold back stabilizer can be removed from the interior of the outer thin box; each of the pair of interlocking flat cardboard sheets can be interlocked and the collapsed opened base can be expanded to receive the interlocked flat cardboard sheets to form a base; the four opposing wedges which can be displaced by the fold back stabilizer to form an aperture for receiving the base; and the fold back stabilizer with two end openings and two side openings can be disposed to receive an apex of each of the four opposing wedges to secure the aperture in an open position, as shown in the drawing.
[0015] The top end of the base can be inserted into the aperture of the outer thin box, and the outer thin box with the base disposed in its aperture can be arranged with the base at the bottom and the top surface at the top to form the disposable lawn table of the present invention. The outer thin box with the base disposed in its aperture can be arranged with the base at the bottom and the top surface at the top to form the table of the present invention.
[0016] These together with other objects of the invention, along with the various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
[0017] Still other advantages will be apparent from the disclosure that follows.
SUMMARY OF THE INVENTION
[0018] The invention relates to a collapsible table comprising a structure for supporting the table and a box with a receptacle space for accessibly holding the structure for supporting the table. The structure for supporting the table comprises a collapsible base having a top end and a bottom end. The collapsible base is selectively configurable between a first configuration in which the base is flattened so that it can be stored in the box and a second configuration in which the base is expanded for supporting the table.
[0019] The box has a top surface, a bottom surface, and at least one side surface. Each of the at least one side surface is disposed between the top surface and the bottom surface. The bottom surface has an aperture that is selectively configurable between a closed configuration in which the aperture is substantially closed and an open configuration in which the aperture is open defining a passageway for receiving the top end of the collapsible base.
[0020] The collapsible base can be selectively configured to the first configuration in which the base is flattened so that it can be stored in the receptacle space of the box for ease of transport, the collapsible base can be removed from the receptacle space of the box and the top end of the collapsible base can inserted into the aperture of the bottom surface of the box, and the collapsible base can be selectively configured to the second configuration in which the base is erect for supporting the table and the top surface of the box can be up righted allowing the top surface to be a table top.
[0021] The present invention also teaches a method for constructing a collapsible table from a box having a receptacle space for accessibly holding a structure for supporting the table, a closeable opening in one of a top surface, a bottom surface with a centrally disposed openable aperture, and an at least one side surface, and the structure for supporting the table, including a collapsible base with a top end having at least one head and a bottom end, comprising steps of opening the closeable opening in one of the top surface, the bottom surface, and the at least one side surface of the box; removing the structure for supporting the table from the box; selectively configuring the collapsible base from a first configuration in which the base is flattened for stowage to a second configuration in which the base is erect for supporting the table; opening the aperture to form a passageway for receiving the top end of the collapsible base; and inserting the top end of the collapsible base into the passageway.
[0022] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated.
[0023] There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWING
[0024] Preferred embodiments of the invention are described hereinafter with reference to the accompanying drawing wherein:
[0025] FIG. 1 is a perspective view of an assembled collapsible table of the instant invention showing the box functioning as a tabletop supported by a collapsible base having feet at its respective corners;
[0026] FIG. 2 is a cross sectional view taken along the line of 1 - 1 of FIG. 1 showing a preferred construction of the corrugated material of the instant invention;
[0027] FIG. 3 is a perspective view of the tabletop being used as a transport box with a handle for transporting the collapsible table of the instant invention and showing particularly the bottom surface of the box which has a series of partial cuts to provide an open able aperture for receiving a top end of the collapsible base;
[0028] FIG. 4 is a perspective view of the collapsible table of the current invention with the elements of the structural support partially removed from the inside of the table top/box;
[0029] FIG. 5 is a exploded perspective view of the collapsible table of the current invention showing an arrangement of the box in position to function as the table top and for receiving the means for opening the open able aperture, the collapsible base and the pair of intersecting sheets;
[0030] FIG. 6 is a perspective view of the aperture of the box partially opened by the means for opening which includes a flat plate that can be inserted to open the open able aperture without contacting the inwardly extending tabs of the bottom surface;
[0031] FIG. 7 is a perspective view of the bottom surface of the box with the openable aperture of the bottom surface fully opened and with the means for opening said aperture disposed within said aperture;
[0032] FIG. 8 is a perspective view of the collapsible table showing the partially folded collapsible base being inserted into the openable aperture;
[0033] FIG. 9 is a fragmentary perspective view of the collapsible table with the collapsible base fully opened within the aperture so that the taps are in the recesses in the side walls of the base and with the pair of interlocking sheets being partially inserted into a bottom opening of the collapsible base ( FIGS. 6-9 show assembly steps in connecting the various elements of the collapsible table.);
[0034] FIG. 10 is a perspective view of the bottom surface of the box of the current invention with a preferred configuration of cuts and fold lines for the aperture shown in a closed configuration for transporting the collapsed base inside;
[0035] FIG. 11 is a fragmentary perspective view of the aperture on the bottom surface of the box in an open configuration;
[0036] FIG. 12 is a fragmentary perspective view of the aperture on the bottom surface of the box in an open configuration with the collapsible base in a partially opened configuration disposed in the passageway of said aperture;
[0037] FIG. 13 is a fragmentary perspective view of the collapsible table with the collapsible base fully opened within the aperture so that the tabs extend into the recess in the opposing side walls of the base;
[0038] FIG. 14 is a exploded perspective view of the collapsible table showing the structure for supporting the table exploded away from the table top/box;
[0039] FIG. 15 is a cross-sectional view taken along the lines 15 - 15 of FIG. 14 showing the preferred construction of the intersecting sheet corrugated wall;
[0040] FIG. 16 is a perspective view of the assembled collapsible table with a round table top/box;
[0041] FIG. 17 is a cut away perspective view of the collapsible table showing a polygonal table top with the base and intersecting sheets disposed within the base and the base disposed within the aperture and further showing feet on the base and the interlocking stiffeners;
[0042] FIG. 18 is a cut away perspective view showing access to the structure for supporting the table accessible through the top surface of the box;
[0043] FIG. 19 is a cut away perspective view of another embodiment of the collapsible table with a plurality of apertures in the bottom surface of the box and a corresponding number of heads extending from the top of the base through a plurality of apertures of the bottom surface of the box;
[0044] FIG. 20 is a cross-sectional view taken along the line 20 - 20 of FIG. 19 showing a corrugated head disposed in the passageway of one of the apertures in the bottom surface of the box;
[0045] FIG. 21 is a cross-sectional view taken along the line 21 - 21 of FIG. 19 showing one of the heads of the base extending through the aperture to support the underside of the top surface of the box;
[0046] FIG. 22 is an exploded cut away fragmentary perspective view of another embodiment of the collapsible table showing a polygonal aperture and a complementary base cross-section, with the base having an elongated stiffener that has a maximum lateral dimension that is greater than the length of any one peripheral edge of the passageway; and
[0047] FIG. 23 is a cross-sectional view of the base taken along the lines 23 - 23 of FIG. 22 showing the collapsible table with the stiffener disposed between the respective crease lines of the base.
DETAILED DESCRIPTION OF THE INVENTION
[0048] The preferred embodiments depicted in the drawing comprise a collapsible table with a table top convertible from a box. Without departing from the generality of the invention disclosed herein and without limiting the scope of the invention, the discussion that follows, will refer to the invention as depicted in the drawing.
[0049] The preferred embodiments of the apparatus depicted in the drawing comprise a collapsible table 1 comprising a structural support for the portable table including a collapsible base 2 with a top end 22 and a bottom end 20 , and a table top 4 including a box 11 having a top surface 14 , a bottom surface 16 , and at least one side surface 15 . Each of the at least one side surface 15 is disposed between the top surface 14 and the bottom surface 16 proximate a respective peripheral edge thereof, with at least one of the at least one side surface having a closeable opening 26 for accessing a receptacle space 13 inside of the box 4 for storing the structural support.
[0050] Additionally, the bottom surface 16 has an openable aperture 24 for receiving the top end 22 of the collapsible base 2 into the receptacle space 13 inside of the box 4 . In this way, the collapsible table can be readily transported in the table top as a box with the structural support including the collapsible base disposed therein, and it can assembled as a table unit with the collapsible base being removed from the receptacle space inside the box, and with the top end of the collapsible base inserted into the openable aperture of the box and unfolded to form the structural support of the table in which the top surface 14 of the box can be up righted allowing the top surface to be an upper surface of the table top.
[0051] Preferably, as shown in FIG. 5 , the collapsible base comprises an elongated open ended multi-sided sleeve 46 with a polygonal cross section with at least two opposite sides that are parallel. Each of the at least two opposite sides that are parallel have a centrally elongated crease 3 line for folding, whereby, the at least two opposite sides can be folded along the crease lines and the collapsible base can be collapsed to fit inside the box. In the preferred embodiment as shown in the drawing, there are four side surfaces. As shown in FIGS. 1, 5 and 9 , the cross section of the unfolded sleeve is square. At least one of the two opposing sides that are parallel have centrally disposed creased line for folding.
[0052] As best shown in FIGS. 1, 4 , 5 , 8 and 9 , the bottom end of the collapsible base has a plurality of feet 10 . Each of the plurality of feet is adapted for resting on an extraneous surface, which may be uneven, for supporting the collapsible table.
[0053] Referring to FIG. 3 , the openable aperture for receiving the top end of the collapsible base comprises a first set of partial cut crease lines 5 forming a square corresponding generally to the cross sectional dimensions of an unfolded collapsible base and a second set of partial cut crease lines 6 forming a square with each of the crease lines forming an inner square with each of its creased lines at a distance no greater than the width of the box from the respective outer crease lines. Also shown are a pair of partial transverse intersecting cuts 8 centrally disposed forming four opposing triangular segments 38 . Each of the partial transverse intersecting cuts extends diagonally from an intersection of the partial cut crease lines of the outer square to an opposite corner of the square with a central section 40 proximate to the intersection of the partial transverse intersecting cuts remaining uncut to maintain partial integrity of the bottom surface.
[0054] The length of each of the partial transverse intersecting cuts corresponds to the length of the diagonal dimension of the unfolded cross section of the unfolded collapsible base.
[0055] As shown in FIGS. 3 , and 6 - 9 , the openable aperture of the bottom surface has opposing tabs extending into the aperture 24 from opposing peripheral edges and the collapsible base has corresponding recesses disposed along disposing sides thereof which are adapted to receive the tabs of the bottom surface when the collapsible base 2 is unfolded. Removal of the base from the table top is restricted independent of collapsing the collapsible base before withdrawing the base from the table top. See FIG. 9 .
[0056] Additionally, the structural support of the collapsible table of this important invention comprises at least one flat sheet ( 30 , 32 ) having a length equal to the length of the elongated sleeve and a width corresponding to the cross-sectional length of the unfolded collapsible base. As shown in FIG. 5 , the structural supporting may have a pair of interlocking flat sheets ( 30 , 32 ), each having length equal to the length of the elongated sleeve and a width corresponding to the cross-sectional length of the unfolded collapsible base. A first of the pair of interlocking sheets 30 has a centrally disposed cuts 42 extending from a bottom surface thereof to a medial point, and the second 32 of the pair of interlocking sheets may have a centrally disposed cuts 44 extending from a top edge thereof to a medial point, as shown in FIG. 5 . The pair of interlocking sheets can be interlocked along the respective cuts, as shown in FIG. 9 . The interlocking sheets can be inserted into the bottom opening of the collapsible base to provide additional structural stability for the collapsible table.
[0057] Additionally, the respective bottom edge of each of the pair of interlocking sheets may have extended feet corresponding in length to the feet of the collapsible base and further has a centrally disposed foot.
[0058] Furthermore, the collapsible table may further comprise a means for opening 28 the openable aperture of the bottom surface of the table top independent of the contact with the inwardly disposed tabs 7 of the bottom surface 16 comprising a flat sheet having dimensions corresponding to the cross sectional dimensions of the collapsible base. Recesses 34 in the collapsible base are adapted to receive the tabs 7 .
[0059] The collapsible table may further comprise a handle 12 extending from at least one of the plurality of side surfaces of the box.
[0060] As can be readily appreciated from the foregoing and the drawing, various methods of making a collapsible table from a convertible box are disclosed by this invention.
[0061] The collapsible table 1 taught by the instant invention comprises a structure for supporting the table and a box 11 with a receptacle space 13 for accessibly holding the structure for supporting the table. The structure for supporting the table comprises a collapsible base 2 having a top end 22 and a bottom end 20 . The collapsible base is selectively configurable between a first configuration in which base is flattened so that it can be stored, as shown in FIGS. 4 and 18 , and a second configuration in which the base is erect for supporting the table, as shown in FIGS. 1, 16 , 17 , and 19 . The box 11 has a top surface 14 , a bottom surface 16 , and at least one side surface 15 ; each of the at least one side surface is disposed between the top surface and the bottom surface. The bottom surface 16 has an aperture 24 that is selectively configurable between to a closed configuration in which the aperture is substantially closed, as shown in FIGS. 3, 5 , 10 and 14 , and an open configuration in which the aperture is open defining a passageway for receiving the top end of the collapsible base, as shown in FIGS. 5-9 , 11 - 13 , and 16 - 17 .
[0062] The collapsible base 2 can be selectively configured to the first configuration in which base is flattened so that it can be stored in the receptacle space 13 of the box for ease of transport, the collapsible base can be removed from the receptacle space of the box and the top end 22 of the collapsible base can inserted into the aperture 24 of the bottom surface 16 of the box 4 , and the collapsible base can be selectively configured to the second configuration in which the base is erect for supporting the table and the top surface 14 of the box can be up righted allowing the top surface to be a table top.
[0063] Furthermore, access to the structure for supporting the table for removal from the receptacle space inside the box is through a closeable opening 9 in one of the top surface 14 , the bottom surface 16 , and the at least one side surface 13 . The bottom surface 16 of the box 4 may have a plurality of opposing tabs 7 extending into the passageway and the base has at least two opposing sides 17 , each of the at least two opposing sides has at least one recess 34 for receiving one of the plurality of opposing tabs 7 , each of the at least one recess 34 is at a predetermined distance from the top end 22 of the base 2 so that the top end of the base supports an underside 14 a of the top surface 14 of the box 4 when the top end 22 of the collapsible base is disposed in the passageway 25 in the second configuration and each of the plurality of opposing tabs 7 is disposed in one of the at least one recess 34 , so that removal of the erect base 2 from the passageway 25 of the table top (box 4 ) is restricted independent of collapsing the collapsible base before withdrawing the base 2 from the table top and the table top is supported by the base.
[0064] Additionally, referring to FIG. 6 , the structure for supporting the table further may comprise means for opening 28 the aperture 24 of the bottom surface of the box independent of contact with the opposing tabs 7 extending into the passageway including a flat rigid sheet has dimensions corresponding to the cross-sectional dimensions of the erect collapsible base 2 .
[0065] The aperture 24 preferably comprises a predetermined array of die cuts 8 and crease lines ( 5 , 6 ) in the bottom surface of the box, so that through the application of an applied force to the aperture 24 will cause separation along the die cuts 8 allowing the crease lines to fold to create the passageway 25 . At least one of the crease lines 5 is preferably parallel to a peripheral edge 27 of the passageway 25 . In a preferred embodiment, the predetermined array of die cuts are intersecting diagonals, as best shown in FIG. 3 , extending through the aperture. In another preferred embodiment, the predetermined array of die cuts 8 are two parallel lines defining opposing edges of the passageway and a line perpendicular to and medially intersecting each of the two parallel lines, as shown in FIG. 10 .
[0066] Because the collapsible table is designed to be transportable and lightweight, the structure for supporting the table and the box may be made of cardboard. The cardboard is preferably corrugated, as shown in FIGS. 2, 15 , and 20 . Additionally, at least the top surface 14 of the box 4 may have a water resistant coating ( 14 b , 14 c ). Alternatively, at least one of the structure for supporting the table and the box may be comprised of plastic and the plastic may be corrugated.
[0067] Variations are contemplated for the interconnection between the box and the structure for supporting the table. The overall shape of the passageway 25 through the bottom surface 16 of the box 4 may be polygonal—one example of which is shown in FIG. 22 , with the base being sized to fit the passageway. As best shown in FIGS. 22 and 23 , the second configuration of the base 4 may have a polygonal cross-section with a maximum transverse dimension that is less by a predetermined amount than a maximum transverse dimension of the passageway and with a minimum transverse dimension that is less by a predetermined amount than a minimum transverse dimension of the passageway. The overall shape of the passageway through the bottom surface of the box may be substantially square and the second configuration of the base has a square cross-section that is sized to fit the passageway, as shown in various figures throughout the drawing.
[0068] So that the table top/box 4 does not spin on the base 2 , the base is adapted for use with the passageway 25 of the box so that dependent rotation, about the centerline of the base, between the second configuration of the base and box exists. Preferably, the second configuration of the base 2 comprises an elongated open ended multi-sided sleeve 46 with a polygonal cross section sized to fit the passageway with at least two opposing parallel sides 48 , each at least two opposing parallel sides is joined to another side by a crease line 3 , and each of the at least two opposing parallel sides has a longitudinally disposed central crease line 3 a for folding. In this way, the at least two opposing sides 48 can be folded along the crease lines 3 a to allow the base 2 to be flattened and stored inside the box 4 , and the at least two opposing sides 48 can be flattened unfolding the crease lines to allow the base (sleeve 48 ) to be erect to fit in the passageway 25 and support the table top/box 4 .
[0069] As shown in FIGS. 5, 14 , and 19 , the base may comprise at least two elongated interlocking stiffeners ( 30 , 32 ). Each of the at least two elongated interlocking stiffeners has a maximum lateral dimension that is less than a maximum transverse dimension of the passageway 25 and have a length equal to the length of the elongated sleeve 46 , the stiffeners are disposable in the erect base, and each of the at least two interlocking stiffeners has a centrally disposed longitudinal cut ( 42 and 44 , respectively) extending from an end surface to a medial point. Thus, the at least two interlocking stiffeners can be interlocked along each of the longitudinal cuts and the interlocking stiffeners can be inserted into a bottom opening of the erect collapsible base to provide additional structural stability for the collapsible table. In another embodiment, as shown in FIG. 23 , the structural support may further comprise at least one elongated stiffener 31 that has a length not exceeding the length of the elongated sleeve and a width corresponding to a maximum transverse dimension of the erect collapsible base 4 .
[0070] As shown in FIGS. 22 and 23 , the collapsible table provides the second configuration of the base comprises an elongated open ended multi-sided sleeve 46 with a polygonal cross section sized to fit the passageway with at least two opposing sides 17 , each of the at least two opposing sides has a longitudinally disposed central crease line 3 for folding, so that the at least two opposing sides 17 can be folded along the crease lines to allow the base to be flattened and stored inside the box 4 , and the at least two opposing sides can be flattened unfolding the crease lines to allow the base to be erect to fit in the passageway and support the table top. Additionally, the base may comprise an elongated stiffener 31 having a maximum lateral dimension that is greater than the length of any one peripheral edge of the passageway and has a length not exceeding the length of the elongated sleeve, the stiffener is disposed between the respective crease lines to maintain the base in an erect configuration.
[0071] The bottom end 20 of the collapsible base may have a plurality of feet 10 with each of the plurality of feet being adapted for resting on an extraneous surface for supporting the collapsible table. Moreover, the base may comprise two elongated interlocking stiffeners ( 30 , 32 ) adapted for snug insertion into the erect base 2 . Each of the two interlocking stiffeners preferably has a centrally disposed longitudinal cut extending from an end surface to a medial point a respective bottom edge of each of the pair of interlocking sheets has extended feet 10 a corresponding in length, number and pattern of distribution to the feet of the collapsible base 4 , and the respective bottom edge of each of the pair of interlocking sheets further has at least one foot 10 b that is centrally disposed when the two interlocking stiffeners are disposed in the sleeve. Preferably, all of the plurality of feet of the collapsible base and all of the feet of the two elongated interlocking stiffeners are protected against moisture penetration by one of a plurality of moisture impermeable coverings 21 , as shown in FIG. 17 . The plurality of moisture impermeable coverings may be plastic.
[0072] As shown in FIGS. 12-14 , the collapsible table may have a handle extending from at least one of the at least one side surface of the box.
[0073] The collapsible table 1 of the present invention can comprise a structure for supporting the table and a box 4 with a receptacle space 13 for accessibly holding the structure for supporting the table. The structure for supporting the table may have a collapsible base 2 with a top end 22 and a bottom end 20 , and the collapsible base may be selectively configurable between a first configuration in which base is flattened so that it can be stored and a second configuration in which the base is erect for supporting the table. The box 4 may have a top surface 14 , a bottom surface 16 , and at least one side surface 15 . Each of the at least one side surface is disposed between the top surface and the bottom surface. The structure for supporting the table is accessibly removable from the receptacle space 13 inside the box through a closeable opening 9 in one of the top surface 14 , the bottom surface 16 , and the at least one side surface 15 . The bottom surface may have an aperture 24 that is selectively configurable between a closed configuration in which the aperture is substantially closed and an open configuration in which the aperture is open defining a passageway 25 for receiving the top end 22 of the collapsible base 2 . The passageway 25 is adapted for use with the base 2 so that dependent rotation, about the centerline of the base, between the second configuration of the base 2 and box 4 exists, and the aperture 24 comprises a predetermined array of die cuts 8 and crease lines ( 5 , 6 ) in the bottom surface 16 of the box 4 , so that through the application of an applied force to the aperture will cause separation along the die cuts allowing the crease lines to fold to create the passageway 25 .
[0074] In this way, the collapsible base 2 can be selectively configured to the first configuration in which base is flattened so that it can be stored in the receptacle space 13 of the box for ease of transport, the collapsible base can be removed from the receptacle space of the box and the top end 22 of the collapsible base 2 can inserted into the aperture 24 of the bottom surface of the box, and the collapsible base can be selectively configured to the second configuration in which the base is erect for supporting the table and the top surface of the box can be up righted allowing the top surface to be a table top.
[0075] In another preferred embodiment, the collapsible table 1 may comprise a structure for supporting the table and a box 4 with a receptacle space 13 for accessibly holding the structure for supporting the table. The structure for supporting the table may have a collapsible base 2 has a top end 22 and a bottom end 20 with the top end 22 of the collapsible base 2 having at least one head 50 . The collapsible base is selectively configurable between a first configuration in which base is flattened so that it can be stored and a second configuration in which the base is erect for supporting the table. The box has a top surface, a bottom surface, and at least one side surface, and each of the at least one side surface is disposed between the top surface and the bottom surface. The bottom surface has at least one aperture 24 corresponding in number and pattern of distribution to the number and pattern of distribution of the at least one head 50 . Each of the at least one aperture has an open configuration defining a passageway 25 for receiving one of the at least one head 50 of the top end 22 of the collapsible base 2 . Thus, the collapsible base can be selectively configured to the first configuration in which base is flattened so that it can be stored in the receptacle space of the box for ease of transport, the collapsible base can be removed from the receptacle space of the box, the collapsible base can be selectively configured to the second configuration in which the base is erect for supporting the table, and each of the at least one head of the top end of the collapsible base can inserted into one of the at least one aperture of the bottom surface of the box, and the top surface of the box can be up righted allowing the top surface to be a table top.
[0076] Additionally, the at least one aperture 24 comprises a plurality of apertures and the top end of the collapsible base may have a plurality of heads corresponding in number and pattern of distribution to the number and pattern of distribution of the plurality of apertures, as shown in FIG. 19 .
[0077] Furthermore, as best shown in FIG. 21 , each of the plurality of heads 50 has sufficient height to enter the passageway 25 and extend to an underside 14 a of the top surface 14 of the box 4 . Moreover, access to the structure for supporting the table for removal from the receptacle space inside the box is preferably through a closeable opening in one of the top surface, the bottom surface, and the at least one side surface. An important feature is for the base to be adapted for use with the passageway 25 of the box 4 so that dependent rotation, about the centerline of the base, between the second configuration of the base 2 and box 4 exists.
[0078] An additional feature which allows the collapsible table 1 to be used conveniently for displaying and cooling bottles of wine is to provide the base with at least one slot 52 , as shown in FIG. 19 , disposed in at least one of the sides of the multi-sided sleeve 46 , for receiving a wine bottle. Moreover, the base can be filled with ice (not shown) to cool the bottle and its contents.
[0079] Preferably, the bottom end 20 of the collapsible base 2 has a plurality of feet 10 , with each of the plurality of feet being adapted for resting on an extraneous surface for supporting the collapsible table.
[0080] Another embodiment of the collapsible table comprises a structure for supporting the table and a box with a receptacle space for accessibly holding the structure for supporting the table. The structure for supporting the table will comprise a collapsible base 2 has a top end and a bottom end, with the top end of the collapsible base having a plurality of heads 50 of a predetermined height. The collapsible base will be selectively configurable between a first configuration in which base is flattened so that it can be stored and a second configuration in which the base is erect for supporting the table.
[0081] Moreover, the box has a top surface, a bottom surface, and at least one side surface, and each of the at least one side surface is disposed between the top surface and the bottom surface. The bottom surface 16 has a plurality of apertures 24 corresponding in number and pattern of distribution to the number and pattern of distribution of the plurality of heads 50 , and each of the a plurality of apertures have an open configuration defining a passageway for receiving one of the a plurality of heads of the top end of the collapsible base with each of the plurality of heads extending to an underside of the top surface of the box. The box will have a closeable opening in one of the top surface, the bottom surface, and the at least one side surface for removably access of the structure for supporting the table. The passageway of the box will be adapted for use with the base so that dependent rotation, about the centerline of the base, between the second configuration of the base and box exists.
[0082] In this way, the collapsible base can be selectively configured to the first configuration in which base is flattened so that it can be stored in the receptacle space of the box for ease of transport, the collapsible base can be removed from the receptacle space of the box, the collapsible base can be selectively configured to the second configuration in which the base is erect for supporting the table, and each of the a plurality of heads of the top end of the collapsible base can inserted into one of the a plurality of apertures of the bottom surface of the box, and the top surface of the box can be up righted allowing the top surface to be a table top.
[0083] Also methods for constructing a collapsible table 1 from a box 4 having a receptacle space 13 for accessibly holding a structure for supporting the table, a closeable opening 9 in one of a top surface 14 , a bottom surface 16 with a centrally disposed openable aperture 24 , and an at least one side surface 15 , and the structure for supporting the table, including a collapsible base 2 with a top end 22 having at least one head 10 and a bottom end 20 is taught by this important invention. The method comprises opening the closeable opening 9 in one of the top surface 14 , the bottom surface 16 , and the at least one side surface 15 of the box 4 ; removing the structure for supporting the table from the box; selectively configuring the collapsible base 2 from a first configuration in which the base is flattened for stowage to a second configuration in which the base is erect for supporting the table; opening the aperture 24 to form a passageway 25 for receiving the top end 22 of the collapsible base 2 ; and (b) inserting the top end 22 of the collapsible base into the passageway. This method is best illustrated in FIGS. 4-9 , and 10 - 14 . See also FIG. 18 for an illustration of removing the structure for supporting the table from the box through the top surface 14 of the box 4 .
[0084] The method for constructing a collapsible table may further comprise the step of supporting the bottom end of the collapsible base on a grounding surface to allow the top surface to be a upwardly disposed as a table top of the collapsible table. Moreover, the method for constructing a collapsible table may further comprise the steps of removing the top end of the collapsible base from the passageway; closing the aperture; selectively configuring the collapsible base from the second configuration in which the base is erect for supporting the table to the first configuration in which the base is flattened for stowage; opening the closeable opening; and stowing the structure for supporting the table in the receptacle space of the box.
[0085] Preferably, a method for constructing a collapsible table from a box have a receptacle space for accessibly holding a structure for supporting the table, a closeable opening in one of a top surface, a bottom surface with a centrally disposed openable aperture, and an at least one side surface, and the structure for supporting the table, including a collapsible base with a top end have at least one head and a bottom end, comprise opening the closeable opening in one of the top surface, the bottom surface, and the at least one side surface of the box; removing the structure for supporting the table from the box; selectively configuring the collapsible base from a first configuration in which the base is flattened for stowage to a second configuration in which the base is erect for supporting the table and the at least one head corresponds in number and pattern of distribution to the number and pattern of distribution of the at least one aperture; and inserting each of the at least one head into a corresponding one of the at least one aperture.
[0086] Additionally, said method for constructing a collapsible table may further comprise the step of supporting the bottom end of the collapsible base on a grounding surface to allow the top surface to be a upwardly disposed as a table top of the collapsible table.
[0087] Furthermore, said method for constructing a collapsible table may comprise the steps of removing the top end of the collapsible base from the passageway; closing the aperture; selectively configuring the collapsible base from the second configuration in which the base is erect for supporting the table to the first configuration in which the base is flattened for stowage; opening the closeable opening; and stowing the structure for supporting the table in the receptacle space of the box.
[0088] Where the at least one head of the collapsible table comprises a plurality of heads and the at least one aperture comprises a plurality of apertures corresponding in number and pattern of distribution to the number and pattern of distribution of the plurality of heads, the method for constructing a collapsible table may comprise the step of inserting each of the plurality of heads into a corresponding one of the plurality of apertures.
[0089] Lastly, the method for constructing a collapsible table may further comprise the step of opening each of the at least one aperture to form at least one passageway for receiving one of the at least one head.
[0090] While this invention has been described in connection with the best mode presently contemplated by the inventor for carrying out his invention, the preferred embodiments described and shown are for purposes of illustration only, and are not to be construed as constituting any limitations of the invention. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. Those skilled in the art will appreciate that the conception upon which this disclosure is base, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scop of the present invention.
[0091] My invention resides not in any one of these features per se, but rather in the particular combinations of some or all of them herein disclosed and claimed and it is distinguished from the prior art in these particular combinations of some or all of its structures for the functions specified.
[0092] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0093] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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An easily transportable collapsible table in which a box with a support structure inside converts to a table top with the support structure as its base. The box provides substantial structural integrity for the table top and it is easily assembled on site. The collapsible table can be disassembled, restored in the box and reused, or disposed of after a single use.
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FIELD OF THE INVENTION
[0001] The present invention relates to biocidal and antifouling aqueous solutions combining biocidal effects of low pH and active bromine.
BACKGROUND OF THE INVENTION
[0002] An undesired accumulation of organisms or organic residues in liquid volumes or on wet surfaces is controlled by a variety of methods, including mechanical treatments, modifying water concentration, applying organic and inorganic biocidal materials, changing temperature, etc. There is perpetual demand for new methods, because known methods are not always applicable, and new situations incessantly appear, as well as new or resistant contaminants. Active chlorine is popular, frequently in the form of hypochlorite alkali solutions. Alkali solutions are not always desirable, and also it was observed that active bromine is biocidally more efficient than active chlorine. It is therefore an object of the invention to provide a method for manufacturing a biocidal composition based on active bromine.
[0003] It is another object of the invention to provide means for achieving very high biocidal effect on the site of need, eventually by combining simple and available precursor.
[0004] Other objects and advantages of present invention will appear as description proceeds.
SUMMARY OF THE INVENTION
[0005] The invention provides a method for manufacturing a biocidal and antifouling composition in an aqueous mixture for treating industrial waters, comprising the steps of i) providing aqueous solution A containing HBr at a concentration of between 5 wt % and 30 wt %, and urea at a weight ratio of urea/HBr of at least 0.3; ii) providing aqueous solution B comprising NaOCl; and iii) combining said aqueous solutions A and B; wherein said weight ratio of urea/HBr is not higher than 3, and wherein said solutions A and B are combined, optionally with an amount of additional water, in such a ratio of volumes as to provide a pH lower than 6.0. Said pH is usually lower than 5, depending on the dilution of solutions A and B in the treated waters, possibly lower than 4. In concentrated mixtures, usable as stock solutions, the pH may be 3 or lower, possibly 2.5 or lower such as 2.0 or lower.
[0006] The invention relates to a method for manufacturing a biocidal and antifouling composition in an aqueous mixture, the method comprising the steps of i) providing aqueous solution A containing HBr at a concentration of between 5 wt % and 30 wt %, and urea at a weight ratio of urea/HBr of at least 0.3; ii) providing aqueous solution B containing sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOCl (as Cl2) to said HBr in said solution A of from 0.3 to 0.9; and iii) providing said aqueous mixture by combining said aqueous solutions A and B, the solutions A and B being preferably in equal volumes, with an amount of additional water; wherein said solutions A and B create an acidic pH in said aqueous mixture and active bromine in a concentration of up to 20 wt %. According to the practical needs, the invention provides aqueous solutions containing active bromine in a concentration of 12.5 wt % or less, for example 0.1-12.5 wt %, such as 2-8 wt %, or 300-1000 ppm, or 20-1000 ppm, or 20-300 ppm, or 1-20 ppm, or 1-10 ppm, or 0.1-10 ppm. In the first aspect of the invention, said amount of additional water is not higher than the quantity of solutions A and B, and said aqueous mixture has a very low pH, for example 3.0 or less, and contains a very high concentration of the biocidal species, reaching the highest value in a limiting case when said amount of additional water approaches zero. In one embodiment of the first aspect, said amount is a predetermined amount of water adjusting the concentration of the biocidal composition to a desired value, resulting in a mixture ready as a concentrated stock, for example having active bromine of between 0.1 and 20 wt %, usually between 1 and 20 wt %, for anti-fouling treatment in additional aqueous mixtures into which the stock is admixed. In the second aspect of the invention, said amount of additional water in step iii) is higher than the quantity of solutions A and B, and said aqueous mixture contains biocidal species in various dilutions sufficient to prevent or inhibit or eliminate biofouling in the mixture and on the surfaces in contact with the mixture. In one embodiment of the second aspect, said amount of additional water comprises an excess of water in a container or stream to be treated, resulting in an aqueous mixture having an acidic pH and active bromine down to 20 ppm or less, for example down to between 0.1 and 10 ppm.
[0007] The invention relates to a method for disinfection of an aqueous mixture, and for preventing or eliminating biofouling in an aqueous mixture, the mixture comprising effluent water, or waste water, or industrial or agricultural water in a container or in a circuit, comprising steps of i) admixing solution A into said aqueous mixture, wherein said solution A contains HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of from 0.3 to 3; and ii) admixing solution B into said aqueous mixture, wherein said solution B contains an oxidizer, preferably sodium hypochlorite (NaOC1) in an amount corresponding to a weight ratio of NaOCl to said HBr in said solution A of from 0.3 to 0.9; thereby creating active bromine in said mixture. The invention, in one preferred embodiment, relates to a method for disinfection of an aqueous mixture in contact with meat and poultry, and for preventing or eliminating biofouling on a surface of said meat and poultry, comprising steps of i) admixing solution A into said aqueous mixture, wherein said solution A contains HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of from 0.3 to 3; ii) admixing solution B into said aqueous mixture, wherein said solution B contains an oxidizer, preferably sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOCl to said HBr in said solution A of from 0.3 to 0.9; thereby creating active bromine in said mixture; optionally diluting any of said solutions A and B before their combining or after with pure water; and contacting said meat or poultry with said mixture.
[0008] The mixture may comprise a water bulk or a water stream, and said solutions A and B may be admixed in any order, or simultaneously. In one embodiment of the invention, one of the solutions is injected to a water system, and only after dispersing said solution and reaching essentially homogeneity, the other solution is injected to produce the biocidal composition comprising biocidal species in concentrations sufficient for disinfection and to inhibit or eliminate biofouling. The injections of the solutions may be performed simultaneously or in any order, possibly repeatedly. The volumes of injected solutions A and B will be calculated to provide for the desired final active halogen concentration in the treated water and for the desired reagent ratios. In a preferred arrangement, the volumes of solutions A and B will equal.
[0009] Without limiting themselves to any particular theory, the inventors believe that superior anti-biofouling effects of the method of the invention, result not only from the combined activities of low pH and active halogen in killing the organisms, but also from chemical effects of acidic pH on the reactions between active bromine and urea. It is noted that as far as the reagents are employed in accordance with the method of the invention, surprisingly effective antifouling results are achieved, regardless whether the reagents are incorporated into the system simultaneously or separately in any order, and regardless whether the reagents are premixed before injecting into the treated water system or incorporated separately.
[0010] The invention provides a method for manufacturing an aqueous biocidal and antifouling composition comprising the step of i) admixing hydrobromic acid (HBr) and urea into water or aqueous mixture, wherein the amount of admixed HBr corresponds to a final concentration of between 5 wt % and 30 wt %, and wherein the amount of admixed urea corresponds to a weight ratio of urea/HBr of at least 0.3 and not higher than 3; and ii) admixing sodium hypochlorite (NaOCl) directly into the solution obtained in step i) or after diluting said solution of step i) in an amount corresponding to a weight ratio of NaOCl (as Cl 2 )/HBr of between 0.3 and 0.9; thereby obtaining an aqueous solution comprising up to 20 wt % active bromine and a pH of 3.0 or less. In some embodiments, said steps i) and ii) may comprise adding additional water to solutions A and/or B before their admixing to said aqueous mixture.
[0011] Said hydrobromic acid may be added into water or into an aqueous mixture of urea, being in the form of gas or a water solution. Said urea may be added into water or into an aqueous solution of HBr, being in the form of a solid or a water solution or suspension. In a preferred embodiment of the invention, solid urea is admixed into an aqueous solution of HBr. Said NaOCl may be admixed into said water solution, comprising HBr and urea, as an alkali water solution, such as a commercially available mixture. In a preferred embodiment of the invention, said biocidal composition has a pH of 2.5 or less. In one embodiment of the invention, said urea/HBr ratio may be between 0.75 and 1.5, in other embodiment between 1.5 and 2.5. In the method according to the invention, the combined solutions A and B provide an acidic pH; the pH may be 3 or less, such as 2.5 or less, in concentrated mixtures, also usable as stock solutions, whereas in the treated containers or streams the pH may be 4 or less, or eventually 5 or less, or at very low concentrations of active halogen the pH may be 6 or less. In some embodiments of the invention, the stock solutions A and B will be employed by a skilled chemist in such a way, that preliminary mixing tests will decide the mixing ratios in order to provide the required pH.
[0012] In one aspect of the invention, provided is a method comprising the steps of i) admixing hydrobromic acid (HBr) and urea into water or aqueous mixture, wherein the amount of admixed HBr corresponds to a final concentration of between 10 wt % and 30 wt %, and wherein the amount of admixed urea corresponds to a weight ratio of urea/HBr of at least 0.3 and not more than 3, such as between 1 and 3, or between 2 and 3, thereby obtaining a solution having a pH of 0.0 or less; and ii) admixing sodium hypochlorite (NaOCl) into said aqueous mixture or into the solution obtained in step i) in an amount corresponding to a weight ratio of NaOCl (as Cl 2 )/HBr of between 0.3 and 0.9; thereby obtaining an aqueous solution comprising up to 20 wt % active bromine and a pH of 1.5 or less. In another aspect of the invention, provided is a method comprising i) admixing hydrobromic acid (HBr) and urea into water or aqueous mixture, wherein the amount of admixed HBr corresponds to a final concentration of between 5 wt % and 10 wt %, and wherein the amount of admixed urea corresponds to a weight ratio of urea/HBr of between 2 and 3, thereby obtaining a solution having a pH of 1.5 or less; and ii) admixing sodium hypochlorite (NaOCl) into said aqueous mixture or into the solution obtained in step i) in an amount corresponding to a weight ratio of NaOCl/HBr of between 0.3 and 0.9; thereby obtaining an aqueous solution comprising up to 8 wt % active bromine and a pH of 2.5 or less. In still another aspect of the invention, provided is a method comprising i) admixing hydrobromic acid (HBr) and urea into water or aqueous mixture, wherein the amount of admixed HBr corresponds to a final concentration of between 5 wt % and 15 wt %, and wherein the amount of admixed urea corresponds to a weight ratio of urea/HBr of between 0.3 and 3, thereby obtaining a solution having a pH of 1.5 or less; and ii) admixing sodium hypochlorite (NaOCl) into the solution obtained in step i) in an amount corresponding to a weight ratio of NaOCl/HBr of between 0.3 and 0.9, thereby obtaining an aqueous solution comprising up to 12.5 wt % active bromine.
[0013] In other preferred embodiment, the invention is directed to a method providing a biocidal and anti-biofouling composition for treating industrial and agricultural water and a system containing said water, possibly by creating the biocidal halogen in situ, for example by combining at least two liquid streams, one of which comprises aqueous solution of HBr and the other aqueous solution of NaOCl; preferably, one of the streams comprises aqueous solution of HBr and urea, and the other stream comprises an aqueous solution of NaOCl. The solutions may be introduced into the system consecutively in any order, or in parallel, possibly by injecting stock solutions to a tank or a circuit, whose surface needs the anti-biofouling treatment or which contains water to be treated.
[0014] In one aspect, the invention provides a method for preparing a biocidal composition comprising active bromine. In a preferred embodiment, the method comprises combining HBr, urea, and sodium hypochlorite, wherein the components may be combined in any order. Urea is preferably present in the same concentration as HBr, or in an excess, but not more than 3 weight parts of urea per 1 weight part of hydrobromic acid. Sodium hypochlorite is preferably present at a concentration lower than said HBr, but not less than 0.4 weight parts of NaOCl per 1 weight part of HBr. While keeping the above ratios, the method of the invention in one aspect provides a highly concentrated solution comprising up to 30 wt % HBr and up to 20 wt % active bromine. In another aspect of the invention, provided is an acidic biocidal solution comprising down to 10 ppm active bromine in a location where the biocidal activity is desired; in other applications the acidic biocidal solution provided according to the invention comprises down to 1 ppm active bromine in a location where the biocidal activity is desired; in some applications the acidic biocidal solution provided according to the invention comprises down to 0.1 ppm active bromine in a location where the biocidal activity is desired. Said active bromine at a low but still biocidally active concentration is prepared by diluting said highly concentrated solution or by combining diluted solutions comprising HBr, urea, and NaOCl, in any order, possibly in a batch arrangement, or in the form of several liquid streams to be combined. In another preferred embodiment, industrial water is treated by a composition according to the invention, wherein one or two of said three components are present in said industrial water before the start of the treatment, and two or one remaining components are added directly or from stock solutions to said water to be treated, thereby completing the concentrations of all three components to the ranges according to the invention, thereby creating active bromine species and treating said water.
[0015] The invention provides an aqueous biocidal and antifouling composition comprising a mixture of hydrobromic acid (HBr), urea, and a commercial oxidizer, like sodium hypochlorite (NaOCl), wherein said HBr is added to an amount corresponding to a final concentration of between 5 wt % and 30 wt % in a solution A, urea is added to an amount corresponding to a weight ratio of urea/HBr of at least 0.3 and not more than 3; and NaOCl is added to the solution A to an amount corresponding to a weight ratio of NaOCl (as Cl 2 )/HBr of between 0.3 and 0.9. The biocidal composition of the invention contains a high concentration of active bromine, up to 20 wt %. The biocidal composition of the invention exhibits a high acidity, having a pH of 3.0 or less. A biocidal composition according to the invention may act synergistically against biofouling agents by means of high active halogen combined with high acidity, having an active bromine of at least 12.5 wt % and a pH of 3 or less, such as 2.5 or less. The biocidal and antifouling composition according to the invention usually comprises, after combining solutions A and B, urea between 1 and 20 wt %, HBr between 0.5 and 10 wt %, and total chlorine between 0.4 and 8 wt %. In one embodiment, the biocidal and antifouling composition according to the invention comprises, after combining solutions A and B, HBr from 4 to 12 wt %, urea from 4 to 16 wt %, active bromine from 2 to 8 wt %, and a pH of 3.0 or less. In other embodiment, the biocidal and antifouling composition according to the invention comprises HBr from 4 to 12 wt %, urea from 4 to 16 wt, total chlorine from 1 to 4 wt %, and a pH of 3.0 or less. The amounts in wt % relate to the initial quantities in gram of said components per 100 gram of the final composition. This disregards the chemical changes that occur, but a skilled person understands that initial urea is at least partially converted to bromourea, initial active chlorine to sodium chloride, etc.
[0016] The invention is directed to a method of cleaning, and a method of disinfecting, and a method of preventing/removing biofilm accumulation, in industrial and agricultural equipments, comprising contacting the surfaces or volumes to be cleaned with an aqueous composition containing a high active halogen and high acidity.
[0017] In a preferred aspect, the invention provides a method for manufacturing a biocidal and antifouling composition in an aqueous mixture, wherein said aqueous mixture comprises industrial waters selected from cooling water, water for agricultural use, effluent water, water in paper mill process, industrial process water, production aqueous stream, irrigation water, or waste water; the method comprises steps of i) providing aqueous solution A containing HBr at a concentration of between 5 wt % and 30 wt %, and urea at a weight ratio of urea/HBr of at least 0.3 and not more than 3; ii) providing aqueous solution B containing NaOCl in an amount corresponding to a weight ratio of NaOCl (as Cl 2 ) to said HBr in said solution A of from 0.3 to 0.9; and iii) combining said aqueous solutions A and B, optionally after dilution, with said industrial waters, wherein said solutions A and B create an acidic pH in said aqueous mixture and active bromine in a concentration of between 20 ppm and 20 wt %.
[0018] The invention provides a biocidal technology and biocidal system for treating industrial waters, production aqueous streams, cooling towers, waters in pulp and paper industry, effluent waters, irrigation systems and agricultural equipments, and meat and poultry products, comprising two aqueous solutions, A and B, the former containing HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of at least 0.3 and not higher than 3, and the latter containing sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOCl (as Cl 2 ) to said HBr in said solution A of from about 0.3 to about 0.9. Said solutions in the technology and in the system according to the invention are combined to produce a biocidal composition having an acidic pH and containing active halogen of less than 20 wt %. Said solutions may be combined before or after said treatment, for example before or after contacting said treated industrial waters or other treated objects. Said solutions may be diluted with water before being combined. In one aspect, the invention provides a kit for treating industrial waters or industrial water systems, comprising two solutions, which may be combined before the intended use, solution A containing HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of at least 0.3 and not higher than 3, and solution B containing sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOCl (as Cl 2 ) to said HBr in said solution A of from about 0.3 to about 0.9.
DETAILED DESCRIPTION OF THE INVENTION
[0019] It has now been found that biologically contaminated waters can be very efficiently treated by combined effects of active halogen content at acidic pH, comprising admixing concentrated components, or a mixture thereof, into the treated water, the components being selected from urea, acid such as HBr, urea acidic salt, and an oxidizer, where the biocidal species are formed before or after contacting said components with said contaminated waters, for example in situ. For example, a commercial oxidizer, such as hypochlorite, in the presence of urea and HBr may provide the biocidal effects.
[0020] The method and the biocidal composition of the invention provide persistent killing effect and they prevent the development of biofilms even after long time periods, as experimentally demonstrated.
[0021] In a preferred embodiment, the method of the invention comprises contacting the treated volume or surface with at least two liquid streams, one of which comprises an aqueous solution of HBr with urea and the other a commercial oxidizer, such as alkali sodium hypochlorite.
[0022] The method enables to handle even the most arduous biofouling agents, while avoiding the direct use of elemental halogens, or the use of alkali solutions when desired. Simple stable stock solutions may be combined before the desired treatment, comprising, for example, stock solution of HBr mixed with urea, and stock solution of concentrated NaOCl.
[0023] It is believed that the enhanced effects of the composition according to the invention have several reasons. Urea is believed to effectively mediate the oxidizing effects by binding at least a part of the present active halogen in the form of bromourea. Unreacted HBr renders the composition strongly acidic, which by itself would neutralize a part of the biofouling agents. Synergistically, the low pH combines with the oxidizing effects of the active halogen.
[0024] The invention provides a method of treating volumes or surfaces to eliminate or prevent biofouling, while employing concentrated stock solutions of stable precursors that are able to produce biocide species on site from relatively smaller volumes. Compared with many known methods which use unstable or dangerous or environmentally damaging chemicals, the method according to the invention comprises safe transport of concentrated solutions, which are, moreover, stable on prolonged storage. The method according to the invention enables to make anti-biofouling activities more efficient at lower cost.
[0025] The invention is directed to a method providing a biocidal and anti-biofouling composition for treating any one of industrial and agricultural water, a system containing industrial and agricultural water, and meat or poultry. The invention is also directed to a process of preventing or eliminating biofouling in industrial waters, like cooling towers, in pulp and paper industry, in production aqueous streams, in effluent water, in irrigation systems and agricultural applications, in meat and poultry manufacture, or the like. The waters may be treated in static containers or in dynamic streams. In one embodiment, the stream comprises production circuits in paper mill, for example comprising pulp slurry. The treatment may be applied in an effluent to be released from an industrial process. Generally, the method and the composition of the invention are useful in treating waters which are intermediate or terminal streams in industrial and agricultural processes. The aqueous mixtures to be treated according to the invention may, for example, comprise industrial waters selected from cooling water, water for agricultural use, water in paper mill process, or waste water.
[0026] The instant method enables to lower the volumes of reagents employed in anti-biofouling treatments. Both the volumes of reagents injected into the treated waters and the volumes of stock solutions are reduced, simplifying storage, transport and handling.
[0027] The invention is directed to a biocidal technology and to its use in treating industrial waters, the technology comprising two aqueous solutions, A and B, the former containing HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of from 0.3 to about 3, the ratio preferably being at least 1, and the latter containing sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOC1 to said HBr in said solution A of from about 0.3 to 0.9; wherein said solutions are combined to produce a biocidal composition having an acidic pH and containing active halogen of less than 20 wt %. Said solutions may be combined before or after contacting said industrial waters. Said solutions may be optionally diluted with water before being combined. If a solution A contains, for example, 10 wt % HBr and 15 wt % urea, and a solution B contains 8 wt % NaOCl (as Cl 2 ), the two solutions may constitute a kit for treating industrial waters or industrial water systems, comprising two components which are combined before or during the intended use in equal volumes, or in streams having the same flow rates, with or without a third stream of water for dilution.
[0028] The invention relates to a method for making a biocidal composition for treating industrial waters, comprising i) providing aqueous solution A containing HBr at a concentration of between 5 wt % and 30 wt % and urea at a weight ratio of urea/HBr of from 0.3 to about 3, ii) providing solution B containing sodium hypochlorite (NaOCl) in an amount corresponding to a weight ratio of NaOCl to said HBr in said solution A of from about 0.3 to 0.9; and iii) combining said solutions A and B to produce a biocidal composition having an acidic pH and containing active halogen of less than 20 wt %. A person skilled in the art of biocidal compositions might replace hydrobromic acid in said solution A, partially or fully, by other suitable acid and an alternative source of bromide, for example by phosphoric or sulfuric acid in a suitable concentration and NaBr, preferably considering cheap technical grades, but in the most preferred embodiment of the invention, HBr is mainly used. A person skilled in the art of biocidal compositions might replace sodium hypochlorite in said solution B, partially or fully, by other suitable oxidant, for example by DB-DMH, BC-DMH, DB-MEH, and LiOCl, or Ca(OCl) 2 in a suitable concentration, but in the most preferred embodiment of the invention, NaOCl is mainly used.
EXAMPLES
Example 1
[0029] Solution A: In a 100 ml flask, urea was dissolved (17.05 g) in 59.05 g water, followed by the addition of 23.9 g of 48% aqueous HBr (urea 17 wt %, HBr 11.5 wt %). The pH was −0.52. Solution B: 45 g of an aqueous commercial NaOCl solution (11.2 wt % Cl 2 ). Solution A and solution B were added simultaneously during 10 min into a 500 ml round bottom flask containing water (360 g) and equipped with a magnetic stirrer. Ratio urea/HBr was about 1.5, ratio NaOC1/HBr was about 0.5. An orange solution was obtained (pH 1.25), showing an absorption at 267 nm (UV). Iodometric titration detected 2.3 wt % active bromine.
Example 2
[0030] Solution A: In a 100 ml flask, urea was dissolved (12.8 g) in 75.3 g H2O, followed by the addition of 11.95 g of 48% aqueous HBr (urea 12.8% wt %,
[0031] HBr 5.75 Wt %). The pH was 1.05. Solution B: 38.3 g of an aqueous commercial NaOC1 solution (13.2 wt % as Cl 2 ). Solution A and solution B were added simultaneously during 5 min to a 1000 ml round bottom flask containing water (870 g) and equipped with a magnetic stirrer bar. Ratio urea/HBr was about 2.2, ratio NaOCl/HBr was about 0.9. An orange solution was obtained, (pH 2.5), showing an absorption at 265-7 nm (UV). Iodometric titration detected active bromine of 0.7 wt %. The addition of water was done in order to simulate the dilution of the composition when used in streams, but more concentrated mixtures can be obtained.
Example 3
[0032] Solution A: Solid urea (174.0 g) was dissolved in water (80 g) and in an aqueous solution of 48% HBr (244.3 g; 117.3 g as pure) to obtain 584.3 g (urea-41.6% wt %, HBr-28.03% wt %). Solution B: An aqueous solution of 10.3% NaOCl (1000 g, 103 g as Cl2). The two solutions were added dropwise in parallel to obtain a yellowish solution of bromourea (1418.3 g).
Example 4
[0033] Solution A: Solid urea pure (260 g) was dissolved in an aqueous solution of aqueous 48% HBr (244.3 g, 117.3 g as pure) to obtain 584.3 g (urea-44.5%, HBr-20.07%). Solution B: An aqueous solution of 10.3% NaOCl (1000 g, 103 g as Cl2) The two solution were added dropwise in parallel to obtain a yellowish solution of biocidal efficacy (1584.3 g).
[0034] While the invention has been described using some specific examples, many modifications and variations are possible. It is therefore understood that the invention is not intended to be limited in any way, other than by the scope of the appended claims.
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The invention provides a biocidal and antifouling composition comprising hydrobromic acid, urea and sodium hypo-chloride from highly concentrated precursors and a process for manufacturing the composition.
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BACKGROUND OF THE INVENTION
This invention relates to novel structural and pharmacological analogs of prostacyclin (PGI 2 ). In particular, the present invention relates to prostacyclin-type compounds wherein the C-5 to C-6 double bond of prostacyclin is isomerized to the C-4 to C-5 position.
Prostacyclin is an endogenously produced compound in mammalian species, being structurally and biosynthetically related to the prostaglandins (PG's ). In particular, prostacyclin exhibits the following structure and atom numbering: ##STR1##
5,6-Dihydroprostacyclin exhibits the following structure and atom numbering: ##STR2##
As is apparent from inspection of formulas I and II, prostacyclin and 5,6-dihydroprostacyclin (i.e., PGI 1 ) bear a structural relationship to PGF 2 α, which exhibits the following structure and atom numbering: ##STR3##
As is apparent by reference to formula III, prostacyclin and 5,6-dihydroprostacyclin may be trivially named as a derivative of PGF-type compounds. Accordingly, prostacyclin is trivially named 9-deoxy-6,9α-epoxy-(5Z)-5,6-didehydro-PGF 1 and 5,6-dihydro prostacyclin is named 9-deoxy-6,9α-epoxy-PGF 1 . For description of the geometric stereoisomerism employed above, see Blackwood et al., Journal of the American Chemical Society 90, 509 (1968). Further, for a description of prostacyclin and its structural identification, see Johnson et al., Prostaglandins 12, 915 (1976).
For convenience, the novel prostacyclin analogs described herein will be referred to by the trivial, artrecognized system of nomenclature described by N. A. Nelson, Journal of Medicinal Chemistry, 17, 911 (1974) for the prostaglandins. Accordingly, all of the novel prostacyclin derivatives herein will be named as 9-deoxy-PGF 1 -type compounds or alternatively and preferably as PGI 1 or PGI 2 derivatives.
In the formulas above, as well as in formulas hereinafter, broken line attachments to any ring indicate substituents in "alpha" (α) configuration i.e., below the plane of such ring. Heavy solid line attachments to any ring indicate substituents in "beta" (β) configuration, i.e., above the plane of such ring. The use of wavy lines (˜) herein will represent attachment of substituents in either the alpha or beta configuration or attachment in a mixture of alpha and beta configurations.
The side-chain hydroxy at C-15 in the above formulas is in S or R configuration, as determined by the Cahn-Ingold-Prelog sequence rules. See J. Chem. Ed. 41:16 (1964). See also Nature 212, 38 (1966) for discussion of the stereochemistry of the prostaglandins, which discussion applies to the novel prostacyclin analogs herein. Further, the carboxy-terminated side chain is attached to the heterocyclic ring of PGI in either the alpha or beta configuration, which by the above convention represents the (6R) or (6S) configuration, respectively. Expressions such as C-4, C-5, C-6, C-15, and the like, refer to the carbon atom in the prostaglandin or prostacyclin analog which is in the position corresponding to the position of the same number in PGF 2 α or prostacyclin, as enumerated above.
Molecules of PGI 1 , PGI 2 , and the novel, asymmetric prostacyclin analogs each have several centers of asymmetry, and can exist in racemic (optically inactive) form and in either of the two enantiomeric (optically active) forms, i.e., the dextrorotatory and levorotatory forms. As drawn, the above formula for PGI 2 corresponds to that endogenously produced in mammalian tissues. In partuclar, refer to the stereoconfiguration at C-8 (alpha), C-9 (alpha), C-11 (alpha), and C-12 (beta) of endogenouslyproduced prostacyclin. The mirror image of the above formula for prostacyclin represents the other enantiomer. The racemic forms of prostacyclin contains equal numbers of both enantiomeric molecules, and the above formula I and its mirror image is needed to represent correctly the corresponding racemic prostacyclin.
For convenience hereinafter, use of the term prostaglandin ("PG") or prostacyclin ("PGI 2 ") will mean the optically active form of that prostaglandin or prostacyclin thereby referred to with the same absolute configuration as PGF 2 α, obtained from mammalian tissues.
The term "prostaglandin-type" or "prostacyclin-type" (PG-type or PGI-type) product, as used herein, refers to any monocyclic or bicyclic cyclopentane derivative herein which is useful for at least one of the same pharmacological purposes as the prostaglandins or prostacyclin, respectively.
The formulas as drawn herein, which depict a prostaglandin-type or prostacyclin-type product or an intermediate useful in their respective preparations, each represent the particular steroisomer of the prostaglandin-type or prostacyclin-type product which is of the same relative stereochemical configuration as a corresponding prostaglandin or prostacyclin obtained from mammalian tissues, or the particular stereoisomer of the intermediate which is useful in preparing the above stereoisomer of the prostaglandin-type or prostacyclin-type products.
The term "prostacyclin analog", as used herein, represents that stereoisomer of a prostacyclin-type product which is of the same relative stereochemical configuration as prostacyclin obtained from mammalian tissues or a mixture comprising that stereoisomer and the enantiomer thereof. In particular, where a formula is used to depict a prostacyclin-type product herein, the term "prostacyclin analog" refers to the compound of that formula or a mixture comprising that compound and the enantiomer thereof.
Subsequent to any invention disclosed herein trans-4,5-didehydro-PGI 1 was reported by Nicolaou, et al., J. C. S. Chem. Comm. 1977:331-332 and Corey, et al., JACS 99:2006-2008 (1977).
SUMMARY OF THE INVENTION
The present specification particular discloses:
I. a prostacyclin analog of the formula ##STR4## wherein Z 2 is ##STR5## wherein one p and q is the integer zero or one and the other is the integer zero;
wherein Z 1 is
(1) --(CH 2 ) g --CH 2 --CH 2 --, or
(2) --(CH 2 ) g --CH 2 --CF 2 --,
wherein g is the integer zero, one, or 2;
wherein R 8 is hydrogen, hydroxy, or hydroxymethyl;
wherein Y 1 is
(1) trans--CH═CH--,
(2) cis--CH═CH--, or
(3) --CH 2 CH 2 --,
wherein M 1 is ##STR6## wherein R 5 is hydrogen or alkyl with one to 4 carbon atoms, inclusive,
wherein L 1 is ##STR7## a mixture of ##STR8## wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro;
wherein X 1 is
(1) --COOR 1 wherein R 1 is hydrogen; alkyl of one to 12 carbon atoms, inclusive; cycloalkyl of 3 to 10 carbon atoms, inclusive; aralkyl of 7 to 12 carbon atoms, inclusive phenyl; phenyl substituted with one, two or three chloro or alkyl of one to 3 carbon atoms; phenyl substituted in the para position by ##STR9## wherein R 25 is methyl, phenyl, acetamidophenyl, benzamidophenyl, or --NH 2 ; R 26 is methyl, phenyl, --NH 2 , or methoxy; and R 27 is hydrogen or acetamido; inclusive, phenacyl, i.e., ##STR10## phenacyl substituted in the para position by chloro, bromo, phenyl, or benzamido; or a pharmacologically acceptable cation;
(2) --CH 2 OH;
(3) --ch 2 nl 2 l 3 wherein L 2 and L 3 are hydrogen or alkyl of one to 4 carbon atoms, inclusive; or
(4) --COL 4 , wherein L 4 is
(a) Amino of the formula --NR 21 R 22 ; wherein R 21 and R 22 are hydrogen; alkyl of one to 12 carbon atoms, inclusive; cycloalkyl of 3 to 10 carbon atoms, inclusive; aralkyl of 7 to 12 carbon atoms, inclusive; phenyl phenyl substituted with one, 2, or 3 chloro, alkyl of one to 3 carbon atoms, inclusive, hydroxy, carboxy, alkoxycarbonyl of one to 4 carbon atoms, inclusive, or nitro; carboxyalkyl of one to 4 carbon atoms, inclusive; carbamoylalkyl of one to 4 carbon atoms, inclusive; cyanoalkyl of one to 4 carbon atoms, inclusive; acetylalkyl of one to 4 carbon atoms, inclusive; benzoylalkyl of one to 4 carbon atoms, inclusive; benzoylalkyl substituted by one, 2, or 3 chloro, alkyl of one to 3 carbon atoms, inclusive, hydroxy, alkoxy of one to 3 carbon atoms, inclusive, carboxy, alkoxycarbonyl of one to 4 carbon atoms, inclusive, or nitro; pyridyl; pyridyl substituted by one, 2, or 3 chloro, alkyl of one to 3 carbon atoms, inclusive, or alkoxy of one to 3 carbon atoms, inclusive; pyridylalkyl of one to 4 carbon atoms, inclusive; pyridylalkyl substituted by one, 2, or 3 chloro, alkyl of one to 3 carbon atoms inclusive, hydroxy, or alkoxy of one to 3 carbon atoms, inclusive; hydroxyalkyl of one to 4 carbon atoms, inclusive; dihydroxyalkyl of one to 4 carbon atoms, and trihydroxyalkyl of one to 4 carbon atoms; with the further proviso that not more than one of R 21 and R 22 is other than hydrogen or alkyl;
(b) cycloamino selected from the group consisting of ##STR11## wherein R 21 and R 22 are as defined above; (c) carbonylamino of the formula --NR 23 COR 21 , wherein R 23 is hydrogen or alkyl of one to 4 carbon atoms and R 21 is as defined above;
(d) sulphonylamino of the formula --NR 23 SO 2 R 21 , wherein R 21 and R 22 are as defined above; or
(e) hydrazino of the formula --NR 23 R 24 , wherein R 23 is as defined above and R 24 is amino of the formula --NR 21 R 22 . as defined above, or cycloamino, as defined above;
wherein R 7 is
(1) --(CH 2 ) m --CH 3 , ##STR12## wherein m is the integer one to 5, inclusive, h is the integer zero to 3, inclusive; s is the integer zero, one, 2, or 3, and T is chloro, fluoro, trifluoromethyl, alkyl of one to 3 carbon atoms, inclusive, or alkoxy of one to 3 carbon atoms, inclusive, with the proviso that not more than two T's are other than alkyl; and the pharmacologically acceptable acid addition salts thereof when X 1 is --CH 2 NL 2 L 3 .
II. a prostacyclin analog of the formula ##STR13## wherein X 1 , Z 1 , Z 2 , p, q, R 8 , M 1 , L 1 , and R 7 are as defined above; and
wherein Y 2 is --C.tbd.C--,
and the pharmacologically acceptable acid addition salts thereof when X 1 is --CH 2 CH NL 2 L 3 .
III. a prostacyclin analog of the formula ##STR14## wherein X 1 , Z 2 , p, q, R 8 , M 1 , L 1 , and R 7 are as defined above;
wherein Z 3 is trans--CH═CH--,
wherein Y 3 is
(1) trans--CH═CH--,
(2) cis--CH═CH--,
(3) --ch 2 ch 2 --, or
(4) --C.tbd.C--
and the pharmacologically acceptable acid addition salts thereof when X 1 is --CH 2 NL 2 L 3 .
For the novel compounds herein wherein Z 1 is --(CH 2 ) g --CH 2 --CF 2 --, such compounds are referred to herein as 2,2-difluoro-PG-type compounds. Further, compounds herein wherein Z 3 is trans --CH═CH-- are named as trans-2,3 -didehydro-PG-type compounds.
When q is zero and g is one or 2, the compounds described herein are additionally named as 2a-homo-PG-type or 2a,2b-dihomo-PG-type compounds, respectively. In this event the additional methylene or ethylene group is considered for the purposes of nomenclature as though it were inserted between the carbon atoms C-2 and C-3. Further, such additional carbon atoms are denoted as C-2a and C-2b, counting from the C-2 to the C-3 carbon atoms, respectively.
When q is one and g is zero, one, or 2, the novel compounds herein are further designated as 7a-homo-PG-type, 2a,7a-dihomo- or 2a,2b,7a-trihomo-PG-type compounds respectively. In the former case, a methylene group between C-7 and the cyclopentane ring is considered to have been inserted, thereby resulting in the attachment of this ring to C-7a. In the latter cases, the rationale for the nomenclature is as described above for compounds wherein g is one or two.
Moreover, when p is one the compounds herein are referred to as 9-deoxy-6,9α-epoxymethylene-PGF 1 -type compounds.
The novel prostacyclin analogs herein wherein R 8 is hydrogen or hydroxymethyl are respectively referred to as 11-deoxy-PG-type or 11-deoxy-11-hydroxymethyl-PG-type compounds. Additionally, when Y 1 , Y 2 , or Y 3 is cis--CH═CH--, --CH 2 CH 2 --, or --C.tbd.C--, the novel compounds thereby referred to are named as 13-cis-PG-type, 13,14-dihydro-PG-type, or 13,14-didehydro-PG-type compounds, respectively.
Compounds herein wherein M 1 is ##STR15## and R 5 is alkyl are referred to as 15-alkyl-PG-type compounds.
With the exception of the 13-cis-PG-type compounds described above, all the above compounds exhibiting a hydroxy or alkoxy moiety in the beta configuration at C-15 are additionally referred to as 15-epi-PG-type compounds. For the 13-cis-PG-type compounds herein, only compounds exhibiting the hydroxy of alkoxy moiety in the alpha configuration at C-15 are referred to as 15-epi-PG-type compounds. The rationale for this system of nomenclature with respect to the natural and epimeric configurations at C-15 is described in U.S. Pat. No. 4,016,184, issued Apr. 5, 1977.
When R 7 is --(CH 2 ) m --CH 3 wherein m is as defined above, the novel compounds herein are named as 19,20-dinor-PG-type, 20-nor-PG-type, 20-methyl-PG-type or 20-ethyl-PG-type compounds when m is one, 2, 4, or 5, respectively
When R 7 is ##STR16## wherein T and s are as defined above, and neither R 3 nor R 4 is methyl, the novel compounds herein are named as 16-phenyl-17,18,19,20-tetranor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 16-(substituted phenyl)-17,18,19,20-tetrnor-PG-type compounds. When one and only one of R 3 and R 4 is methyl or both R 3 and R 4 are methyl, then the corresponding compounds wherein R 7 is as defined in this paragraph are named as 16-phenyl- or 16-(substituted phenyl)-18,19,20-trinor-PG-type; or 16-methyl-16-phenyl- or 16-methyl- or 16-(substituted phenyl)-18,19,20-trinor-PG-type compounds, respectively.
When R 7 is ##STR17## wherein T and s are as defined above, the novel compounds herein are named as 17-phenyl-18,19,20-trinor-PG-type compounds, when s is 0. When s is one, 2, or 3, the corresponding compounds are named as 17-(substituted phenyl)-18,19,20-trinor-PG-type compounds.
When R 7 is ##STR18## wherein T and s are as defined above, the novel compounds herein are named as 18-phenyl-19,20-dinor-PG-type compounds, when s is 0. When s is one, 2, or 3, the corresponding compounds are named as 18-(substituted phenyl)-19,20-dinor-PG-type compounds.
When R 7 is ##STR19## wherein T and s are as defined above, the novel compounds herein are named as 19-phenyl-20-nor-PG-type compounds, when s is 0. When s is one, 2, or 3, the corresponding compounds are named as 19-(substituted phenyl)-20-nor-PG-type compounds.
When R 7 is ##STR20## wherein T and s are as defined above, and neither R 3 nor R 4 is methyl, the novel compounds herein are named as 16-phenoxy-17,18,19,20-tetranor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 16-(substituted phenoxy)-17,18,19,20-tetranor-PG-type compounds. When one and only one of R 3 and R 4 is methyl or both R 3 and R 4 are methyl, then the corresponding compounds wherein R 7 is as defined in this paragraph are named as 16-phenoxy- or 16-(substituted phenoxy)-18,19,20-trinor-PG-type compounds or 16-methyl-16-phenoxy- or 16-substituted phenoxy)-18,19,20-trinor-PG-type compounds, respectively.
When at least one of R 3 and R 4 is not hydrogen then (except for the 16-phenoxy or 16-phenyl compounds discussed above), there are thusly described the 16-methyl-PG-type (one and only one of R 3 and R 4 is methyl), 16,16-dimethyl-PG-type (R 3 and R 4 are both methyl), 16-fluoro-PG-type (one and only one of R 3 and R 4 is fluoro), and 16,16-difluoro-PG-type (R 3 and R 4 are both fluoro) compounds For those compounds wherein R 3 and R 4 are different, the prostaglandin analogs so represented contain an asymmetric carbon atom at C-16. Accordingly, two epimeric configurations are possible: "(16S)" and "(16R)". Further, there is described by this invention the C-16 epimeric mixture: "(16RS)".
When X 1 is --CH 2 OH, --CH 2 NL 2 L 3 , or tetrazolyl, the novel compounds herein are named respectively as 2-decarboxy-2-hydroxymethyl-PG-type compounds, 2-decarboxy-2-aminomethyl-PG-type compounds, or 2-decarboxy-2-tetrazolyl-PG-type compounds.
Then X 1 is --COL 4 the novel compounds herein are named as PG-type, amides. Further when X 1 is --COOR 1 , the novel compounds herein are named as PG-type, esters and PG-type, salts when R 1 is not hydrogen.
Finally, the NOMENCLATURE TABLE herein describes the convention by which trivial names are further assigned for the novel compounds herein;
NOMENCLATURE TABLE______________________________________Z.sub.2 p q Compound type______________________________________(1) 0 0 (6S)-9-deoxy-6,9α- epoxy-trans-4,5- didehydro-PGF.sub.1 -type compounds ##STR21## 0 1 (6S)-7a-homo-9-deoxy- 6,9α-epoxy-trans-4 ,5- didehydro-PGF.sub.1 -type compounds 1 0 (6S)-9-deoxy-6,9α- epoxymethylene- trans-4,5-didehydro- PGF.sub.1 -type compounds(2) 0 0 (6R)-9-deoxy-6,9α- epoxy-trans-4,5- didehydro-PGF.sub.1 -type compounds ##STR22## 0 1 (6R)-7a-homo-9-deoxy- 6,9α-epoxy-trans,4 ,5- didehydro-PGF.sub.1 -type compounds 0 1 (6R)-9-deoxy-6,9α- epoxymethylene- trans-4,5-didehydro- PGF.sub.1 -type compounds______________________________________
Examples of alkyl of one to 12 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomeric forms thereof.
Examples of cycloalkyl of 3 to 10 carbon atoms, inclusive, which includes alkyl-substituted cycloalkyl, are cyclopropyl, 2-methylcyclopropyl, 2,2-dimethylcyclopropyl, 2,3-diethylcyclopropyl, 2-butylcyclopropyl, cyclobutyl, 2-methylcyclobutyl, 3-propylcyclobutyl, 2,3,4-triethylcyclobutyl, cyclopentyl, 2,2-dimethylcyclopentyl, 2-pentylcyclopentyl, 3-tert-butylcyclopentyl, cyclohexyl, 4-tert-butylcyclohexyl, 3-isopropylcyclohexyl, 2,2-dimethylcyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, and cyclodecyl.
Examples of aralkyl of 7 to 12 carbon atoms, inculsive, are benzyl, 2-phenethyl, 1-phenylethyl, 2-phenylpropyl, 4-phenylbutyl, 3-phenylbutyl, 2-(1-naphthylethyl), and 1-(2-naphthylmethyl).
Examples of phenyl substituted by one to 3 chloro or alkyl of one to 4 carbon atoms, inclusive, are p-chlorophenyl, m-chlorophenyl, 2,4-dichlorophenyl, 2,4,6-trichlorophenyl, p-tolyl, m-tolyl, o-tylyl, p-ethylphenyl, p-tert-butylphenyl, 2,5-dimethylphenyl, 4-chloro-2-methylphenyl, and 2,4-dichloro-3-methylphenyl.
Examples of ##STR23## wherein T is alkyl of one to 3 carbon atoms, inclusive, fluoro, chloro, trifluoromethyl, or alkoxy of one to 3 carbon atoms, inclusive; and s is zero, one, 2, or 3, with the proviso that not more than two T's are other than alkyl, are phenyl, (o-, m-, or p-)tolyl, (o-, m-, or p-)ethylphenyl, 2-ethyl-p-tolyl, 4-ethyl-o-tolyl, 5-ethyl-m-tolyl, (o-, m-, or p-)propylphenyl, 2-propyl-(o-, m-, or p-)tolyl, 4-isopropyl-2,6-xylyl, 3-propyl-4-ethylphenyl, (2,3,4-, 2,3,5-, 2,3,6-, or 2,4,5-trimethylphenyl, (o-, m-, p-)fluorophenyl, 2-fluoro-(o, m-, or p-)tolyl, 4-fluoro-2,5-xylyl, (2,4-, 2,5-, 2,6-3,4-, or 3,5-)difluorophenyl, (o-, m-, or p-)chlorophenyl, 2-chloro-p-tolyl, (3-, 4-, 5-, or 6-)chloro-o-tolyl, 4-chloro-2-propylphenyl, 2-isopropyl-4-chlorophenyl, 4-chloro-3,5-xylyl, (2,3-, 2,4-, 2,5-, 2,6-, 3,4-, or 3,5-(dichlorophenyl, 4-chloro-3-fluorophenyl, (3-, or 4-(chloro-2-fluorophenyl, o-, m-, or p-trifluoromethylphenyl, (o-, m-, or p-methoxyphenyl, (o-, m-, or p-)ethoxyphenyl, (4- or 5 -)chloro-2-methoxyphenyl, and 2,4-dichloro(5- or 6-)methylphenyl.
Examples of phenyl esters substituted in the para position (i.e. X 1 is --COOR 1 , R 1 is p-substituted phenyl) include p-acetamidophenyl ester, p-benzamidophenyl ester, p-(p-acetamidobenzamido)phenyl ester, p-(p-benzamidobenzamido)phenyl ester, p-amidocarbonylamidophenyl ester, p-acetylphenyl ester, p-benzylphenyl ester, p-amidocarbonylphenyl ester, p-methoxycarbonylphenyl ester, p-benzoyloxyphenyl ester, p-(p-acetamidobenzoyloxy)phenyl ester, and p-hydroxybenzaldehyde semicarbazone ester.
Examples of novel prostacyclin amides herein (i.e. X 1 is COL 4 ) include the following:
(1) Amides within the scope of alkylamino groups of the formula --NR 21 R 22 are methylamide, ethylamide, n-propylamide, n-butylamide, n-pentylamide, n-hexylamide, n-heptylamide, n-octylamide, n-nonylamide, n-decylamide, n-undecylamide and n-dodecylamide, and isomeric forms thereof. Further examples are dimethylamide, diethylamide, di-n-propylamide, di-n-butylamide, methylethylamide, methylpropylamide, methylbutylamide, ethylpropylamide, ethylbutylamide, and propylbutylamide. Amides within the scope of cycloalkylamino are cyclopropylamide, cyclobutylamide, cyclopentylamide, 2,3-dimethylcyclopentylamide, 2,2-dimethylcyclopentylamide, 2-methylcyclopentylamide, 3-tert-butylcyclopentylamide, cyclohexylamide, 4-tert-butylcyclohexylamide, 3-isopropylcyclohexylamide, 2,2-dimethylcyclohexylamide, cycloheptylamide, cyclooctylamide, cyclononylamide, cyclodecylamide, N-methyl-N-cyclobutylamide, N-methyl-N-cyclopentylamide, N-methyl-N-cyclohexylamide, N-ethyl-N-cyclopentylamide, N-ethyl-N-cyclohexylamide, dicyclopentylamide, and dicyclohexylamide. Amides within the scope of aralkylamino are benzylamide, 2-phenylethylamide, 2-phenylethylamide, N-methyl-N-benzylamide, and dibenzylamide. Amides within the scope of substituted phenylamino are p-chloroanilide, m-chloroanilide, 2,4-dichloroanilide, 2,4,6-trichloroanilide, m-nitroanilide, p-nitroanilide, p-methoxyanilide, 3,4-dimethoxyanilide, 3,4,5-trimethoxyanilide, p-hydroxymethylanilide, p-methylanalide, m-methylanilide, p-ethylanilide, t-butylanilide, p-carboxyanilide, p-methoxycarbonylanilide, o-carboxyanilide and o-hydroxyanilide. Amides within the scope of carboxyalkylamino are carboxymethylamide, carboxyethylamide, carboxypropylamide, and carboxybutylamide. Amides within the scope of carbamoylalkylamino are carbamoylmethylamide, carbamoylethylamide, carbamoylpropylamide, and carbamoylbutylamide. Amides within the scope of cyanoalkylamino are cyanomethylamide, cyanoethylamide, cyanopropylamide, and cyanobutylamide. Amides within the scope of acetylalkylamino are acetylmethylamide, acetylethylamide, acetylpropylamide, and acetylbutylamide. Amides within the scope of benzoylalkylamino are benzoylmethylamide, benzoylethylamide, benzoylpropylamide, and benzoylbutylamide. Amides within the scope of substituted benzoylalkylamino are p-chlorobenzoylmethylamide, m-chlorobenzoylmethylamide. 2,4-dichlorobenzoylmethylamide, 2,4,6-trichlorobenzoylmethylamide, m-nitrobenzoylmethylamide, p-nitrobenzoylmethylamide, p-methoxybenzoylmethylamide,2,4-dimethoxybenzoylmethylamide, 3,4,5-trimethoxybenzoylmethylamide, p-hydroxymethylbenzoylmethylamide, p-methylbenzoylmethylamide, m-methylbenzoylmethylamide, p-ethylbenzoylmethylamide, t-butylbenzoylmethylamide, p-carboxybenzoylmethylamide, m-methoxycarbonylbenzoylmethylamide, o-carboxybenzoylmethylamide, o-hydroxybenzoylmethylamide, p-chlorobenzoylethylamide, m-chlorobenzoylethylamide, 2,4-dichlorobenzoylethylamide, 2,4,6-trichlorobenzoylethylamide, m-nitrobenzoylethylamide, p-nitrobenzoylethylamide, p-methoxybenzoylethylamide, p-methoxybenzoylethylamide, 2,4-dimethoxybenzoylethylamide, 3,4,5-trimethoxybenzoylethylamide, p-hydroxymethylbenzoylethylamide, p-methylbenzoylethylamide, m-methylbenzoylethylamide, p-ethylbenzoylethylamide, t-butyl-benzoylethylamide, p-carboxybenzoylethylamide, m-methoxycarbonylbenzoylethylamide, o-carboxybenzoylethylamide, o-hydroxybenzoylethylamide, p-chlorobenzoylpropylamide, m-chlorobenzoylpropylamide, 2,4-dichlorobenzoylpropylamide, 2,4,6-trichlorobenzoylpropylamide, m-nitrobenzoylpropylamide, p-nitrobenzoylpropylamide, p-methoxybenzoylpropylamide, 2,4-dimethoxybenzoylpropylamide, 3,4,5-trimethoxybenzoylpropylamide, p-hydroxymethylbenzoylpropylamide, p-methylbenzoylpropylamide, m-methylbenzoylpropylamide, p-ethylbenzoylpropylamide, t-butylbenzoylpropylamide, p-carboxybenzoylpropylamide, m-methoxycarbonylbenzoylpropylamide, o-carboxybenzoylpropylamide, o-hydroxybenzoylpropylamide, p-chlorobenzoylbutylamide, m-chlorobenzoylbutylamide, 2,4-dichlorobenzoylbutylamide, 2,4,6-trichlorobenzoylbutylamide, m-nitrobenzoylmethylamide, p-nitrobenzoylbutylamide, p-methoxybenzoylbutylamide, 2,4-dimethoxybenzoylbutylamide, 3,4,5-trimethoxybenzoylbutylamide, p-hydroxymethylbenzoylbutylamide, p-methylbenzoylbutylamide, m-methylbenzoylbutylamide, p-ethylbenzoylbutylamide, t-butylbenzoylbutylamide, p-carboxybenzoylbutylamide, m-methoxycarbonylbenzoylbutylamide, o-carboxybenzoylbutylamide, o-hydroxybenzoylmethylamide. Amides within the scope of pyridylamino are α-pyridylamide, β-pryidylamide, and γ-pryidylamide. Amides within the scope of substituted pyridylamino are 4-methyl-α-pyridylamide, 4-methyl-β-pyridylamide, 4-chloro-α-pyridylamide, and 4-chloro-β-pyridylamide. Amides within the scope of pyridylaklylamino are α-pyridylmethylamide, β-pyridylmethylamide, γ-pyridylmethylamide, α-pyridylethylamide, β-pyridylethylamide, γ-pyridylethylamide, α-pyridylpropylamide, β-pyridylpropylamide, γ-pyridylpropylamide, α-pyridylbutylamide, β-pyridylbutylamide, and γ-pyridylbutylamide. Amides within the scope of substituted pyridylalkylamino are 4-methyl-α-pyridylmethylamide, 4-methyl-β-pyridylmethylamide, 4-chloropyridylmethylamide, 4-chloro-β-pyridylmethylamide, 4-methyl-α-pyridylethylamide, 4-methyl-β-pyridylethylamide, 4-chloropyridylethylamide, 4-chloro-β-pyridylethylamide, 4-methyl-α-pyridylpropylamide, 4-methyl-β-pyridylpropylamide, 4-chloro-pyridylpropylamide, 4-chloro-β-pyridylpropylamide, 4-methyl-β-pyridylbutylamide, 4-methyl-α-pyridylbutylamide, 4-chloropyridylbutylamide, 4-chloro-β-pyridylbutylamide, 4-methyl-β-pyridylbutylamide. Amides within the scope of hydroxyalkylamino are hydroxymethylamide, α-hydroxyethylamide, β-hydroxyethylamide, α-hydroxypropylamide, β-hydroxypropylamide, γ-hydroxypropylamide, 1-(hydroxymethyl)ethylamide, 1-(hydroxymethyl)propylamide, (2-hydroxymethyl)propylamide, and α,α-dimethyl-β-hydroxyethylamide. Amides within the scope of dihydroxyalkylamino are dihydroxymethylamide, α,α-dihydroxyethylamide, α,β-dihydroxyethylamide, β,β-dihydroxyethylamide, α,α-dihydroxypropylamide, α,β-dihydroxypropylamide, α,γ-dihydroxypropylamide, β,β-dihydroxypropylamide, β,γ-dihydroxypropylamide, γ,γ-dihydroxypropylamide, 1-(hydroxymethyl)2-hydroxyethylamide, 1-(hydroxymethyl)-1-hydroxyethylamide, α,α-dihydroxybutylamide, α,β-dihydroxybutylamide, α,γ-dihydroxybutylamide, α,δ-dihydroxybutylamide, β,β-dihydroxybutylamide, β,γ-dihydroxybutylamide, β,δ-dihydroxybutylamide, γ,γ-dihydroxybutylamide, γ,δ-dihydroxybutylamide, δ,δ-dihydroxybutylamide, and 1,1-bis(hydroxymethyl)ethylamide. Amides within the scope of trihydroxyalkylamino are tris(hydroxymethyl)methylamide and 1,3-dihydroxy-2-hydroxymethyl-propylamide.
(2) Amides within the scope of the cycloamino groups described above are pyrrolidylamide, piperidylamide, morpholinylamide, hexamethyleneiminylamide, piperazinylamide, pyrrolinylamide, and 3,4-didehydropiperidinylamide.
(3) Amides within the scope of carbonylamino of the formula --NR 23 COR 21 are methylcarbonylamide, ethylcarbonylamide, phenylcarbonylamide, and benzylcarbonylamide. Amides within the scope of sulfonylamino of the formula --NR 23 SO 2 R 21 are methylsulfonylamide, ethylsulfonylamide, phenylsulfonylamide, p-tolylsulfonylamide, benzylsulfonylamide.
(4) Hydrazides within the scope of the above hydrazino groups are hydrazine, N-aminopiperidine, benzoylhydrazine, phenylhydrazine, N-aminomorpholine, 2-hydroxyethylhydrazine, methylhydrazine, 2,2,2-hydroxyethylhydrazine and p-carboxyphenylhydrazine.
The term "pharmacologically acceptable acid addition salt" refers to those known acid addition salts of amine-containing compounds which are relatively non-toxic and readily acceptable to the host animal. Especially preferred are those acid addition salts which facilitate pharmaceutical formulation (e.g., more readily crystalline, etc.) or are readily and easily available for use. In particular, examples of acids from which such salts may be prepared are hydrochloric acid, hydrobromic acid, sulphuric acid, phosphoric acid, and other acids such as tartaric acid, fumaric acid, maleic acid, methanesulfonic acid, and p-toluene sulfonic acid.
The term "pharmacologically acceptable cation" refers to those pharmacologically acceptable salts of the prostacyclin-type carboxylic acids (X 1 is --COOH) described above which are conventionally employed with prostaglandins. In particular, such pharmacologically acceptable salts include pharmacologically acceptable metal cations, amine cations, and quarternary amonium cations. Additionally, basic amino acids such as arginine and lysine are employed. Further, certain amine cations such as THAM [tris(hydroxymethyl)amino methyl] and adamanamine are especially useful for the present purposes. Additionally, U.S. Pat. No. 3,016,184, issued Apr. 5, 1977 (particularly column 29), describes salts which are likewise preferred for the present purposes.
The novel prostacyclin analogs disclosed herein produce smooth muscle stimulation.
Accordingly, the novel prostacyclin analogs disclosed herein are used as agents in the study, prevention, control, and treatment of diseases, and other undesirable physiological conditions, in mammals, particularly humans, valuable domestic animals, pets, zoological specimens, and laboratory animals (e.g., mice, rats, rabbits and monkeys).
The novel prostacyclin analogs herein are extremely potent in causing stimulation of smooth muscle, and are also highly active in potentiating other known smooth muscle stimulators, for example, oxytocic agents, e.g., oxytocin, and the various ergot alkaloids including derivatives and analogs thereof. Therefore, they are useful in place of or in combination with less than usual amounts of these known smooth muscle stimulators, for example, to relieve the symptoms of paralytic ileus, or to control or prevent atonic uterine bleeding after abortion or delivery, to aid in expulsion of the placenta, and during the puerperium. For the latter purpose, the compound is administered by intravenous infusion immediately after abortion or delivery at a dose in the range about 0.01 to about 50 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, subcutaneous, or intramuscular injection or infusion during puerperium in the range 0.01 to 2 mg. per kg. of body weight per day, the exact dose depending on the age, weight and condition of the patient or animal.
The novel prostacyclin analogs herein are thus surprisingly and unexpectedly useful for pharmacological purposes, rendering these compounds pharmacological as well as structural analogs of prostacyclin. Moreover, the prostacyclin analogs herein exhibit a more prolonged chemical stability, facilitating their formulation and use as pharmacological agents.
Further, the novel prostacyclin analogs of the present invention where X 1 is --COOR 1 or --COL 4 and of the 15α-hydroxy configuration ##STR24## are useful as antithrombotic, antiulcer, antiasthma, and antidermatosis agents, as indicated below:
(a) Platelet Aggregation Inhibition.
These novel prostaglandin analogs are useful whenever it is desired to inhibit platelet aggregation, to reduce the adhesive character of platelets, or to remove or prevent the formation of thrombi in mammals, including man. For example, these compounds are useful in the treatment and prevention of myocardial infarcts, to treat and prevent post-operative thrombosis, to promote patency of vascular grafts following surgery, and to treat conditions such as atherosclerosis, arteriosclerosis, blood clotting defects due to lipemia, and other clinical conditions in which the underlying etiology is associated with lipid imbalance or hyperlipidemia. Other in vivo applications include geriatric patients to prevent cerebral ischemic attacks and long term prophylaxis following myocardial infarcts and strokes. For these purposes, these compounds are administered systemically, e.g., intravenously, subcutaneously, intramuscularly, and in the form of sterile implants for prolonged action. For rapid response, especially in emergency situations, the intravenous route of administration is preferred. Doses in the range about 0.01 to about 10 mg. per kg. of body weight per day are used, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
The preferred dosage form for these compounds is oral, although other non-parenteral routes (e.g., buccal, rectal, sublingual) are likewise employed in preference to parenteral routes. Oral dosage forms are conventionally formulated (tablets, capsules, et cetera) and administered 2 to 4 times daily. Doses in the range of about 0.05 to 100 mg./kg. of body weight per day are effective.
The addition of these compounds to whole blood provides in vitro applications such as, storage of whole blood to be used in heart-lung machines. Additionally whole blood containing these compounds can be circulated through organs, e.g. heart and kidneys, which have been removed from a donor prior to transplant. They are also useful in preparing platelet rich concentrates for use in treating thrombocytopenia, chemotherapy, and radiation therapy. In vitro applications utilize a dose of 0.001-1.0 μg/ml of whole blood.
(b) Gastric Secretion Reduction.
These novel prostacyclin analogs are also useful in mammals, including man and certain useful animals, e.g., dogs and pigs, to reduce and control gastric secretion, thereby reduce or avoid gastrointestinal ulcer formation, and accelerate the healing of such ulcers already present in the gastrointestinal tract. For this purpose, these compounds are injected or infused intravenously, subcutaneously, or intramuscularly in an infusion dose range about 0.1 μg. to about 20 μg. per kg. of body weight per minute, or in a total daily dose by injection or infusion in the range about 0.01 to about 10 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
Preferably, however, the novel prostacyclin analogs are administered orally or by other nonparenteral routes. As employed orally, one to 6 administrations daily in a dosage range of about 1.0 to 100 mg./kg. of body weight per day is employed. Once healing of the ulcers has been accomplished the maintenance dosage required to prevent recurrence is adjusted downward so long as the patient or animal remains asymptomatic.
(c) NOSAC-Induced Lesion Inhibition. These novel prostacyclin analogs herein are also useful in reducing the undesirable gastrointestinal effects resulting from systemic administration of anti-inflammatory prostaglandin synthetase inhibitors, and are used for that purpose by concomitant administration of the prostaglandin derivative and the anti-inflammatory prostaglandin synthetase inhibitor. See Partridge et al., U.S. Pat. No. 3,781,429, for a disclosure that the ulcerogenic effect induced by certain non-steroidal anti-inflammatory agents in rats is inhibited by concomitant oral administration of certain prostaglandins. Accordingly these novel prostacyclin analogs herein are useful, for example, in reducing the undesirable gastrointestinal effects resulting from systemic administration of indomethacin, phenylbutazone, and aspirin. These are substances specifically mentioned in Partridge et al. as non-steroidal, anti-inflammatory agents. These are also known to be prostaglandin synthetase inhibitors.
The anti-inflammatory synthetase inhibitor, for example indomethacin, aspirin, or phenylbutazone is administered in any of the ways known in the art to alleviate an inflammatory condition, for example, in any dosage regimen and by any of the known routes of systemic administration.
(d) Bronchodilation. (Antiasthma) These novel prostacyclin analogs are also useful in the treatment of asthma. For example, these compounds are useful as bronchodilators or as inhibitors of mediators, such as SRS-A, and histamine which are released from cells activated by an antigen-antibody complex. Thus, these compounds control spasm and facilitate breathing in conditions such as bronchial bronchitis, bronchiectasis, pneumonia and emphysema. For these purposes, these compounds are administered in a variety of dosage forms, e.g., orally in the form of tablets, capsules, or liquids; rectally in the form of suppositories; parenterally, subcutaneously, or intramuscularly, with intravenous administration being preferred in emergency situations; by inhalation in the form of aerosols or solutions for nebulizers; or by insufflation in the form of powder. Doses in the range of about 0.01 to 5 mg. per kg. of body weight are used 1 to 4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. For the above use these prostacyclin analogs can be combined advantageously with other anti-asthmatic agents, such as sympathomimetics (isoproterenol, phenylephrine, ephedrine, etc.); xanthine derivatives (theophylline and aminophylline); and corticosteroids (ACTH and prednisolone).
These compounds are effectively administered to human asthma patients by oral inhalation or by aerosol inhalation. For administration by the oral inhalation route with conventional nebulizers or by oxygen aerosolization it is convenient to provide the instant active ingredient in dilute solution, preferably at concentrations of about 1 part of medicament to form about 100 to 200 parts by weight of total solution. Entirely conventional additives may be employed to stabilize these solutions or to provide isotonic media, for example, sodium chloride, sodium citrate, citric acid, sodium bisulfite, and the like can be employed. For administration as a self-propelled dosage unit for administering the active ingredient in aerosol form suitable for inhalation therapy the composition can comprise the active ingredient suspended in an inert propellant (such as a mixture of dichlorodifluoromethane and dichlorotetrafluoroethane) together with a co-solvent, such as ethanol, flavoring materials and stabilizers. Instead of a co-solvent there can also be used a dispensing agent such as oleyl alcohol. Suitable means to employ the aerosol inhalation therapy technique are described fully in U.S. Pat. No. 2,868,691 for example.
(e) Dermatosis Reversal.
These novel prostacyclin analogs are useful for treating proliferating skin diseases of man and domesticated animals, including psoriasis, atopic dermatitis, non-specific dermatitis, primary irritant contact dermatitis, allergic contact dermatitis, basal and squamous cell carcinomas of the skin, lamellar ichthyosis, epidermolytic hyperkeratosis, premalignant sun-induced keratosis, non-malignant keratotis, acne, and seborrheic dermatitis in humans and atopic dermatitis and mange in domesticated animals. These compounds alleviate the symptoms of these proliferative skin diseases: psoriasis, for example, being alleviated when a scale-free psoriasis lesion is noticeably decreased in thickness or noticeably, but incompletely cleared, or completely cleared.
For these purposes, these compounds are applied topically as compositions including a suitable pharmaceutical carrier, for example as an ointment, lotion, paste, jelly, spray, or aerosol, using topical bases such as petrolatum, lanolin, polyethylene glycols, and alcohols. These compounds, as the active ingredients; constitute from about 0.1% to about 15% by weight of the composition, preferably from about 0.5% to about 2%. In addition to topical administration, injection may be employed, as intradermally, intra- or peri-lesionally, or subcutaneously, using appropriate sterial saline compositions.
Within the scope of the novel prostacyclin analogs described above, certain compounds are preferred in that they exhibit increased potency, selectivity of action, or otherwise represent especially convenient and useful agents.
Accordingly, preferred compounds are those wherein p and q are the integer zero. Further, with respect to Z 1 , preferred compounds are those wherein Z 1 is --(CH 2 ) g --CH 2 --CH 2 --. Further, g is preferably the integer zero or 2, most preferably being zero. With respect to the Y 1 moiety, preferred compounds are those wherein Y 1 is trans--CH═CH-- or --CH 2 CH 2 --, the most especially preferred compounds being those wherein Y 1 is trans--CH═CH--. With respect to the M 1 moiety, preferred compounds are those wherein M 1 is ##STR25## R 5 is preferably hydrogen, methyl, or ethyl, most preferably being hydrogen or methyl.
With respect to the L 1 moiety, those compounds wherein R 3 and R 4 are the same are preferred. Further preferred are those compounds herein wherein at least one of R 3 , R 4 , and R 5 is hydrogen. In the event Y 1 , Y 2 , or Y 3 is cis--CH═CH-- or --C.tbd.C--, compounds wherein R 3 , R 4 , and R 5 are all hydrogen are preferred.
With respect to the integers m, h, and s, it is preferred that m be the integer 3, h be the integer zero or one and s be the integer zero or one. Further, T is preferably chloro, fluoro, or trifluoromethyl.
Further preferred are the carboxylic acids or derivatives, i.e., esters, especially the p-substituted phenyl esters, and amides. With respect to the novel amides herein, preferred compounds are those wherein R 21 and R 22 are preferably hydrogen or alkyl of one to 8 carbon atoms, inclusive, being the same or different, preferably with the total number of carbon atoms in R 21 and R 22 being less than or equal to 8. More especially preferred are those amides wherein R 21 and R 22 are hydrogen or alkyl of one to 4 carbon atoms, inclusive, being the same or different, with the total number of carbon atoms in R 21 and R 22 being less than or equal to 4. Further, R 23 is preferably hydrogen.
The charts herein describe the method by which the novel prostacyclin analogs herein are prepared from known or readily synthesized starting materials.
With respect to these charts, p, q, L 1 , M 1 , X 1 , X 2 , X 3 , Y 1 , Y 3 , Z 1 , Z 2 , Z 3 , R 1 , R 7 , and R 8 are as defined above.
R 36 is --OR 10 , --CH 2 OR 10 , or hydrogen, wherein R 10 is a readily acid hydrolyzable blocking group such as tetrahydrofuranyl or tetrahydropyranyl. For examples of blocking groups especially contemplated by the present invention see U.S. Pat. No. 4,016,184, issued Apr. 5, 1977. R 38 is --OSi(G 1 ) 3 , --CH 2 OSi(G 1 ) 3 , or hydrogen, where --Si(G 1 ) 3 are silyl groups, particularly those described in U.S. Pat. No. 4,016,184.
Further, X 2 is --COOR 11 , --CH 2 OR 10 , or --COL 4 , wherein R 11 is an ester within the scope of R 1 , wherein R 1 is defined above and R 10 and L 4 are as defined above. M 6 is ##STR26## and M 7 is ##STR27## wherein R 5 , --Si(G 1 ) 3 , and R 10 are as defined above.
Y 4 is trans--CH═C(Hal), wherein Hal is chloro, bromo, or iodo. Ac is acetyl and SePh is phenylselenyl.
X 3 is --COOR 11 , --CH 2 OH, --COL 4 , wherein R 11 and L 4 are as defined above.
With respect to Chart A a method is provided whereby the formula XXI PGF 2 α (q is zero) or cis-4,5-didehydro-PGF 2 α (q is one) compound is transformed to the novel prostacyclin analogs of formula XXIII.
The various formula XXI compounds employed as starting materials in the present synthesis are conveniently prepared from known or readily available starting materials. Formula XXI encompasses compounds deoxygenated at C-11 (11-deoxy-PG-type compounds) or substituted at C-11 by an hydroxymethyl in place of the hydroxy (11-deoxy-11-hydroxymethyl-PG-type compounds). These compounds are prepared by methods known in the art from corresponding PGA 2 - or cis-4,5-didehydro PGA 1 -type compounds. Such PGA 2 - or cis-4,5-didehydro-PGA 1 -type compounds are conveniently prepared by acid dehydration of the corresponding PGE 2 - or cis-4,5-didehydro-PGE 1 -type compounds referred to above. Thus, all of the various compounds within the scope of formula XXI represent either known prostaglandin analogs or can be readily prepared by employment of conventional chemical reactions on known prostaglandin type starting materials.
By a variation of the procedure of Chart A, the formula XXI PGF 2 α or cis-4,5-didehydro-PGF 1 α compounds depicted therein are in mono- or bis-etherated form, whereby the respective hydroxyls, except for the C-9 hydroxy are transformed to corresponding ether derivatives. Ether groups are selected from those R 10 blocking groups known to be successfully and conventionally employed in this synthesis of prostaglandin type products from various intermediates, being readily hydrolyzable from the formula XXIII product under acid conditions. Most particularly, tetrahydrofuranyl is a convenient and readily available moiety employed for such purposes. ##STR28##
With respect to Chart A, the formula XXI PGF 2 α- or 9-deoxy-9α-hydroxymethyl PGF 2 -type compounds is transformed to the formula XXIII prostacyclin analogs herein by acetylpalladiocyclization, yielding the formula XXII bicyclic intermediate, followed by elimination, yielding the formula XXIII product.
With respect to this two step procedure outlined above, preferred reaction solvents are lower alkanol, particularly methanol but including, for example, isopropanol and tert-butanol. Further, the cyclization/elimination is ordinarily complete within several hours, the reaction being run for convenience at 0°-50° C.
The two step cyclization/elimination described above is also undertaken by the procedure described in Nicolaou, et al. J.C.S. Chem. Communications 1977: 331-332, wherein a phenylselenocyclization is followed by elimination in anhydrous potassium carbonate and methanol, yields the formula XXIII product.
By an optional and preferred procedure according to Chart A, the formula XXI or formula XXII 11,15-bis(ethers) according to R 10 are employed in place of the free hydroxy compounds therein, yielding on elimination an etherified formula XXIII product. By this optional and preferred procedure, the R 10 ethers are thereafter hydrolyzed under mild acetic conditions (tetrahydrofuran in aqueous acetic acid), yielding the formula XXIII product.
The etherified compounds corresponding to formula XXI are obtained by methods known in the art or are themselves known in the art and the etherified compounds corresponding to formula XXII are prepared by methods known in the art. See the references referred to above with respect to such R 10 ethers.
Chart B provides a method whereby the formula XXXI PGF 2 α-type compound is transformed to the various formula XXXV 4,5,13,14-tetradehydro-PGI 1 -type products of the present invention.
The formula XXXII compound of Chart B is prepared from the formula XXXI compound by halocyclization. When Hal of the formula XXXII compound is iodo, this halocyclization proceeds by reacting the formula XXXI compound with potassium iodide or an alkali metal carbonate or bicarbonate in an organic system containing iodide. In the latter case, solvents such as methylene chloride are employed. Further, reaction temperatures at or below ambient temperature, preferably about 0° C. are employed. The reaction is then quenched by addition of sodium sulfate and sodium carbonate, yielding the formula XXXII iodo compound. When Hal is bromo, a convenient brominating agent is N-bromosuccinimide. Solvents such as methylene chloride are employed and the reaction proceeds at between 0° and ambient temperature to completion. When recovery of pure formula XXXII product is desired, chromatographic methods for its isolation in pure form are employed. High pressure liquid chromatography is an especially useful technique for this purpose.
The formula XXXIII compound is then prepared from the formula XXXII compound by transforming any free hydroxyls to their corresponding R 10 ethers. Methods provided in the reference above are employed in this transformation.
The formula XXXIV compound is then obtained from the formula XXXIII compound by a double dehydrohalogenation. By this method, the formula XXXIII 5,14-dihalo PG-type compound is transformed to the formula XXXIV 4,5,13,14-tetradehydro PGI 1 -type compound.
For this double dehydrohalogenation, basic conditions are employed. Preferably, dehydrohalogenation proceeds in a mixture of lower alkanol and dimethyl sulfoxide as reaction solvent and potassium tert-butoxide as base. The formula XXXIV compound thusly obtained is then hydrolyzed to the formula XXXV prostacyclin analogs herein under mild acetic conditions. For example, mixtures of tetrahydrofuran and aqueous acetic acid are employed.
Chart C provides a method whereby the 2,3,4,5-tetradehydro-prostacyclin analogs of formula XLVII-LI are prepared from the formula XLI PGF 2 α-type compound.
With respect to Chart C the formula XLII compound is prepared from the formula XLI compound by halocyclization, as described in Chart B.
This formula XLII compound is then transformed to the corresponding formula XLIII silyl ether by methods known in the art. See for example the reference provided above.
The formula XLIV compound is then prepared from the formula XLIII compound by α-phenylselenization. Accordingly, in the preparation of this phenylselenyl derivative, the formula XLIII compound is first reacted with Lithio-N-isopropylcyclohexylamine, thereby generating the C-2 anion corresponding to formula XLIII. Finally, this anion is reacted with diphenylselenide, yielding a formula XLIV compound.
Thereafter, the formula XLV compound is prepared by hydrolysis of the silyl groups, employing mild acidic conditions (e.g., the mineral acid).
The formula XLV compound is then transformed to the formula XLVI compound by dehydrophenylselenization, yielding a trans-2,3-didehydro-5-halo-PGI 1 -type intermediate.
This formula XLVI intermediate is then dehydrohalogenated to the formula XLVII compound under basic conditions, as described above. This formula XLVII ester is then saponified (e.g., potassium hydroxide in methanol), yielding the formula XLIX acid. This acid is then transformed herein by amidization to the formula L prostacyclin analogs. Further, when L 4 is NH 2 , the formula L prostacyclin amides are reduced with lithium aluminum hydride to the corresponding formula LI 2-decarboxy-2-aminomethyl compound (L 2 and L 3 are hydrogen). This 2-decarboxy-2-aminomethyl compound is then transformed to corresponding secondary and tertiary amines (either one or both of L 2 and L 3 are alkyl) by methods known in the art. See for methods of preparing the various 2-decarboxy-2-aminomethyl analogs herein the procedures of U.S. Pat. No. 4,028,350.
Alternatively, the formula XLVII compound is reduced to the formula XLVIII 2-decarboxy-2-hydroxymethyl compound by methods known in the art for the transformation of prostaglandin analogs to corresponding prostanols. Accordingly, lithium aluminum hydride reduction is employed in this transformation. See U.S. Pat. No. 4,028,419 for a description of the preparation of such C-1 alcohols for certain bicyclic prostaglandin analogs.
Finally, Chart D provides an alternative method for the preparation of the 2,3,4,5-tetradehydro PGI-type compounds herein, which comprises employing a formula LXI 2,3-didehydro-PGF 2 α-type compound according to formula LXI and thereafter halocyclizing and dehydrohalogenating this compound to the formula XLIII product. In accordance with Chart D, methods described above for halocyclization and dehydrohalogenation are employed.
According to the above charts, the novel prostacyclin analogs herein are obtained first as primary alcohols, esters, or amides. When, however, the corresponding carboxylic acids are desired, these acids are prepared by hydrolysis of the corresponding ester using conventional methods. For example, the hydrolysis proceeds by reacting the esterified form of the prostacyclin analog with base in a water-alkanol mixture. Thus, sodium hydroxide and methanol is employed to hydrolyze the ester to the corresponding sodium salt.
The pharmacologically acceptable salts of these carboxylic acids are then obtained by neutralization with a corresponding base. Conventional techniques of isolation and recovery of the salt are employed.
When the acid addition salts are desired, reaction of the prostacyclin analog with the acid corresponding to the acid addition salt to be prepared yields the desired product.
With respect to the novel PG-type amides (X 1 is -COL 4 ) and p-substituted phenyl esters (R 1 is p-substituted phenyl, such compounds are prepared as follows:
With regard to the preparation of the p-substituted phenyl esters disclosed herein, such compounds are prepared by the method described in U.S. Pat. No. 3,890,372. Accordingly, by the preferred method described therein, the p-substituted phenyl ester is prepared first by forming a mixed anhydride, particularly following the procedures described below for preparing such anhydrides as the first step in the preparation of amino and cycloamino derivatives.
This PG-type anhydride is then reacted with a solution of the phenol corresponding to the p-substituted phenyl ester to be prepared. This reaction proceeds preferably in the presence of a tertiary amine such as pyridine. When the conversion is complete, the p-substituted phenyl ester has been recovered by conventional techniques.
Having prepared the PG-type carboxylic acids, the corresponding carboxyamides are then prepared by one of several amidation methods known in the prior art. See, for example, U.S. Pat. No. 3,981,868, issued Sept. 21, 1976 for a description of the preparation of the present amino and cycloamino derivatives of prostaglandin-type free acids and U.S. Pat. No. 3,954,741, describing the preparation of carbonylamino and sulfonylamino derivatives of prostaglandin-type free acids.
The preferred method by which the present amino and cycloamino derivatives of the novel prostacyclin type free acids are prepared is, first by transformation of such free acids to corresponding mixed acid anydrides. By this procedure, the prostaglandin-type free acid is first neutralized with an equivalent of an amine base, and thereafter reacted with a slight stoichiometric excess of a chloroformate corresponding to the mixed anhydride to be prepared.
The amine base preferred for neutralization is triethylamine, although other amines (e.g., pyridine, methyldiethylamine) are likewise employed. Further, a convenient, readily available chloroformate for use in the mixed anhydride production is isobutyl chloroformate.
The mixed anhydride formation proceeds by conventional methods and accordingly the PGF-type free acid is mixed with both the tertiary amine base and the chloroformate in a suitable solvent (e.g., aqueous tetrahydrofuran), allowing the reaction to proceed at -10° to 20° C.
Thereafter, the mixed anhydride is converted to the corresponding amino or cycloamino derivative by reaction with the amine corresponding to the amide to be prepared. In the case where the simple amide (-NH 2 ) is to be prepared, the transformation proceeds by the addition of ammonia. Accordingly, the corresponding amine (or ammonia) is mixed with the mixed anhydride at or about -10° to +10° C., until the reaction is shown to be complete. For highly volatile amines, acid addition salts thereof (e.g., methylamine hydrochloride) are employed in place of the corresponding free base (e.g., methylamine).
Thereafter, the novel PGP-type amino or cycloamino derivative is recovered from the reaction mixture by conventional techniques.
The carbonylamino and sulfonylamino derivatives of the presently disclosed PG-type compounds are likewise prepared by known methods. See, for example, U.S. Pat. No. 3,954,741 for description of the methods by which such derivatives are prepared. By this known method, the prostaglandin-type free acid is reacted with a carboxyacyl or sulfonyl isocyanate, corresponding to the carbonylamino or sulfonylamino derivative to be prepared.
By another, more preferred method the sulfonylamino derivatives of the present compounds are prepared by first generating the PG-type mixed anhydride, employing the method described above for the preparation of the amino and cycloamino derivatives. Thereafter, the sodium salt of the corresponding sulfonamide is reacted with the mixed anhydride and hexamethylphosphoramide. The pure PG-type sulfonylamino derivative is then obtained from the resulting reaction mixture by conventional techniques.
The sodium salt of the sulfonamide corresponding to the sulfonylamino derivative to be prepared is generated by reacting the sulfonamide with alcoholic sodium methoxide. Thus, by a preferred method methanolic sodium methoxide is reacted with an equal molar mount of the sulfonamide. The sulfonamide is then reacted, as described above, with the mixed anhydride, using about four equivalents of the sodium salt per equivalent of anhydride. Reaction temperatures at or about 0° C. are employed.
With regard to the phenacyl or substituted phenacyl esters herein, see U.S. Pat. No. 3,979,440 for a description of their preparation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following examples and preparations.
All temperatures are in degrees centigrade.
IR (infrared) absorption spectra are recorded on a Perkin-Elmer Model 421 infrared spectrophotometer.
Except when specified otherwise, undiluted (neat) samples are used.
UV (Ultraviolet) spectra are recorded on a Cary Model 15 spectrophotometer.
NMR (Nuclear Magnetic Resonance) spectra are recorded on a Varian A-60, A-60D, or T-60 spectrophotometer in deuterochloroform solutions with tetramethylsilane as an internal standard (downfield).
Mass spectra are recorded on an CEG model 110B Double Focusing High Resolution Mass Spectrometer or an LKB Model 9000 Gas-Chromatograph-Mass Spectrometer. Trimethylsilyl derivatives are used, except where otherwise indicated.
"Brine", herein, refers to an aqueous saturated sodium chloride solution.
The A-IX solvent system used in thin layer chromatography is made up from ethyl acetate-acetic acid-2,2,4-trimethylpentane-water (90:20:50:100) according to M. Hamberg and B. Samuelsson, J. Biol. Chem. 241, 257 (1966).
Skellysolve-B (SSB) refers to mixed isomeric hexanes.
Silica gel chromatography, as used herein, is understood to include elution, collection of fractions, and combination of those fractions shown by TLC (thin layer chromatography) to contain the pure product (i.e., free of starting material and impurities).
Melting points (MP) are determined on a Fisher-Johns or Thomas-Hoover melting point apparatus.
THF refers to tetrahydrofuran.
Specific Rotations, [α], are determined for solutions of a compound in the specified solvent at ambient temperature with a Perkin-Elmer Model 141 Automatic Polarimeter.
EXAMPLE 1: trans-4.5-Didehydro-6β-PGI 1 , methyl ester (IV: X 1 is --COOCH 3 , Z 1 is --(CH 2 ) 2 --Z 2 is ##STR29## p and q are zero, R 8 is hydroxy, Y 1 is trans--CH═CH--, R 3 and R 4 of the L 1 moiety and R 5 of the M 1 moiety are all hydrogen, and R 7 is n-butyl), its 6α-isomer, and its corresponding free acid.
Refer to Chart A.
A. Molecular oxygen at ambient temperature is passed through a stirred solution of 4.7 g. of PGF 2 α, methyl ester, 11,15-bis(α-ethoxyethyl ether), 0.206 g. of palladium acetate, and 1.833 g. of copper II acetate in 46 ml. of methanol and 3.7 ml. of water for 2.5 hours. Additional palladium acetate (0.206 g.) is then added and after an additional 2.5 hours the resulting mixture is filtered through diatomaceous earth and the filter solids washed with methanol and ethyl acetate. The combined filtrate is then evaporated under reduced pressure and the residue taken up in ethyl acetate and water (100 ml. each). The aqueous layer is then extracted with ethyl acetate and the combined organic extract is then washed with brine, dried over magnesium sulfate, and concentrated to yield 5.05 g. of crude trans-4,5-didehydro-PGI 1 , methyl ester, 11,15-bis(α-ethoxyethyl ether) as a brown oil. The brown oil is then chromatographed on 500 g. of silica gel, packed and eluted with 30% ethyl acetate and Skellysolve B, yielding 2.77 g. of pure intermediate. NMR absorptions are observed at 5.85-5.2, 5.0-2.9, 3.65, and 2.4δ.
B. The reaction product of Part A (3.27 g.) in a mixture of 19 ml. of tetrahydrofuran, 38 ml. of water, and 114 ml. of ethyl acetate is heated to 40° C. for 4 hours. The resulting mixture is then diluted with 350 ml. of water and lyophilized. The residue is then dissolved in diethyl ether and washed with 1 normal aqueous potassium bicarbonate and brine. Ethereal extracts are then dried over magnesium sulfate and concentrated to yield 2.2 g. of crude trans-4,5-didehydro-PGI 1 , methyl ester as an oil. This oil is then chromatographed on 50 g. of silica gel, packed and eluted with 50% acetone in methylene chloride, yielding 2.06 g. of 6α- and 6β-epimerically mixed title product. A 1.25 g. sample of the epimeric mixture is then chromatographed on 200 g. of silica gel eluting with 30% acetone in methylene chloride, yielding a 0.46 g. sample enriched in the less polar, 6α-isomer. This 6α enriched sample is then rechromatographed on 2 silica columns in series using a 50% acetone in hexane diluent to yield 0.14 g. of pure trans 4,5-didehydro-6α-PGI 1 , methyl ester as a waxy solid. Melting point is 63°-73° C. Elemental Analysis: Found C,68.45; H, 9.57. Infrared absorptions are observed at 3500, 3420, 1735, 1720, 1315, 1260, 1210, 1080, 1050, 1025, and 970 cm -1 . The mass spectrum for the trimethylsilyl derivative exhibits a high resolution peak at 510.3183 and other peaks at 495, 479, 439, 420, 349, 323, 199, and 173. NMR absorptions are observed at 5.8-5.4, 4.45-2.7, 3.67, and 2.4δ. Silica gel TLC Rf is 0.41 in acetone and methylene chloride (1:1).
From the original chromatographic separation a 0.89 g. sample of about 90% pure trans-4,5-didehydro-6β-PGI 1 , methyl ester is rechromatographed on two silica columns in series eluting with 50% acetone in methylene chloride to yield 0.375 g. of 99% pure 6β-product and 0.359 g. of pure 6β-product as oils. NMR absorptions are observed at 5.8-5.3, 4.65-2.9, 3.63, and 2.36δ. The mass spectrum for the trimethylsilyl derivative exhibits a high resolution peak at 510.3193 and other peaks at 495, 479, 439, 420, 354, 307, and 173. Silica gel TLC Rf is 0.36 in acetone and methylene chloride (1:1).
C. The reaction product of Part B (the 6β-isomer, 0.42 g.) in 20 ml. of 95% aqueous ethanol is purged with nitrogen and 4 ml. of 1 N aqueous sodium hydroxide is added. After 2.5 hours at ambient temperature the resulting mixture is then concentrated under reduced pressure and the residue dissolved in water. The aqueous solution is then acidified with potassium bisulfate (0.6 g.) and extracted with ethyl acetate. The organic extracts are then washed with brine, dried over magnesium sulfate, concentrated to yield a colorless oil containing crude title free acid. Chromatographing on 50 g. of acid-washed silica gel packed with 20% acetone in methylene chloride and eluted with 20-60% acetone in methylene chloride yields 0.33 g. of pure title free acid as a yellow oil. The mass spectrum for the trimethylsilyl derivative exhibits high resolution peak at 568.3454 and other peaks at 553, 497, 478, 463, 407, 399, 279, 225, 199, 173, and 117.
Following the procedure of Example 1 but employing each of the various formula XXI PGF 2 α, cis-4,5-didehydro-PGF 1 α (q is 1), or 9,11-deoxy-9α-hydroxymethyl PGF 2 , compounds of formula XXI in place of PGF 2 α, methyl ester, there are prepared each of the corresponding formula XXIII trans 4,5-didehydro-6α- or 6β- PGI 1 type products as methyl esters or free acids.
EXAMPLE 2: trans-4,5,13,14-Tetradehydro-6β-PGI 1 methyl ester (Formula V: X 1 is --COOCH 3 , Z 1 is --(CH 2 ) 2 --, Z 2 is ##STR30## p and q are zero, R 8 is hydroxy, R 3 and R 4 of the L 1 moiety and R 5 of the M 1 moiety are all hydrogen, and R 7 is n-butyl) and its free acid.
Refer to Chart B.
A. A solution of 14-bromo-PGF 2 α, methyl ester (1.9 g.) in methylene chloride (30 ml.) is added to a suspension of molecular iodine (2.85 g.), potassium iodide (1.80 g.), sodium acetate (0.92 g.), and water (6 ml.). The resulting mixture is then stirred for 2 hours, treated with 2 N aqueous sodium sulfite (20 ml.), washed successively with 5% aqueous sodium bicarbonate and 5% aqueous sodium chloride, dried, and concentrated to yield 2.95 g. of crude 9-deoxy-6,9α-epoxy-5-iodo-14-bromo-PGF 1 α, methyl ester. A 0.13 g. aliquot of crude product is chromatographed on 13 g. of acid-washed silica gel, eluting with ethyl acetate and benzene (3:7), to yield 0.088 g. of pure formula XXXII product. NMR absorptions are observed at 0.89, 1.1-3.18, 3.66, 3.6-4.8, and 5.88δ. The mass spectrum for the trimethylsilyl derivative exhibits a high resolution peak at 701.1183, a molecular ion at 716, and other peaks at 645, 637, 589, 547, 529, 510, and 173. Infrared absorptions are observed at 3380, 1740, 1655, 1230, 1170, 1080, and 1050 cm -1 .
B. The reaction product of Part A (1.0 g. of crude, unchromatographed product) in methylene chloride (10 ml.) is treated with dihydropyran (3 ml.) and a 3 ml. solution of methylene chloride saturated with pyridine hydrochloride. After 20 hours the resulting mixture is then diluted with diethyl ether, washed successively with 5% aqueous sodium bicarbonate and 5% aqueous sodium chloride, dried, and concentrated to a 1.12 g. residue of 9-deoxy-6,9α-epoxy-5-iodo-14-bromo-PGF 1 α, methyl ester, 11,15-bis(tetrahydropyranol ether). NMR absorptions are observed at 0.9, 1.05-2.20, 2.2-3.2, 3.2-4.35, 3.66, 4.35-4.15, and 5.7-6.1δ. Infrared absorptions are observed at 2900, 2820, 1760, 1440, 1350, 1210, 1125, 1090, 1035, 1025, 970, and 910 cm -1 .
C. A solution of 1.1 g. of the reaction product in Part B in dimethyl sulfoxide (15 ml.) and methanol (1.5 ml) is treated with potassium tert-butoxide (0.504 g.) for 20 hours. The resulting dark solution is then diluted with water (60 ml.), cooled, acidified with 5% aqueous phosphoric acid, and extracted with diethyl ether. Ethereal extracts are then washed with brine, dried, and concentrated to yield 0.173 g. of crude trans-4,5,13,14-tetradehydro-6β PGI 1 , 11,15-bis(tetrahydropyranyl ether), which is esterified with excess ethereal diazomethane yielding the formula, XXXIV product. This crude formula XXXIV product exhibits characteristic NMR absorptions at 5.5-5.8 and 2.41δ.
D. The crude reaction product of Part C (0.168 g.) in acetic acid (6 ml.) is treated with water (3 ml.) at 40° C. for 3 hours. The resulting solution is then extracted with 250 ml. of methanol and concentrated to yield 0.106 g. of crude title methyl ester as a yellow residue. Chromatographing on 50 g. of silica gel, eluting with Skellysolve B and ethyl acetate (1:1) yielding 76.1 mg. of pure methyl ester. The mass spectrum for the trimethylsilyl derivative exhibits a high resolution peak at 508.3025 and additional peak at 421.
E. A solution of the reaction product of Part B (3 g.) in a mixture of dimethyl sulfoxide and methanol (17:3, 10 ml.) is treated with potassium tert-butoxide (1.69 g.) in the same dimethylsulfoxide-methanol mixture (35 ml.). After 14 hours additional potassium tert-butoxide (0.85 g.) is added and the reaction maintained for an additional 21 hours. The resulting mixture is then quenched by addition of 2 N aqueous sodium hydroxide (20 ml.) and water (20 ml.). After an additional 12 hours the resulting mixture is cooled, yielding a semi-solid residue which is acidified with phosphoric acid at 0° C. and extracted with ethyl acetate. The ethereal extracts are then washed with 5% aqueous sodium chloride, dried, and concentrated to yield 2.116 g. of crude trans-4,5,13,14-tetradehydro-6β-PGI 1 , 11,15-bis(tetrahydropyranyl ether). This crude title product is then chromatographed on acid-washed silica gel (170 g.) eluting with mixtures of Skellysolve B and ethyl acetate, to yield 0.3326 g. of pure bis(tetrahydropyranyl ether).
F. A solution of 0.33 g. of the reaction product of Part E in acetic acid (20 ml.) is treated with water (10 ml.) at 40° C. for 3.5 hours. The resulting mixture is then diluted with water (25 ml.) and lyophilized to a yellow residue. This residue is then chromatographed on acid-washed silica gel (60 g.) eluting with mixtures of ethyl acetate and hexane to yield 0.0925 g. of pure title free acid.
Following the procedure of Part B, there are obtained each of the various formula XXXV products from the corresponding formula a XXXI PGF-type compounds in free acid or ester form.
EXAMPLE 4: trans-4,5,13,14-Tetradehydro-15-epi-6β-PGI 1 (Formula V as in Example 2 except that the hydroxy of the M 1 moiety is in the beta configuration).
Refer to Chart B.
A. Following the procedure of Example 2, Parts A and B, 15-epi-14-bromo-PGF 2 α, methyl ester is transformed to 9-deoxy-6,9α-epoxy 5-iodo-14-bromo-15-ept-PGF 1 α, methyl ester, 11,15-bis(tetrahydropyranyl ether).
B. A solution of the reaction product of Part A (0.350 g.) is transformed according to the procedure of Example 2, Part F to 90.5 mg. of pure title product.
EXAMPLE 5: trans, trans-2,3,4,5-Tetradehydro-PGI 1 , methyl ester (Formula VI: X 1 is --COOCH 3 , p and q are zero, R 8 is hydroxy, Y 3 is trans--CH═CH--, R 3 and R 4 are the L 1 moiety and R 5 of the M 1 moiety are all hydrogen, and R 7 is n-butyl) and its free acid.
Refer to Chart C.
A. 9-Deoxy-6,9α-epoxy-5-iodo PGF 1 α, methyl ester (2 g., prepared according to procedure of Example 2, Part A from PGF 2 α, methyl ester) is dissolved in 26 ml. of tetrahydropyran at ambient temperature. Thereafter, hexamethyldisilane (4.6 ml.) is added, followed by addition of 1.2 ml. of trimethylsilyl chloride. In about 10 to 15 minutes a white precipitate forms and concentration under reduced pressure and filtration through diatomaceous earth followed by a second concentration yields 2.42 g. of 9-deoxy-6,9α-epoxy-5-iodo PGF 1 α, methyl ester, 11,15-bis(trimethylsilyl ether), a formula XLIII compound.
B. A mixture of N-isopropylcyclohexylamine in 30 ml. of tetrahydrofuran cooled to -28° C. for 15 minutes is added the reaction product of Part A (2.4 g.) in 20 ml. of tetrahydrofuran. Thereafter 1.6 molar n-butyllithium in hexane (4.7 ml.) is added and the resulting mixture stirred for 30 minutes. Thereafter diphenylselenide (1.76 g.) in 15 ml. of tetrahydrofuran is added at -78° C. and stirring is continued at this temperature for an additional hour. The resulting mixture is then allowed to warm to 0° C. and poured into ammonium chloride (150 ml.) in diethyl ether (150 ml.). Extraction with diethyl ether and washing of the ethereal extracts with water and brine, drying over sodium sulfate, and concentrating under reduced pressure yields 4.10 g. of crude 9-deoxy-6.9α-epoxy-2-phenylselenyl-5-iodo-PGF 1 α, methyl ester 11,15-bis(trimethylsilyl ether).
C. The crude reaction product of Part B (2.98 g.) is then stirred with 80 ml. of a methanol and citric acid mixture (3:1) for 30 minutes. Thereafter the solution was decanted and 50 ml. of methanol added and the resulting mixture concentrated under reduced pressure and the residue dissolved in methylene chloride, washed with water, dried, and concentrated to yield 3.81 g. of crude formula XLV product: 9-deoxy-6,9α-epoxy-2-phenylselenyl-5-iodo-PGF 1 α, methyl ester. This crude product is then purified by chromatographing on 350 g. of silica gel, eluting with acetone and methylene chloride mixtures to yield 1.87 g. of pure product.
D. Thirty percent aqueous hydrogen peroxide (3.29 g.) is added to the reaction product Part C in 65 ml. of methylene chloride at ambient temperature. Vigorous stirring is initiated for 1 hour, whereupon the layers are separated and the organic layer is washed with 5% aqueous sodium bicarbonate, saturated sodium bicarbonate, and brine. The aqueous washings are then extracted with methylene chloride and the combined organic extracts are then dried yielding 1.5 g. of crude formula XLVI compound: 9-deoxy-6,9α-epoxy trans-2,3-didehydro-5-iodo-PGF 1 α, methyl ester. This crude product is then chromatographed on 20 g. of silica gel eluting with acetone and diethyl ether (1:2) to yield 540 mg. of pure formula XLVI product. The high resolution mass spectrum for the trimethylsilyl derivative exhibits a peak at 637.1876 and other peaks are observed at 652, 749, 363, and 173.
E. Thirty-three ml. of dry benzene and 1.2 ml. of dry DBN at ambient temperature are combined with 590 mg. of the reaction product of Part D at 40° C. for 30 min. Thereafter, the reaction mixture is washed with water, dried, and concentrated to yield 497 mg. of crude title methyl ester. This crude product is then chromatographed on 60 g. of silica gel eluting with acetone and methylene chloride to yield 427 mg. of pure title methyl ester as a yellow oil. The mass spectrum exhibits a high resolution peak for this trimethylsilyl derivative at 508.3040 and other peaks are observed at 493, 477, 437, 418, 403, 347, and 328. Specific optical rotation is +51° at 5.1 g.ml. in chloroform.
F. The reaction product of Part E (100 mg.) in 3 ml. of methanol at ambient temperatures is combined with 0.95 ml. of 3 N aqueous potassium hydroxide with stirring. After 1.5 hours at ambient temperature and an additional hour at 50° C. 67 mg. of potassium t-butoxide in methanol is added and the reaction continued at ambient temperature. Thereupon a mixture of 75 ml. of ethanol and 5 ml. of 2 N aqueous potassium bisulfate is added adjusting pH to about 3. Upon addition of 20 ml. of water the organic and aqueous layers are separated and the aqueous layer is saturated with sodium chloride and extracted with ethyl acetate. The combined organic extracts are then dried and concentrated yielding 44 mg. of title free acid. The high resolution mass spectrum for the trimethylsilyl derivative exhibits a peak at 566.3282 and other peaks are observed at 551, 495, 426, 405, and 356.
Following the procedure of Example 4, the various formula XLI compounds are transformed to corresponding formula XLVII esters and formula XLVIII acids.
Further, the resulting formula XLVII acids are reduced to the corresponding formula XLVIII primary alcohols with lithium aluminum hydride and the formula XLIX esters transformed to the formula L amides by amidization methods described above. Finally, the formula L amides are reduced with lithium aluminum hydride to the corresponding formula LI primary amines which are thereafter mono or dialkylated by methods known in the art.
Likewise, the acids and esters described in and following Examples 1-4 are transformed to corresponding amides, primary alcohols, or amines as described above.
EXAMPLE 6: trans-4,5-Didehydro-6β-PGI 1 , p-phenylphenacyl ester and its 6α isomer
A. trans-4,5-Didehydro-6α-PGI 1 , 25 ml. of methyl cyanide, 1.5 g. of p-phenylphenacyl bromide and 1 ml. of diisopropylethylamine are combined at ambient temperature for 1 hr. and thereafter diluted with potassium bisulfate and ethyl acetate. The ethyl acetate extracts are then washed with brine, dried over magnesium sulfate, and concentrated to yield 0.44 g. of an oil which crystallizes on standing. Recrystallization from methyl acetate yields 0.26 g. of pure trans-4,5-didehydro-6α-PGI 1 , p-phenylphenacyl ester, 0.26 g. Melting point is 92-96° C. The mass spectrum exhibits a high resolution peak for the trimethylsilyl derivative at 690.3749 and infrared absorptions are observed at 3450, 1735, 1710, 1610, 1460, 1375, 1235, 1170, 1050, 965, 890, 835, and 765 cm -1 .
B. Following the procedure of Part A, trans-4,5-didehydro-6β-PGI 1 is transformed to 0.65 g. of crystalline 6β title product. Recrystallization from ethyl acetate and hexane yields 0.38 g. of pure 6β isomer. Melting point is 105-107° C. NMR absorptions are observed at 7.2-8.1, 5.4-5.75, 5.3, 3.5-4.7, and 0.9δ. Infrared absorptions are observed at 3450, 1740, 1715, 1615, 1460, 1375, 1240, 1170, 790, 840, 765, 725, and 690 cm -1 .
Following the procedure of the above examples, but employing the appropriate PGF 2 α-type, cis-4,5-didehydro-PGF 2 α-type or 9-deoxy-9-hydroxymethyl-PGF 2 α-type starting material, there are prepared
trans-4,5-didehydro-6α-PGI 1 -type compounds;
trans-4,5-didehydro-6α-PGI 1 -type compounds;
trans,trans-2,3,4,5-tetradehydro-6α-PGI 1 -type compounds;
trans,trans,2,3,4,5-tetradehydro-6β-PGI 1 -type compounds;
7a-homo-trans-4,5-didehydro-6α-PGI 1 -type compounds;
7a-homo-trans-4,5-didehydro-6β-PGI 1 -type compounds;
7a-homo-trans,trans-2,3,4,5-tetradehydro-6α-PGI 1 -type compounds;
7a-homo-trans,trans-2,3,4,5-tetradehydro-6β-PGI 1 -type compounds;
(6R)- or (6S)-trans-4,5-didehydro-9-deoxy-6,9α-epoxymethylene-PGF 1 -type compounds; or
(6R)- or (6S)-trans,trans-2,3,4,5-tetradehydro-9-deoxy-6,9α-epoxymethylene-PGF 1 -type compounds in free acid, amide, or ester form which exhibit the following side chain substituents:
15-Methyl;
16-Methyl;
15,16-Dimethyl-;
16,16-Dimethyl-;
16-Fluoro-;
15-Methyl-16-fluoro-;
16,16-Difluoro-;
15-Methyl-16,16-difluoro-;
17-Phenyl-18,19,20-trinor-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
17-(m-chlorophenyl)-18,19,20-trinor-;
17-(p-fluorophenyl)-18,19,20-trinor-;
15-Methyl-17-phenyl-18,19,20-trinor-;
16-Methyl-17-phenyl-18,19,20-trinor-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-;
16-Fluoro-17-phenyl-18,19,20-trinor-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-;
16-Phenyl-17,18,19,20-tetranor-;
15-Methyl-16-phenyl-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-;
16-Phenyl-18,19,20-trinor-;
15-Methyl-16-phenyl-18,19,20-trinor-;
16-Methyl-16-phenyl-18,19,20-trinor-;
15,16-Dimethyl-16-phenyl-18,19,20-trinor-;
16-Phenoxy-17,18,19,20-tetranor-;
15-Methyl-16-phenoxy-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
16-Phenoxy-18,19,20-trinor-;
15-Methyl-16-phenoxy-18,19,20-trinor-;
16-Methyl-16-phenoxy-18,19,20-trinor-;
15,16-Dimethyl-16-phenoxy-18,19,20-trinor-;
13,14-Didehydro-;
16-Methyl-13,14-didehydro-;
16,16-Dimethyl-13,14-didehydro-;
16-Fluoro-13,14-didehydro-;
16,16-Difluoro-13,14-didehydro-;
17-Phenyl-18,19,20-trinor-13,14-didehydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenyl-18,19,20-trinor-13,14,-didehydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenoxy-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
13,14-Dihydro-;
16-Methyl-13,14-dihydro-;
16,16-Dimethyl-13,14-dihydro-;
16-Fluoro-13,14-dihydro;
16,16-Difluoro-13,14-dihydro-;
17-Phenyl-18,19,20-trinor-13,14-dihydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenyl-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenoxy-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
13-cis-;
16-Methyl-13-cis-;
16,16-Dimethyl-13-cis-;
16-Fluoro-13-cis-;
16,16-Difluoro-13-cis-;
17-Phenyl-18,19,20-trinor-13-cis-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13-cis-;
17-(m-chlorophenyl)-18,19,20-trinor-13-cis;
17-(p-fluorophenyl)-18,19,20-trinor-13-cis-;
16-Methyl-17-phenyl-18,19,20-trinor-13-cis-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13-cis-;
16-Fluoro-17-phenyl-18,19,20-trinor-13-cis-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13-cis-;
16-Phenyl-17,18,19,20-tetranor-13-cis-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13-cis-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13-cis-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13-cis-;
16-Phenyl-18,19,20-trinor-13-cis-;
16-Methyl-16-phenyl-18,19,20-trinor-13-cis-;
16-Phenoxy-17,18,19,20-tetranor-13-cis-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13-cis-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13-cis-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-13-cis-;
16-Phenoxy-18,19,20-trinor-13-cis-;
16-Methyl-16-phenoxy-18,19,20,-trinor-13-cis-;
2,2-Difluoro-;
2,2-Difluoro-15-methyl-;
2,2-Difluoro-16-methyl-;
2,2-Difluoro-16,16-dimethyl-;
2,2-Difluoro-16-fluoro-;
2,2-Difluoro-16,16-difluoro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-fluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(p-fluorophenyl)-17,19,19,20-tetranor-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-
2,2-Difluoro-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-13,14-didehydro-;
2,2-Difluoro-16-fluoro-13,14-didehydro-;
2,2-Difluoro-16,16-difluoro-13,14-didehydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Diflouro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13,14-didehydro-
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-didehydro
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-13,14-dihydro-;
2,2-Difluoro-16-methyl-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-13,14-dihydro-;
2,2,16-Trifluoro-13,14-dihydro-;
2,2,16,16-Tetrafluoro-13,14-dihydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxyl)-17,18,19,20tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor 13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-13-cis-;
2,2-Difluoro-16-methyl-13-cis-;
2,2-Difluoro-16,16-dimethyl-13-cis-;
2,2,16-Trifluoro-13-cis-;
2,2,16,16-Tetrafluoro-13-cis-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13-cis-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13-cis-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13-cis-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13-cis-;
2,2-Difluoro-16-(methyl-17-phenyl-18,19,20-trinor-13-cis-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13-cis-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13-cis-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13-cis-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13-cis-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13-cis-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13-cis-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13-cis-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13-cis;
trans-2,3-Didehydro-;
trans-2,3-Didehydro-15-methyl-;
trans-2,3-Didehydro-16-methyl-;
trans-2,3-Didehydro-16,16-dimethyl-;
trans-2,3-Didehydro-16-fluoro-;
trans-2,3-Didehydro-16,16-difluoro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-phenoxy-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-;
trans-2,3-Didehydro-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-13,14-didehydro-;
trans-2,3-Didehydro-16,16-dimethyl-13,14-didehydro-;
trans-2,3-Didehydro-16-fluoro-13,14-didehydro-;
trans-2,3-Didehydro-16,16-difluoro-13,14-didehydro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
trans-2,3-didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-13,14-dihydro-;
trans-2,3-Didehydro-16,16-dimethyl-13,14-dihydro-;
trans-2,3-Didehydro-16-fluoro-13,14-dihydro-;
trans-2,3-Didehydro-16,16-difluoro-13,14-dihydro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14 -dihydro-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehdyro-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-13-cis-;
trans-2,3-Didehydro-16-methyl-13-cis-;
trans-2,3-Didehydro-16,16-dimethyl-13-cis-;
trans-2,3-Didehydro-16-fluoro-13-cis-;
trans-2,3-Didehydro-16,16-difluoro-13-cis-;
trans-2,3-Didehydro-17-phenyl-18,19,20,-trinor-13-cis-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-13,-cis-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-phenyl-18,19,20,-trinor-13-cis-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13-cis-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13-cis-;
trans-2,3-Didehydro-16-phenoxy-18,19,20,-trinor-13-cis-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13-cis-;
and their corresponding 11-deoxy-PGF 1 and 11-deoxy-11-hydroxymethyl-PGF 1 analogs.
Further following the procedures described above there is prepared the corresponding 2-decarboxy-2-hydroxymethyl type compounds by reduction of the corresponding carboxylic acid esters and the corresponding 2-decarboxy-2-aminomethyl type compound by reduction of the novel prostacyclin-type amides with lithium aluminum hydride. See especially U.S. Pat. No. 4,028,350, describing the preparation of C-1 amine and C-1 alcohol analogs of certain bicyclic prostaglandins. Further, for the above carboxylic acids, the corresponding pharmacologically acceptable salts are prepared by neutralization with the appropriate base. For the 2-decarboxy-2-aminomethyl-type compounds, pharmacologically acceptable acid addition salts are prepared by neutralization with the acid corresponding to the salt to be prepared.
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This invention relates to certain structural and pharmacological analogs of prostacyclin (PGI 2 ) wherein the C-5 to C-6 double bond is isomerized to the C-4 to C-5 position. These novel trans-4,5-didehydro-5,6-dihydro prostacyclin-type compounds are useful as smooth muscle stimulators.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention in general to the field of thread winding equipment, and in particular to a new and useful device for transferring the end of the thread of a bobbin or cop from the bobbin core to a suction hole, that is coverable by a closing member, on a spooling frame, where the starting end of the thread before transfer preferably extends into the free bobbin opening that is directed toward the device.
Spooling frame shave a plurality of bobbin receptacles arranged serially in which bobbins, particularly of the type known as cops, are inserted. The thread or the like--hereinafter the term "thread" will be used, but should not be construed limitatively--is drawn off in the spooling frame from the bobbin and wound into a new bobbin, particularly a cross-wound bobbin. In the process, the thread is check for bad spots and cleaned. Bad spots are cut out. Customarily every bobbin is situated in a holder that rotates around a central axis somewhat like a revolver and holds a plurality, five or six, for example, of bobbins. After unwinding and ejection of the empty bobbin core, this device is moved forward one position at a time. In the free recess or receptacle provided for the purpose, a new bobbin to be unwound is inserted. One end of the thread on this bobbin--referred to herein as the "starting end of the thread"--is tucked into one of the openings of the bobbin prior to insertion. During processing the bobbins assume an upright but slightly inclined position, so that they stand on one end, while the other free end points upward, generaly at a slant. The opening of this free end of the bobbin, as noted, holds the starting end of the thread.
The "rewinding" of said inserted bobbin onto a bobbin to be newly wound is accomplished completely automatically. In general, however, it is necessary for the staring end of the thread to be first brought over into a suction hole of the spooling frame. With the aid of the closing member and/or the suction draught it is held there. The segment of thread between the suction hole and the bobbin is automatically taken up by the spooling machine and wound around the new core.
SUMMARY OF THE INVENTION
The object of the invention, therefore, is to create a device of the kind described above with which the starting end of the thread can be transferred automatically from the bobbin to the suction hole of the spooling machine.
Accordingly, another object of the invention is to provide a device for transferring the starting end of a thread on a bobbin with a bobbin core having a free bobbin opening, from the free bobbin opening to a suction hole of a spooling frame carrying the bobbin, comprising a suction member having a suction duct, said suction duct being divided along its length and functioning for pneumatically connecting the free bobbin opening with the suction hole, suction member drive means connected to said suction member for moving one end of said suction duct into the proximity of the free bobbin opening and teh opposite end of said duct into the proximity of the suction hole, a closing member or element movably mounted over the suction hole for opening and closing the suction hole, actuating means connected to said closing member for moving said closing member to opening and close the suction hole, and duct opening means connected to said suction member for opening said suction duct along its divided length to permit exit of the starting end of the thread.
The suction member of this device is positioned over the free end of the bobbin, but need not necessarily enclose the corresponding end of the bobbin or core securely or tightly. It should, however, be close enough to the free end of the core that there is no difficulty in aspirating the starting end of the thread which has been tucked into the hole or free opening of the core. The starting end of the thread is then sucked in by the suction duct, one end of which is associated with the free bobbin opening and the other with the suction hole of the spooling frame. The suction draught is strong enough and the suction time long enough to unwind enough thread from the spool so that a sufficient amount of the thread can be sucked into the suction hole of the frame. Then the device must be raised by suitable means. So that the thread is not pulled out of the suction hole in the process, a crosswise outlet of the device is first opened up, through which the transferred starting end of the thread can exit. To be more precise, the starting end of the thread remains where it is, at least at first, and the device is simply moved away from the starting end of the thread. The crosswise outlet is created by dividing the suction duct in two down or along its length and moving one half of the duct away from the other. In principle it is unimportant whether one moves only one half of the duct or both at the same time. The width of the crosswise outlet should be of such a dimension that the starting end of the thread can confortably pass through it, and in particular can fall out of it by its own weight.
In a further improvement on the invention it is proposed that the suction member consist of two hinged suction member sections. In this case, the crosswise outlet is between the axis of the hinge and the free opening of the bobbin. The two sections of the suction member can pivot relative to one another, and the term "hinged" expresses the fact that the crosswise outlet is located somewhat below the axis of pivoting or the hinge axis, which axis need not necessarily be horizontal. In the embodiment shown, for instance, the hinge axis is not horizontal, but on a slant.
Another development of the invention is to have the hinge axis located at the rear end of the suction member from the standpoint of its advancing direction and to have the body of the suction member consist essentially of two plates. When they are swung apart, the crosswise outlet is open; in other words, it is created by the gap that appears between the two plates.
A preferred embodiment of the invention is characterized by having a centering funnel on the end of the suction duct towards the free and of the bobbin. It can be designed so that both further thread windings or coils and even a thread end lying outside on the cop in the area of the centering funnel can be sucked up. The axis of the centering funnel runs, at least when in its operating position, roughly in the same direction as the axis of the bobbin or cop. The bobbins are not in a precisely defined position in the spooling frame; rather, the free end of the bobbin can be positioned within a given range. The centering funnel should thus be dimensioned so that it can be placed normally over the free bobbin or core end. Said core end then slides along the inner wall of the funnel, so that once the movement of placing the funnel is completed the free end of the bobbin is aligned with the funnel pipe or the like.
Another variation on the invention is to have a funnel-like expansion at the end of the suction duct towards the suction hole. Here again, the axis of the funnel in its operating position lines up at least approximately with the axis of the associated end of the suction duct. It is particularly advantageous to have a sealing collar located just before the funnel-shaped expansion of the end of the suction duct on the suction hole side. It is preferably made of a flexible material such as rubber or plastic. Due to the funnel-shape, this end of the duct, too, can be reliably applied to the suction hole of the spooling frame. It is advisable to put the closing member into its release position before applying the sealing collar.
A further improvement on the invention is characterized by having the suction duct in the shape of an arc and having a lateral half of the duct in each plate of the body of the suction member. In this way one can design and preferably even dimension the two plates the same.
A further development on the invention provides that in a device for a spooling frame where the closing member or element for the suction opening is designed as a rotating or sliding plate with an air through hole, in the release position of the suction hole the air through hole is covered by the sealing collar. Leaks are thus avoided at the critical spot, so that the effectiveness of the suction device is insured.
Another variation on the invention consists in making the closing member movable by a first controllable electromagnet. Since the closing member executes a sliding or rotating motion, the magnet should preferably be a solenoid. The return of the closing member can be effected by the force of a spring.
A further preferred embodiment of the invention is characterized in that the electromagnet is connected to a pivoting lever that engages specifically via its free end with the closing member, preferably with an edge of the closing member. In the latter case the closing member is dish-shaped. One form in particular is to place a roller on the free end of the closing member to cut down on friction. In addition, it is proposed that the pivoting lever be returned to starting position by a return spring, which may, for example, consist of a coil spring on the axis of rotation. The axis of rotation of the lever runs in particular perpendicular to the direction of the axis of rotation of the plates and also perpendicular to the plane of the plates. Another variation on the invention consists of allowing both plates of the body of the suction member to swing open and back together by means of a second controllable electromagnet. If said magnet only accomplishes the opening, the closing is effected either by the force of gravity of by the force of a spring. In a particularly advantageous version the second electromagnet is a rotary magnet, and the two plates of the body of the suction member can be swung open and shut by means of at least one link control. With the latter, one can dispense with a spring for closing. with a link or cam control, the rotary motion of the magnet is transformed into a pivoting or swinging motion by the use of an inclined plane.
A further development of the invention is characterized in that the axis of rotation of the rotary magnet supports a level, particularly a two-armed lever having two pins. The pins engage arc-shaped slots of control lugs which are each on a corresponding plate of the body of the suction member. The axis of rotation of the rotary magnet is parallel to the pivoting axis of the plates. The arc shaped slots naturally do not run concentric to the magnet's axis of rotation, but rather in a narrowing direction in order to create the abovementioned "inclined plane." In the embodiment given as an example, the relationships are so set up that in the starting position, i.e. when the suction member is closed, the two pins and the axis of rotation of the solenoid are on a plane that runs preferably perpendicular to the open direction.
The suction member and the device for actuating the closing member of the suction hole are, in a further development of the invention, mounted on a support which is capable of moving back and forth in approximately the longitudinal direction of the bobbin. This support is at first so oriented with respect to the bobbin that the centering funnel can be set upon the free bobbin end by a simple, straight-line movement.
Another development of the invention consists in having a preferably plate-shaped bearing member guide mounted on the support around an axle that is perpendicular to the forward direction of the support and parallel to the pivoting axis of the plates of the suction member and is centerd by a spring in a base position. If, because the bobbin is in an extreme position in its spooling frame holder, the free end of the bobbin or core cannot get inside the funnel, but comes to rest on the rim of the centering funnel, the pivoting bearing of the suction member via the plate-shaped bearing member causes the latter to swing. The swinging comes about simply because of the off-center application of force with respect to the pivoting axis of the bearing member. This prevents damage to the bobbin or jamming of the device.
This safety precaution also works when the bobbin is inside the centering funnel and the device jams in its suction position while the bobbin feed device moves, and also and especially when, with the device in suction position, the bobbin holder on the spooling frame continues to rotate by at least one unit.
In this connection, an advantageous version of the invention provides for a stationary switch connected with the support and a switching member connected with the bearing member, which together constitute a shut-off device for a bobbin feed device. The deflection of the plate-shaped bearing member can be combined with an acoustical and/or optical warning device. After correct orientation of the bobbin and return of the deflected bearing member with the devices situated theron, the automatic thread transfer can be resumed.
Another preferred embodiment of the invention is characterized in that the support is slidably and lockably mounted on a guide mechanism or base mechanism of the device that runs roughly parallel to the longitudinal axis of the bobbin. This guide mechanism insures precision in the advance of the support and hence also the suction member, as well as the actuating device for the closing member. However it offers yet another advantage, which is that the support can be moved up and down, particularly inclined to the vertical, by means of an electric motor. the motor can move the support and the parts connected with it forward and back both quickly and in a manner adjusted to the situation. One particular consideration here is that one can use an appropriate drive motor or drive control which will offer at least the choice of a rapid and a crawl motion.
Another particular variation of the invention in this regard is characterized by a number of switches on or along the guide mechanism for controlling at least the electric motor and the electromagnets by acting together with a switching element on the support. The latter need not necessarily be directly connected with the support. Thus, when the support moves past the switches, which are specifically arranged so that at least some of them come one behind the other in the direction of travel of the support, this leads, at least during the advance motion of the suction member, to simultaneous and/or serial switching procedures, with the switching to be described in greater detail.
The driving motor, in a particularly advantageous version, is a permanently excited motor, particularly one with a four quandrant drive control. In a further development of the invention, it is provided that the motor drives, particularly indirectly, a threaded spindle that runs parallel to the guide mechanism of the support and engages with a pivoting but nonsliding nut or the like mounted on the support. A turn of the spindle thus results in a shifting of the nut and all parts unshiftably coupled with it. By varying the rotary motion one can alter the shifting motion.
Another development of the invention consists of providing a monitoring device for the thread in the suction duct of the suction member. With its aid one can determine whether, on completion of the procedure, the starting end of the thread has actually been sucked up and carried to the suction hole of the spooling frame. A convenient device for this purpose is an optical monitoring device with a light source and a detector. It can be hooked up both with a warning signal and also with the controls, so that the thread transfer process can be repeated a number of times.
Another variation on the invention is characterized in that a compressed air duct empties out into the suction duct, its outlet being directed toward the suction hole of the spooling machine. It thus produces by aspiration a suction effect on the bobbin and replaces or possibly reinforces a suction draught in the suction line of the spooling machine that has the suction hole. Another improvement on the invention is characterized by at least one rolling or sliding element for slidable mounting of the device on a lengthwise guide rail of the spooling frame. This makes it possible to move the device from one work station on the spooling machine to the next. This happens more particularly with the aid of a driving motor and a control mechanism which insures that the device does not move forward to the next work station on the spooling frame until the starting end of the thread has actually been transferred at the station at which it is currently stopped.
A further object of the present invention is to provide a device for transferring the starting end of a thread which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularlity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which the preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below on the basis of the drawings, wherein:
FIG. 1 is a side view of the inventive device, partially cut away;
FIG. 2 is a partial view of FIG. 1 taken in the direction of arrow A and with the suction hole structure and spool frame removed;
FIG. 3. is a partial sectional view of FIG. 1 taken along the line B--B.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the device in its operating position, i.e. most of its components are in an inclined position. The device is used to transfer the starting end 11 of the thread of a bobbin 1, of the kind known as a cop, from the bobbin core 2 to a suction hole 3 of a spooling frame 4. Of the frame 4, however, only the portion of a bobbin holder 5 is to be seen, that is rotationally symmetrical and rotates about an axis 6 of the frame. Frame 4 possesses a number of receptacles 7, holding one bobbin 1 each, that are disdistributed around the circumference of the frame and moved ahead step by step, so that at any given moment one bobbin 1 is in the position shown in the drawing with respect to the transfer device. Hence, in the thread transfer position, the bobbin 1 or its longitudinal axis 8 is inclined at an angle 10 to the vertical 9.
Before the bobbin 1 is inserted in the bobbin holder 5, the starting end 11 of the thread is stuck into one of the bobbin openings, which after insertion in the bobbin holder 5 projects above the latter and thus constitutes the free bobbin opening 12. Each spooling frame possesses a plurality of such bobbin holders, particularly at equal intervals side by side on frame 4. The thread is unwound from the bobbin core 2 in the spooling machine, checked and "refined" by the removal of bad spots, and then rewound into a new bobbin, preferably a cross-wound bobbin. For this purpose it is necessary for the starting end 11 of the thread to be brought to the suction hole 3 and held there until the segment of thread between bobbin 1 and suction hole 3 is grasped by an appropriate organ and fed to the spooling frame for further processing.
Pursuant to the invention, the starting end 11 of the thread is transferred automatically with this novel device from the bobbin 1 to the suction hole 3. For this purpose, a suction member 13 with a suction duct 14 is set on top of the free bobbin opening 12, the suction duct being arc-shaped in the embodiment used as an example. A pneumatic link is thus created between the bobbin 1, or the free bobbin opening 12, and the suction hole 3 of the spooling frame. With the help of the suction prevailing in the suction duct 14 the starting end 11 of the thread is sucked out of the inside of the core 2 and transported, while a segment of thread is unwound from the bobbin 1, through the suction duct 14 into the air duct 15 of the spooling machine, the free end of which duct constitues the abovementioned suction hole 3. In this case one utilizes the partial vacuum device usually to be found on a spooling frame. Instead of that, however, it is readily possible to have a compressed air duct 16 feed into the suction duct 14 as shown by way of example with dot-dash lines in FIG. 1. The compressed air thus fed in also results, by aspiration, in a suction effect in duct 14, so that with the aid of compressed air one can suction up the starting end of the thread and transport it to duct 15. Moreover, one can set up a monitoring device at an appropriate spot with which to check or ascertain that the transfer of the starting end of the thread from the bobbin 1 to the spooling frame 4 has taken place. A convenient device for the purpose is an optical monitoring device in the area of the suction duct 14.
The bobbin 1 will not necessarily be in the position shown in FIG. 1 in the bobbin holder 5; instead, it may be somewhat askew; in other words, the free end of the bobbin may swivel into or out of or across the projection plane. In order to set the suction member 13 reliably on the free end of the core notwithstanding its position in holder 5, a centering funnel 17 is provided on the end of the suction duct 14 that is toward the free bobbin opening 12. On the other of the suction duct 14 (the one towards the suction hole 3) another funnel-like expansion 18 is provided. to this is fastened a sealing collar 19 of a soft, elastic material such as rubber, plastic of the like. During the thread transfer operation, however, collar 19 does not lie directly on the upper end on the air duct 15, but on an intervening closing member or element 21 for the suction hole 3, which closing member 21 is constructed in the shape of a dish with its edge 20 bent down. This closing member is eccentrically rotatably or slidably mounted on the top of the bobbin holder 5. It has a through hole or aperture 22 that, in the starting position, in other words, before the centering funnel 17 is set on the free end of the bobbin, is situated to the side of the suction hole, so that the suction hole is covered by the closing member 21. Not until the closing member is slid or turned in the manner to be described below, is the pneumatic connection between the air duct 15 and the suction duct 14 established via the through hole 22. The sealing collar 19 is not pressed on until after the opening of the suction hole 3.
When the starting end of the thread is transferred into the suction hole 3, the suction member 13 must be taken off. This occurs by lifting in the direction indicated by arrow 23. In order to prevent the starting end of the thread from being carried along in this lifting movement, a cross-wise outlet for the thread is first opened up. The crosswise thread outlet is made possible by the fact that the suction member consists of two sections 26 and 27 (FIG. 2) hinged together around an axis 24. These sections can be folded in on one another or opened up, as needed. While the suction is operating the two sections, in particular the two halves, are naturally folded together--as shown in FIG. 2 with solid lines--whereas they are swung out away from one another as shown by broken lines in FIG. 2 in particular while the device is raised in order to create the crosswise outlet 25.
The two hinged sections 26 and 27 of the suction member are essentially plate-shaped elements. They are constructed so that one half of the suction duct 14 is defined and situated in each of them. As a result, each suction member section also bears, i.e. laterally, half a centering funnel 17 and half of funnel 18 with half a collar 19.
From the drawing one can also see that the hinge axis 24 is situated at the rear end of the suction member 13 with respect to the direction 28 in which it is lowered into place. The two hinged plates constitute the body 29 of the suction member.
The closing member 21 is movable by means of a first controllable electromagnet 30. Its armature is coupled via a bolt 31 to a lever 32 that pivots in the direction indicated by the double arrow 33. The axis of rotation 34 of the lever lies, pursuant to FIG. 1, over the solenoid 30, and the lever is one-armed. At its free end it bears a roller 72. In FIG. 1, the operating position of the lever 32 is shown with solid lines. Its starting position is shown in broken lines. In this starting position the closing member 21 still holds the suction hole 3 closed. If current is applied to the solenoid 30, the armature moves the lever 32 from the position shown with broken lines to that shown with solid lines, whereby upon contact of the pivoting lever roller 72 against the exterior of the closing member bent down dish edge 20, the closing member 21 is pivoted or shoved into its shifted position, in other words, the position in which the suction hole 3 is released or opened, as shown in solid lines. The deflected parts, i.e. the lever 32 and the closing member or element 21, can be returned to starting position by the force of return springs after the solenoid 30 is deenergized. A return spring for the lever 32 is located by or in the solenoid 30.
The spreading of the two plates or sections 26 and 27 of the body 29 of the suction member is also accomplished with the aid of a magnet, specifically a second controllable electromagnet 35. It should preferably be a rotary magnetic that opens and shuts the two plates or sections 26 and 27 of the suction member via a preferably doubled link control 36 shown in FIG. 2.
For this purpose, the axis of rotation 47 of the second magnet 35 bears a double-armed 38, on each end of which is situated one of the pins 39 or 40 of the link control. Each engages in an arc-shaped slot 41 or 42 of the control lug 43 or 44 of the corresponding plate or the corresponding section 26, 27 of the suction member. If the armature of the magnet turns, it results in a pivoting movement of the double-armed lever 38 with the pins 39 and 40. Because of the path of the arc-shaped slots, which is inclined relative to and non-concentric to the axis of rotation 47 (see FIG. 2)
the pins 39 and 40 press the control lugs 43 and 44 and hence the suction member sections 26 and 27 outwardly in the direction of the arrows 45 and 46. The wedge-shaped gap that appears between the two suction member sections 26 and 27 creates the abovementioned crosswise outlet 25 for the transferred thread end. When the suction duct 14 is closed, the axis of rotation of the second magnet 35 and the pins 39 and 40 lie on the same straight line or plane. Furthermore, it is apparent from FIG. 2 that the axis of rotation of the second magnet 35 is positioned parallel to the hinge axis 24 of the plates or suction member sections 26, 27.
The suction member 13 and the mechanism for actuating the closing member 21 of the suction hole 3, basically therefore the lever 32 and the first magnet 30, are carried on a support 48 capable of movement forward and back in roughly the longitudinal direction of the bobbin 1. Between the support and the suction member 13, however, another plate-shaped bearing member or guide 49 intervenes. It is pivotally mounted on the support 48 around an axis 50 so that it can swing in the direction indicated by the double arrow 51. For this purpose the support 48 has two mounting brackets 52 and 53 that receive the bearing member 49 between them. The abovementioned hinge axis 24 for the suction member 13 runs parallel to the axis 50 of the bearing member, as can be seen particularly in FIG. 1. Both figures show that the bearing member 49 is held in its normal position with the aid of two centering devices 54 and 55 intervening between the mounting brackets and the corresponding ends of the bearing member, which devices may be constructed as a kind of snap-lock and permit the bearing member 49 to swing with respect to the support 48 when a swinging impulse greater than the holding force of the snap lock acts on the bearing member 49. This may be the case if the position of the bobbin 1 deviates radically from that shown, so that the free end of the centering funnel 17 hits the free end of the core, or if the bobbin is inside the centering funnel and the device jams in its lowered position while the bobbin feed device moves forward or if the bobbin holder moves forward in the spooling frame while the device is in its lowered position. This creates a torque which is communicated to the bearing member 49 via the hinge axis to which it is connected 24 and thus causes the bearing member to swing. A switching member or actuator 56 connected to the bearing member 49 operatively via the hinge axis 24 shares this deflection movement and thereby actuates a tilt switch 57 stationarily mounted on the support 48, i.e. since bearing member or guide 49, hinge axis 24, body 29, first solenoid magnet 30, lever 32, second rotary magnet 35, and switching member or actuator 56, all rotate about the axis 50 under such deflection movement.
One can make appropriate use of this switching process, for example, to switch off a device for automatic feed of bobbins 1 into the bobbin holder 5.
Switch 57 may be a proximity switch with switching member 56 merely being a metal bar needed to trip the proximity switch. The centering devices 54 and 55 may also be of known design, for example, dish springs which are urged against the sides of bearing member 49 by bolts, the springs having notches which sit in notches of the bearing member to establish the center position but which may move out of the center position with tilting of bearing member 49.
The support 48 is mounted on a guide mechanism or base mechanism 59 of the device in such a way that it can be slid in the direction of the double arrow 58 and locked into position. This guide mechanism runs roughly parallel to the longitudinal axis 8 of the bobbin and the axis of rotation 6 of the bobbin holder 5. This enables the centering funnel 17 to be lowered centrally over the end of the bobbin core 2, which projects upward at the inclined angle 10. The support 48 thus slides up and down at an angle to the vertical, and does so with the aid of an electric motor 60. The latter is a permanently excited motor (i.e. permanent magnet equipped, rather than electromagnet equipped, motor) with a four-quandrant drive control (i.e. fast and slow forward speed, and slow and fast reverse speed, drive for lowering and raising support 48 to shut down position, respectively in conjunction with sequence switches as noted below). Its rotary motion is communicated via a drive mechanism 61, e.g. a toothed belt drive, to a spindle 62 which engages with a nut turnably but unslidably mounted on the support 48. A turn in one direction brings about a raising of the support 48 and all parts unshiftably mounted thereon in the direction of the arrow 23, while a counterturn results in lowering it in the direction of the arrow 28.
FIG. 1 shows that along the guide mechanism 59 are mounted various sequence switches, in particular non-contact (proximity) electrical or electronic switches. They are labelled by reference numbers 63, 64, 65, 66 and 67 and are continuously adjustable on a guide strip 70. They work in conjunction with a switching element 71 that moves along with the support 48 (see FIG. 3).
Starting with the support 48, and hence the suction member 13 as well, in its end raised position, the advance or lowering of the suction member 13 is set in motion by a corresponding order from the electrical drive motor 60, i.e. via a suitable control means switch in conventional automatic timed cycle manner.
At this point the suction member 13 is still closed, i.e. the rotary second magnet 35 for opening the suction duct 14 is not being fed with current and the two sections 26 and 27 are folded together.
After the unit passes in downward direction such that the switching element 71 on the support 48 operates the switch 63, the rotary magnet 35 is switched on and the suction member 13 is thereby opened, and its sections 26 and 27 swung open.
When the switching member 71, which has travelled along with the support 48, reaches switch 64, the current flowing through the second magnet 35 is again interrupted, resulting in the coming together of the two halves of the suction member into operating position, making possible the centering of the cop. Switch 67 is responsible for effecting a switch from the rapid motion heretofore prevailing to a crawl motion of motor 60, in other words, a slower rate of advance. The actuation of switch 65 controls the supply of current to the solenoid 30 and thus when actuated, once the downwardly moving roller 72 reaches and rests against the exterior of the edge 20, under the action of the return springs thereof, causes the lever 32, i.e. against the action of its return spring, to swing in and, in turn, the urging of roller 72 against the edge 20 to move the closing member 21, for the release or opening of the suction hole 3 by the closing member 21 movement, i.e. against the action of the closing member return spring.
Switch 66, finally, puts a stop to forward motion in the direction of the arrow 28 by shutting off motor 60, i.e. when the downwardly moving collar 19 reaches and contacts the now shifted control member 21. When the corresponding command to the motor 60 by the control means switch is given, to the motor 60 the reverse order of the operation of the switches and the parts controlled thereby is effected, such that the support 48 is raised back up starting in slow motion via switch 66 and then continuing in rapid motion via switch 67, and via switches 64 and 65 the suction member 13 is swung open and the closing member 21 is moved into its closed position via its return spring, as the case may be.
When switch 63 is reached, finally, the suction member 13 is swung shut again as the rotary second magnet 35 is deenergized, the motor 60 is shut off and the support 48 is hence stopped. The device of the base mechanism 59 is equipped with rollers 68, sliding blocks or the like on which it can be moved along a guide mechanism, in particular a guide rail 69 on the spooling frame that is perpendicular to the projection plane in FIG. 1.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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In order to transfer the starting end (11) of a thread on a bobbin (1) or cop inserted in a bobbin holder (5) of a spooling frame (4), automatically from the bobbin (1) to a suction hole (3) of the spooling frame (4), a pneumatically operated conveyor device is used. The basic component of this device is a suction member (13) with a suction duct (14) formed of a pair of openable plates (26) and (27), and that can be moved as a unit forward and back in the direction of the axis of the bobbin. Its centering funnel (17) is positioned over the free opening (12) of the bobbin in which the starting end (11) of the thread has previously been tucked. By suction or aspirating compressed air, the starting end of the thread is sucked out of the core and into the suction hole (3). To release the thread connection thus created from bobbin opening (12) to suction opening (3), the suction duct (14) is opened by means of its openable plates (26) and (27). This suction device is preferably combined with a release device for the suction hole (3) which at the appropriate time will control a closing member (21) to pivot or slide so that its through hole (22) is aligned with the suction hole (3) for uncovering or opening the latter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process or method of using survey-grade Global Positioning System (GPS) equipment mounted on a railroad track vehicle which will take close interval measurements of the railroad track position while being under load from the weight of the railroad track vehicle. The measurements will have horizontal and vertical positioning for each location.
2. Description of the Related Art
Using conventional methods, railroad tracks are inspected and/or surveyed by means of a survey technician utilizing a GPS receiver to locate survey features on site. In the conventional survey method, the features are located by placing the GPS receiver on the feature and taking a GPS observation for five seconds. Normally, if a railroad track is to be surveyed, the track must be shut down to traffic which creates a substantial logistical problem. Further, when several tracks are positioned adjacent to one another in close proximity, such as in a hump yard or the like, the survey technicians are exposed to dangerous conditions due to traffic on adjacent tracks. Because of these safety factors, adjacent tracks must be shut down while surveys are being conducted. Further, the conventional survey methods using GPS equipment consume extensive periods of time. Additionally, when a railroad track is surveyed using conventional GPS equipment, such a survey will not reveal or indicate deflection of the track under load as a locomotive or other track vehicles pass over the site.
SUMMARY OF THE INVENTION
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
The method of surveying a railroad track under load is described which comprises the steps of: (1) providing a track vehicle which may be moved along the railroad track; (2) positioning a first GPS receiver on the track vehicle; (3) positioning a second stationary GPS receiver remotely from the first GPS receiver with the stationary GPS receiver being in radio communication with the first GPS receiver; (4) moving the track vehicle along the railroad track so that the first GPS receiver receives data from a plurality of satellites relating to the horizontal position and the vertical elevation of the first GPS receiver at predetermined intervals; and (5) collecting the data received by the first GPS receiver with the height of the first receiver above the railroad track being subtracted thereto to provide the actual vertical elevation of the track at each of the predetermined intervals or locations while the track is under load.
In the preferred embodiment, the first GPS receiver is positioned on the track vehicle so as to be centrally positioned between the rails of the railroad track. In the preferred embodiment, the first GPS receiver is positioned on top of the track vehicle so that the signals from the GPS satellite are not blocked by passing traffic or obstacles. In the preferred embodiment, a data collector which is preferably hand-held is positioned in the track vehicle to collect data from the first GPS receiver.
In a second embodiment of the method, a pair of spaced-apart GPS receivers are positioned on the track vehicle so that data relating to the vertical elevation of each of the rails of the railroad track may be collected and supplied to a pair of data collectors positioned within the track vehicle. In the preferred embodiment, the track vehicle is a locomotive but the vehicle could be a high-rail vehicle or a cargo car, as well.
It is therefore a principal object of the invention to provide an improved method for surveying a railroad track while the track is under load.
A further object of the invention is to provide a method of surveying a railroad track which reduces the risk of personal injury to the survey technicians.
A further object of the invention is to provide a method of surveying a railroad track wherein a GPS receiver is mounted on a track vehicle with the track vehicle being moved along the track while the survey is being conducted.
A further object of the invention is to provide a method of surveying a railroad track which greatly decreases the time needed to survey the track.
A further object of the invention is to provide a method of surveying a railroad track which eliminates the need of closing down adjacent tracks as a track is being surveyed.
A further object of the invention is to provide a method of surveying a railroad track which provides the vertical elevation of the track as the track is being subjected to the weight or load of a track vehicle passing thereover.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
FIG. 1 is a perspective view of a locomotive moving along a railroad track having a GPS receiver mounted on the upper portion thereof which is in communication with a plurality of GPS satellites and a stationary GPS receiver located remotely of the locomotive;
FIG. 2 is a partial perspective view of a locomotive having a GPS receiver mounted thereon which is in communication to a data collector positioned within the locomotive; and
FIG. 3 is a partial perspective view of a locomotive having a pair of GPS receivers mounted thereon which are in communication with a pair of data collectors.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims.
In the drawings, the numeral 10 refers to a conventional railroad track having rails 12 and 14 supported on ties 16 . The numeral 18 refers to a conventional locomotive which is adapted to move along the track 10 in conventional fashion. Although it is preferred that the track vehicle 18 is a locomotive, other track vehicles such as a high-rail vehicle or a cargo car could be utilized. The primary reason for using a locomotive is that it will have a greater weight than high-rail vehicles or cargo cars so as to cause maximum deflection of the rails 12 and 14 when the locomotive passes thereover.
In one embodiment, a conventional GPS receiver 20 is secured to the top of the locomotive 18 so that it may receive data from a plurality of satellites 22 in an unobstructive fashion. Preferably, the GPS receiver 20 is centrally positioned with respect to the rails 12 and 14 to provide data for the center of the track 10 . The height of the GPS receiver 20 above the rails 12 and 14 will be determined in conventional fashion so that the data received by the GPS receiver 20 may be adjusted to subtract the height of the receiver 20 above the rails 12 and 14 from the data received from the GPS satellites 22 . In other words, the data received from the satellite 22 may indicate that the GPS receiver 20 has an elevation of 1,500 feet. The distance between the upper end of the rails 12 and 14 and the GPS receiver may be 15 feet so the data will be adjusted to indicate that the rails 12 and 14 are at an elevation of 1,485 feet.
The numeral 24 refers to a stationary GPS receiver which is positioned remotely of the GPS receiver 20 and which is in communication with the satellites 22 and which is in radio communication with the GPS receiver 20 with both of the receivers observing the same satellite signals thereby increasing the accuracy of the data. If a Virtual Reference Station (VRS) network system is available in the area of the track being surveyed, it will not be necessary to utilize the stationary GPS receiver 24 . The receiver 20 in communication with a hand-held data collector 26 within the locomotive 18 which is being held by a survey technician. The fact that the survey technician may ride inside the locomotive 18 increases the safety factor since the technician does not have to be physically present on the track 10 to locate features. The technician will be able to monitor the GPS satellite quality from the data collector 26 . The data collector 26 is preferably a hand-held device that logs the GPS survey data from the GPS receiver 20 . The data collector 26 communicates with the GPS receiver 20 by connecting a cable 27 between the receiver 20 and the data collector 26 or by using a radio connection. The technician can place descriptions on the GPS observations being logged into the data collector 26 . The technician can also set the parameters of the GPS system to log data at certain intervals. The track vehicle may be moving and the survey observations can be logged and recorded. The vehicle does not have to be stopped in order to log an observation. Logging the data while the locomotive or track vehicle 18 is moving gives the ability to collect a dense amount of data in a small amount of time. The technician may set the parameters to log observations in five foot intervals, which is ten times more dense than the traditional survey requirements. If the track vehicle is traveling at five miles per hour, 1,056 observations can be made at five foot intervals in a one mile stretch, in a 12 minute time frame.
If it is desired to determine the position of each of the rails 12 and 14 , a pair of GPS receivers 20 are placed on the track vehicle 18 with each of the receivers 20 being positioned directly above one of the rails 12 and 14 ( FIG. 3 ). This situation will normally be used where one rail is higher than the other such as in super elevations through curves for example. In this case, an individual data collector 26 will be used for each receiver as seen in FIG. 3 . Both receivers 26 will log data at the same time to compare the difference in elevation on each rail.
Thus it can be seen that a novel method has been provided for surveying a railroad track 10 which provides maximum safety to the survey technician since the survey technician may be positioned within the locomotive or other track vehicle. Further, the survey data is gathered as the locomotive 18 is moved along the track 10 which greatly decreases the time required to complete the survey. The fact that the receiver 20 is located on the top of the track vehicle ensures that the GPS signals will not be blocked by passing traffic, obstacles, etc. Receiver 20 may be secured to the top of the track vehicle 18 in any means as long as it is mounted in a manner that eliminates any movement of the GPS receiver once in place. For example, magnetic mounts may be used, suction cups may be used or the mount for the GPS could be welded to the vehicle 18 .
An extremely important feature of this system is that the elevation of the track may be measured when the track is under load of the weight of the track vehicle which will indicate unstable conditions beneath the track. It can therefore be seen that the invention accomplishes all of its stated objectives.
Although the invention has been described in language that is specific to certain structures and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A method of inspecting or surveying a railroad track under load is described wherein a GPS receiver is mounted on top of the track vehicle such as a locomotive, high-rail vehicle or cargo car with data being collected at predetermined intervals to provide horizontal and vertical data for each location.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for removing luminance nonuniformity and crosstalk occurs on a display using organic electroluminescence and an organic electroluminescence display manufactured by this method.
[0003] 2. Description of Related Art
[0004] Organic electroluminescent elements are configured by sandwiching a material layer between an anode and a cathode. The material layer may comprise a plurality of layers, such as an electron-injecting layer or a hole-injecting layer and an electron-transporting layer or a hole-transporting layer. Its emitting principle is similar to that of the emitting mechanism of light emitting diodes (LED). More specifically, a hole and an electron are fed into a light-emitting layer by the application of a direct current voltage between the anode and the cathode. The electronic state of organic molecules included in the light-emitting layer is changed to the excited state by energy generated by a recombination of the hole and electron in the light-emitting layer. Energy is emitted as light when this quite unstable electronic state falls to a ground state to emit organic light emitting diodes. Accordingly, organic electroluminescence is referred to also as organic light emitting device (OLED).
[0005] In an OLED display, OLED elements are arranged on a substrate, such as a glass substrate as a matrix to be emitted to show information. OLED displays are expected as epoch-making displays because of superiority in electric power consumption, reaction speed, visual field, and luminance compared with other types of displays, such as liquid crystal displays.
[0006] A method for driving OLED elements is roughly divided into two kinds of systems: passive matrix system and active matrix system. As shown in FIGS. 5 ( a ) and 5 ( b ), the passive matrix system is a driving method to intersect an anode 114 and a cathode 116 in a matrix state to selectively emit OLED elements sandwiched at an intersection. On the other hand, as shown in FIGS. 6 ( a ) and 6 ( b ), the active matrix system is a driving method to emit OLED elements by having switching and memory functions for each pixel 130 using a thin film transistor (TFT) 120 .
[0007] Using the passive matrix system enables low production costs of displays because of its simple structure. However, large electric power consumption is required to keep the screen at high luminance because this system indicates information by sequentially emitting lines and using an after-image branded on the eyes. For this reason, the active matrix system for emitting the pixels 130 by aggressively using a TFT 120 has been adopting more despite its high production costs. Compared with the passive matrix system, the active matrix system enables high luminance at a low electric power consumption.
[0008] On the other hand, a conventional method of taking out luminance of an OLED display 110 has two systems: bottom-emitting system and top-emitting system. As shown in FIG. 7 ( a ), the bottom-emitting system takes out light from an insulating substrate side 118 . As shown in FIG. 7 ( b ), the top-emitting system takes out light from a top surface layer side 115 .
[0009] Japanese Patent Publication No. 8-227276 (Cited document 2) discloses embodiments of a method of manufacturing bottom-emitting and top-emitting OLED displays. According to these embodiments, an OLED display shown in FIG. 10 ( a ) is manufactured by the processes shown in FIGS. 10 ( b ) to 10 ( d ). More particularly, as shown in FIG. 10 ( b ), a plurality of parallel first display electrode lines 214 made of indium tin oxide (ITO) or the like are deposited as stripes on a glass substrate 218 . And ribs 222 of polyimides or the like are formed on the first display electrode lines 214 , so that the island shaped first display electrode portions 215 are defined and surrounded as shown in FIG. 10 ( c ). An OLED light-emitting layer 213 is formed on each recess of the glass substrate 218 wherein the ribs 222 are formed. Next, a plurality of parallel stripe second display electrode lines 217 of low resistance metal are vacuum-deposited or sputtered with a shadow mask with parallel slits on the ribs 222 and the light-emitting layers 213 so that the second display electrode lines 217 extend perpendicular to the first display electrode lines 214 .
[0010] In the area surrounded by the ribs 222 , a TFT connected to the first display electrode portions 215 is formed on the glass substrate 218 , where data signal lines and scan signal lines or the like are arranged. As shown in FIG. 10 ( a ), in this embodiment, the OLED display takes out light from the glass substrate side 218 .
[0011] In the active matrix system, however, the aperture ratio is reduced due to TFT, capacitors, and wiring or the like after taking out luminescence from the glass substrate side 218 like the bottom-emitting system. Consequently, when the active matrix system is adopted, the top-emitting system is advantageous. Light is not shielded by the TFT, which results in an increase of the aperture ratio and high luminance when adopting the top-emitting system.
[0012] FIG. 11 shows a cross sectional view of the structure of a top-emitting active matrix OLED display. In FIG. 11 , an OLED display 310 comprises: an insulating substrate 318 ; a thin film transistor (TFT) 320 formed on the insulating substrate 318 ; an insulating layer 319 ; a first electrode 314 ; a material layer 313 ; a second electrode 317 ; and a via hole 326 for connecting the first electrode 314 and the TFT 320 through the insulating layer 319 (For examples, see cited document 1).
[0013] Unlike the bottom-emitting system, the second electrode 317 is required to be made from a transparent material because the OLED display 310 takes out luminescence from the second electrode side 317 . Further, to increase optical transmittance, the second electrode 317 needs to be as thin as possible. Moreover, the second electrode 317 may be laminated covering the entire surface of the OLED display.
[0014] A light-emitting layer included in the material layer 313 of the OLED display 310 emits light to take out the luminescence from the second electrode side 317 .
[0015] Since the structure of such top-emitting active matrix OLED displays is various, the second electrode 317 covering the entire surface of the above-mentioned OLED display may be divided in stripe like the passive matrix system. Further, the via hole 326 in FIG. 11 connects the first electrode 314 to the TFT 320 , but may be used to connect, for examples, the second electrode and the common electrodes.
[0016] One example of a top-emitting active matrix OLED display having ribs will be now described by using FIGS. 8 ( a ) and 8 ( b ).
[0017] AS shown in FIG. 8 ( b ), in an OLED display 110 , ribs 122 are arranged on an insulating substrate 118 in parallel. As shown in FIG. 8 ( a ), OLED elements 112 are sandwiched between ribs 122 . The area of one unit of matrix divided by the ribs 122 and OLED elements 112 are referred to as a cell area 132 . The cells completed by equipping the cell area 132 with the TFT 120 and the OLED elements 112 are referred to as pixels 130 .
[0018] The pixels 130 in each cell area 132 are so configured that an anode 114 and the ribs 122 are formed on the insulating substrate 118 by sandwiching the anode 114 in the column direction of the matrix in parallel as shown in FIG. 8 ( a ). Further, in parallel with the ribs 122 , common electrodes 124 isolated from the anode 114 and the ribs 122 are formed on the insulating substrate 118 . Furthermore, the OLED elements 112 are formed by the lamination of at least a light-emitting layer and a thin film cathode 117 on the upper part of the anode 114 . Moreover, the thin film cathode 117 is laminated on the pixels 130 . And the via holes 126 for conducting the thin film cathode 117 and the common electrodes 124 may be formed in each cell area 132 .
[0019] The thin film cathode 117 is laminated on the entire surface of the OLED display 110 . The thin film cathode 117 is partitioned by the ribs 122 formed among the adjacent cell areas 132 in a column direction when laminating the thin film cathode. The anode 114 is not needed to be optical transparent due to the-top emitting system but may be made from a metal, such as Al.
[0020] Additionally, the cell areas 132 are in a rectangle shape. Each cell area 132 includes OLED elements 112 . The common electrodes 124 are formed on the insulating substrate 118 in parallel with the ribs 122 to be isolated from the anode 114 . The common electrodes 124 may conduct with the thin film cathode 117 through the via holes 126 formed within each cell area. Accordingly, the thin film cathode 117 laminated on the surface of the OLED display 110 is equipotential through the common electrodes 124 .
[0021] When an OLED display 110 having such configuration is driven employing the active matrix and top-emitting systems, a circuit formed by circuit elements, such as the OLED elements 112 and common electrodes 124 are shown in a schematic diagram 4 ( a ) or 4 ( b ) as an ideal example. More specifically, the OLED elements 112 emit light by the application of a forward voltage between the OLED elements 112 through the TFT because of this mechanism. For example, in FIG. 4 ( a ), a current passing via the OLED elements passes into the common electrodes 124 from the surface of the thin film cathode 117 . Following explanation is given using the schematic diagram 4 ( a ) for convenience sake.
[0022] Considering a circuit as shown in FIG. 4 ( a ), a predetermined amount of current always passes through the OLED elements 112 selectively applied by a certain voltage. And a current does not always pass through the OLED elements 112 which are not selected. On the other hand, it is known that the luminance of the OLED elements 112 are virtually in proportional to the current passing through the OLED elements 112 . It follows that the light emission of the selected OLED elements 112 is performed at predetermined luminance and the light emission of the unselected OLED elements 112 is never performed, which results in no unexpected luminance nonuniformity.
[0023] Upon driving the OLED display 110 having the above-mentioned configuration, however, as shown in FIG. 9 , it has turned out that an apparent linear luminance nonuniformity appears on the surface of the display. Especially, such linear luminance nonuniformity distinctly appears on top-emitting active matrix OLED displays wherein ribs 122 are arranged in parallel like the above-mentioned systems. Further, luminance nonuniformity in a spot state easily occurs on the kind of OLED displays without ribs 122 , wherein the entire surface is covered with a thin film electrode.
[0024] (Cited Document 1)
[0025] Japanese Patent Publication No. 2003-22035 (Page 2, FIG. 1 )
[0026] (Cited Document 2)
[0027] Japanese Patent Publication No. 08-227276 (Pages 4 and 5, FIGS. 13 and 14 )
SUMMARY OF THE INVENTION
[0028] An OLED display according to the present invention comprises: an insulating substrate; common electrodes formed on the insulating substrate; a first electrode layer formed in a region adjacent to the common electrodes formed on the insulating substrate by electrically isolating from the common electrodes; an insulating layer which coats on the insulating substrate by respectively opening a first opening window exposing a part of the common electrodes and a second opening window exposing at least a part of the first electrode layer; ribs which form a cell area by crossing the common electrodes on the insulating substrate and surrounding each of the opening windows; a material layer formed on the first electrode layer exposed from the second opening window; and a second electrode layer which coats within the cell area surrounded by the rib and electrically connected to the common electrodes through the first opening window. The crossing walls of these ribs include a reserve tapered shape.
[0029] A method for manufacturing an OLED display according to the present invention comprises: preparing an insulating substrate; forming common electrodes on the insulating substrate; forming a first electrode layer in a region adjacent to the common electrodes formed on the insulating substrate by electrically isolating from the common electrodes; coating on the insulating substrate with an insulating layer by respectively opening a first opening window exposing a part of the common electrodes and a second opening window exposing at least a part of the first electrode layer; forming a cell area on the insulating substrate by surrounding each of the opening windows with ribs across the common electrodes; forming a material layer on the first electrode layer exposed from the second opening window; and forming a second electrode layer electrically connected to the common electrodes through the first opening window by coating within the cell area.
[0030] The method for manufacturing an OLED display according to the present invention comprises: preparing an insulating substrate; forming band-like common electrodes on the insulating substrate; forming a first electrode layer in an region adjacent to the common electrodes formed on the insulating substrate; coating the insulating substrate with an insulating layer; forming ribs wherein the walls are in a reverse tapered shape and a thin insulating layer in a cell area surrounded with the ribs by etching the insulating layer across the common electrodes; forming a first opening window exposing a part of the common electrodes and a second opening window exposing a part of the first electrode layer on the insulating layer within the cell area; forming a material layer on the first electrode layer exposed from the second opening window; and electrically connecting the second electrode layer which coats the material layer to the common electrodes through the first opening window by coating the ribs with the second electrode layer as a mask within the cell area.
BRIEF DESCRIPTION OF THE DRAWING
[0031] FIG. 1 ( a ) is a plan view of an OLED display, FIG. 1 ( b ) is a cross sectional view taken on line A-A of FIG. 1 ( a ), FIG. 1 ( c ) is a cross sectional view taken on line B-B of FIG. 1 ( a ), FIG. 1 ( d ) is a cross sectional view taken on line of C-C of FIG. 1 ( a ), FIG. 1 ( e ) is a cross sectional view taken on line D-D of FIG. 1 ( a ), and FIG. 1 ( f ) is a cross sectional view taken on line E-E of FIG. 1 ( a ) according to the present invention.
[0032] FIG. 2 ( a ) is a cross sectional view of another embodiment of the OLED display of the present invention, and FIG. 2 ( b ) is a cross sectional view of further another embodiment of the OLED display of the present invention.
[0033] FIG. 3 is an equivalent circuit diagram of an OLED display of the present invention.
[0034] FIG. 4 ( a ) is an ideal equivalent circuit diagram of a conventional top-emitting OLED display, and FIG. 4 ( b ) is another ideal equivalent circuit diagram of a conventional top-emitting OLED display.
[0035] FIG. 5 ( a ) is a perspective view of a passive matrix OLED display, and FIG. 5 ( b ) is a plan view of a passive matrix OLED display.
[0036] FIG. 6 ( a ) is a perspective view of an active matrix OLED display, and FIG. 6 ( b ) is a plan view of an active matrix OLED display.
[0037] FIG. 7 ( a ) is a cross sectional view of a bottom-emitting OLED display, and FIG. 7 ( b ) is a cross sectional view of a top-emitting OLED display.
[0038] FIG. 8 ( a ) is a plan view of a conventional OLED display, and FIG. 8 ( b ) is a cross sectional view of FIG. 8 ( a ).
[0039] FIG. 9 shows a top-emitting OLED display having linear luminance nonuniformity.
[0040] FIG. 10 ( a ) is a cross sectional view of a bottom-emitting active matrix OLED display, FIG. 10 ( b ) is a perspective view of an OLED display wherein first display electrode lines, FIG. 10 ( c ) is a perspective view of an OLED display wherein ribs are arranged, and FIG. 10 ( d ) is a perspective view of an OLED display wherein second display electrode lines are formed.
[0041] FIG. 11 is a cross sectional view of a top-emitting active matrix OLED display.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The present invention will now be described in detail. For the sake of convenience, a first electrode refers to an anode and a second electrode refers to a cathode. Further, a first opening window opened in an insulating layer for coating on an insulating substrate refers to a via hole reaching from the surface of the cathode of OLED to common electrodes. An anode is exposed to the inside of a second opening window.
[0043] FIGS. 1 ( a ) to 1 ( f ) are a plan view and cross sectional views per each cut section of an OLED display in an embodiment of the present invention. In this embodiment, as shown in a shaded area of FIG. 1 ( a ), an OLED display 10 is divided into cell areas 32 in matrix state by ribs 22 arranged on an insulating substrate 18 or an insulating layer 19 covering the insulating substrate 18 . Inside the cell area 32 , an anode 14 is formed on the insulating substrate 18 , where common electrodes 24 are formed by being isolated from the anode 14 in parallel with the ribs 22 . In addition, OLED elements 12 formed on the anode 14 by laminating a material layer 13 and a thin film cathode 17 , and via holes 26 conducting the thin film cathodes 17 and the common electrodes 24 are formed within the cell areas 32 .
[0044] The insulating substrate 18 herein may be, for example, a glass substrate. The ribs 22 are ribs made from an insulator, such as polymer and ribs in a reverse tapered shape. The anode 14 may be an electrode made from a metal, such as Al or an electrode made from other materials. Although the common electrodes 24 are preferably made from a metal having superior conductivity and the shape is not limited, as shown in FIG. 1 ( a ), they may be common electrodes 24 . Further, the thin film cathode 17 is prepared by utilizing a transparent electrode material itself or by laminating ordinary metals to be formed with the surface of the cell areas 32 covered. Furthermore, the material layer 13 sandwiched between the anode 14 and thin film cathode 17 may include a plurality of layers, such as an electron or a hole-injecting layer, an electron or a hole-transporting layer other than a light-emitting layer.
[0045] To solve the above-mentioned problems, FIG. 4 ( a ) assumed as equivalent circuit is amended to assume the circuit of FIG. 4 ( c ) as equivalent circuit of a realistic OLED display. The presence of a leakage current passing through the surface of the thin film cathode 17 uniformly laminated on the OLED display needs to be considered in FIG. 4 ( c ).
[0046] Referring to the circuit represented in FIG. 4 ( c ), OLED 1 to OLED 4 are assumed as OLED elements 12 . The OLED elements 12 are respectively connected to TFT 20 within the cell areas 32 and similarly connected to the common electrodes 24 through via holes 26 in the cell areas 32 . Rg shows resistance of the common electrodes 24 . Rc shows resistance among the cell areas 32 . Rvia1 shows average resistance of the via holes 26 . Rvia2 shows resistance of the via holes 26 having resistance different from Rvia1.
[0047] As described in the above-mentioned conventional examples, the thin film cathode of the surface of the OLED display is unidirectionally isolated by the ribs 22 arranged in stripe. However, no isolation is provided among OLED elements formed along the ribs 22 , so that a leakage current may unidimensionally pass among the cell areas through the surface of the thin film cathode. Accordingly, in an equivalent circuit shown in FIG. 4 ( c ), the presence of resistance Rc among the cell areas 32 needs to be considered.
[0048] Further, the via holes 26 are holes to reach from the surface of the thin film cathode 22 to the common electrodes 24 and seems to have large resistance Rvia1 comparing with the thin film cathode 22 in a planar state. Furthermore, the via holes 26 often have nonuniform resistance because it is difficult to keep uniform resistance. Consequently, resistance Rvia2 of via holes 26 different from that of the average via holes 26 has to be taken into consideration in the equivalent circuit diagram of FIG. 3 . The equation of Rvia1>Rvia2>>Rc>>Rg is assumed to be established in the equivalent circuit diagram of FIG. 4 ( c ).
[0049] In the equivalent circuit diagram of FIG. 4 ( c ), such as the above-mentioned figure, current is passed into Rvia2 by passing a leakage current through Rc because Rvia2 is smaller than Rvia1. The effects of the presence of voltage depending on a path reaching Rvia2 enable the current value passing through each of the cell areas 32 to make difference from the estimated current value. As mentioned above, emitting luminance of the OLED elements 12 depends on the current value. As a result, luminance nonuniformity is observed around Rvia2 in the cell areas 32 due to different luminance from other places of the display. Further, the leakage current gives impact on the current passing through the OLED elements in the cell areas 32 near Rvia2, so that luminance nonuniformity easily appears as linear luminance nonuniformity in the direction of the ribs because the thin film cathode 17 which is used as a flowing path is unidirectionally isolated.
[0050] To avoid such luminance nonuniformity, a method for closing off a path where a leakage current passes through by separating an anode and a cathode for each adjacent cell area is adopted. More particularly, a wide range of luminance nonuniformity is replaced with luminance nonuniformity in the cell areas 32 by arranging ribs among the cell areas 32 to interrupt the leakage current passing through the cell areas 32 in FIG. 3 .
[0051] In this embodiment, an OLED display 10 is formed as mentioned below. As shown in FIGS. 1 ( a ) to 1 ( f ), common electrodes 24 are formed on an insulating substrate 18 and then ribs 22 for dividing the insulating substrate into a plurality of cell areas 32 to electrically isolate among each cell area are formed on the insulating substrate 18 and the common electrodes 24 . Next, the anode 14 is formed within the plurality of cell areas 32 and OLED elements 12 are formed by laminating in the order of a material layer 13 and a thin film cathode 17 . Additionally, via holes 26 for electrically conducting the thin film cathode 17 and the common electrodes 24 are formed.
[0052] The ribs 22 are made from an insulator and separate the anode 14 and thin film cathode 17 for each cell area 32 . The thin film cathode 17 and common electrodes 24 in each cell area 32 are ordinarily equal potential because of being connected to each other through the via holes 26 . Even when a potential difference occurs among the cell areas 32 for a particular reason, there is no possibility of the current passing among the cell areas 32 via the surface of the thin film cathode 17 because of isolating each of the cell areas 32 from the other cell areas by the formation of the ribs 22 .
[0053] The ribs 22 are formed by applying a negative typed photo resist onto the insulating substrate 18 employing the spin coat method and being developed after exposure using a photo mask. These ribs are in a reverse tapered shape in 10 μm order previously arranged on the insulating substrate 18 . These ribs in a reverse tapered shape are formed, for example, with a negative-type photo polymer by utilizing the difference of developing speed caused by the difference in amount exposed in the thickness direction.
[0054] Such configuration of an OLED display 10 makes it possible to avoid the above-mentioned leakage current from occurring by electrically isolating each of the cell areas 32 from the thin film cathode 17 on the surface of the thin film cathode 17 . That is, the ribs 22 isolate among OLED elements 12 in cell state, which leads to prevent the current from passing among the cell areas 32 via the surface of the thin film cathode 17 .
[0055] Further, the impact of the ribs 22 made on luminance nonuniformity will be now described using FIG. 3 . Since an anode and a cathode are separated for each cell area 32 by the ribs 22 to close off the path for the leakage current, the current passing through the OLED elements 12 , such as OLED 1 , OLED 2 , and OLED 4 reaches the common electrodes 25 through resistance Rvia1. Accordingly, the current passing through three OLED elements 12 is uniform and the luminance is also uniform.
[0056] However, the current passing through the OLED elements 12 indicated as OLED 3 reaches the common electrodes 24 via resistance Rvia2. From the above-mentioned conditions, Rvia1 is larger than Rvia2, so that the current passing through the OLED elements 12 indicated as OLED 3 becomes larger than the current passing through other OLED elements 12 indicated as OLED 1 , OLED 2 , and OLED 4 . As a result, the luminance of OLED 3 is unexpectedly larger than other 3 OLEDs, which leads to luminance nonuniformity.
[0057] Unlike conventional OLED displays, the OLED display of the present invention is capable of removing the whole linear luminance nonuniformity. More particularly, in FIG. 3 , a wide range of luminance nonuniformity is replaceable with luminance nonuniformity in each of the cell areas 32 .
[0058] The structure of the OLED display according to the present invention is not limited to the above-mentioned embodiments. For example, common electrodes may be formed on the entire surface of the insulating substrate 18 to laminate an insulating layer 19 on the entire surface of the common electrodes 24 , and on the insulating layer 19 , the cell areas 32 may be formed by the ribs 22 .
[0059] An anode 14 is formed within each cell area 32 , and a material layer 13 and a thin film cathode 17 are laminated on the anode 14 in order to form the OLED elements 12 . The ribs 22 are high enough to divide the thin film cathode 17 into each cell area 32 . The via holes 26 for electrically conducting the thin film cathode 17 and the common electrodes 24 are formed by penetrating the anode 14 and insulating layer 19 in this embodiment.
[0060] The OLED display of this embodiment is capable of interrupting the leakage current passing via the surface of the thin film cathode 17 in the cell areas 32 by the arrangement of the ribs among the cell areas 32 . Accordingly, the OLED display of this embodiment is capable of removing a wide range of luminance nonuniformity easily discovered as well as the above-mentioned embodiments.
[0061] Alternatively, as shown in FIG. 2 ( a ), common electrodes 24 may be formed on the entire surface of an insulating substrate 18 , and ribs 22 are arranged on the common electrodes 24 so that cell areas 32 may be formed, and then an insulating layer 19 may be laminated. After that, OLED elements 12 and via holes 26 are formed within each cell area in the same manner as the above-mentioned embodiments. The common electrodes 24 and an anode not shown in figures are isolated by the insulating layer 19 and the thin film cathodes 17 located adjacent to each other are isolated by the ribs 22 in this embodiment as well as the above-mentioned embodiments.
[0062] On the other hand, the ribs 22 may be directly arranged on the insulating substrate 18 in another embodiment shown in FIG. 4 ( b ). Common electrodes 24 , an insulating layer 19 , an anode (not shown in figures), OLED elements (not shown in figures), and a thin film cathode 17 are laminated in order. In this case, a wide range of luminance nonuniformity is removable in the same manner as the OLED display of the above-mentioned embodiments.
[0063] Although a thin film cathode is used in the embodiments of the OLED display according to the present invention described above, a cathode with thicker thickness may be laminated on a material layer 13 . In this case, problems with luminance nonuniformity caused by a leakage current do not become evident so often because resistance of the thick cathode is smaller than that of the thin film cathode 17 and is sufficiently close to resistance of the common electrodes 24 . In addition, it is not so common that such problems of a wide range of luminance nonuniformity become evident when employing the bottom-emitting system for the similar reason.
[0064] Even when resistance of the thick cathode is small, luminance nonuniformity is presumed to appear not in a wide range but locally due to the mechanism of the above-mentioned description. Consequently, a method for removing luminance nonuniformity using the ribs 22 of the present invention is effective regardless of whether using the top-emitting system or the bottom-emitting system. The method for removing luminance nonuniformity using the ribs 22 of the present invention is effective to all OLED displays wherein OLED elements 12 are not electrically insulated from each other on the surface electrode.
[0065] Furthermore, the anode 14 and the thin film cathode 17 may be interchangeable in the above-mentioned embodiments of the present invention. More specifically, similar effects of removing luminance nonuniformity can be obtained in OLED displays wherein OLED elements 12 are formed by forming a cathode on the insulating substrate 18 and laminating the material layer 13 and an anode. In this case, partitioning among the OLED elements by the ribs 22 enables to remove luminance nonuniformity which occurs on OLED displays each having a structure in which the common electrodes are connected to the anode as shown in FIG. 4 ( b ) In each embodiment of the present invention described so far, an insulating substrate 18 is made of glass and the like, but it is not limited to a transparent material as far as the top-emitting system is used for the OLED display. More particularly, the insulating substrate 18 is not particularly limited as far as it is an insulator and may be made of plastic and the like.
[0066] Similarly, the anode is not limited to a transparent material but may be made from a metal, such as Al and a thin plate made of stainless or the like. Further, the above-mentioned first opening window is not limited to be called as via holes and through holes or the like and includes all opening windows for electrically conducting the cathode surface of the OLED elements and common electrodes.
[0067] The ribs 22 preferably include a reverse tapered shape crossing upwardly on a second electrode layer and may be so-called cathode ribs. In this case, the ribs 22 also act as a role of a shadow mask at the time of laminating the cathode. Alternatively, the ribs 22 may be exclusively used for shutting down the continuity among the cell areas 32 . In this case, the ribs 22 are not limited to particular shape and material or the like as long as isolation among the cell areas 32 can be obtained.
[0068] Additionally, the cell areas 32 surrounded by the ribs 22 are in a rectangle shape partitioned in a row direction and a column direction, but the shape of the cell areas 32 are not particularly limited. The shape may be in other polygonal shape, such as triangle shape and the like. Alternatively, the shape of the cell area 32 may be a round shape or an oval shape. The shape and size of each of the cell areas 32 may be arbitrary.
[0069] The cell areas 32 in such shape are disposed on the row and column in matrix state. Alternatively, these cell areas 32 are aligned in such a manner to form a polygonal grating, such as a triangle grating and a hexagonal grating. These cell areas 32 may be arbitrarily disposed.
[0070] There have thus been shown and described a novel OLED display and a method for manufacturing thereof which fulfill all the objects and advantages sought therefor. Many changes, modifications, variations, combinations, and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, Which is to be limited only by the claims which follow. This application claims priority from Japanese Patent Application No. 2003-209273, which is incorporated herein by reference.
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An organic light emitting diode display comprises: an insulating substrate; common electrodes; a first electrode layer formed in a region adjacent to the common electrodes formed on the insulating substrate by electrically isolating from the common electrodes; an insulating layer which coats on the insulating substrate by respectively opening a first opening window exposing a part of the common electrodes and a second opening window exposing at least a part of the first electrode layer; ribs which form a cell area by crossing the common electrodes on the insulating substrate and surrounding each of the opening windows; a material layer formed on the first electrode layer exposed from the second opening window; and a second electrode layer which coats within the cell area surrounded by the ribs and electrically connected to the common electrodes through the first opening window.
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BACKGROUND OF THE INVENTION
The invention is based on a double-acting magnetic valve as generally defined hereinafter. A magnetic valve has already been described which operates by superimposing the fields of one permanent magnet and two electromagnets. In this magnetic valve, to effect the opening and closing movements, respectively, one or the other of the magnetic coils at a time is supplied with current. The structural size means that the magnetic force is small.
OBJECT AND SUMMARY OF THE INVENTION
The magnetic valve according to the invention has the advantage over the prior art that the structural size is diminished, or in other words the specific magnetic force is increased. Because permanent magnets are introduced between the poles of the electromagnetic circuits, the full magnetic flux density is attained despite the dispersion of the magnetic flux in the gap between the armature and the poles. The number of poles can therefore be increased, as compared with known embodiments. As a result, it is possible to reduce the mass of the armature and the self-resonance of the switch system is increased, so that the movement energy of the armature is dissipated within a brief time, and vibration and recoiling of the armature in the time prior to the next switching event are precluded. Since there are no radial magnet gaps, the forces in the radial direction in the magnetic valve according to the invention are also diminished, while friction losses are simultaneously lessened as well.
The invention will be better understood and further objects and advantages thereof will become more aparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in cross section a first exemplary embodiment of a magnetic valve according to the invention;
FIG. 2 is a section taken along the line II--II in FIG. 1; and
FIG. 3 shows a second exemplary embodiment of a magnetic valve according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The magnetic valve shown in the drawing is located in a housing embodied in two parts, a cup-shaped valve housing 1 and a flat housing bottom 2. At least two magnetic coils 3 are located in the housing, disposed symmetrically with the center axis of the magnetic valve. Alternatively, any other even number of magnetic coils 3 is possible. FIGS. 1 and 2 show an embodiment having four magnetic coils 3, spaced apart from one another by approximately the same distance. Each magnetic coil 3 includes a core 4 of soft-magnetic material that extends parallel to the center axis of the magnetic valve, and each core 4 is joined via a radially extending crossbar 5 to a first pole piece 6 that also extends parallel to the center axis. The core 4, crossbar 5 and first pole piece 6 form a soft-magnetic first conductor body 16, which is U-shaped and, with the first pole piece 6, each first conductor body 16 at least partly surrounds a respective magnetic coil 3 on its side toward the center axis of the magnetic valve. The first pole pieces 6 grouped about the center axis of the magnetic valve together form a first pole body 7, which has a preferably cylindrical jacket. A second conductor body 36 rests, with a contact step 35, on the side of each core 4 remote from the crossbar 5, and with a second pole piece 37 partly surrounds each associated magnetic coil 3 on its side toward the center axis of the magnetic valve. The second pole pieces 37 are oriented toward and spaced axially apart from the first pole pieces 6 and together form a second pole body 8 having a preferably cylindrical jacket. The first pole body 7 and second pole body 8 each have a continuous coaxial bore 9 and 10, respectively. The bore 10 in the second pole body 8 is adapted to receive a projection 11, that is provided on the valve housing 1 and which is arranged to protrude into the interior thereof. A cylindrical valve body 12 is guided, for instance by means of protrusions 13 secured to the circumference of the valve body 12, in the bores 9 of the first pole body 7 comprising the pole pieces 6. The annular gap 20 formed between the bore 9 of the first pole body 7 and the valve body 12 serves to enable the inflow and outflow of fluid on the occasion of positive displacement by a magnet armature 14, for instance when the magnetic valve is used in the control of fuel supply to an internal combustion engine. This magnet armature 14 is in the form of a disk, the circular end faces of which are approximately the same size as the end faces oriented toward them of the pole bodies 7 and 8. The thickness of the magnet armature 14 is less than the axial spacing between the pole bodies 7 and 8; as a result, one air gap forms between the magnet armature 14 and the first pole body 7, and another forms the magnet armature 14 and the second pole body 8. The valve body 12 and the magnet armature 14 are joined together in such a way that when the valve body 12 is in contact with the projection 11, a gap 15 remains between the second pole body 8 and the magnet armature 14. Upon a movement of the magnet armature 14 in the opposite direction, toward the first pole body 7, the valve body 12 rests with a closing head 38 on a valve seat 18 that cooperates with the closing head 38 and is embodied by the opening of a coaxial bore 17 in the housing bottom 2. In this case, a gap 19 remains between the magnet armature 14 and the first pole body 7.
FIG. 2 shows the structure of the first pole body 7 (because of symmetry, this is applicable to the pole body 8 as well). In the exemplary embodiment shown, having four magnetic coils 3, the cylindrical first pole body 7 is divided into four first pole pieces 6 and four permanent magnets 21.
The cross-sectional shape of first pole pieces 6 is approximately that of a sector of a solid cylinder, each being approximately one-fourth of a circle segment having flat sides 40. The associated flat sides 40 of two adjacent first pole pieces 6 extend spaced apart from one another, and one of the flat permanent magnets 21 is inserted in between each two facing flat sides 40 in such a way that the four first pole pieces 6 in the form of quarter solid cylinders and the four permanent magnets 21 together form a closed circular cross section. The arrangement of the first pole piece 6 and the permanent magnets 21 is such that the face 22 of each first pole piece 6, which simultaneously forms the circular circumference of the first pole piece and is also part of the outer jacket of the cylindrical first pole body 7, is oriented toward the core 4 that cooperates with that particular first pole piece 6.
As already indicated, the above description relates to a magnetic valve having four magnetic coils 3. If some other whole number of magnet coils is used, then the number of cores 4, first pole pieces 6, permanent magnets 21 and crossbars 5 varies in the same way. The approximately quarter-circular shape of the first pole pieces 6 shown here then varies as well, to become approximately one-half, one-sixth, or some other fraction of a circle.
The permanent magnets 21 are poled such that the north and south poles of a permanent magnet 21 are oriented each toward a respective face 40 of adjacent first pole pieces 6, which extend along and in contact with this face 40. Like magnetic poles of adjacent permanent magnets are in contact with the faces 40 of a given pole piece 6. Each pole piece 6 is bordered on its sides by two permanent magnets 21, and its faces 40 are contacted by like poles of each two magnets 21: N-N for the first pole piece, S-S for the next, N-N for the third, and so on around the circle. Each first pole piece 6 located between each two adjacent permanent magnets 21 is thus subjected to a permanent homogeneous magnetization, which corresponds to the magnetization of the faces of the permanent magnets 21 resting laterally against it. The number of first pole pieces 6 magnetized as south poles is equal to the number of first pole pieces 6 magnetized as north poles.
The second pole body 8 is structurally like the first pole body 7 and is located mirror-symmectrically opposite it, so that permanent magnets 21 located opposite one another have like pole arrangements.
A fluid flow conduit 32 is formed in the housing bottom 2, discharging into a chamber 33 that surrounds the valve body 12 in the vicinity of the closing head 38. At the valve seat 18, the chamber 33 merges with the bore 17.
The electric triggering of the magnetic coils 3 is done such that each two opposite cores 4 have the same direction of the induced magnetic flux, and each two adjacent cores 4 have the opposite direction of the induced magnetic flux. Together with the magnetic fields generated in the first and second pole bodies 7 and 8 by the permanent magnets 21, triggering the magnetic coils 3 with current of a predetermined polarity changes the magnetic flux in the axis air gaps 15, 19 at the magnet armature 14, thus either amplifying the magnetic flux in the gap 15 and attenuating it in the gap 19, or vice versa. The magnet armature 14 and the valve body 12 react to this either by moving toward the second pole body 8 or by moving toward the first pole body 7.
The magnetic induction of the permanent magnets 21 that is required can be calculated as follows:
If B P represents the permanent magnetic field and B E the intensity of the electromagnetic field, then the following equation applies to the force on the magnet armature 14, with the constant C:
F=C ((B.sub.P +B.sub.E).sup.2 -(B.sub.P -B.sub.E).sup.2) (1)
where the first element in parentheses represents the force in the gap 15, for instance, and the second element in parentheses represents the force in the gap 19. By applying the binomial theorem,
F=4C B.sub.P B.sub.E. (2)
The applicable equation for the force generated by the soft-iron magnet is:
F.sub.E =C(B.sub.E).sup.2 (3)
Comparing equations (2) and (3) the result is that for
B.sub.P ≧1/4B.sub.E (4)
the force F upon the magnet armature 15 becomes greater than the force F E of the soft-iron magnet; thus by superimposing the permanent magnet field, the result is a reinforcement of the force acting upon the magnet armature 14.
The net force ΔF, which is often more important, is already greater from
B.sub.P ≧1/8B.sub.E (5)
on, according to equation (2), because of the reversible polarity of B E and thus of F.
The operating principle of the magnetic valve according to the invention may be explained as follows, taking into account the operative magnetic forces in the lower part of the magnetic valve of FIG. 1, between the first pole body 7 and the magnet armature 14. For the sake of clarity, those first pole piece 6 of the first pole body 7 that become south poles under the influence of the permanent magnets 21 are identified as 25, while those that become north poles under the influence of the permanent magents 21 are identified as 26.
If current flows through the magnetic coils 3 in such a way that the electromagnetic flux also causes the pole pieces 26 to become north poles and the pole pieces 25 to become south poles, then by superimposition with the pole characteristic defined by the permanent magnets 21, the result is a reinforcement of the magnetic flux in the gap 19. The result is a force upon the magnet armature 14 in the direction toward the first pole body 7 and thus the closure of the valve seat 18 by the closing head 38.
On the other hand, if current flows through the magnetic coils 3 in such a way that electromagnetic flux causes the pole pieces 25 to become north poles and the pole pieces 26 to become south poles, then by superimposition with the pole characteristic defined by the permanent magnets 21 the result is an attenuation of the magnetic flux in the gap 19.
The above discussion of the operating principle related solely to the magnetic force operative in the gap 19. Since the position and polarity of the permanent magnets 21 inside the upper, second pole body 8 remote from the valve seat 18 are identical to those inside the first pole body 7, influence upon the forces acting on the magnet armature is exerted in such a way that whenever the forces of the permanent magnetic field and the electrical magnetic field are superimposed and thus reinforce one another in the gap 19 nearer the valve, there is a simultaneous subtraction of the operative force of the two magnetic fields in the gap 15 remote from the valve, and vice versa. Thus a double force action can be said to be involved, and the magnetic valve can be said to be double-acting.
A particularly advantageously designed embodiment of the magnetic valve acording to the invention, having four magnetic coils 3, is shown in FIG. 3, in which individual elements functioning the same as those of FIGS. 1 and 2 are identified by the same reference numerals. A particularly advantageous feature is the simple structure of the first pole body 7 (this applies equally to the second pole body 8 in this case). Two flat permanent magnets 29 are inserted, with their flat sides parallel to one another, into this first pole body 7, which is again preferably cylindrical, such that the permanent magnets 29 are disposed spaced apart by the same distance from the central longitudinal axis of the magnetic valve. The distance by which the two permanent magnets 29 are spaced apart from one another is suitably equal to or greater than the diameter of the bore 9 that receives the valve body 12. If the spacing between the two permanent magnets 29 is greater than the diameter of the bore 9, then the cylindrical first pole body 7 is symmetrically divided by the two permanent magnets 29 into two first outer pole pieces 30, 34, having the cross-sectional shape of a segment of a circle, and a first central pole piece 31. In the borderline case, where the distance between the two permanent magnets 29 is equal to the diameter of the bore 9, the first central pole piece 31 is divided into two independent halves, each symmetrical to the central longitudinal axis.
The flat permanent magnets 29 are magnetically induced and installed in such a manner that that the flat sides forming facing poles each have the same polarity. The outward-facing flat sides of the permanent magnets 29 likewise have the same polarity. The connection between the cores 4 and the first outer pole pieces 30, 34 cooperating with them, or the first center pole piece 31, is brought about in the same manner as in the first exemplary embodiment shown in FIG. 1, that is, in a U-shaped first conductor body 16. The permanent magnets 29 are inserted into the first pole body 7 in such a way that their flat sides extend parallel to the particular two first conductor bodies 16 that contain the first central pole piece 31.
The advantage of the embodiment shown in FIG. 3 of a magnetic valve according to the invention is that only two permanent magnets 29 are used, with the same mode of operation as that attained in an embodiment having four permanent magnets 21 as shown in FIG. 2.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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A magnetic valve that is switchable in two directions is proposed. The valve comprises an armature, which is firmly joined to a valve body; at least two magnetic coils disposed in one plane and having ferromagnetic cores inserted in them; and two pole bodies, which are joined to the cores and with them belong to the electromagnetic circuit, and acts on the oppositely located flat sides of the armature. Permanent magnets are inserted into the pole bodies in such a way that the operative surface area of the pole bodies is divided into a number of zones, each having a homogeneous magnetic orientation in which the number of zones is equal to the number of magnetic coils.
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TECHNICAL FIELD
The present invention relates to an improvement in a manually operable mechanism for a vehicle.
BACKGROUND ART
A parking lever disposed in the vicinity of a grip of a handlebar of a motorcycle is known from, for example, Patent Literature 1 and 2.
The parking lever disclosed in Patent Literature 1 is pivotably provided in the vicinity of a left grip of a handlebar of a motorcycle. The parking lever is connected via a parking lever cable to a parking brake mechanism provided in a rear wheel of the motorcycle. When the parking lever is in a non-operated position located away from the left grip, a parking brake is released. When the parking lever pivots to an operated position located along the length of the left grip, the parking brake mechanism is actuated to apply the parking brake. When a driver starts the vehicle with the parking lever in the operated position, he grips the left grip. By gripping the left grip, he identifies the parking lever located along the left grip and remembers to release the parking brake before starting the vehicle.
For releasing the parking brake, the driver must manually operate the parking lever for pivotal movement of the parking lever from the operated position to the non-operated position. However, he would undesirably spend a lot of time and effort on such a manual operation of the parking lever before starting the vehicle.
Patent Literature 2 discloses a parking lever vertically pivotable on a horizontal support shaft extending longitudinally of a vehicle, and an operational lever (a clutch lever) horizontally pivotable on a vertical support shaft. The parking lever is disposed between the operational lever and a handlebar. When the operational lever is horizontally pivoted on the vertical support shaft towards the handlebar, a distal end portion of the operational lever presses a releasing portion of the parking lever to cause vertical pivotal movement of the parking lever on the horizontal support shaft for releasing a parking brake. That is, the operational lever and the parking lever are designed to provide a specific structure for converting a force causing the horizontal pivotal movement of the operational lever into a force causing the vertical pivotal movement of the parking lever.
The provision of such a specific structure undesirably results in an increased cost of components of the operational lever and the parking lever. Furthermore, the conversion of the force causing the horizontal pivotal movement of the operational lever into the force causing the vertical pivotal movement of the parking lever may not be smoothly made.
In addition, since the parking lever is disposed on the operational lever, the vertical pivotal movement of the parking lever provides unpleasant appearance. To make the appearance of the parking lever inconspicuous, one may propose downsizing the parking lever. However, operation of the downsized parking lever requires a great force.
There is a need to provide a mechanism for a parking brake of a vehicle, which mechanism includes a simple structure that can be operated in a short time in such a manner as to achieve smooth force conversion.
PRIOR ART LITERATURE
Patent Literature
Patent Literature 1: Japanese Patent Application Laid-Open Publication No. 2001-63675
Patent Literature 2: Japanese Patent Application Laid-Open Publication No. 2004-279649
SUMMARY OF INVENTION
It is therefore an object of the present invention to provide a mechanism for a parking brake of a vehicle, which mechanism includes a simple structure that can be operated in a short time in such a manner as to achieve smooth force conversion.
According to an aspect of the present invention, there is provided a manually operable mechanism for a vehicle having a handlebar to be operated by an operator for steering the vehicle, which mechanism comprises: a first manual operation member pivotably attached to the handlebar through a first support shaft, the first manual operation member being operable by the operator to pivot on the first support shaft; a second manual operation member pivotably attached to the handlebar through a second support shaft disposed in the vicinity of and in parallel to the first support shaft; and the first manual operation member having an output portion, the second manual operation member having an input portion to be pressed by the output portion of the first operation member during pivotal movement of the first manual operation member on the first support shaft such that the second manual operation member pivots on the second support shaft.
In a preferred form of the invention, the second manual operation member is pivotable between an operated position and a non-operated position, and wherein, when the second manual operation member is in the operated position, the second manual operation member is urged by a predetermined urging force in a direction opposite to a direction toward the non-operated position, and when the second manual operation member pivots towards the non-operated position through a given angle, the second manual operation member is urged by the urging force in the direction toward the non-operated position.
Preferably, the first manual operation member, the second manual operation member and the second support shaft are disposed such that, when the first manual operation member pivots against the urging force through an angle smaller than a predetermined angle, the second manual operation member is pivoted by the output portion of the first manual operation member pressing the input portion of the second manual operation member, and when the first manual operation member pivots through an angle larger than the predetermined angle, the second manual operation member is pivoted by the urging force urging the second manual operation member in the direction toward the non-operated position and the input portion of the second manual operation member moves away from the output portion of the first manual operation member so as to allow the second manual operation member to pivot independently of the first manual operation member.
In a further preferred form of the invention, the second manual operation member comprises a parking brake operated to hold the vehicle in a parked state.
The first manual operation member has the output portion formed integrally therewith and the second manual operation member has the input portion formed integrally therewith. The input portion is pressed by the output portion during the pivotal movement of the first manual operation member on the first manual support shaft such that the second manual operation member pivots on the second support shaft. Since operation of the first manual operation member moves the second manual operation member, the parking brake can be readily released.
When the first manual operation member is pivoted through the angle larger than the predetermined angle, the second manual operation member is urged by the urging force in such a direction as to release the parking brake and the input portion moves away from the output portion so as to allow the second manual operation member to pivot independently of the first manual operation member. After the second manual operation member is pivoted independently of the first manual operation member, the first manual operation member is pivotable independently, which is useful for an operator.
The size of the second manual operation member may be freely set. Thus, the second manual operation member may have a large size.
Preferably, the first manual operation member, the first support shaft and the second support shaft are disposed forward of the handlebar when the vehicle is viewed in top plan, and wherein, when a parking brake is released, the second manual operation member is located rearward of a front edge of the first manual operation member and forward of a rear edge of the handlebar in such a manner that a distal end of the second manual operation member does not interfere with a range of movement of an operational portion of the first manual operation member.
When the parking brake is released, the distal end portion of the second manual operation member is located without interfering with the range of the movement of the operational portion of the first manual operation member. It becomes possible to prevent the operator from unintentionally operating the second manual operation member when he operates the first manual operation member. That is, the operator may easily operate the first manual operation member because he is not subject to constraints attributed to the second manual operation member in operating the first manual operation member. The second manual operation member is disposed rearward of the front edge of the first manual operation member and forward of the rear edge of the handlebar, which makes the second manual operation member inconspicuous for improved appearance of the second manual operation member.
In a preferred form of the invention, the second manual operation member is pivotable between an operated position to apply a parking brake and a non-operated position to release the parking brake, and wherein the output portion of the first manual operation member and the input portion of the second manual operation member are disposed in such a manner as to prevent the second manual operation member from pivoting to the operated position when the first manual operation member is operated by a maximum amount.
In other words, it becomes possible to prevent the second manual operation member from pivoting to the operated position during operation of the first manual operation member.
In a further preferred form of the invention, the output portion of the first manual operation member provides a first turning radius defined as a distance between the output portion and the first support shaft, and the input portion of the second manual operation member provides a second turning radius defined as a distance between the input portion and the second support shaft, the first radius being larger than the second radius.
A small amount of the pivotal movement of the first manual operation member makes a large amount of the pivotal movement of the second manual operation member.
In a still further preferred form of the invention, the second manual operation member is disposed in such a manner as to pivot on the second support shaft within a range that does not extend rearward beyond a rear face of an auxiliary member attached to the handlebar when the vehicle is viewed in top plan.
The second manual operation member thus arranged does not provide an obstruction to the operator.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view showing a vehicle including a manually operable mechanism in accordance with the present invention;
FIG. 2 is a top plan view of the manually operable mechanism shown in FIG. 1 ;
FIG. 3 is an exploded perspective view showing the manually operable mechanism shown in FIG. 2 ;
FIG. 4 is a view showing a relation between a second manual operation member and an upper bracket;
FIG. 5 is the view of FIG. 4 with the second manual operation member pivoted to an operated position to apply a parking brake;
FIG. 6 is a view showing the second manual operation member in the operated position;
FIG. 7 is a view showing a first manual operation member pivoted in such a direction as to move the second manual operation member to a non-operated position to release the parking brake;
FIG. 8 is a view showing the first manual operation member pressing the second manual operation member in a direction towards the non-operated position; and
FIG. 9 is a view showing an alternative to the second manual operation member shown in FIG. 7 .
DESCRIPTION OF EMBODIMENTS
Certain preferred embodiments will be discussed below with reference to the accompanying drawings.
Referring to FIG. 1 , there is shown a straddle-type vehicle for motorcycle) 1 arranged such that a driver sits on a seat 7 of the vehicle 1 with his legs positioned astride of the seat 7 . The vehicle 1 includes a vehicle body frame 2 , a front wheel 3 positioned forward of the frame 2 and a rear wheel 4 positioned rearward of the frame 2 . Attached to the center of the frame 2 is an engine 5 . Disposed above the engine 5 are a fuel tank 6 and the seat positioned rearward of the fuel tank 6 . Located forward of the fuel tank 6 are a handlebar 11 to be operated by a driver for controlling the front wheel 3 to steer the vehicle 1 , and a manually operable mechanism 10 provided on the handlebar 11 in accordance with the present invention. It is to be noted that the vehicle 1 is not be limited to the motorcycle and may be three-wheeled or four-wheeled straddle-type vehicle.
The manually operable mechanism 10 includes a first manual lever (a first manual operation member) 13 pivotably attached to the handlebar 11 through a first support shaft 12 such that the first manual lever is pivoted by the driver on the first support shaft 12 , and a second manual lever (a second manual operation member) 15 attached to the handlebar 11 through a second support shaft 14 in such a manner as to pivot on the second support shaft 14 . The second support shaft is disposed in the vicinity of the first support shaft 12 .
The handlebar 11 has a left grip 16 . A left switch box (an ancillary member) 17 is attached to a vicinity of the left grip 16 . A support member 20 for the manually operable mechanism 10 is attached to a vicinity of the left switch box 17 , and carries a bolt 18 and a U-shaped fitting 19 . The first manual lever 13 is attached to the support member 20 by the first support shaft 12 . Connected to the first manual lever 13 is a clutch wire or brake wire 21 . The second manual lever 15 is attached to the support member 20 by the second support shaft 14 . Connected to the second manual lever 15 is a parking brake wire 22 .
The first manual lever 13 includes an operational portion 23 to be operated or gripped by the driver. Since the first manual lever 13 is pivotable on the first support shaft 12 , the operational portion 23 is movable within a region A defined by phantom lines L 1 , L 2 . The second manual lever 15 shown in FIG. 2 is in a position where a parking brake is released. When the second manual lever 15 is in such a position, the second manual lever 15 does not interfere with the region A. This means that the driver does not unintentionally operate the second manual lever 15 when he operates the first manual lever 13 . The driver can more freely operate the first manual lever 13 because he is not subject to constraints attributed to the second manual lever 15 in operating the first manual lever 13 .
As shown in FIG. 3 , the first manual lever 13 includes a flange portion 36 having a hole 24 for allowing the first support shaft 12 to pass through the hole 24 . The first manual lever 13 further includes an output portion 26 formed integrally with and positioned oppositely from the operational portion 23 . The output portion 26 is preferably in the form of a projection but may take a variety of configurations.
The support member 20 for the manually operable mechanism 10 includes a body 27 , a lower bracket 29 attached to the body 27 by a screw 28 , and an upper bracket 32 attached to the body 27 by a screw 31 . A switch case 34 may be attached to a lower surface of the body 27 by a bolt 33 .
The body 27 of the support member 20 includes a recessed portion 35 for allowing the handlebar 11 to be fitted in the recessed portion 35 , and a pocket portion 37 for receiving the flange portion 36 of the first manual lever 13 .
The flange portion 36 of the first manual lever 13 is inserted within the pocket portion 37 of the body 27 and the first support shaft 12 is inserted through the pocket portion 37 and the flange portion 36 , with a torsion spring 38 , washers 39 , a stopper plate 41 and a nut 42 tightened onto a lower part of the first support shaft 12 . With this arrangement, the first manual lever 13 is pivotably attached to the body 27 of the support member 20 .
The second support shaft 14 includes a lower pin 14 a and an upper pin 14 b . The second manual lever 15 is pivotably attached to the lower bracket 29 by the lower pin 14 a and to the upper bracket 32 by the upper pin 14 b . The second manual lever 15 includes an operational portion 43 and an input portion 44 integral with the operational portion 43 . The input portion 44 is preferably in the form of a projection but may take a variety of configurations.
Attached to the upper bracket 32 is a hollow wire connecting member 45 covered with a resin cover 46 . Similarly, another hollow wire connecting member 45 is attached to the body 27 of the support member 20 and covered with a resin cover 46 . The body of the support member 20 has a front face covered with a cover 47 .
As shown in FIG. 4 , the upper bracket 32 includes a curved surface 48 for guiding the parking brake wire 22 . The parking brake wire 22 is connected through an end ball 49 to a portion of the second manual lever 15 , which portion is located in the vicinity of the second support shaft 14 . The parking brake wire 22 shown in FIG. 4 is in a position where a parking brake (not shown) is released. The parking brake wire 22 in such a position is not in contact with the curved surface 48 of the upper bracket 32 . The parking brake wire 22 shown in FIG. 4 is urged by a spring (not shown) in such a direction (the right direction of FIG. 4 ) as to release the parking brake. With the parking brake wire 22 thus urged, the second manual lever 15 is urged in such a manner as to pivot counterclockwise on the second support shaft 14 .
As shown in FIG. 5 , a line 51 passing through the center of the second support shaft 14 and the center of the end ball 49 and a centerline (an axial line) 52 of the parking brake wire 22 define an angle θ therebetween.
When the second manual lever 15 is pivoted by a driver's hand in a clockwise direction on the second support shaft 14 , the end ball 49 is shifted upward to a position above the second support shaft 14 . With the end ball 49 positioned above the second support shaft 14 , the angle θ is “plus” (or θ>0). When the angle θ is “plus”, the second manual lever 15 is urged by the parking brake wire 22 in such a manner as to pivot clockwise on the second support shaft 14 . During the clockwise pivotal movement of the second manual lever 15 , the parking brake wire 22 is guided by the curved surface 48 to thereby prevent the parking brake wire 22 from making tight contact with an exit of the hollow wire connecting member 45 . This can result in extended life of the parking brake wire 22 .
When the end ball 49 is positioned below the second support shaft 14 , the angle θ is “minus” (or θ<0). That is, as the second manual lever 15 is pivoted counterclockwise from the position shown in FIG. 5 , the end ball 49 is shifted downward to a position below the second support shaft 14 to thereby change the angle θ from “plus” through “zero” to “minus”. With the angle θ being “minus”, the second manual lever 15 is urged by the parking brake wire 22 in such a manner as to pivot counterclockwise on the second support shaft 14 . Therefore, whether the second manual lever 15 is urged by the parking brake wire 22 to pivot clockwise or counterclockwise depends upon whether the angle θ is “plus” or “minus”.
Discussion will be made as to how the manually operable mechanism 10 operates with reference to FIG. 6 to FIG. 8 .
Referring to FIG. 6 , the second manual lever 15 is shown pulling the parking brake wire 22 with the parking brake held in an applied position.
As shown in FIG. 7 , when the driver operates the operational portion 23 of the first manual lever 13 to cause the first manual lever 13 to pivot on the first support shaft 12 counterclockwise through an angle smaller than a predetermined angle, the output portion 26 of the first manual lever 13 comes into abutment on and presses the input portion 44 of the second manual lever 15 . By the output portion 26 pressing the input portion 44 , the second manual lever 15 is pivoted counterclockwise on the second support shaft 14 against an urging force of the parking brake wire 22 .
When the first manual lever 13 is further pivoted counterclockwise through the predetermined angle with the output portion 26 pressing the input portion 44 , the second manual lever 15 is further pivoted counterclockwise. At this point, the angle θ is changed from “plus” to “zero”.
As shown in FIG. 8 , when the first manual lever 13 is further pivoted counterclockwise through an angle greater than the predetermined angle, the second manual lever 15 is further pivoted counterclockwise. At this point, the angle θ is changed from “zero” to “minus”. With the angle θ being “minus”, the input portion 44 moves away from the output portion 26 and the second manual lever 15 is pivoted counterclockwise toward a position (shown by a phantom line) by the urging force of the parking brake wire 22 , as indicated by an arrow. When the second manual lever 15 is pivoted counterclockwise to the position shown by the phantom line, the parking brake is released for allowing the vehicle 1 to travel.
As can be seen from the foregoing descriptions made with reference to FIG. 6 to FIG. 8 , when the first manual lever 13 is pivoted through an angle smaller than the predetermined angle, the output portion 26 of the first manual lever 13 presses the input portion 44 of the second manual lever 15 to thereby cause the second manual lever 15 to pivot in such a direction as to release the parking brake. When the first manual lever 13 is pivoted through an angle larger than the predetermined angle, the second manual lever 15 is pivoted by the urging force of the parking brake wire 22 in such a direction as to release the parking brake and the input portion 44 of the second manual lever 15 moves away from the output portion 26 of the first manual lever 13 so as to allow the second manual lever 15 to pivot independently of the first manual lever 13 . After the second manual lever 15 pivots independently of the first manual lever 13 , the first manual lever 13 is pivotable independently, which is easier-to-use for the driver.
Since the first manual lever 13 includes the output portion 26 for pressing the input portion 44 of the output portion 26 , it becomes possible to operate the second manual lever by operating the first manual lever, which provides an easy operation of releasing the parking brake.
When the first manual lever 13 is fully gripped by the driver's left hand to further pivot counterclockwise from the position shown in FIG. 8 and the second manual lever 15 is pivoted by the driver's right hand clockwise from the position shown by the phantom line of FIG. 8 , the output portion 26 of the first manual lever 13 serves as a stopper and limits movement of the input portion 44 of the second manual lever 15 . As a result, the second manual lever 15 , which has been pivoted clockwise, automatically pivots back to the position shown by the phantom line of FIG. 8 . That is, when the first manual lever 13 is counterclockwise pivoted by the maximum amount or more than a predetermined amount, the second manual lever 15 can not be pivoted clockwise to a position where the parking brake is applied. This arrangement prevents the vehicle 1 from starting to travel with the parking brake applied.
The output portion 26 of the first manual lever 13 moves in a curve or arc of a first radius (first turning radius) R 1 during the pivotal movement of the first manual lever 13 on the first support shaft 12 . The first turning radius R 1 is defined as a distance between the first support shaft 12 and the output portion 26 of the first manual lever 13 . The input portion 44 of the second manual lever 14 moves in a curve or arc of a second radius (second turning radius) R 2 during the pivotal movement of the second manual lever 14 on the second support shaft 14 . The second turning radius R 2 is defined as a distance between the second support shaft 14 and the input portion 44 . The first turning radius R 1 is larger than the second turning radius R 2 . With the first turning radius R 1 larger than the second turning radius R 2 , a small amount of pivotal movement of the first manual lever 13 can causes a large amount of pivotal movement of the second manual lever 15 . Therefore, when the first manual lever 13 pivots counterclockwise through a small angle, the second manual lever 14 pivots through an angle which is so large that the input portion 44 moves away from the output portion 26 of the first manual lever 13 so as to allow the first manual lever 13 to pivot independently of the second manual lever 15 . That is, the first manual lever 13 can be operated independently of the second manual lever 14 in a short time after the first manual lever 13 is pivoted counterclockwise from the position shown in FIG. 6 , which provides improved operability of the first manual lever 13 .
FIG. 9 shows a manually operable mechanism according to another embodiment of the present invention. The manually operable mechanism includes the second manual lever 15 having a distal end at a position located forward of a rear face of the left switch box 17 when the second manual lever 15 is pivoted to a position where the second manual lever 15 is directed perpendicularly to the handlebar 11 , as shown in FIG. 9 . That is, the distal end of the second manual lever 15 directed perpendicularly to the handlebar 11 is forward offset by a distance “a” from the level of the rear face of the left switch box 17 . The distance “a” can be easily set by devising the configuration of the second manual lever 15 and the location of the second support shaft 14 . Even if an object is flown from a rear side of the handlebar 11 towards the second manual lever 15 , the object hits against the switch box 17 without interfering with the second manual lever 15 .
The second manual lever 17 may be provided on a right grip of the handlebar 11 . The vehicle 10 may be a three-wheeled or four-wheeled one employing the handlebar.
Although the first manual operation member and the second manual operation member have been described as being applied to the manual levers 13 , 15 , the first and second manual operation members may be of dial-type.
INDUSTRIAL APPLICABILITY
The manually operable mechanism for a parking brake, according to the present invention is suitable for use in a motorcycle.
LEGEND
10 —manually operable mechanism; 11 —handlebar; 12 —first support shaft; 13 —first manual operation member; 14 —second support shaft second manual operation member; 20 —support member; 26 —output portion; 44 —input portion; 54 —front edge of first manual operation member; 55 —rear edge of handlebar
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A manual operator for a vehicle, wherein the manual operator can be simply operated, has a good appearance, and allows a sufficient space for a manual operator for a parking brake. A first manual operator ( 13 ) pivotably mounted on a handlebar ( 11 ) has an output section ( 26 ) mounted so as to be pivotable about the center of a first support shaft ( 12 ). A second manual operator ( 15 ) has an input section ( 44 ) provided so as to be pivotable about a second support shaft ( 14 ) when pushed by the output section ( 26 ). The second manual operator ( 15 ) is a manual operator adapted for a vehicle parking brake and capable of setting the vehicle to a parked state.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to latching mechanisms for stacked drawer arrangements, for example, in filing cabinet, which mechanisms act to allow withdrawal of only one drawer at a time. Such arrangements are intended to maintain the stability of the stack against tipping.
2. Background of the Invention
The provision of anti-tip latching arrangements has presented a large number of practical problems and a large amount of prior art exists. Generally, anti-tip mechanisms require great precision in installation of the anti-tip interactive components secured, for example, to a filing cabinet, and of the related actuating pins carried by the cabinet drawers.
There are at least two basic arrangements conventionally used. In the first of these arrangements, each drawer is associated with a single vertical bar of similar height to the height of the respective drawer. Each bar is itself associated with a stop to prevent withdrawal of its associated drawer. The bars and their stops are positionable such that all the stops except one are located to block withdrawal of their respective drawers.
In the second conventional arrangement, each drawer is associated with a pair of vertical bars (split bars), each pair being associated with a stop for the respective drawer. The system works in a somewhat similar manner to that described for the first system, but this second system may be more versatile in that each stop may be located at the junction between bars of each pair and the length of each bar of the pair may be selected at will.
When using the second, split bar system, it may be possible to locate stops on or about the level of the drawer track. In fact, U.S. patent application No. 384,792 to Pratzer and assigned to the same assignee as the present invention, discloses and claims a system which is mountable on a drawer track rather than on the filing cabinet wall or other wall as was previously thought necessary. This may allow for some degree of lesser accuracy in installation.
Other patents representative of the art are U.S. Pat. No. 4,768,844 issued Sept. 6th, 1988 to Ludwig and U.S. Pat. No. 4,429,930 issued February 1984 to Blouin.
While the prior art is replete with examples of anti-tipping mechanisms some general problems remain. Among these are the fact that it is necessary to provide both an upper and a lower stop for the vertical bars to limit the total spacing in which it is possible to adjust them. Moreover, in existing systems the positions of the upper and lower stops must be accurate so that the resultant spacing between them is accurate. Thus, if the total space available for adjustment is too large it may be possible to withdraw more than one drawer at a time. Sequential or concurrent withdrawal of two drawers may also be possible in some cases due to "sponginess" between adjacent bars, which are supposedly located in the non-withdrawal positions.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a drawer interlock system for stacked drawers which operates by inter-related movements of stacked members associated with the drawers between locking and releasing positions. In which latching means rigidly, vertically attaches adjacent members to one another in the retracted position of all the drawers and in which preliminary withdrawal movement of any one single drawer from the stack actuates the latching means to detach a respective single pair of members.
The mechanism may comprise a plurality of stacked bars associated with the drawers and movable axially between locking and releasing positions. A drawer latch cam for each drawer is adapted to be engaged with the respective drawer in a closed position and adapted to be disengaged from the drawer in an open position. The drawer latch cam is pivotally mounted on a one of a pair of adjacent upper and lower bars for pivotal movement between the open and closed positions. A bar latch is associated with each drawer latch cam and is fixed in position with respect to a respective cam for movement therewith. The bar latch securely attaches, in the closed position of the respective cam, the other of the pair of upper and lower bars in stacked, end-to-end, adjacent relationship with said one bar, and, in the open position of the respective cam, releases said other bar. Translating means is provided responsive to pivotal opening movement of the drawer latch cam, to translate said pivotal movement into axial movement between the said pair of upper and lower bars to move said one bar between its releasing position and to locking position together with any bars stacked.
The drawer latch cam may conveniently be carried fixedly by a shaft which is pivotable in an aperture through said one bar. The bar latch may comprise hook adapted to engage said other bar which hook is either integral with the drawer latch cam is carried fixedly on the same shaft as the drawer latch cam to pivot with it.
The said one bar may suitably be a lower bar. In this case, the shaft carrying the drawer latch cam and the bar latch may extend pivotably through a bearing through the upper end of the bar and the bar latch may extend upwardly to engage the upper bar. Suitably, the projection from the upper bar may be a shaft extending through the upper bar from a cam follower adapted to move vertically in following a cam surface of the drawer latch cam as it pivots between its open and closed positions.
Each drawer latch cam may have a fork adapted to engage a pin projecting from a respective drawer to actuate movement of the cam on each of withdrawal or retraction of the respective drawer.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example with reference to the drawings, in which:
FIG. 1 shows a number of stacked drawers, the drawing being partially broken away to show an embodiment of the invention;
FIG. 2 is an exploded view of the mechanism of FIG. 1 in the drawer closed condition;
FIG. 3 is a similar exploded view to that of FIG. 2 but in the drawer open condition;
FIG. 4 is a diagrammatic representation of the mechanism of FIGS. 1 to 3;
FIG. 5 shows a simplified diagram of another embodiment of the invention in the drawer closed condition;
FIG. 6 shows the embodiment of FIG. 5 in the drawer open condition; and
FIG. 7 is an exploded view of the embodiment of FIGS. 5 and 6 in the drawer closed condition.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, it will be seen that the cabinet according to the invention is shown generally as 10 having a side wall 12.
Typically, filing cabinets come with a Plurality of drawers in a variety of numbers, depending upon the requirements of the user. Such drawers are shown generally as 20, and will be seen to comprise side panels 22, a back panel 24, a bottom panel 28 and a front panel 29. Typically, in the case of file drawers, for example, such drawers are mounted on telescopic extendable slides indicated as 30.
In order to avoid tipping of the cabinet on opening more than one heavy drawer at a time, drawer interlocks are provided such that when one drawer has been opened, the remaining drawers are locked shut. This then forces persons to close a drawer, before any others can be opened.
In some cases, it is possible to combine such a drawer interlock system with a key lock system for actually locking the filing drawers as a security measure when the office is unoccupied.
It will of course be appreciated that the drawer interlock system according to the invention can be provided with such a key lock system if desired, in a manner well known in the art, the details of which are omitted for the sake of clarity. Such drawer interlock systems are common utilizing stacked vertical bars 44 movable vertically between drawer locking and drawer releasing positions. However, such systems may not guard against simultaneous withdrawal of drawers and there may be too much play or sponginess between adjacent bars.
The drawer interlock system according to the invention is shown in more detail in FIGS. 2 and 3. It will be seen to comprise a plurality of drawer interlock cams, each of which is shown as 40, and which may be provided either one cam to each drawer, or two such cams, one on either side of each drawer if desired for greater security. In this case it will of course be appreciated that the mechanism which is shown in FIGS. 2 and 3 would be provided on the right and left hand side walls of the cabinet 10. For the purposes of this discussion, however, only one such mechanism will be described, it being understood that the description would be equally applicable to the interlock mechanism on the other end of the cabinet, if such was provided.
The cam 40 is fixedly mounted on a pivot shaft for example, through a part 43 of the shaft of square section to prevent rotation of the cam 40 or shaft 42. The shaft 42 pivots in a bearing 45 through a lower slide bar 44b of a pair of slide bars 44a and 44b. Pivot shaft 42 passes through square hold 48 in cam 40 and may be mounted to a drawer slide 30. Alternatively the mounting may be to the cabinet sidewall 12.
A bar latch 70 is also fixedly mounted on pivot shaft 42 through a square hole 78 and a square section end 73 of the pivot shaft 42. The bar latch 70 comprises a hook portion 72 forming a recess 74 to engage a projection 82 from upper slide bar 44a. Projection 82 is conveniently a pin pivoting in a bearing 84 in upper slide bar 44a and connected to a cam follower 80 of cam surface 47 is formed as a step between limbs of the cam 40 one of which limbs comprises fork 46 and the other of which includes the pivot axis of drawer latch cam 40.
The drawer latch cam 40 comprises a fork 46 to engage a pin 50 of any drawer 20 in such a manner that withdrawal of drawer 20 in the direction of the arrows A shown in FIGS. 2 and 3, and corresponding movement of pin 50 in fork 46 will act to rotate cam 40 and shaft 42 with bar latch 70 from the position shown in FIG. 2 to that shown in FIG. 3. Pin 50 is suitably connected to drawer 20 through a mounting plate 52.
When a person attempts to open any drawer 20 when all the drawers 20 are in their retracted locations, pin 50 will start to move in the direction of arrow A (FIGS. 1 and 2). If rotation of cam 40 is blocked (as will be later described), fork 46 will, with pin 50 act as a latch against drawer opening. If rotation of cam 40 is not blocked, then pin 50 will act to rotate cam 40 and shaft 42 in the direction of arrow B (FIG. 3) through 90° into the position shown in FIG. 3. Bar latch 70 will also rotate so that hook 72 engaging pin 82 will rotate so that recess 74 is vertical and open to the top to allow upward movement of pin 82.
Cam surface 47 tilts through the diagonal to the vertical with rotation of cam 40 tending to turn cam follower 80 eccentrically with it. Pin 82 of cam follower 80 is however constrained for vertical movement only in guide slot 92 of guide 90 for slide bars 44. Thus, instead of turning with cam surface 47, the cam follower 80 slides up the diagonal surface presented to it by cam surface 47 and pin 82 rises out of recess 74 forcing upper slide bar 44a to rise also in the direction of arrow C (FIG. 3).
When the Pin 50 has turned the cam 40 and hence the fork 46 through 90°, then the cam follower 80 is in its highest position. In this position, guide surface 84 abuts against stop pins 94 of a static guide 96. Guide 96 has a prong 98 on which a vertical slot 49 of upper slide bar 44a slides. Prong 98 together with slot 49 acts as a further guide to keep bar 44a vertical and, as a stop to prevent further upward movement of bar 44a. Guide surfaces 84 of cam follower 80 bear or pins 94 on the one hand, and cam follower surface 85 bears against rotated cam 40 at bearing edge 43 to fix the distance of separation between upper bar 44a and lower bar 44b. Since upper bar 44a may not rise further lower bar 44b is fixedly (while respective drawer 29 is open) separated from it the positions of these two bars are fixed.
Thus, when a drawer 20 is open it is not possible to open lower drawers. In order to open such lower drawers it is necessary to raise the respective slide bar 44a by the mechanism described. Since the slide bars are stacked and due to the already open drawer, a pair of members of the stack are fixed, upward adjustment of the lower members is no longer possible. Downward adjustment may be blocked by a fixed base.
If upward adjustment of slide bars 44 above those associated with the already open drawer is also inhibited, then opening of upper drawers will also be stopped. Various means are conventional for achieving this, for example, the provision of an upper stop above the stacked bars of the provision of further members 96 having prongs 98 or other means. Generally, the provision of such means is conventional but problems have remained in providing such means incorporating rigidity and lack of sponginess in the connection between two abutting stacked bars.
FIGS. 5, 6 and 7 illustrate another embodiment of a slightly simpler construction. A fork 146 associated with a cam 140 is engagable with a drawer pin 150 and is integral with a bar latch 170.
In this case, the bar latch 170, the drawer latch cam 140 and fork 146 are pivotable on a lower slide bar 44b on a pivot pin 142.
Withdrawal of the drawer in the direction of arrow D, fork 146 pivots anti-clockwise so that an L-shaped cam 141 of the drawer latch 140 pivots to bear against cam follower 180 fixed directly to the base of upper slide bar 44a through at least one pin 200 extending through a vertical guide slot 192.
Bar latch hook 172 with is associated recess 174 engage pin 182 directly attached to the lower slide bar 44b. The operation of this embodiment is generally similar to that of the first embodiment, the open position of the drawer being shown in FIG. 6.
FIG. 7 shows a exploded view to better illustrate the parts shown in diagrammatically in FIGS. 5 and 6.
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A batching mechanism for an anti-tipping drawer mechanism rigidly attaches adjacent stacked drawers in the retracted position, thus mitigating the tendency to looseness in the mechanism. Preliminary withdrawal movement of any one drawer detaches the latching means and thereafter, further movement of the drawer actuates anti-tipping latching of the other drawers.
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RELATED APPLICATIONS
This invention provides novel benzoylphenylurea insecticides and novel methods of inhibiting cockroaches, ants, fleas, and termites.
BACKGROUND OF THE INVENTION
A broad class of benzoylphenylurea insecticides is disclosed in U.S. Pat. No. 3,748,356. European Patent Application 263438 discloses that certain N-substituted phenyl-N'-substituted benzoyl-N-methylureas are highly safe to beneficial aquatic Crustacea while exhibiting equal or superior insecticidal activities to non-alkylated analogs. Hexaflumuron, a commercially significant benzoylphenylurea, is disclosed in U.S. Pat. No. 4,468,405. Use of hexaflumuron in methods of controlling termites is disclosed in WO 93/24011. Use of hexaflumuron to control cockroaches is disclosed in WO 94/03066. The compound N- 3,5-dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)phenyl!-N'-(2,6-difluorobenzoyl)urea is disclosed in DE 3827133 and European Patent Application A 243,790, but there was no disclosure of the unexpected activity of the compound against cockroaches, ants, fleas, and termites.
We have discovered that certain benzoylphenylurea compounds, some of which are novel, have substantially greater activity against cockroaches, ants, fleas, and termites than would have been expected based on comparison with the closest prior art, i.e., hexaflumuron. Another significant property of the novel compounds of the invention is their surprisingly low toxicity to Daphnia.
SUMMARY OF THE INVENTION
The invention provides a method of controlling cockroaches, ants, fleas, or termites which comprises delivering a effective amount of a compound of the formula (I): ##STR2## wherein R 1 and R 2 are H, methyl, or ethyl, to a location where control of cockroaches, ants, fleas, or termites is desired.
More specifically, the invention provides:
A method of controlling cockroaches which comprises a compound of the formula (I), in an amount effective to control cockroaches, to a location where control of cockroaches is desired;
A method of controlling ants which comprises delivering a compound of the formula (I), in an amount effective to control ants, to a location where control of ants is desired.
A method of controlling fleas which comprises delivering a compound of the formula (I), in an amount effective to control fleas, to a location where control of fleas is desired; and
A method of controlling termites which comprises delivering a compound of the formula (I), in an amount effective to control termites, to a location where control of termites is desired.
The invention also provides novel compounds of the formula (II) ##STR3## wherein R 1 ' and R 2 ' are H, methyl, or ethyl, provided that at least one of R 1 ' and R 2 ' is methyl or ethyl.
DETAILED DESCRIPTION OF THE INVENTION
Intermediate 1: 2,6-difluorobenzoyl isocyanate ##STR4##
A mixture of 0.52 g of 2,6-difluorobenzamide and 0.33 ml of oxalyl chloride was stirred under reflux in 15 ml 1,2-dichloroethane overnight. Solvent was removed under vacuum and 10 ml 1,2-dichloroethane was added. Solvent was removed under vacuum to leave the title intermediate, which could be used directly or dissolved in 1,2-dichloroethane and stored for future use.
Intermediate 2: 3,5-Dichloro-4-(1,1,2,3,3,3-hexafluoropropoxy)aniline ##STR5##
To a solution of 2.0 g of 4-amino-2,6-dichlorophenol in 40 mL tetrahydrofuran at room temperature was added 0.7 g of 87% potassium hydroxide. The mixture was warmed to 40° C. and stirred for 10 minutes, then chilled to 0° C. Hexafluoropropene was bubbled in for 5 minutes, and the mixture stirred at room temperature over night. It was then concentrated under vacuum to dryness. The residue was dissolved in 50 mL dichloromethane and washed with 20 mL brine solution. The organic layer was separated and filtered through phase separation filter paper and then concentrated under vacuum to an oil. This was diluted with 50 mL dichloromethane and 50 mL heptane and re concentrated to give 3.05 g of 3,5-dichloro-4-(1,1,2,3,3,3-hexafluoropropoxy)aniline as a brown oil. Proton and 19 F nmr spectra were consistent with the proposed structure.
Intermediate 3: 3,5-Dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)aniline ##STR6##
To a solution of 2.50 g 3,5-dichloro 4-(1,1,2,3,3,3-hexafluoropropoxy)aniline in 60 mL acetonitrile under an atmosphere of nitrogen at room temperature there was added 2.57 g 1-chloromethyl-4-fluoro-1,4-diazoniabicyclo 2.2.2! octane bis (tetrafluoroborate) SELECTFLUOR™ (Air Products) portion wise over a 10 minute period. The mixture was warmed to 70° C. over a one hour period, then cooled to room temperature and poured into 100 mL of saturated sodium bicarbonate solution. The product was extracted with 150 mL ethyl acetate. The organic layer was separated, washed with 50 mL of brine solution, separated, and dried over magnesium sulfate. The magnesium sulfate was removed by filtration, and the filtrate was concentrated under vacuum to give a dark oil 2.52 g. The product was chromatographed using a Michel-Miller low pressure silica gel column eluted with 6:1 heptane/ethyl acetate. Like fractions were pooled and concentrated under vacuum to a brown oil 1.19 g. The proton and 19 F nmr spectra were consistent with the proposed structure. Anal. calcd C 9 H 4 Cl 2 F 7 N 1 O 1 : C, 31.24; H, 1.17; N, 4.05. Found: C, 31.52; H, 1.15; N, 4.02.
Intermediate 4: 3,5-Dichloro-2-fluoro-4-(1,12,3,3,3-hexafluoropropoxy)-N-ethyl aniline ##STR7##
To a solution of 0.28 g 3,5-dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy) aniline in 8 mL glacial acetic acid at room temperature under an atmosphere of nitrogen was slowly added 0.31 g sodium borohydride. The addition was carried out over a 1.5 hour period through a solid addition funnel between 25°-34° C. with ice water cooling. The mixture was stirred at room temperature over night. Then the reaction mixture was added to 80 mL water and the pH was carefully adjusted to 7 by adding solid sodium carbonate. The product was extracted with 80 mL ethyl acetate. The organic layer was separated, washed with brine solution, separated, and dried over magnesium sulfate. The magnesium sulfate was removed by filtration, and the filtrate was concentrated under vacuum to give a brown oil 0.29 g. The product was chromatographed using a Michel-Miller low pressure silica gel column eluted with 9:1 heptane/ethyl acetate. Like fractions were pooled and concentrated under vacuum to give 0.19 g of a tan oil. 1 H-NMR d 1.28 (t, 3H), 3.17 (q, 4H), 3.95 (bs, 1H), 4.94-5.21 (md, 1H), 6.59 (d, 1H). Anal. calcd C 11 H 8 Cl 2 F 7 N: C, 35.31; H, 2.16; N, 3.74. Found: C, 35.32; H, 2.14; N, 3.74.
Preparation of Products
Compound 1: N- 3,5-Dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)phenyl!-N'-(2,6-difluorobenzoyl)urea ##STR8##
To a solution of 1.31 g 3,5-dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy) aniline in 5 mL 1,2-dichloroethane under an atmosphere of nitrogen at room temperature was added 0.87 g 2,6-difluorobenzoyl isocyanate dissolved in 10 mL dichloroethane dropwise over a 10 minute period. The mixture was stirred, warmed to 40° C. for a one hour period, then concentrated under vacuum to a brown solid 2.0 g. The mixture was chromatographed using a Michel-Miller low pressure silica gel column eluted with 4:1 dichloromethane/heptane. Like fractions were pooled and concentrated under vacuum to give 1.67 g of a light tan solid, mp 156°-7° C. Proton and 19 F nmr spectra were consistent with the proposed structure. Anal. calcd C 17 H 7 Cl 2 F 9 N 2 O 3 : C, 38.58; H, 1.33; N, 5.29. Found: C, 38.64; H, 1.40; N, 5.44.
Compound 2: N- 3,5-Dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)phenyl!-N'-(2,6-difluorobenzoyl)-N-ethylurea ##STR9##
To a solution of 1.00 g 3,5-dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)-N-ethyl aniline in 2 mL 1,2-dichloroethane under an atmosphere of nitrogen at room temperature there was added 0.54 g 2,6-difluorobenzoyl isocyanate dissolved in 6 mL dichloroethane dropwise over a 10 minute period. The mixture was stirred and warmed to 40° C. for a 1.5 hour period. Analysis by thin layer chromatography silica gel 4:1 heptane/ethyl acetate indicated incomplete reaction. To the mixture was added 0.13 g 2,6-difluorobenzoyl isocyanate in 1.5 mL 1,2-dichloroethane, and the mixture was warmed at 40° C. for 2.5 hour. Analysis by TLC indicated complete reaction. The reaction mixture was concentrated under vacuum to give an oil 1.64 g, which was chromatographed using a Michel-Miller low pressure silica gel column eluted with 4:1 heptane/ethyl acetate. Like fractions were pooled and concentrated under vacuum to give a white solid 0.87 g, mp 106°-14° C. Proton nmr and mass spectra were consistent with the proposed structure. Anal. calcd C 19 H 11 Cl 2 F 9 N 2 O 3 : C, 40.95; H, 1.99; N, 5.03. Found: C, 40.89; H, 1.92; N, 5.03.
Compound 3: N- 3,5-Dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)phenyl!-N'-(2,6-difluorobenzoyl)-N'-ethyl urea ##STR10##
Dissolve 1.65 g N- 3,5-dichloro-2-fluoro-4-(1,1,2,3,3,3-hexafluoropropoxy)phenyl!-N'-(2,6-difluorobenzoyl) urea in 10 mL N,N-dimethylformamide and add 0.22 g 87% potassium hydroxide. Chill to 0° C. and add 0.97 g iodoethane. Stir at 0° C. for a 7 hour period. Store in freezer at 0° C. over night. Analysis by thin layer chromatography silica gel dichloromethane shows product forming with starting urea remaining. The reaction was treated as above at 0° C. for the next two days. Additional amounts of iodoethane, 1.94 g, and 0.10 g 87% potassium hydroxide were added. Pour reaction mixture into 50 mL brine solution and extract with 80 mL ethyl acetate. Separate organic layer and dry over magnesium sulfate. Filter drying agent and concentrate the filtrate under vacuum to a red oil 2.63 g. Chromatograph using a Michel-Miller low pressure silica gel column and elute with 2:1 heptane/dichloromethane. Pool like fractions and concentrate under vacuum to 0.18 g of a pink solid, mp 105°-06° C. Proton nmr and mass spectra were consistent with the proposed structure. Anal. calcd C 19 H 11 Cl 2 F 9 N 2 O 3 : C, 40.95; H, 1.99; N, 5.03. Found: C, 40.99; H, 1.85; N, 4.98.
Biological Activity
German cockroach 2nd instars (Blattella germanica)
Continuous, low-dose ingestion exposure (treated cornmeal)
Rates: 0.19, 0.78, 3.12, 12.5, 50, 200 ppm
______________________________________ LC.sub.50 (ppm)Compound 21 days 42 days______________________________________Compound 1 <2.2 <0.78Compound 2 0.35 0.26Compound 3 8.0 1.5hexaflumuron >200 >200______________________________________
Under continuous exposure, Compounds 1,2, and 3 were far more active than hexaflumuron.
German cockroach 2nd instars (Blattella germanica)
Limited ingestion exposure (48 hr) to treated cornmeal
Rates: 1, 10, 100, 1000, 10000 ppm
______________________________________ LC.sub.50 (ppm)Compound 21 days 42 days______________________________________Compound 1 <22.2 <9.1Compound 2 21.1 12.8hexaflumuron >10,000 >10,000______________________________________
Under limited exposure, Compounds1 and 2 were more potent than hexaflumuron at both 21 and 42 days after exposure.
Cat Flea (Ctenocephalides felis)
Continuous exposure of larvae to treated media, impact on subsequent adult emergence
Rates: 0.1, 1.0, 10, 100, 1000 ppm
______________________________________Compound LC.sub.50 (ppm) LC.sub.90 (ppm)______________________________________Compound 1 2.8 22Compound 2 12.7 18.6hexaflumuron 65.7 333.5______________________________________
Compounds1 and 2 were both far more efficacious than hexaflumuron against cat fleas.
Subterranean Termite (Reticulitermes flavipes)
Continuous exposure (56 days) to treated paper
Rates: 0.78, 3.12, 12.5, 50, 200 ppm
______________________________________ LC.sub.50 (ppm) LT.sub.50 (days) forCompound 35 days 56 days 200 ppm trt______________________________________Compound 1 31.2 <0.78 27.6Compound 2 <0.78 <0.78 not calc.hexaflumuron >200 1.3 33.8______________________________________
Under continuous exposure, Compounds1 and 2 were more potent and quicker acting than hexaflumuron.
Subterranean Termite (Reticulitermes flavipes)
Limited exposure (7 days) with mortality determined at 14, 28, 42, and 56 days
______________________________________Compound LT.sub.50 (days) for 10000 ppm treatment______________________________________Compound 1 23.7hexaflumuron 32.9______________________________________
Under limited exposure, a high rate of Compound 1 induced more mortality earlier than did hexaflumuron.
Ant Studies
Laboratory ant bait studies were carried out with Red Imported Fire Ant (RIFA) (Solenopsis invicta) and Pharaoh Ant (Monomorium pharaonis). Chitin synthesis inhibitors, such as the compounds of the invention, control ants by killing the molting larvae and/or pupae and potentially preventing the hatching of eggs. Because adult workers are not affected, control is measured by effects on the brood. The studies involved 3-4 day exposure to bait. These limited exposure studies more accurately represent real world bait availability than continuous exposure.
______________________________________ Time to Time to Achieve Achieve Concentration 50% Brood 90% BroodCompound tested Species Reduction Reduction*______________________________________Compound 1 0.1%* RIFA 2 wks 3 wks 0.1% Pharaoh 4 wks NA (70% @ 13 wks)Hexaflumuron 0.1% RIFA NA NA 0.25% RIFA 4 wks 10 wks 0.1% Pharaoh NA NA______________________________________ *Only concentration tested. NA = did not achieve specified percent brood reduction.
Percent brood reduction achieved at end of study listed in parenthesis.
Compound 1 is significantly more potent than hexaflumuron based on a short exposure study with RIFA.
Activity against Daphnia
48 hr exposure to treated water
______________________________________Compound LC.sub.50 (ppb) in water______________________________________Compound 1 5.0Compound 2 >100Compound 3 >100Hexaflumuron 68.1______________________________________
Compounds 2 and 3, the alkylated derivatives of Compound 1, were much less active against Daphnia than were Compound 1 and hexaflumuron; this is surprising since the activities of Compound 1, 2, and 3 in cockroaches are quite similar.
Formulations
In order to facilitate the application of the compounds of formula (I) to the desired locus, or to facilitate storage, transport or handling, the compound is normally formulated with a carrier and/or a surface-active agent.
A carrier in the present context is any material with which the compound of formula (1) (active ingredient) is formulated to facilitate application to the locus, or storage, transport or handling. A carrier may be a solid or a liquid, including a material which is normally gaseous but which has been compressed to form a liquid. Any of the carriers normally used or known to be usable in formulating insecticidal compositions may be used.
Compositions according to the invention contain 0.0001 to 99.9% by weight active ingredient. Preferably, compositions according to the invention contain 0.001 to 10.0% by weight of active ingredient though proportions as low as 0.0001% may be useful in some circumstances.
Suitable solid carriers include natural and synthetic clays and silicates, for example natural silicas such as diatomaceous earths; magnesium silicates, for example talcs; magnesium aluminium silicates, for example attapulgites and vermiculites; aluminium silicates, for example kaolinites, montmorillonites and micas; calcium carbonate; calcium sulphate; ammonium sulphate; synthetic hydrated silicon oxides and synthetic calcium or aluminium silicates; elements, for example carbon and sulfur; natural and synthetic resins, for example coumaronne resins, polyvinyl chloride, and styrene polymers and copolymers; solid polychlorophenols; bitumen; waxes; agar; and solid fertilizers, for example superphosphates. Cellulose based materials, for example wood, sawdust, agar, paper products, cotton linter, or Methocel®, as well as the other solid carriers that are themselves attractive to or at least non-repellant to termites are particularly suitable and preferable. Mixtures of different solids are often suitable. For example, a mixture of wood flour and agar formulated as a moisture containing solid would be preferable.
Suitable liquid carriers include water; alcohols, for example isopropanol and glycols; ketones, for example acetone, methyl ethyl ketone, methyl isobutyl ketone, isophorone and cyclohexanone; ethers; aromatic or aliphatic hydrocarbons, for example benzene, toluene and xylene; petroleum fractions, for example kerosene and light mineral oils; chlorinated hydrocarbons, for example carbon tetrachloride, perchloroethylene and trichloroethane; polar organic liquids, such as dimethyl formamide, dimethyl acetamide, dimethyl sulfoxide and N-methylpyrrolidone; oils derived from plants, such as corn oil and peanut oil. Mixtures of different liquids are often suitable, for example a mixture of isophorone with a polar organic solvent such as N-methylpyrrolidone, as are mixtures of solid and liquid carriers.
Pesticidal compositions are often formulated and transported in a concentrated form which is subsequently diluted by the user before application. The presence of small amounts of a carrier which is a surface-active agent facilitates this process of dilution. Thus it is suitable to use at least one carrier in such a composition which is a surfaceactive agent. For example, the composition may contain at least two carriers, at least one of which is a surface-active agent.
A surface-active agent may be an emulsifying agent, a dispersing agent or a wetting agent; it may be nonionic or ionic. Examples of suitable surface-active agents include the sodium or calcium salts of polyacrylic acids and lignin sufonic acids; the condensation of fatty acids or aliphatic amines or amides containing at least 12 carbon atoms in the molecule with ethylene oxide and/or propylene oxide; fatty acid esters of glycerol, sorbitol, sucrose or pentaerythritol; condensates of these with ethylene oxide and/or propylene oxide; condensates of these with ethylene oxide and/or propylene oxide; condensation products of fatty alcohol or alkyl phenols, for example p-octylphenol or p-octylcresol, with ethylene oxide and/or propylene oxide; sulfates or sulfonates of these condensation products; alkali or alkaline earth metal salts, preferably sodium salts, or sulfuric or sulfonic acid esters containing at least 10 carbon atoms in the molecule, for example sodium lauryl sulphate, sodium secondary alkyl sulfates, sodium salts of sulfinated castor oil, and sodium alkylaryl sulfonates such as dodecylbenzene sulfonate; and polymers of ethylene oxide and copolymers of ethylene oxide and propylene oxide.
Pesticidal compositions may for example be formulated as wettable powders, dusts, granules, baits, solutions, emulsifiable concentrates, emulsions, suspension concentrates and aerosols.
Wettable powders usually contain 25, 50 or 75% weight of active ingredient and usually contain in addition to solid inert carrier, 3-10% weight of a dispersing agent and, where necessary, 0-10% weight of stabilizer(s) and/or other additives such as penetrants or stickers.
Dusts are usually formulated as a dust concentrate having a similar composition to that of a wettable powder but without a dispersant, and are diluted in the field with further solid carrier to give a composition usually containing 0.5-10% weight of active ingredient.
Granules are usually prepared to have a size between 10 and 100 BS mesh (1.676-0.152 mm), and may be manufactured by, for example, agglomeration or impregnation techniques. Generally, granules will contain 0.01-75% weight active ingredient and 0-10% weight of additives such as stabilizers, surfactants, slow release modifiers and binding agents. The so-called "dry flowable powders" consist of relatively small granules having a relatively high concentration of active ingredient. Of particular interest in current practice are the water dispersible granular formulations. These are in the form of dry, hard granules that are essentially dust-free, and are resistant to attrition on handling, thus minimizing the formation of dust. On contact with water, the granules readily disintegrate to form stable suspensions of the particles of active material. Such formulation contain 90% or more by weight of finely divided active material, 3-7% by weight of a blend of surfactants, which act as wetting dispersing, suspending and binding agents, and 1-3% by weight of a finely divided carrier, which acts as a resuspending agent. Baits are prepared by, for example, combining a mixture of a suitable food source, such as sawdust for termites or grain or meal for cockroaches, with an amount of active ingredient sufficient to provide the desired result; for example, from about 0.001% to about 20% weight active ingredient and forming the mixture into a paste by the addition of about 1% to 5% of a water based binder such as agar. The paste-like mixture may be applied as is or may be packed into a housing such as a hollowed out wooden dowel or a plastic tube or bait station. In other embodiments, sheets of paper or cardboard can be sprayed with or dipped in a diluted formulation containing the active ingredient. Baits are a preferable embodiment of the present invention.
Emulsifiable concentrates usually contain, in addition to a solvent and, when necessary, co-solvent, 10-50% weight per volume active ingredient, 2-20% weight per volume emulsifiers and 0-20% weight per volume of other additives such as stabilizers, penetrants and corrosion inhibitors.
Suspension concentrates are usually compounded so as to obtain a stable, non-sedimenting flowable product and usually contain 10-75% weight active ingredient, 0.5-15% weight of dispersing agents, 0.1-10% weight of suspending agents such as protective colloids and thixotropic agents, 0-10% weight of other additives such as defoamers, corrosion inhibitors, stabilizers, penetrants and stickers, and water or an organic liquid in which the active ingredient is substantially insoluble; certain organic solids or inorganic salts may be present dissolved in the formulation to assist in preventing sedimentation or as anti-freeze agents for water.
Aqueous dispersions and emulsions are compositions which may be obtained by diluting a wettable powder or a concentrate with water. The said emulsions may be of the water-in-oil or of the oil-in-water type, and may have a thick `mayonnaise`-like consistency.
The method of applying a compound of Formula (I) to combat termites comprises applying the compound, conveniently in a composition comprising the compound of Formula (I) and a carrier as described above, to a locus or area to be treated for the termites, such as soil or timber, already subject to infestation or attack by termites or intended to be protected from infestation by termites. The active ingredient is, of course, applied in an amount sufficient to effect the desired action of combatting termite infestation. This dosage is dependent upon many factors, including the carrier employed, the method and conditions of the application, whether the formulation is present at the locus in the form of a film, or as discrete particles or as a bait, the thickness of film or size of particles, the degree of termite infestation, and the like.
Proper consideration and resolution of these factors to provide the necessary dosage of the active ingredient at the locus to be protected are within the skill of those versed in the art. In general, however, the effective dosage of the compound of the invention at the locus to be protected--i.e., the dosage to which the termite has access--is of the order of 0.001 to 1.0% based on the total weight of the composition, though under some circumstances the effective concentration may be as little as 0.0001% or as much as 2%, on the same basis.
When used to control cockroaches, it is preferred to use the active ingredient in a treated bait or as a surface treatment.
When used to control ants, it is preferred to use the active ingredient in a liquid bait or granular bait.
When used to control termites, it is preferred to use the active ingredient in a cellulose based bait.
When used to control fleas, it is preferred to use the active ingredient on a treated substrate.
Suitable formulations include granular, paste, or dust cockroach bait, SP or WP cockroach and/or flea sprayables, cellulose-based termite baits, liquid or granular ant baits, feed-through or topical animal treatment for fleas.
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Compounds of the formula (I) ##STR1## wherein R 1 and R 2 are H, methyl, or ethyl, have unexpected activity against cockroaches, ants, fleas, and termites. Compounds wherein at least one of R 1 and R 2 is methyl or ethyl are novel.
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CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to the following copending and commonly assigned United States Patent Applications by the same inventors, each of which was filed on the same day as the instant application, and each of which is hereby expressly incorporated by reference:
i) STRAINER AND VALVE RELEASE, Ser. No. 10/427,446; and
ii) FAN BAFFLE, Ser. No. 10/427,448.
FIELD OF THE INVENTION
This invention relates to the field of pumps for paint and related coating materials.
BACKGROUND OF THE INVENTION
In the past, various forms of pumps have been used to deliver paint (or other similar coating material) to a spray gun for atomization in airless spraying. Such pumps have included piston pumps, where the pistons have been driven using a variety of mechanisms, such as eccentric cams, scotch yokes, or cranks and connecting rods to convert rotary to linear motion. Each of these approaches have suffered from various drawbacks, both technical and economic.
The present invention overcomes shortcomings of the prior art by using a unique mechanism in an assembly which is both technically and economically efficient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a paint pump apparatus useful in the practice of the present invention.
FIG. 2 is an exploded view of the apparatus of FIG. 1 .
FIG. 3 is a side section elevation view of the apparatus of FIG. 1 , taken along line 3 — 3 of FIG. 4 .
FIG. 4 is an end section elevation view of the apparatus of FIG. 1 , taken along line 4 — 4 of FIG. 3 .
FIG. 5 is a free-body side elevation view of a swashplate assembly from FIG. 3 to illustrate certain aspects of the present invention.
FIG. 6 is a perspective view of a rocker arm useful in the practice of the present invention.
FIG. 7 is a top plan view of the rocker arm of FIG. 6 .
FIG. 8 is a side section elevation view of the rocker arm of FIG. 6 , taken along line 8 — 8 of FIG. 10 .
FIG. 9 is a bottom plan view of the rocker arm of FIG. 6 .
FIG. 10 is an end section elevation view of the rocker arm of FIG. 6 , taken along line 10 — 10 of FIG. 7 .
FIG. 11 is an end elevation view of the rocker arm of FIG. 6 , with a fragmentary section view taken along line 11 — 11 of FIG. 7 .
FIG. 12 is a fragmentary section view of a socket of the rocker arm of FIG. 6 , taken along line 12 — 12 of FIG. 10 .
FIG. 13 is a fragmentary section view of a socket of the rocker arm of FIG. 6 , taken along line 13 — 13 of FIG. 10 .
FIG. 14 is a fragmentary section view of a socket of the rocker arm of FIG. 6 , taken along line 14 — 14 of FIG. 10 .
FIG. 15 is a perspective view of the rocker arm of FIG. 6 , assembled together with a piston and useful in the practice of the present invention.
FIG. 16 is an end section view of the rocker arm and piston, taken along line 16 — 16 of FIG. 15 .
FIG. 17 is a fragmentary section elevation view of a portion of FIG. 3 , showing parts of the swashplate assembly with the piston at a bottom dead center position.
FIG. 18 is a fragmentary section elevation view of a portion of FIG. 3 , showing parts of the swashplate assembly with the piston at a top dead center position.
FIG. 19 is a fragmentary section bottom plan view of a portion of FIG. 3 , showing parts of the swashplate assembly with the piston at a mid stroke position.
FIG. 20 is an alternative embodiment for the rocker arm useful in the practice of the present invention.
FIG. 21 is a side view to illustrate certain features of a piston useful in the practice of the present invention.
DETAILED DESCRIPTION
Referring to the Figures, and most particularly to FIGS. 1–4 , a paint pump apparatus 20 useful in the practice of the present invention may be seen. Apparatus 20 is intended to pump paint and similar coatings at high pressure to a spray gun (not shown) for application to a surface to be coated via airless spraying. As will be described infra, the apparatus 20 utilizes a swashplate action to drive a piston in a reciprocating manner without relying on return springs or paint back pressure on the piston to maintain contact between the piston and swashplate on the return stroke.
Apparatus 20 includes a paint reservoir 22 and a pump assembly 24 carried by a frame 26 . Reservoir 22 may have a cover 28 . Frame 26 preferably has a handle portion 30 and a pair of foot portions 32 , 34 . Foot portions 32 and 34 are received in a base 36 which supports pump assembly 24 . It is to be understood that a high pressure hose (not shown) is connected to an outlet 38 of the pump assembly 24 after a cap 40 is removed. The high pressure hose is also connected to an airless spray gun (not shown) for delivering paint or other coating material to a surface (not shown) desired to be coated. An inlet 42 of the pump assembly 24 is in fluid communication with reservoir 22 , and sealed against leakage therebetween by one or more O-rings 44 . As may be seen most clearly in FIG. 4 , paint is delivered by gravity from reservoir 22 to inlet 42 of the paint pump assembly 24 . As is conventional, a return tube 46 is provided from a pump and valve housing 48 containing inlet 42 and outlet 38 . Return tube 46 will return paint from the pump to the reservoir during a “priming” mode. A mechanical switch 50 enables transfer from the “priming” mode to a “run” mode wherein paint is delivered to the outlet 38 instead of the return tube 46 . An ON-OFF electrical switch 52 enables power from a power cord 54 (when connected to electrical supply, not shown) to be delivered to an electric motor 56 . Motor 56 (or another form of prime mover, such as a gasoline engine, not shown) provides mechanical power for pump assembly 24 .
Referring now most particularly to FIGS. 3 and 5 , a gear box 58 couples motor 56 to a spider 60 which is journalled for rotation in pump assembly 24 by a bearing 62 and provides direct drive to a swashplate 64 via a shaft 66 on which the spider 60 and swashplate 64 are rigidly mounted. Referring now also to FIGS. 17 and 18 , a distal end 68 of shaft 66 is journalled for rotation in a pump assembly housing 70 by a bushing 72 .
Referring again to FIGS. 3 , 17 and 18 , an inlet check valve 74 is positioned in inlet 42 . Similarly an outlet check valve 76 is positioned in outlet 38 .
FIG. 5 illustrates a swashplate assembly 80 , which includes the spider 60 , bearing 62 and swashplate 64 all mounted on shaft 66 . Assembly 80 also includes a rocker arm 82 , a piston 84 , a sleeve bearing or bushing 86 , a seal 88 , and a spring 90 . Additionally, assembly 80 includes an annular thrust plate 92 , thrust bearing 94 and an annular radial spacer 96 as part of the swashplate 64 , as may be seen most clearly in FIGS. 17 , 18 and 19 . Returning to FIG. 5 , spring 90 is shown in solid lines 98 to illustrate the spring itself in a relaxed state and spaced apart from its operating position, and is shown in chain lines 100 in its operating position, where it is urging the rocker arm 82 towards the swashplate 64 . Spring 90 preferably applies at least a 10 pound force on rocker arm 82 in the embodiment shown. Rocker arm 82 has a keyhole shaped recess 102 which is engaged with a generally spherical head 104 of piston 84 , as may be most clearly seen in FIGS. 15 and 16 . In operation, swashplate 64 is rotated by motor 56 acting through gear box 58 and spider 60 when pump assembly 24 is to be operated, since swashplate 64 is carried on shaft 66 . Rocker arm is constrained in a congruent cavity 106 (see FIG. 19 ) in pump and valve housing 48 , but is free to oscillate in a rocking motion when driven by rotation of swashplate 64 . The piston 84 follows the motion of keyhole recess 102 , reciprocating in a substantially linear motion, since it is constrained by sleeve bearing 86 against side motion caused by side loads imposed on the head 104 of piston 84 as the swashplate 64 tilts with respect to the piston 84 during operation. Reciprocation of piston 84 will draw paint into a pumping chamber 119 through inlet 42 and deliver paint under pressure via outlet 83 .
Referring now to FIGS. 6–14 , various details of the rocker arm 82 may be seen. Arm 82 is preferably molded of an acetal resin polymer such as is offered under the trademark Delrin by DuPont. Arm 82 has a pair of arched support legs 108 spanned by a first bridge 110 containing the key hole shaped recess 102 , and further spanned by a second bridge 112 having a dome 114 therein. Dome 114 preferably has a spherical radius of 0.75 inches and the recess 102 preferably has a spherical recess 103 with a radius of 0.25 inches in the embodiment shown. A pair of slightly raised shoulders or ramps 116 are located on the underside of bridge 110 , adjacent lateral sides of the key hole shaped recess 102 to limit the amount to which the piston 84 can pivot laterally up to an angle 118 (shown in FIG. 16 ) of ±2 degrees. Details of shoulders 116 may be seen in FIGS. 9 , 13 and 14 . It is to be understood that the piston 84 is retained to the rocker arm 82 in a “snap fit” or detent arrangement wherein the socket end 110 of the rocker arm will temporarily deform to receive the piston, and thereafter retain the piston, while allowing a limited range of angular motion between the piston 84 and the rocker arm 82 . The range of angular motion permitted is sufficient to permit piston 84 to remain aligned with the sleeve bearing 86 as the rocker arm 82 pivots to follow the motion of swashplate 64 . Bearing 86 maintains piston 84 in substantially constant cylindrical alignment with the cylinder chamber 119 in housing 48 as piston 84 reciprocates to provide the pumping action from pump assembly 24 . It is to be understood, however that piston 84 preferably has a slight radial degree of freedom with respect to bearing 86 , preferably between about 0.0025 inches and 0.0005 inches, which has been found to improve the life of seal 88 . This is achieved in the embodiment shown and described by having a bore in the sleeve bearing 86 with a diameter of 0.439 +0.000 −0.001 inches with the piston diameter described infra.
Referring now most particularly to FIG. 15 , dome 114 exhibits a characteristic elongated footprint 156 , corresponding to a wear pattern resulting from contact between dome 114 and plate 92 of swashplate assembly 80 .
Referring to FIG. 17 , swashplate 64 has an axis of rotation 120 . A plane of a drive surface 122 of the swashplate 64 is indicated by line 124 . Line 126 represents a plane which is perpendicular to the axis of rotation 120 . The drive surface 122 of swashplate 64 is preferably predetermined to be a profile angle 128 of 8 degrees, as measured between planes 124 and 126 , keeping in mind that FIG. 17 shows swashplate 64 at a bottom dead center position for piston 84 .
Referring now to FIG. 21 , piston 84 is preferably formed of 440 C stainless steel, (preferably heat treated to Rc 56–58) and preferably has a head portion 130 and a main cylindrical body portion 132 . A diameter 152 of the main cylindrical portion 154 is preferably 0.437±0.0005 inches. The head portion 130 has a ball-joint-like surface 134 formed with a generally spherical radius profile indicated by radius 136 , which, in the embodiment shown, is preferably 0.25 inches. The head portion 130 has a convex end surface 138 with a generally spherical profile preferably having a radius 140 greater than radius 136 . In the embodiment shown, radius 140 is preferably 0.75 inches. A cylindrical surface 142 (of preferably 0.5 inches diameter) connects the convex end surface 138 and the ball-joint-like surface 134 . The main cylindrical body has a cone shaped surface 144 spaced apart from and facing the ball-joint-like surface 134 . Cone shaped surface 144 is connected to the ball-joint-like surface by a concave cylindrical neck portion 146 preferably having a 0.031 inch radius 148 for the embodiment shown. Cone shaped surface 144 preferably has a cone angle 150 substantially equal to the profile angle 128 of the swashplate 64 , which in this embodiment is preferably 8 degrees. The piston is preferably machined to a finish of 32 microinches, except for a distal end 152 which is preferably finished to 15 microinches for a distance 154 of 0.62 inches, which includes the “working” portion of the piston 84 in contact with seal 88 . Convex end surface 138 exhibits a characteristic circular or toroidal footprint 158 , corresponding to a wear pattern resulting from contact between the end surface 138 of head portion 130 of piston 84 and plate 92 of swashplate assembly 80 . Footprint 158 results from rotation of piston 84 in the pump assembly 24 during operation.
Referring now to FIG. 20 , spring 90 may be replaced with one or more integrally formed cantilevered fingers 160 , preferably two pair of such fingers, with one pair of fingers located on each of opposite lateral sides of the rocker arm 82 ′.
In operation, it is to be understood that the piston pump assembly 24 operates from a source of rotary power such as electric motor 56 (or an alternative power source, not shown, such as an internal combustion engine). The rotary power source rotatingly drives a swashplate assembly 80 which in turn is in contact with a rocker arm 82 . The swashplate reciprocates the rocker arm, causing the piston to pump paint in a reciprocating motion by driving the piston in a first direction and by action of the rocker arm returning the piston in a second direction opposite to the first direction. This eliminates the need for a piston return spring commonly found in prior art swashplate pump designs. In the present invention, the rocker arm and piston contact the swashplate at diametrically opposite regions of the swashplate, more particularly contacting the annular thrust plate 92 . The needle bearing 94 is interposed between the thrust plate 92 and a backing plate 95 . The piston is guided by the sleeve bearing 86 , and cup seal 88 prevents paint from leaking past the piston out of the pumping chamber 119 . As the piston moves from the position shown in FIG. 17 to the position shown in FIG. 19 , paint is drawn from the reservoir 22 through the inlet check valve 74 . As the piston moves from the position shown in FIG. 19 to the position shown in FIG. 17 paint is moved out of the pumping chamber 119 past the outlet check valve 76 to be delivered to a spray gun (not shown).
It is to be understood that the numerical values for radii, angles and other parameters of the embodiment described may be varied from those stated, while still remaining within the scope of the present invention.
The invention is not to be taken as limited to all the details thereof as modifications and variations thereof may be made without departing from the spirit or scope of the invention.
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A piston pump assembly with a rotatingly driven swashplate in driving relationship with a rocker arm and piston engaged with one end of the rocker arm. A spring urges the rocker arm and piston into contact with an annular ring carried by a bearing in the swashplate. The spring may be a separate leaf spring or may be formed integrally with the rocker arm. The rocker arm engagement with the piston uses a spherical ball-joint-like surface. The contact between each of the rocker arm and piston and the annular ring utilize spherical surfaces on the rocker arm and piston, with an elongated footprint on the rocker arm and a circular footprint on the piston. The piston is allowed a slight radial play in operation.
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TECHNICAL FIELD
[0001] The present invention relates to a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder. More particularly, the present invention relates to such a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder, in which the piston fastened to a cylinder rod of the hydraulic or pneumatic cylinder can be prevented from being loosened from the cylinder rod due to vibration occurring during the work.
BACKGROUND OF THE INVENTION
[0002] As shown in FIG. 1 , a general hydraulic or pneumatic cylinder includes:
[0003] a cylindrical tube 1 that is opened at both ends thereof;
[0004] a cylinder rod 3 that linearly reciprocates in the tube 1 and includes a screw portion 2 formed at one end thereof;
[0005] a piston 4 that is screw-fastened to the screw portion 2 and is configured to partition the inside of the tube 1 into a large chamber and a small chamber to form a pressure when the cylinder rod 3 reciprocates in the tube;
[0006] a head cover 5 that prevents a hydraulic fluid from leaking through an opening formed at one side of the tube 1 ; and a cushion ring 6 that absorbs a mechanical shock of the piston 4 and the head cover 5 when the cylinder rod 3 is driven to extend to a maximum position.
[0007] In the drawings, non-explained reference numerals 7 and 8 denote a head rod and a cover end that allow the hydraulic or pneumatic cylinder to be rotatably mounted on an attachment of an excavator.
[0008] The fixed position of the piston of the hydraulic or pneumatic cylinder should be always constant in order to secure a stroke to completely perform a function of the hydraulic or pneumatic cylinder.
[0009] Meanwhile, the excavator is mainly used in an environment where the work conditions are poor. The piston of the hydraulic cylinder is exposed to an propulsive force, a severe vibration, and a shock by a high-pressure hydraulic fluid repeatedly applied to the piston.
[0010] For this reason, various loosening preventive mechanisms are used to prevent the piston 4 from being loosened from the cylinder rod 3 . However, a loss of torque of the piston 4 with respect to the screw portion 2 of the cylinder rod 3 frequently occurs due to the shock repeatedly applied to the piston 4 , and there is a high possibility that the internal parts of the hydraulic cylinder will be damaged due to the loosening of the piston 4 .
[0011] Thus, hydraulic cylinder manufacturers employ the following methods as means for preventing the piston from being loosened from the cylinder rod after screw-fastening the piston to the cylinder rod:
[0012] 1) A method for fixing the piston using a set screw, a key or a bolt;
[0013] 2) A method for fixing the piston using a lock nut;
[0014] 3) A method for fixing the piston using a nylon nut; and
[0015] 4) A method for fixing the piston using a double nut of a left and right screw.
[0016] As shown in FIGS. 2( a ), 3 ( a ) and 3 ( b ), a set screw for preventing the piston from being loosened from the cylinder rod in a hydraulic or pneumatic cylinder in accordance with the prior art is configured such that after a piston 4 is screw-fastened to a screw portion 2 of the cylinder rod 3 , a screw hole 9 is axially formed in a mutual screw engagement portion of the cylinder rod 3 and the piston 4 and the set screw 10 is fasteningly engaged with the screw hole 9 .
[0017] As shown in FIG. 2( b ), a set screw for preventing the piston from being loosened from the cylinder rod in a hydraulic or pneumatic cylinder in accordance with the prior art is configured such that a piston 4 is screw-fastened to a first screw portion 3 a of the cylinder rod 3 and a lock nut 11 formed integrally with the piston 4 is screw-fastened to a second screw portion 3 b formed to have a diameter smaller than that of the first screw portion. In this case, a radial set screw 10 is fasteningly engaged with a screw hole penetratingly formed in the lock nut 11 in a radius direction of the lock nut 11 so as to prevent the piston 4 from being loosened from the cylinder rod.
[0018] As shown in FIG. 2( c ), a set screw for preventing the piston from being loosened from the cylinder rod in a hydraulic or pneumatic cylinder in accordance with the prior art is configured such that a piston 4 is screw-fastened to a first screw portion 3 a of the cylinder rod 3 and a lock nut 11 is screw-fastened to a second screw portion 3 b formed to have a diameter smaller than that of the first screw portion. In this case, a set screw 10 is fasteningly engaged with a screw hole penetratingly formed in the lock nut 12 in a radius direction of the lock nut 12 so as to prevent the piston 4 from being loosened from the cylinder rod.
[0019] As described above, in the case where a torque of the set screw 10 additionally engaged with the screw hole to prevent the piston 4 from being loosened from the cylinder rod 3 is lost due to vibration applied to the piston 4 , the set screw 10 is loosened or is separated from a fixed position thereof, and thus a function of completely preventing the loosening of the piston 4 cannot be expected.
[0020] For this reason, as shown in FIGS. 3( a ) and 3 ( b ), the piston 4 is screw-fastened to the screw portion 2 of the cylinder rod 3 and the set screw 10 is fasteningly engaged with the screw hole 9 in an axial or radial direction in such a manner as to caulk an inlet portion of the screw hole 9 so as to completely prevent the piston 4 from being loosened from the cylinder rod 3 .
[0021] As shown in FIG. 3( a ), in the case where a worker strikes four points around the inlet portion of the screw hole to caulk the inlet portion into a depth of 1-3 mm using a punching tool, a striking force or a caulking position of the punching tool is not uniform or a problem associated with stability of caulking modification is caused. For this reason, the set screw 10 engaged with the screw hole 9 to prevent the piston 4 from being loosened from the cylinder rod 3 may be separated from the screw hole.
[0022] As shown in FIG. 3( b ), in the case where the set screw 10 engaged with the screw hole 9 to prevent the piston 4 from being loosened or separated from the cylinder rod 3 is loosened from the screw hole or separated from a fixed position thereof, the internal parts of a hydraulic cylinder may be damaged to degrade a performance thereof. In addition, a problem is involved in that the hydraulic cylinder may be damaged, leading to physical losses or casualties during the work.
SUMMARY OF THE INVENTION
[0023] Accordingly, the present invention has been made to solve the aforementioned problems occurring in the prior art, and it is an object of the present invention to provide a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder, in which the piston is fastened to a cylinder rod and a pitch of a screw thread of a remaining screw portion is modified after assembling a set screw for preventing the piston from loosened from the cylinder rod so that resistance of the piston against being loosened from the cylinder rod can be maximized owing to a relative pitch difference between a screw thread of an assembly portion and a screw thread of the remaining screw portion, thereby preventing the piston from being loosened from the cylinder rod.
[0024] Another object of the present invention is to provide a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder, in which the piston is semi-permanently prevented from loosened from a cylinder rod so that damage of the internal parts of a hydraulic cylinder can be prevented and safety accidents and casualties occurring due to damage of the hydraulic cylinder during the work can be prevented.
Technical Solution
[0025] To achieve the above object, in accordance with an embodiment of the present invention, there is provided a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder including a tube, a cylinder rod that linearly reciprocates in the tube, the piston fastened to a screw portion of the cylinder rod, and a set screw that prevents the piston from being loosened from the cylinder rod, the method comprising the steps of:
[0026] forming a screw hole in a mutual screw engagement portion of the cylinder rod and the piston and fasteningly engaging the set screw with the screw hole; and
[0027] pressing a remaining space portion of the screw hole in an engagement direction of the set screw using a press mechanism after fasteningly engaging the set screw with the screw hole to modify a pitch of a screw thread of an inlet portion of the screw hole.
[0028] In a preferred embodiment of the present invention, the press mechanism may include:
[0029] a hammer; and
[0030] a press tool detachably mounted on the hammer, the press tool including a caulking guide portion coupled to a wrench hole of the set screw to secure a center position of caulking around the set screw and the screw hole during the caulking, and a stopper formed so as to extend from an inner end of the caulking guide portion to adjust a depth of the remaining space portion during the caulking.
[0031] A pitch of a screw thread of the pressed remaining space portion is modified to be equal to at least ⅓ of the pitch of the screw thread of the screw hole.
[0032] An impact hammer may be used as the hammer.
[0033] A vibrator may be used as the hammer.
[0034] A punching device may be used as the hammer.
[0035] In accordance with another embodiment of the present invention, there is provided a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder including a tube, a cylinder rod that linearly reciprocates in the tube, the piston fastened to a first screw portion of the cylinder rod, a lock nut fastened to a second screw portion formed so as to extend from the cylinder rod, the second screw portion having a diameter smaller than that of the first screw portion, and a set screw that prevents the piston 4 from being loosened from the cylinder rod, the method including the steps of:
[0036] penetratingly forming a screw hole in the lock nut in a radius direction of the lock nut and fasteningly engaging the set screw with the screw hole; and pressing a remaining space portion of the screw hole in an engagement direction of the set screw using a press mechanism after fasteningly engaging the set screw with the screw hole to modify a pitch of a screw thread of an inlet portion of the screw hole.
[0037] The lock nut may be formed so as to extend integrally with the piston or may be formed so as to be separated from the piston.
Advantageous Effect
[0038] The caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention as constructed above has the following advantages.
[0039] The piston can be semi-permanently prevented from loosened from the cylinder rod through the modification of the pitch of the screw thread of the remaining space portion of the screw hole with which the set screw is fasteningly engaged for the purpose of preventing the piston from being loosened. In addition, damage of the internal parts of a hydraulic cylinder or the like can be prevented by preventing the piston from being loosened, and safety accidents and casualties occurring due to damage of the hydraulic cylinder during the work can be prevented.
[0040] Besides, the caulking operation is performed using a hammering tool so that fatigue of a worker due to the caulking can be reduced and the caulking time can be shortened, thereby reducing the manufacturing cost.
[0041] Further, the caulking position of the press tool around the center of the screw hole with which the set screw is engaged can be accurately secured and the depth of the screw thread whose pitch is modified can be adjusted, thereby improving precision of the modification of the pitch of the screw thread of the remaining space portion during the caulking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which: FIG. 1 is a schematic view showing a general hydraulic or pneumatic cylinder;
[0043] FIGS. 2 a to 2 c are schematic views showing a set screw for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with the prior art;
[0044] FIGS. 3 a and 3 b are schematic views showing a caulking operation for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with the prior art;
[0045] FIG. 4 is a schematic view showing a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention;
[0046] FIG. 5 is a schematic view showing a press tool used in a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention;
[0047] FIG. 6 is a process flow chart showing a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention; and
[0048] FIGS. 7 a and 7 b are schematic views showing a state in which a set screw is fastened to a lock nut in a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with another embodiment of the present invention.
EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS
[0049] 10 : set screw
[0050] 15 : screw hole
[0051] 16 : remaining space portion
[0052] 17 : screw thread
[0053] 18 : screw thread
[0054] 19 : caulking guide
[0055] 20 : stopper
[0056] 21 ; press tool
[0057] 22 : lock nut
DETAILED DESCRIPTION OF THE INVENTION
[0058] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter.
[0059] As shown in FIGS. 4 to 6 , the present invention is directed to a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder including a tube 1 , a cylinder rod 3 that linearly reciprocates in the tube 1 , the piston 4 fastened to a screw portion 2 of the cylinder rod 3 , and a set screw 10 that prevents the piston 4 from being loosened from the cylinder rod 3 .
[0060] The caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention includes the steps of:
[0061] axially forming a screw hole 15 in a mutual screw engagement portion of the cylinder rod 3 and the piston 4 and fasteningly engaging the set screw with the screw hole; and
[0062] pressing a remaining space portion 16 of the screw hole 15 in an engagement direction of the set screw using a press mechanism after fasteningly engaging the set screw 10 with the screw hole 10 to change a screw thread pitch of an inlet portion of the screw hole 15 .
[0063] As shown in FIG. 5 , the press mechanism includes
[0064] a hammer (not shown); and
[0065] a press tool 21 including a shank portion 21 a detachably mounted on the hammer, a body portion 21 b formed so as to extend from the shank portion 21 a , a caulking guide portion 19 formed so as to protrude from one end of the body 21 b and coupled to a wrench hole 10 a of the set screw 10 to secure a center position of caulking around the set screw 10 and the screw hole 15 during the caulking, and a stopper 20 formed so as to extend from an inner end of the caulking guide portion 19 to adjust a depth of the remaining space portion 16 during the caulking.
[0066] A pitch of a screw thread of the pressed remaining space portion 16 can be modified to be equal to at least ⅓ to ½ of the pitch of the screw thread of the screw hole 15 .
[0067] The hammer that can be used in the present invention is an impact hammer.
[0068] The hammer that can be used in the present invention is a vibrator.
[0069] The hammer that can be used in the present invention is a punching tool.
[0070] As shown in FIGS. 7 a and 7 b , the present invention is directed to a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder including a tube 1 , a cylinder rod 3 that linearly reciprocates in the tube 1 , the piston 4 fastened to a first screw portion 3 a of the cylinder rod 3 , a lock nut 22 fastened to a second screw portion 3 b formed so as to extend from the cylinder rod 3 , the second screw portion having a diameter smaller than that of the first screw portion, and a set screw 10 that prevents the piston 4 from being loosened from the cylinder rod 3 .
[0071] The caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with another embodiment of the present invention includes the steps of:
[0072] forming a screw hole 22 a in the lock nut 22 in a radius direction of the lock nut and fasteningly engaging the set screw 10 with the screw hole 22 a ; and pressing a remaining space portion 16 of the screw hole in an engagement direction of the set screw 10 using a press mechanism after fasteningly engaging the set screw 10 with the screw hole 22 a to modify a pitch of a screw thread of an inlet portion of the screw hole 22 a.
[0073] As shown in FIG. 7( a ), the lock nut 22 can be formed so as to extend integrally with the piston 4 .
[0074] As shown in FIG. 7( b ), the lock nut 22 can be formed so as to be separated from the piston 4 .
[0075] In this case, a configuration of the caulking method in accordance with another embodiment of the present invention is substantially the same as that of the caulking method in accordance with an embodiment of the present invention, except that the set screw 10 that prevents the piston 4 from being loosened from the cylinder rod 3 is fastened to the lock nut 22 . Thus, the detailed description thereof will be omitted to avoid redundancy.
[0076] Hereinafter, a use example of a caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0077] As shown in FIGS. 4 to 6 , the piston 4 is fastened to the screw portion 2 of the cylinder rod 3 and the screw hole 15 is axially formed in the mutual screw engagement portion of the cylinder rod 3 and the piston 4 (S 10 ).
[0078] In step S 20 , the set screw 10 is fasteningly engaged with the screw hole 15 so as to prevent the piston 4 from being loosened from the cylinder rod 3 .
[0079] In step S 30 , the caulking guide portion 19 of the press tool 21 of which the shank portion 21 a is mounted on the hammer is fittingly inserted into the wrench hole 10 a of the set screw 10 through the remaining space portion 16 of the screw hole 15 .
[0080] In step S 40 , the remaining space portion 16 is pressed in an engagement direction of the set screw 10 due to the caulking of the press tool 2 mounted on the hammer so that a pitch of a screw thread 18 of the inlet portion of the screw hole 15 is modified. In this case, the modification amount of the pitch of the screw thread 18 of the remaining space portion 16 is determined by a thickness (t) of the stopper 20 of the press tool 21 , and the pitch of the screw thread 18 of the pressed remaining space portion 16 is preferably modified to be equal to about ⅓ of a pitch of a screw thread 17 of the screw hole 15 .
[0081] In this case, the caulking guide portion 19 of the press tool 21 is fittingly inserted into the wrench hole 10 a after passing through the remaining space portion 16 , and thus the caulking position of the press tool 21 around the center of the screw hole 15 can be accurately secured and a striking force of the hammer can be maintained uniformly during the caulking of the press tool using an impact hammer, leading to an increase in the precision of the modification of the pitch of the screw thread 18 of the remaining space portion 16 during the caulking.
[0082] As a result of a modification test of the pitch of the screw thread 18 of the inlet portion of the screw hole 15 after the set screw 10 is fasteningly engaged with the screw hole 15 , the values listed in Table 1 below could be confirmed.
[0083] In case of a test A, if the depth of the remaining space portion 16 of the screw hole 15 is 1 mm and a modified pitch of the screw thread 18 of the pressed remaining space portion 16 is 0.7 mm, the pitch of the screw thread 18 is modified to be equal to about ½ of the pitch of the screw thread 17 of the screw hole 15 . Thus, it was confirmed that the set screw 10 can be loosened and mass production is impossible due to occurrence of a serious burr.
[0084] In case of a test B, if the depth of the remaining space portion 16 of the screw hole 15 is 3 mm and a modified pitch of the screw thread 18 of the pressed remaining space portion 16 is 0.8-1.2 mm, the pitch of the screw thread 18 is modified to be equal to about ⅓ to ½ of the pitch of the screw thread 17 of the screw hole 15 . Thus, it was confirmed that the value of the modified pitch of the screw thread 18 of the pressed remaining space portion 16 is desirable.
[0085] In case of a test C, if the depth of the remaining space portion 16 of the screw hole 15 is 4 mm and a modified pitch of the screw thread 18 of the pressed remaining space portion 16 is 0.8-1.3 mm, the pitch of the screw thread 18 is modified to be equal to about ⅓ to ½ of the pitch of the screw thread 17 of the screw hole 15 . Thus, it was confirmed that the value of the modified pitch of the screw thread 18 of the pressed remaining space portion 16 is desirable.
[0086] In case of a test D, if the depth of the remaining space portion 16 of the screw hole 15 is 2.5 m and a modified pitch of the screw thread 18 of the pressed remaining space portion 16 is 1.2 mm, the pitch of the screw thread 18 is modified to be equal to about ½ of the pitch of the screw thread 17 of the screw hole 15 . Thus, it was confirmed that mass production is impossible due to occurrence of a serious burr.
[0087] As can be been in the modification test results of the pitch of the screw thread 18 of the inlet portion of the screw hole 15 , if the depth of the remaining space portion 16 of the screw hole 15 exceeds 4 mm, a pitch is created which is not modified during the caulking due to an excessive depth of the remaining space portion 16 , resulting in a shift of the set screw 100 in the screw hole 16 . On the other hand, if the depth of the remaining space portion 16 of the screw hole 15 is less than 3 mm, the pitch of the screw thread 18 is modified to be equal to about ½ of the pitch of the screw thread 17 of the screw hole 15 . Thus, the set screw 10 can be loosened and a serious burr may occur.
[0000]
TABLE 1
A
B
C
D
Depth (mm)
1
3
4
2.5
of remaining
space portion
Modified
0.7
0.8-1.2
0.8-1.3
1.2
pitch (mm)
Max torque
130
150
150
120
Caulking
Mass production
Excel-
Excel-
Mass production
ability
is impossible
lent
lent
is impossible
[0088] As described above, the remaining space portion 16 is caulked by the press tool 21 fitted into the wrench hole 10 a of the set screw 10 after the set screw 10 is fasteningly engaged with the screw hole 15 so that the piston 4 can be semi-permanently prevented from loosened from the cylinder rod 3 due to a relative pitch difference between the screw thread 17 of an assembly portion to which the set screw 10 is fastened and the screw thread 18 of the remaining space portion 16 (i.e., the pitch of the screw thread 18 of the remaining space portion 16 is relatively smaller than that of the screw thread 17 of the assembly portion)
INDUSTRIAL APPLICABILITY
[0089] In accordance with the caulking method for preventing a piston from being loosened in a hydraulic or pneumatic cylinder in accordance with the present invention as constructed above, the piston can be semi-permanently prevented from loosened from the cylinder rod through the modification of the pitch of the screw thread of the remaining space portion of the screw hole with which the set screw is fasteningly engaged for the purpose of preventing the piston from being loosened. In addition, the caulking operation is performed using a hammering tool so that fatigue of a worker due to the caulking can be reduced and the caulking time can be shortened. Further, the caulking position of the press tool around the center of the screw hole with which the set screw is engaged can be accurately secured and the depth of the screw thread whose pitch is modified can be adjusted.
[0090] While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
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Disclosed is a caulking method for preventing a piston from being loosened, capable of preventing the piston coupled to a cylinder rod of a hydraulic or pneumatic cylinder from being loosened by the vibration or the like generated during work. Provided is a caulking method for preventing a piston of a hydraulic or pneumatic cylinder from being loosened, the hydraulic or pneumatic cylinder comprising a tube, a cylinder rod reciprocating linearly within the tube, a piston coupled to a screw part of the cylinder rod, and a set screw for preventing the piston from being loosened from the cylinder rod, the caulking method comprising a step of forming screw holes in the screw coupling part of each of the cylinder rod and the piston and coupling the set screw into the screw holes; and a step of compressing the residual space of the screw holes in the direction of coupling the set screw by a compression device after coupling the set screw to the screw holes so as to deform the pitch of the thread in an inlet portion of the screw hole.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to PCT Application No. PCT/NO97/00147 filed Jun. 6, 1997 which claims priority from Norwegian Patent Application No. 962429 filed Jun. 6, 1996.
BACKGROUND OF THE INVENTION
The invention relates to a method and a device for facilitating the insertion of a coiled tube into an oil or gas well, and for applying of impact energy to stuck objects in an oil or gas well.
On inserting a coiled tube into an oil or gas well, in the following referred to as a well, the length of insertion is limited by friction between the coiled tube and the wall of the well. Even if the coiled tube is straightened in a separate straightening apparatus before being introduced into the well, it will adopt the form of a wave or a helix in the well. As the coiled tube is being pushed further and further down the well, and there are more points of contact between the coiled tube and the wall of the well, the total friction increases to a level at which the end of the coiled tube does not proceed further into the well. Further supply of coiled tube only leads to more turns being formed in the helix adopted by the coiled tube.
As is quite natural, the problem arises especially in wells of long horizontal stretches, in which weights at the end of the coiled tube will not contribute to stretching out the coiled tube.
It is known to mount a remotely controlled, motor driven propulsion device, a well tractor, at the end of the coiled tube to draw the coiled tube into the well. A well tractor is expensive and complex, and operational disturbances may easily occur. Furthermore, it is difficult to construct well tractors which are able to proceed and provide sufficient force in wells of small cross-sections. The cross-section is always smallest at the innermost/downmost part of a well, and long wells may also have the smallest cross-sections.
Objects that are stuck in a well, are most commonly loosened by applying impact energy to them. An impact tool which has been arranged to a drill string or a coiled tube, is inserted down to the stuck object and is activated. Known impact tools use a pre-tensioned spring which accelerates a mass, a hammer, which after having achieved appropriate speed, strikes against a stop transferring impact energy to the stuck object. Before each stroke the spring is tensioned by means of a hydraulic mechanism which is activated by a pressure liquid in the drill string or the coiled tube. The spring energy is released when the pre-tensioning has reached a predetermined value. A drawback of this known solution is that very powerful and space-consuming springs have to be provided to achieve the required impact energy. Another known type of impact tool is periodically extended and lifts the drill string or coiled tube which is above the impact tool, and then lets the drill string or coiled tube drop again, so that the mass of the drill string or the coiled tube causes a hammer effect. This type of impact tool has the unfavourable effect that impacts are transferred to the hole drill string or coiled tube in such a way that the couplings and other equipment arranged thereto, may be damaged.
The object of the invention is to provide a method and a simple, inexpensive device for facilitating the insertion of a coiled tube into a well, and for applying impact energy to objects which are stuck in a well. The aim is reached through features as indicated in the following description and subsequent claims.
According to the invention the aim is reached through applying impact changes or pressure strokes to a liquid flowing through a coiled tube or drill string. A pressure stroke in a coiled tube will contribute to briefly overcoming frictional forces between a coiled tube and the wall of the well, so that the coiled tube may be introduced a little further into the well by each pressure stroke.
Pressure strokes may be transferred to a stuck object by the coiled tube or drill string in a known manner being lead into contact with, and possibly attached to, the stuck object. Pressure strokes may also be used to accelerate a mass, a hammer, which in a manner known in itself, strikes against a stop which transfers impact energy to the stuck object.
Pressure strokes is achieved, according to the invention, by periodical shut-off of a liquid flow in the coiled tube or drill string, a valve device being located at or near the outlet of the coiled spring. The valve device may advantageously be such, that it is activated once the liquid flow exceeds a predetermined flow rate. Then it is possible to carry out ordinary well operations by a lower and normal flow rate, and if a need for pressure changes arises, the flow rate is increased to activate the valve device.
To achieve the best possible effect, the valve device should be such, that after having shut off, it remains shut long enough for the pressure rise to spread in the liquid, and so that after having opened, it remains open long enough to re-establish full flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of a preferred valve device for the periodical shut-off of the liquid flow in a coiled tube or a drill string is described in the following with reference to the accompanying drawings, in which
FIG. 1 schematically shows a sectional side view of a part of a valve device in its opened starting position;
FIG. 2 shows the valve devised in closed position;
FIG. 3 shows the valve device as it is about to open and revert to its starting position;
FIG. 4 schematically shows a cross-section of the housing and valve body of the valve device;
FIG. 5 schematically shows a cross-section of a damping device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 reference numeral 1 indicates a valve device which can open and close periodically for a liquid flow. The valve device 1 which is shown in vertical position, comprises an external tubular housing 2 , in which are provided movable parts.
Before the invention is described further, it should be mentioned that the shown housing 2 and said movable parts are shown schematically. This provides a clearly set out figure, and the way of working of the invention will be easily understood. In practice, the housing 2 will be divided into several parts which are typically joined up as a housing 2 by means of threaded couplings which are made pressure tight by means of seals. Shoulders and other items which in the figure appear as parts of the housing 2 , may in practice be separate parts which in known manner are secured inside the housing 2 . Further, movable parts in the housing 2 may in the same way be made up of several parts. The division is necessary to enable production of the valve device in machine tools or other production equipment. Division is also necessary to enable mounting of movable parts in the housing 2 . It is common that down-hole tools have an external tubular housing, and that within the housing are arranged both fixed and movable parts. A skilled person will undertake a division suitable for the equipment that he wants to use for the production, and at the same time take into account that the device shall be mountable and dismountable.
The housing 2 is further shown without end couplings as such are well known from other down-hole equipment.
Inside the housing 2 is arranged an axially displaceable slide 3 which at its lower end is provided externally with three separate annular seals 4 , 5 , 6 mentioned from the top downwards. A channel 7 in the slide 3 ends at its bottom end in the lower end surface of the slide 3 , and at the top in a transverse hole in the slide 3 , between the seals 4 , 5 .
The slide 3 is retained in an upper starting position by a pre-tensioned spring 9 which is supported by a first annular shoulder 10 inside the housing 2 , and works on the underside of an external shoulder 11 at the upper end of an axially displaceable cylindrical sleeve 12 , which at its lower end is attached to the slide 3 . The sleeve 12 is at its bottom provided with openings 13 , so that liquid can flow through the sleeve 12 . Below the shoulder 10 there is, inside the housing 2 , a second annular shoulder 14 . The shoulders 10 , 14 are provided with respectively seal 15 and 16 , which are arranged to form a sliding tightening against the outer surface of the sleeve 12 . The shoulders 10 , 14 define an upper annular space 17 , a central annular space 18 and a lower annular space 19 . At the central annular space 18 the housing 2 has a larger internal diameter than the adjacent annular spaces 17 and 19 . The housing 2 may have the same internal diameter at the annular space 17 as at the annular space 19 .
Below the shoulder 14 there is in the annular space between the housing 2 and the sleeve 12 an annular piston 20 with seals 21 , 22 which rest tighteningly against the housing 2 and the sleeve 12 , respectively. The underside of the shoulder 14 and the top side of the piston 20 thus define a portion 23 of the annular space between the housing 2 and the sleeve 12 . A channel 24 in the shoulder 14 connects the portion 23 of the annular space with the annular spaces 17 , 18 , 19 above the shoulder 14 .
The annular spaces 17 , 18 , 19 and 23 are filled with hydraulic oil or another liquid. The underside of the piston 20 is exposed to the liquid which is conveyed by the valve device 1 , and ensures that always the same pressure prevails in the liquid in the annular spaces 17 , 18 , 19 and 23 as in the rest of the valve device 1 . The annular space 23 with the piston 20 serves as a reservoir and a pressure accumulator for the annular spaces 17 , 18 , 19 .
The sleeve 12 is externally provided with an upper collar 25 and a lower collar 26 which are both located between the shoulders 10 , 14 . The stroke length of the sleeve 12 is restricted by the collars 25 , 26 abutting the shoulders 10 , 14 . The diameter of the upper collar 25 is adapted to the diameter of the housing 2 at the upper annular space 17 , and the diameter of the lower collar 26 is adapted to the diameter of the housing 2 at the lower annular space 19 , so that there is little clearance between the housing 2 and the collars 25 , 26 . The distance between the collars 25 , 26 is such, that they may be brought, separately or simultaneously, into the central annular space 18 by displacing the sleeve 12 axially in the housing 2 . When the collars 25 , 26 are in the annular space 18 , there will, due to the larger outer diameter of the annular space 18 , be a greater clearance outwards towards the housing 2 , than when the collars 25 , 26 are in the annular spaces 17 and 19 , respectively.
In each of the collars 25 , 26 has been provided, in the form of a relatively narrow channel 27 and 28 , respectively, or in another manner, a limited cross-section, by which liquid may flow through or past the collars 25 , 26 when these are moved within the annular space 17 and 19 , respectively. In each of the collars 25 , 26 is further arranged a check valve 29 and 30 , respectively, of a larger cross-sections than the channels 27 , 28 . The flow resistance past the collars 25 , 26 thus become direction dependent when the collars 25 , 26 are moved in the annular space 17 and the annular space 19 , respectively. In one direction liquid may pass the collar 25 through both channel 27 and check valve 29 , and the flow resistance is small. In the opposite direction liquid may only pass the collar 25 in a restricted cross-section provided by the channel 27 and the clearance between the collar 25 and the housing 2 . When the collar 25 is in the annular space 17 , this provides great flow resistance. This is correspondingly also the case for the collar 26 when it is in the annular space 19 .
The check valve 29 in the collar 25 is arranged to open for liquid from the upper side of the collar 25 to its underside. The check valve 30 is arranged opposite, to open for liquid from the underside of the collar 26 to its upper side. If the sleeve 12 is displaced, this entails great flow resistance for the one of the collars 25 , 26 which is being moved in the direction towards the annular space 18 , and little resistance for the collar 25 , 26 which is simultaneously being moved in the direction from the annular space 18 . A collar 25 , 26 which is in the annular space 18 , provides little flow resistance independently of the direction of motion, as liquid may pass outside the collar. If the sleeve 12 is subjected to a downward force which is greater than the force from the spring 9 , the sleeve 12 (and thereby the slide 3 ) will move slowly downwards because of the flow resistance in the channel 27 in the collar 25 . When the collar 25 enters the annular space 18 , the flow resistance is reduced, and the sleeve 12 is quickly moved to a lower end-position, in which the lower collar 26 abuts the shoulder 14 , as the check valve 30 will open for the liquid flow. If the downward force is removed, the spring 9 will seek to bring the sleeve 12 and the slide 3 back into the upper position. The check valve 30 will then close, and the speed of the sleeve 12 is restricted by the flow resistance in the channel 28 . The channels 27 , 28 serve as flow resistors. The check valve 29 in the upper collar 25 will open for liquid flow, so that there will be little flow resistance when the collar 25 is displaced in the annular space 17 . When the collar 26 enters the annular space 18 , the flow resistance is reduced, and the sleeve 12 is quickly displaced towards the upper end-position.
An axially displaceable tubular valve body 31 encloses the lower part of the slide 3 , so that the seals 4 , 5 , 6 form a sliding tightening against the inner surface of the valve body 31 . The seals 4 , 5 , 6 thus define an upper annular space 32 and a lower annular space 33 between the slide 3 and the valve body 31 , and thereby liquid cannot flow directly through the valve body 31 . In the side wall of the valve body 31 , above the area of the seal 4 , are arranged gates 34 , 35 , so that liquid flowing into the upper end of the valve body 31 , may flow through the gates 34 and 35 out into an annular space 36 between the valve body 31 and the housing 2 . Further, in the side wall of the valve body 31 , below the area of the seal 4 , are arranged further gates 37 , 38 , so that liquid may flow from the annular space 36 into the annular space 32 or the annular space 33 , depending on the position of the slide 3 relative to the valve body 31 . A pre-tensioned spring 39 , resting on the shoulder 41 inside the housing 2 , works against the underside of an external shoulder 42 on the valve body 31 , retaining the latter in an upper starting position.
Below the gates 37 , 38 , the valve body 31 is provided with a flow restriction 42 ′ in the form of an increased outer diameter, which limits the cross-section of the annular space 36 at the lower end of the valve body 31 . At the flow restriction 42 ′ the valve body 31 is provided with external ribs 43 slidably resting on the housing 2 , see FIG. 4 .
The lower end of the valve body 31 is provided with a seal surface 44 arranged to be capable of tightening against a valve seat 45 in the housing 2 , when the valve body 31 is displaced to a lower position.
When both the slide 3 and the valve body 31 are in the starting position, the annular space 33 communicates with the annular space 36 through the gates 37 , 38 , as is shown in FIG. 1 .
Liquid may flow into the upper end of the valve device 1 , down through the sleeve 12 , through the openings 13 , into the valve body 31 at the upper end thereof, through the gates 34 , 35 , out into the annular space 36 , past the flow restriction 42 ′, further past the seal surface 44 and valve seat 45 , out through the lower part of the valve device 1 .
If the flow rate is increased, the flow restriction 42 ′ will cause such a great pressure fall that a resulting force working on the valve body 31 , will overcome the force from the spring 39 and displace the valve body 31 to a lower position, in which its sealing surface 44 seals against the valve seat 45 , see FIG. 2 .
The liquid flow through the valve device 1 comes to a stop, which results in a pressure rise in the liquid above the valve seat 45 . An increasing pressure difference from the upper side to the underside of the valve seat 45 is caused, and this effects an increasing downward force which works on the valve body 31 and retains the seal surface 44 against the valve seat 45 . It also effects an increasing downward force working on the slide 3 . When the resulting force against the slide 3 exceeds the force from the spring 9 , the slide 3 is displaced downwards, and the sleeve 12 is brought along.
At the beginning the slide 3 will be displaced slowly downwards because of the flow resistance when the collar 25 is displaced downwards in the annular space 17 . After some time, greatly determined by the cross-section of the channel 27 and the length of the annular space 17 , the collar 25 enters the annular space 18 . The sleeve 12 and the slide 3 is then displaced quickly towards a lower position, as already explained.
As a consequence of the slide 3 being displaced downwards in the valve body 31 , communication between the annular space 36 and the annular space 32 is established through the channels 37 , 38 , see FIG. 3 . Liquid may then flow from the annular space 36 to the annular space 32 and further through the bore 8 and the channel 7 out through the lower part of the valve device 1 .
The liquid flow established entails a pressure fall on the upper side of the valve seat 45 , and the spring 39 will, after a short while, lift the valve body 31 , so that it does not tighten against the valve seat 45 .
Thereby, liquid may flow past the flow restriction 42 as well as through the gates 37 , 38 , the bore 8 and the channel 7 , and the pressure may be equalized in the valve device 1 .
The spring 9 seeks to lift the sleeve 12 and the slide 3 to the upper starting position, but the flow resistance of the collar 26 in the annular space 19 makes this happen slowly. After a while, which is greatly determined by the cross-section of the channel 28 and the length of the annular space 19 , the collar 26 enters the annular space 18 . The flow resistance is reduced as liquid may pass outside the collar 26 , and the spring 9 quickly brings the sleeve 12 and the slide 3 to the upper starting position, see FIG. 1 .
The process is periodically repeated as long as a sufficiently great liquid flow is being pressed through the valve device 1 .
The collars 25 , 26 with channels 27 , 28 , check valves 29 , 30 and the annular spaces 17 , 18 , 19 , filled with liquid, constitute a damping device limiting the speed of the valve body 31 during part of the movement of the valve body 31 .
An alternative embodiment of a damping device is described in the following with reference to FIG. 5, in which reference numerals of values exceeding one hundred are used, and so that components having the same or corresponding functions as those of the damping device already described, have been given the same reference numerals plus one hundred. Thus, in FIG. 5, is shown a part of a tubular housing 102 , corresponding to the housing 2 , and in which the upper part of a slide 103 , corresponding to the slide 3 , is shown. The slide 103 is kept in an upper starting position by a pre-tensioned spring 109 which rests on an annular shoulder 110 inside the housing 102 and works against the underside of a plate 111 attached to the slide 103 at the upper end thereof. Liquid may pass the plate 111 through openings 113 in the plate 111 .
Below the shoulder 110 there is provided in the housing 102 a concentric fixed sleeve 112 . There is a clearance between the housing 102 and the sleeve 112 , external radial lugs or ribs 112 ′ supporting the sleeve 112 internally in the housing 102 , so that liquid may pass outside the sleeve 112 .
The slide 103 runs through the sleeve 112 which is open at its upper end. In the sleeve 112 is arranged a shoulder 114 with a seal 115 which slidingly tightens against the slide 103 . At the lower end of the sleeve 112 is arranged a seal 116 with also tightens slidingly against the slide 103 . The seals 115 , 116 define an upper annular space 117 , a central annular space 118 and a lower annular space 119 between the slide 103 and the sleeve 112 . At the central annular space 118 the sleeve 112 has a larger internal diameter than at the adjacent annular spaces 117 , 119 . The sleeve 112 may have the same internal diameter at the annular space 117 as at the annular space 119 .
Above the shoulder 114 , in the sleeve 112 there is an annular piston 120 with seals 121 , 122 slidingly tightening against the sleeve 112 and the slide 103 , respectively. The underside of the piston 120 and the upper side of the shoulder 114 thus define a portion 123 of the annular space between the slide 103 and the sleeve 112 . A channel 124 in the shoulder 114 connects the portion 123 of the annular space to the annular spaces 117 , 118 , 119 below the shoulder 114 . The annular spaces 117 , 118 , 119 and the annular space portion 123 are filled with hydraulic oil or another liquid. The upper side of the piston 120 is exposed to the liquid conveyed in the valve device 1 , and ensures that always the same pressure prevails in the liquid in the annular spaces 117 , 118 , 119 and 123 as in the rest of the valve device. The annular space portion 123 serves as reservoir and pressure accumulator for liquid in the annular spaces 117 , 118 , 119 .
The slide 103 is externally provided with a fixed upper collar 125 and a fixed lower collar 126 located between the seals 115 , 116 . The diameter of the upper collar 125 is adapted to the annular space 117 , and the diameter of the lower collar 126 is adapted to the annular space 119 , so that there is little clearance between the sleeve 112 and the collars 125 , 126 . The distance between the collars 125 , 126 is such that they may be brought, separately or simultaneously, into the central annular space 118 through axial displacement of the slide 103 . When the collars 125 , 126 are in the annular space 118 , there will be larger clearance between the sleeve 112 and the collars 125 , 126 than when the collars 125 , 126 are in the annular space 117 , 119 .
In each of the collars 125 , 126 is provided, in the form of a relatively narrow channel 127 and 128 , respectively, a limited cross-section by way of which liquid may flow through or past the collars 125 , 126 when these are moved in the annular space 117 and 119 , respectively. The channels 127 , 128 serve as flow restrictors. In each of the collars 125 , 126 is further provided a check valve 129 and 130 , respectively, of a larger cross-sections than the channels 127 , 128 . The flow resistance past the collars 125 , 126 is thus direction dependent when the collars 125 , 126 are in the annular space 117 and 119 , respectively. When the slide is forced downwards by the pressure created when the valve body 31 closes, the annular spaces 117 , 118 , 119 filled with liquid, the collars 125 , 126 with channels 127 , 128 and check valves 129 , 130 , will delay the movement of the slide 103 in a manner corresponding to that explained for the annular spaces 17 , 18 , 19 and the collars 25 , 26 with channels 27 , 28 and check valves 29 , 30 .
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Method for overcoming friction between a coiled tube and the wall of a well by an oil- or gas well, and for enabling application of impact energy to loosen stuck objects in a well. Pressure changes are applied to a liquid flowing in the coiled tube by periodically shutting off the liquid flow at or near the outlet of the coiled tube. Pressure changes, pressure strokes, are applied by means of a valve device comprising a valve body ( 31 ) arranged to seal against a valve seat ( 45 ) and to shut off the liquid flow whenever the flow rate exceeds a predetermined value, and to remain shut until the pressure in the liquid upstream of the valve body ( 31 ) is lower than a predetermined value, and that the valve body ( 31 ) has a slide ( 3 ) arranged thereto, which is arranged to open for a liquid flow past the valve body ( 31 ), to reduce, thereby, the pressure in the liquid upstream of the valve body ( 31 ) whenever the pressure in the liquid upstream of the valve body ( 31 ) exceeds a predetermined value. A damping device in which pistons in the form of collars ( 25, 26 ), channels ( 27, 28 ) and check valves ( 29, 30 ) are moved in annular spaces ( 17, 18, 19 ) filled with liquid, contributes to the valve device being closed long enough for a pressure rise to spread in the liquid in the coiled tube, and being open long enough for full liquid flow to be established before the next shut-off.
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REFERENCE TO CO-PENDING APPLICATIONS
Priority is claimed as a 371 of international application number PCT/IL2009/000506, filed on May 21, 2009, which claims priority to Israeli patent application serial number 191743, filed on May 27, 2008.
FIELD OF THE INVENTION
The present invention relates to compositions and a method employing natural components for killing lice and their eggs.
BACKGROUND OF THE INVENTION
Head lice infestation is a widespread problem. Head lice infest a new host by close contact between individuals, making social contacts among children and parent-child interactions more likely routes of infestation than shared combs, brushes, towels, clothing, beds or closets. Head-to-head contact is by far the most common route of lice transmission. Children between 4 and 13 years of age are the most frequently infested group.
Humans are hosts of three different kinds of lice: head lice, body lice and pubic lice. The head lice ( Pediculus humanus capitis ) are wingless insects that spend their entire life on human scalp and feed exclusively on human blood. Humans are the only known host of this parasite.
The life cycle of the head lice includes three stages: egg, nymph and mature louse. Louse eggs are generally laid within 1 cm of the scalp surface, and attached to the hair by glue secreted by the adult female. A viable egg hatches to the first nymphal stage six to nine days after oviposition, and after three moltings develops to nymph 2, nymph 3 and eventually, after ten days, it matures to either a male or a female louse. The females lay an average of 3-4 eggs daily, and a generation lasts for about four weeks.
Traditionally, head lice infestations have been treated by applying kerosene on the infected hair, but this practice is painful and potentially very dangerous. Another method of prevention, especially among children, includes shaving the hair or cutting it very short, however, this method is not recommended nowadays due to possible psychological damage to the child.
Commercially available pediculicides used for topical treatment of head lice include organochlorines (lindane, DDT), organophosphates (malathion), carbamates (carbaryl), pyrethrins (pyrethrum), and pyrethroids (permethrin, phenothrin, bio-allethrin). Nevertheless, these pediculicides may rapidly lose their efficacy because of the development of resistant lice.
Natural products tested clinically and found to be safe and effective could be very important in the control of head lice, as the complexity of the active ingredients may prevent the rapid development of resistance. The natural products are more acceptable to consumers who may be concerned with the dangers of the use of chemical pediculicides. Several plant products such as aniseed, coconut, neem and tea tree oils are used in different available compositions for the treatment of head lice infestation. For example, EP 1 512 409 describes the treatment of head lice and their eggs by a composition comprising at least one essential oil, dried peppermint leaves, a tea and garlic. GB 2 341 091 discloses a formulation for treating head lice comprising a combination of tea tree oil, lavender oil and eucalyptus oil. U.S. Pat. No. 6,342,253 combines anise oil, tea tree oil and lemon oil for repelling head lice.
However, the European Cosmetic Toiletry and Perfumery Association, COLIPA, published in Recommendation No. 12 of December 2002 that tea tree oil should not be used in cosmetic products in a way that results in a concentration greater than 1% tea tree oil being applied to the body.
There is still a need for the development of new effective compositions for the treatment of lice because of the following reasons:
1. most of the available pediculicide formulations kill only the lice, while the eggs remain unaffected and continue to hatch. Hence, the researcher's approach is directed towards the development of compositions that kill not only lice, but also their eggs; 2. some pediculicides have to be applied on the head for long periods of time, which leads to compliance problems, especially with children; 3. some compositions cause irritation or sting, or may cause other inconveniences to the user; 4. several available natural formulations contain relatively high concentrations of tea tree oil, which may cause irritation.
It is therefore an object of the present invention to provide a non-toxic composition for the elimination of lice and their eggs.
It is another object of the invention to provide a composition that is highly effective in killing lice and their eggs.
Other objects of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
In one aspect the invention relates to a pediculicidal composition for killing both lice and their eggs, comprising a mixture of tea tree oil, geranium oil, neem oil, andiroba oil, rosemary oil and lemongrass oil, characterized in that the composition is diluted in a solvent composition comprising SD alcohol 40, diethylhexyl adipate, cyclopentasiloxane, and dimethicone.
According to a preferred embodiment of the invention the composition comprises 0.1-3% tea tree oil, 0.5-4% geranium oil, 0.3-3% neem oil, 0.1-2% andiroba oil, 0.5-3.5% rosemary oil, 0.8-4% lemongrass oil, 8-12% SD alcohol 40, 4.5-6% diethylhexyl adipate, 45.5-58.2% cyclopentasiloxane and 25-32% dimethicone.
A preferred composition according to the invention comprises about 1% tea tree oil, about 1% geranium oil, about 1% neem oil, about 1% andiroba oil, about 1% rosemary oil, about 1% lemongrass oil, about 10% SD alcohol 40, about 5% diethylhexyl adipate, about 50% cyclopentasiloxane and about 28% dimethicone.
The invention also encompasses a method for killing lice and their eggs, comprising applying to a subject suffering from lice infestation a topical composition consisting of a mixture of tea tree oil, geranium oil, neem oil, diethylhexyl adipate, andiroba oil, rosemary oil and lemongrass oil, SD alcohol 40, cyclopentasiloxane and dimethicone.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a composition for the elimination of lice and their eggs, comprising specific combinations of essential oils and carrier fluids, and a method for using the same.
The term “essential oil” as used herein refers to a hydrophobic liquid containing volatile aroma compound derived from a plant. The term “carrier fluid” as used herein refers to a solvent in which the essential oils of the present invention are diluted. These fluids can be, for instance, alcohols such as ethanol, polyols such as glycerol, non-essential oils and silicones such as cyclopentasiloxane and dimethicone.
It has now been surprisingly found that certain combinations of essential oils comprising tea tree oil, geranium oil, neem oil, andiroba oil, rosemary oil and lemongrass oil, when diluted in a solvent comprising SD alcohol 40, diethylhexyl adipate, cyclopentasiloxane and dimethicone, are extremely effective in killing lice and their eggs. The resulted pediculicide, provided in the present invention, is based on natural products, non-toxic, and mild.
Preferably, the pediculicidal composition comprises essential oils in the following amounts: 0.1-5% tea tree oil and more preferably 0.1-3%, 0.5-4% geranium oil, 0.3-3% neem oil, 0.1-2% andiroba oil, 0.5-3.5% rosemary oil and 0.8-4% lemongrass oil.
Unless otherwise indicated, all percentages given herein are by weight and based on the total composition.
Preferably, the pediculicidal composition comprises carrier fluids in the following amounts: 8-12% SD alcohol 40, 4.5-6% diethylhexyl adipate 45.5-58.2% cyclopentasiloxane and 25-32% dimethicone.
More Preferably, the composition of the present invention comprises about 1% tea tree oil, about 1% geranium oil, about 1% neem oil, about 1% andiroba oil, about 1% rosemary oil, about 1% lemongrass oil, about 10% SD alcohol 40, about 5% diethylhexyl adipate, about 50% cyclopentasiloxane and about 28% dimethicone.
According to one aspect of the invention, the pediculicidal composition can be safely applied to the skin, hair and scalp of adults and children over three years old, for up to 15 minutes.
The pediculicidal composition of the present invention may be provided in various forms, for instance, in the form of a shampoo, a conditioner, a gel, a spray, and a cream. According to the preferred embodiment, the composition is in the form of oil in spray without gas.
The invention will be further described and illustrated in the following examples.
EXAMPLES
Safety Assessment
A preferred composition comprising 1% tea tree oil, 1% geranium oil, 1% neem oil, 1% andiroba oil, 1% rosemary oil, 2% lemongrass oil, 13% SD alcohol 40, 5% diethylhexyl adipate, 47% cyclopentasiloxane and 28% dimethicone was evaluated for the exposure risk for consumers. The composition was found to be in conformity with the requirements of the French Decree 2000-569 of 23 Jun. 2000 and to the Code of Sante Publique Art R-5131-2 and 3 Section I and II as in the Cosmetic European Directive 76/769, 93/95 and 2003/15 modified, and not likely to harm health when used under the normal conditions.
General Procedures
All formulations described hereinafter were tested for their pediculicidal and ovicidal activity under laboratory conditions, according to the following procedures:
1. Protocol for lice: Body lice ( Pediculus humanus humanus ) are reared in the laboratory according to the method described by Cole (Cole, M. M. 1966. Body lice. In: Insect colonization and mass production. Smith, C. N. (ed.), Academic Press, N. York, p. 15-24). For each test, 50 lice (10 males, 10 females and 30 nymphs) were placed on a 7-cm white filter paper disc and exposed to 1 g of the test formulation. The lice were left in contact with the substance for 15 min. They were removed from the filter paper, washed with normal shampoo (1:20) for 1 min and then with tap water for 1 min. After treatment, lice were transferred to a fresh filter paper disc and incubated overnight at optimum temperature and humidity. Mortality was determined after 24 hours.
2. Protocol for eggs: Lice were placed on human hair every other day for 5 days and left for 24-48 hours for oviposition. Fifty eggs, 2-6 days old were treated the same way as lice. The number of hatched and non-hatched eggs was counted after 10 days.
As a negative control, lice treated with 40% ethyl alcohol, were used. Each formulation was tested in triplicate.
The Cole method uses body lice rather than head lice since head lice are not successfully reared in the laboratory.
The essential oils comprising the formulations of the invention are referred to herein according to their trade name, while the carrier fluids are used by their INCI name. Table 1 presents the different ingredients of the formulations by their trade name, INCI name, CAS name, manufacturer and Catalog No. of the manufacturer.
TABLE 1
Trade
Manu-
Catalog No.
name
INCI Name
CAS No.
facturer
(Manufacturer)
Tea tree
Melaleuca
68647-73-4
Dullberg
744-125
oil
alternifolia
(Tea Tree)
leaf oil
Geranium
Pelargonium
8000-46-2
Citrus
21150
oil
graveolens
and
Flower oil
allied
Neem oil
Melia
68956-68-7
Dullberg
741-525
azadirachta
seed oil
Crodamol
Diethylhexyl
103-23-1
Croda
DS03781/
DOA
adipate
0190/M95
Andiroba
Carapa
352458-32-3
Beraca
RF3110
oil
guaianensis
seed oil
Rosemary
Rosmarinus
8000-25-7
Citrus
4223
oil
officinalis
and
(Rosemary)
allied
leaf oil
Lemon-
Cymbopogon
8007-02-1
Citrus
C: 5520
grass oil
schoenanthus
and
oil
allied
Ethanol
SD Alcohol 40
64-17-15
Gadot
810113996
SDA 40
Silicone
Cyclopenta-
541-02-6
Momen-
7390 SF 1202
volatile
siloxane
tive
245
Silicone
Dimethicone
9006-65-9;
Momen-
6408 Oil M 350
oil
63148-62-9;
tive
200/350
9016-00-6;
Example 1
Formulation samples A-J as well as a composition according to the invention, identified as P-782, all containing different concentrations of essential oils diluted in different carrier fluids, were prepared and tested for their pediculicidal and ovicidal activity.
TABLE 2
P-
A
B
C
D
E
F
G
H
I
J
782
Tea tree oil
10
5
10
5
5
1
1
1
1
1
1
Geranium oil
2
5
5
5
5
5
1
5
1
5
1
Neem oil
3
3
3
3
3
3
3
1
1
3
1
Diethylhexyl
—
—
—
16
5
5
5
5
5
—
5
adipate
Andiroba oil
1
1
1
1
1
1
1
1
1
1
1
Rosemary oil
1
1
1
1
1
1
1
1
1
1
1
Lemongrass oil
3
2
2
2
2
2
1
2
2
2
1
Eutanol G
80
83
78
—
—
—
—
—
—
—
—
SD Alcohol 40
—
—
—
8.3
9.5
10
10.5
10.5
10.7
10.6
10.7
Cyclopenta-
—
—
—
37.7
44
46
49
47.1
49.4
48.8
49.9
siloxane
Dimethicone
—
—
—
21
24.5
26
27.5
26.4
27.9
27.6
28.4
Lice Mortality %
54
63
23
100
100
100
100
100
100
100
100
Egg Mortality %
31
41
27
73
91
77
37
40
42
34
80
The test results in Table 2 show that the use of SD alcohol 40, diethylhexyl adipate, cyclopentasiloxane and dimethicone as carrier fluids (formulation samples D-N) instead of eutanol G (formulation samples A-C) significantly increases both the pediculicidal and the ovicidal activity of the composition of the invention. Moreover, the results of the lice and egg mortality clearly demonstrate that samples D-N killed 100% of the lice, yet affected the eggs in different percentages. This fact indicates that fine tuning of the different ingredients comprising the formulations is required in order to achieve maximal ovicidal efficiency. Formulation E, which exhibited the highest egg mortality (91%), was not chosen to be the final composition due to the relatively high total concentration of essential oils in it. The composition according to the present invention, formulation P-782, killed 100% of the lice and 80% of the eggs.
The pediculicidal and ovicidal effect of P-782 on lice and their eggs was further tested 5, 10 and 15 minutes after treatment. The formulation rapidly killed the lice, and even after 5 minutes of exposure, they exhibited a mortality rate of 100%. Nevertheless, the elimination of 80% of the eggs required their exposure to P-782 for 15 minutes.
Example 2
The efficacy of composition P-782 of Example 1 in killing lice and their eggs was compared with two commercially available pediculicides, soled under the trade names Finale and Chick Chack. Finale is a natural tea tree oil spray, comprising 10% tea tree oil, rosemary oil, lavender oil, eucalyptus oil, mentha oil, geranium oil, and tocopheryl acetate, manufactured by NSP, Hadera, Israel. This formulation exceeds by ten fold COLIPA recommendations regarding tea tree oil concentrations. Chick Chack is a natural composition rich in essential oils, which contains coconut oil, anise oil, Ylang-Ylang oil and isopropyl alcohol, manufactured by CST NOVIS, Kiryat Malachi, Israel.
TABLE 3
Finale
Chick Chack
P-782
Lice mean % mortality
62
100
100
Eggs mean % mortality
14
55-59
80
Table 3 shows that Finale poorly succeeded in killing both lice and their eggs. Although P-782 and Chick Chack eliminated all lice, Chick Chack was much less efficient than P-782 in killing the eggs: Therefore, the specific formulation of the present invention is clearly superior to compositions currently available on the market.
Example 3
The composition of Example 1 in the form of a spray is applied to an individual suffering from head lice in the following manner:
1. Spray the lotion over dry hair and scalp; 2. Leave the lotion on for 15 minutes; 3. Wash the hair with regular shampoo to remove the lotion; 4. Repeat steps 1-3 after 10 days.
Example 4
A sensation test for formulation P-782 was carried out on 20 children between the ages 8 and 12 by their mothers (the average age being 10). The composition was applied to the dry hair and scalp of the subjects, remained for 15 minutes and was then washed off with the subject's regular shampoo. The procedure was repeated after seven days. Only 10-15% of the mothers reported irritation occurrences during the application of the composition and the 15 minutes wait, and one subject reported a singe in the eye area. 80% of the mothers were satisfied with the feeling sensation and the ease of use of the composition.
Example 5
A sensation test for composition P-782 was carried out on 21 women of age 20 years and up. The composition was applied to the dry hair and scalp of the subjects, remained for 15 minutes and was then washed off with the subject's regular shampoo. The procedure was repeated after seven days. 19% of the women reported irritation occurrences during the application of the composition and the 15 minutes wait, and 14% reported slight burning sensation in the eye area. Most of the subjects were satisfied with the feeling sensation and the ease of use of the composition.
While this invention has been described in terms of some specific examples, many modifications and variations are possible. It is therefore understood that within the scope of the appended claims, the invention may be carried out in a manner different from that specifically described.
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A non-toxic, highly effective composition for the elimination of lice and their eggs is provided. The composition contains natural products, namely plant oils, beside harmless cosmetic additives.
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FIELD OF THE INVENTION
This invention is directed to the field of semiconductor wafer processing, and more particularly, to a novel wafer handling station.
BACKGROUND OF THE INVENTION
Various thin-films and other structures are formed on the surfaces of semiconductor wafers during the several phases of the integrated circuit fabrication processes. In a typical case, the wafers to be processed are disposed into so-called boats, and the wafer-loaded boats are placed on a so-called boat loading mechanism operable to transfer the tube-load of wafer-loaded boats into the thermal reaction chamber of a processing furnace tube. One or more reactants in gas phase, controllably released in the thermal reaction chamber, pyrolically decompose and are surface catalyzed by the wafers to form the intended thin-film structures thereon. The boat loading mechanism is operative after selected thin-film formation to remove the tube-load of wafer-loaded boats from the thermal reaction chamber, and the same or another process is repeated on the same or another tube-load of wafer loaded boats.
Typically, several processing furnace tubes are arrayed in a vertically stacked relation, and each is provided with a separate boat-loading mechanism. The plural processing furnace tubes are operable in parallel so that the system throughput is limited theoretically only by the number of processing furnace tubes.
To realize the theoretically achievable throughout in a practicable automated furnace system, several objectives become important. Not only must several tube-loads of wafers be available at a given time, but also they should be made available in such a way that operator assistance is minimized and operator intervention is as infrequent as possible. After wafer processing, several tube-loads of coated wafers must be received and expeditiously stored until an operator or some mechanism provided therefor removes them from the system. Further, the several tube-loads of wafers must be maintained in a very clean state, so that they are not contaminated either by air-borne contaminates during transfer or by cross-contamination from a prior tube-load of already processed wafers.
SUMMARY OF THE INVENTION
The wafer transfer station of the present invention is able to accept and deliver multiple tube-loads of wafers for processing, to receive multiple-tube loads of wafers after processing, and to store both multiple tube-loads of carriers while their associated wafers are being processed and to store multiple tube-loads of wafer-loaded carriers awaiting processing. An operator or some mechanism need only input and remove the individual wafer loaded carriers from the wafer handling station. Contamination is controlled by an air-flow system and modular construction, and cross-contamination is prevented by the provision of separately dedicated input and outgoing product surfaces and of separate dedicated wafer manipulation tools.
The wafer handling station of the present invention includes an input port and an output port. Carriers loaded with wafers to be processed are input in the input port and the same carriers after processing are output at the output port. The station of the instant invention includes input storing means for storing plural carriers input into the input port in a multiple tube-load input queue, and includes output storing means for storing the plural carriers ready to be output into the output port in a multiple tube-load output queue. The wafer handling station further includes arraying and intermiate storage means coupled to the input storing means for arraying the carriers in the input queue into plural, spacially separated arrays of carriers each defining either a different tube-load of wafers to be processed or the empty carriers of multiple tube-loads of wafers being processed in a correspondingly different storage location. Transfer means coupled between the arraying and intermediate storage means and an inclinable transfer pad assembly defining an elevator-transport access port are disclosed for transferring the wafers from any selected one of the arrays of carriers defining a tube-load of wafers in the array and intermediate storage means to the elevator-transport access port, for transferring coated wafers from the elevator-transport access port back into the corresponding one of the arrays of carriers defining the same tube-load after processing, and for transferring the individual arrays of carriers with the coated wafers to the output storing means. Means are dislcosed that are cooperative with the inclinable transfer pad assembly for presenting different surfaces to outgoing and returning tube-loads of product so that the possibility of any cross-contamination therebetween is substantially eliminated at the elevator-transport access port. A robot is incorporated in the transfer means that is operable with different pick-up fingers respectively dedicated to outgoing and returning tube-loads of product to further prevent the possibility of cross-contamination. The transfer means includes independently actuatable portions that are selectively operable in a test mode to allow operator access to the wafers of a single carrier to provide data from which further process decisions can be made. An air-flow sub-system operative to induce selected pressure differentials is provided for controlling and preventing air-borne particulate contamination.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, objects, and advantages of the present invention will become apparent as the invention becomes better understood by referring to the following solely exemplary and non-limiting detailed description of a preferred embodiment thereof, and to the drawings, wherein:
FIG. 1 is a perspective view illustrating an exemplary automated furnace system having the wafer handling station according to the present invention;
FIG. 2 is a perspective view of the wafer handling station of the present invention;
FIG. 3 is a broken-away perspective view of the wafer handling station of the present invention;
FIG. 4 is a perspective view illustrating an elevator sub-assembly of the wafer handling station according to the present invention;
FIG. 5 is a perspective view illustrating a horizontal transfer sub-assembly of the wafer handling station of the present invention;
FIG. 6 is a partially pictorial sectional view illustrating the horizontal transfer sub-assembly with a wafer-loaded carrier thereon of the wafer handling station of the present invention;
FIG. 7 is a perspective view illustrating a bracket member of the wafer handling station of the present invention;
FIG. 8 is a sectional, partially pictorial, view illustrating the wafer handling station of the present invention;
FIG. 9 is a partially schematic, sectional view useful in illustrating the operation of a vertical transfer sub-assembly of the wafer handling station of the present invention;
FIG. 10 is a perspective view illustrating an inclinable transfer pad sub-assembly defining an elevator-transport access port of the wafer handling station of the present invention;
FIG. 11 is an elevational view, partially sectional, and partially pictorial, of the wafer handling station of the present invention;
FIG. 12 is a partially pictorial, side elevational view of the elevator-transport access port of the wafer handling station according to the present invention;
FIG. 13 is an end, partially pictorial, elevational view of the elevator-transport access port of the wafer handling station according to the present invention; and
FIG. 14 is a broken-away perspective view illustrating an air-flow system of the wafer handling station of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, generally designated at 10 is a perspective view illustrating an exemplary automated furnace system having the wafer handling station according to the present invention. A furnace generally designated 12 has a plurality, preferably four, of elongated and horizontally extending processing furnace tubes generally designated 14 that are arrayed in a vertical stack. An input gas manifold generally designated 16 is mounted to the rear of the furnace 12 for injecting reactant in gas phase into the several processing tubes 14, and a scavenger manifold generally designated 18 is mounted to the front of the furnace 12 for establishing an intended atmospheric condition along regions of the processing tubes 14 defined adjacent their mouths. The temperature of, and the type and quantity of the reactants in gas phase injected into corresponding ones of the processing tubes 14, are determined by the particular process being run on a batch of semiconductor wafers as will be readily appreciated by those skilled inthe art.
A loading island generally designated 20 is mounted to the front of the furnace 12. The loading island has plural boat loading mechanisms 22, preferably four, one for each of the processing tubes 14. The boat loading mechanisms 22 are axially aligned with the corresponding axes of the processing tubes 14 and preferably include a cantilevered paddle, not shown, for loading and unloading individual tube-loads of wafers into and out of the corresponding processing tube. Other boat-loading mechanisms such as wheel barrows and the like can readily be employed without departing from the inventive concept. The loading island 20 preferably includes an air control system 24 to help prevent particulate and other contamination of the tube-loads of wafers positioned on the several boat loading mechanisms 22. The air control system may be, for example, a vertical or a horizontal laminar flow hood respectively for directing a vertical or a horizontal cleansing stream past each of the boat loaders 22, and may be, as another example, a nitrogen/air purge.
A transfer station generally designated 26 is provided confronting and in laterally spaced relation with the loading island 20. The transfer station 26 includes a plurality of longitudinally extending and vertically stacked cantilevered shelves 28, corresponding in number to the number of processing furnace tubes, that severally define a transfer and queuing location for receving tube-loads of wafers that are individually dedicated to a corresponding one of the processing furnace tubes.
A wafer handling station that is the subject of the instant disclosure and generally designated 30 to be described is mounted in front of the loading island 24. As appears more fully below, the wafer handling station 30 includes an input port generally designated 32, an output port generally designated 34, an elevator-transport access port generally designated 36, and a plurality of quartzware queuing shelves generally designated 38 superadjacent the elevator port 36. A mechanical queuing station, not shown, could as well be used.
An X, Z, and Y movable elevator generally designated 40 is mounted in laterally-spaced relation to the longitudinal axis of the processing furnace tubes 14 for translation horizontally along an X axis defined between the furnace 12 and the wafer handling station 30, for translation along a Z axis defined vertically between the lowest and highest shelf locations of the transfer station 26 and the transfer and the queuing station 38, respectively, and for motion along a Y-axis defined orthogonally to the X and Z axes for transporting individual tube-loads of wafers between the boat loading mechanisms 22, the shelves 28 of the transfer station 26, the elevator-transport access port 36, and the quartzware queuing shelves 38. While any suitable elevator mechanism may be employed, it is preferred that it be the one disclosed in co-pending United States Utility patent application Ser. No. 734,919, entitled BOAT TRANSFER AND QUEUING FURNACE AND METHOD, of the same inventive entity and assignee as herein.
In the operation of the system 10, an operator individually inserts a plurality of carriers having wafers to be processed into the input port 32. The wafer handling station 30 is operative to array the inserted carriers into plural tube-loads of wafers to be processed, and maintains the several tube-loads in separate locations. The wafer handling station is then operative to transfer the wafers of any selected tube-load of wafer-loaded carriers into quartzware previously located at the elevator-transport access port for elevator pick-up. The elevator removes the quartzware having each tube-load of wafers either to the transfer shelves 28 or to the boat loaders 22. While one batch of wafers is being processed in the corresponding processing furnace tube, the wafer transfer station 30 is operative to make available another tube-load of wafers for processing at the elevator-transport access port, or to transfer a batch of coated wafers delivered by the elevator to the elevator-transport access port back into their original carriers and in their original order. The tube-loads of processed wafers may then be either temporarily stored by the wafer transfer station or the operator may remove them through the output port. The quartzware in which the wafers of each tube-load of wafers are loaded from their associated carriers is queued on the shelves of the queuing area 38. Any suitable quartzware, such as the carriers described hereinbelow, can be employed.
Referring now to FIGS. 2 and 3, the wafer handling station 30 includes a housing member 42 in which all the operative sub-assemblies to be described are disposed. The housing 42 is preferably fabricated of a stainless steel skeleton, not shown, which supports the various sub-assemblies, and is finished preferably by electropolished stainless steel sheets suitable for clean-room usage. The input port 32 and the output port 34 are preferably disposed through a sidewall of the housing 42 intermediate the top and bottom of the housing. The dimensions of the housing are selected such that the region below the input port 32 is sufficiently large to accommodate plural carriers input into the input port while the area defined above the output port 34 is sufficiently large to accommodate plural carriers output to the output port after processing.
Referring now to FIGS. 2, 3, and 4, and elevator sub-assembly generally designated 44 in FIG. 4 is internally mounted in the housing 42 in the region defined below the input port 32, and a similar sub-assembly is internally mounted in the housing 42 in the region defined above the output port 34. Each of the input and output elevators include a pair of vertically oriented continuous belts 46, 48 that are spaced apart by a distance selected to accommodate the width dimension of the plural carriers 50 that are severally inserted in, and received from, the input and the output ports 32, 34 respectively. The belts 46, 48 are mounted for circulating motion respectively on upper and lower shafts 52, 54 and 56, 58. The lower shafts 54, 58 are coupled to an elevator drive stepping motor 60 via a belted wheel arrangement generally designated 62. Confronting pairs of elongated angle brackets 64, 66 are fastened to the belts 46, 48 in spaced-apart relation along the direction of motion of the belts, with each of the pairs of confronting brackets 64, 66 defining a vertically movable shelf therebetween into which the carriers 50 are slidably inserted. In the preferred embodiment, the dimension of the belts perpendicular to their direction of motion is selected to accommodate two (2) carriers horizontally, and the dimension of the belts along their direction of motion is selected to accommodate six (6) carriers vertically.
Carriers having wafers to be processed are horizontally loaded in pairs into the input port 32, and are received and positively supported in the associated angle brackets 64, 66. The drive motor 60 rotates the drive shaft 58 such that the just inserted carrier pairs are moved down incrementally towards the bottom of the wafer transfer station. Nominally two tube-loads of input carriers can in this manner be temporarily stored in the input queue. Similarly, carriers having already processed wafers therein that are moved into the output port 34 in pairs in a manner to be described are moved by the output elevator upwardly into the output queue defined by the region above the output port 34. As will readily be appreciated, the input and output elevators in the preferred embodiment are thereby able to maintain in the input and output queues up to twelve (12) wafer-loaded carriers at any given time, which represent nominally two (2) tube-loads of wafers to be processed and two (2) tube-loads of processed product.
Referring now to FIGS. 3, 5, and 6, a horizontal transfer sub-assembly generally designated 68 in communication with the input elevator is provided for moving the carriers in the lowest location of the input queue. The horizontal transfer sub-assembly 68 preferably is constituted as an input walking beam operative to rectilinearly move the carriers pairwise, although other suitable transfer mechanisms can be employed without departing from the inventive concept. The input walking beam includes a walking, carrier-receiving platform 70 that extends substantially from side-to-side of the wafer handling station and at the bottom thereof. The illustrated platform 70 is in the form of carrier supporting plural fingers, but any suitable geometry such as a plate can also be employed. An elongated upstanding plate 72 is fastened to the walking platform 70 along one of its lateral edges. First and second slotted members 74, 76 are fastened in spaced-apart relation to and projecting from the plate 72 on the side thereof confronting the walking platform 70.
A pair of spaced support plates 78, 80 are slidably mounted on upper and lower linear bearings 82, 84 one to either side of the slotted member 74, and a pair of spaced support plates 86, 88 are slidably mounted on upper and lower linear bearings 90, 92 one to either side of the slotted member 76. A Z motor 94 is mounted to the support 78 the shaft of which is journaled therethrough. A disk 96 is mounted for rotation with the shaft of the Z motor 94. The disk 96 has an eccentric post 98 mounted thereto having a roller bearing 100 that extends through the slot of the slotted member 74 and is eccentrically mounted to a disk 102 mounted for rotation with a shaft 104 journaled in the members 80, 86. A disk 106 is mounted for rotation with the shaft 104 and has an eccentric roller post 108 extending through the slot of the slotted member 76 and fastened to a disk 110 mounted for rotation in the support 88.
A X drive shaft 112 is journaled through the supports 78, 80 and is mounted for rotation with the shaft of a X drive motor 114. A rotary motion to linear motion convertor 116 fastened to the member 80 is operatively coupled to the shaft 112. The convertor 116 preferably is a so-called ROHLIX drive assembly.
The Z-motor 94 controls the platform 70 for controlled motion along the Z axis, and the X motor 114 controls the motion of the platform 70 along the X direction. As the shaft of the motor 94 is controllably rotated, the disks 96, 102 and the disks 106, 110 rotate between the upstanding spaced plates 78, 80 and the plates 86, 88. The posts 98, 108 gang the confronting walls of the slotted members 74, 76 moving the members either upwardly along the Z direction or downwardly in the reverse direction along the Z axis. The elongated plate 72 is thereby displaced vertically, and therewith the platform 70 moves either upwardly or downwardly in dependence on the sense of rotation of the Z motor 94. With controlled rotation of the X-motor 114, the drive 116 converts the rotary motion of the shaft 112 into linear motion along the X direction. The supports 78, 80 and the supports 86, 88 therewith move along the X-direction on the linear bearings 82, 84 and on the bearings 90, 92 in a direction determined by the sense of rotation of the X-drive motor 114.
The elevator 44 (FIG. 4) successively delivers the lowermost pairs of the carriers in the input queue to the walking beam carrier receiving platform 70 of the input walking beam 68. The walking beam 68 is then repetitively operative to lift the platform 70 in Z, to step the platform in X, to move the platform in the negative Z direction, and then to move the platform in the negative X direction back to its "home" position. The walking beam cycles four-times in the preferred embodiment, so that six (6) carriers are longitudinally aligned in a row defining a tube-load of wafers to be processed. The 4th cycle is needed to correctly position the carriers in the ferriswheel.
Referring now to FIGS. 3, 6, and 7, the carrier pairs are severally walked into a selected one of a plurality of tube-load defining bracket members generally designated 118 carried by a ferris-wheel sub-assembly generally designated 119. The bracket members 118 are open-rectangular frames constituted by elongated side rails 120 and end rails 122. Flanges 124 are provided along the bottom of each of the rails 120 that define shelves for receiving and supporting the outwardly projecting flanges 126 carried by the plastic carriers 50 (also viewable in FIG. 4). Axially aligned angled-bearings 128 are provided on each of the end rails 122 of the several brackets 118, and the brackets 118 are severally hung on corresponding ones of axially-aligned and confronting shafts 130 projecting from vanes 132 radially formed on wheels 134 mounted for rotation with a shaft 136 operatively coupled to a motor 140 (FIG. 8). In the preferred embodiment, the vanes 132 have eight-pairs of the axially aligned posts 130, and eight tube-load defining brackets 118. As will be appreciated, the brackets 118 can then be loaded with eight (8) spacially separated arrays of carriers each defining a different tube-load in a correspondingly different storage location.
As best seen in FIG. 7, a lifting member generally designated 138 is fastened to each of the end rails 122 of the several brackets 118. The members 138 include spaced, substantially V-shaped portions 140, 142 the confronting walls of which define a first channel portion generally designated 144 therethrough that is of a comparatively small dimension in regions of the bracket 138 proximate the "V" thereof, and a second channel portion generally designated 146 of comparatively large dimension in regions thereof remote from the "V" of the rails 138.
Referring now to FIGS. 3, 8 and 9, a vertical transfer sub-assembly generally designated 150 is provided superadjacent the ferriswheel sub-assembly 119 for lifting and lowering any selected tube-load of carriers. The vertical transfer sub-assembly 150 preferably includes first and second vertically-oriented ball screw assemblies 152, 154 having axially movable rams 156, 158. Motors 160, 162 are provided for raising and lowering the associated rams 156, 158 by suitable actuation of the ball screws 152, 154.
As best seen in FIG. 9, each of the rams 156, 158 is provided with a ball member 160 on its free end that is connected via a resilient shaft 161 to the corresponding one of the ball screw assemblies 152, 154. The actuators 160, 162 are operable to lower the rams 156, 158 to that vertical position that intersects the locus traced by the vanes 132, during their rotation by the shaft 136. While in their lowered position, the shaft 136 is then controllably rotated, and the vanes 132 rotate therewith in the direction of an arrow 168. The upstanding lifting rails 138 thereof (FIG. 7) therewith trace a circular locus. The resilient member 161 of the rams 156, 158 is received through the slot 144, and the enlarged ball 160 carried on the free end of the arms 156, 158 is received through the slot 146 thereof. The actuators 160, 162 then move the ball screws 152, 154 upwardly in such a way that the balls 160 abut the "V" portion of the lifting rails 138 of the associated brackets 118. With continued upward translation of the rams 156, 158, the angle members 128 of the selected carrier-loaded bracket 118 are lifted off the posts 130 as illustrated by an arrow 170 (FIG. 9), and therewith the selected tube-load of carriers are moved to an upper transfer position generally designated at 163 and illustrated in FIGS. 3 and 8.
A door sub-assembly generally designated 172 in FIG. 8 is provided between the vertical transfer sub-assembly 150 and the ferriswheel sub-assembly 119 to preserve an intended clean condition in the ferriswheel sub-assembly. The door sub-assembly 172 includes a closure member 174 that is slidably moved by a continuous belt 176 between its illustrated closed conditionand an open position, not illustrated, that allows the rams 156, 158 to be received into the ferriswheel sub-assembly. The walking beam carrier receiving platform 70 of the input walking beam sub-assembly 68 is selectably positionable between its operative position illustrated in solid line, and a collasped position illustrated in dashed outline 177 (FIG. 8), that allows unimpeded rotation of the vanes 132.
Referring now to FIGS. 8 and 10, quartzware generally designated at 180 is provided at the elevator-transport access port 36 by the elevator 40 (FIG. 1). In the illustrated embodiment, the quartzware 180 includes an intermediate carrier generally designated 182, and plural four-rail boats 184 resting in the carrier 182. U-shaped members 186 are provided along the bottom of the intermediate carrier 182, preferably four, for receiving a corresponding one of the four tines of the elevator 40 (FIG. 1). Although in the preferred embodiment a boat-loaded intermediate carrier is employed, it is possible to use other quartzware configurations for receiving a tube-load of wafers without departing from the inventive concept, such as the quartzware disclosed and claimed in copending United States Utility patent application Ser. No. 784,347, entitled APPARATUS AND METHOD FOR BOATS-ONLY LOADING, of the same inventive entity and assignee as herein.
The intermediate carrier 182 is supported by an inclined transfer pad sub-assembly generally designated 188 to be described, and a horizontal transfer sub-assembly generally designated at 190 is mounted to the wafer loading station 30 for moving the wafers in the plastic carriers into the quartzware for processing and for moving the processed wafers from the intermediate carrier back to their associated plastic carriers after processing. In the preferred embodiment, the horizontal transfer sub-assembly includes a robot having an arm 192, such as the precision robot and arm assembly commercially available from Precision Robots, Inc., although other suitable transfer mechanisms, such as commercially available wafer mass transfer robots, can be employed as well without departing from the inventive concept. The robot arm 192 has six degrees of movement freedom in the preferred embodiment, and is operable in well-known manner under PROM control to serially transfer individual ones of the wafers between the quartzware and the associated carriers. The robot arm is selectably operative to accommodate different wafer spacings in the carriers and quartzware, and is selectably operative to place the wafers in any intended spaced-apart relation and spacial orientation including a back-to-back orientation useful in many coating processes. As schematically illustrated by dashed boxes 194, 196, the robot arm 192 is operable to exchange its pick-up hands to always use only one hand for wafers to be processed and to use a different dedicated hand for wafers after processing. In this way, cross-contamination and particulate transfer between outgoing and return wafers that would otherwise result if the same pick-up hands were employed is substantially eliminated.
Briefly referring to FIGS. 8 and 11, the ferriswheel sub-assembly 117, the vertical transfer sub-assembly 150, the inclined transfer pad sub-assembly 188, the robot 190 and its arm 192, and an output horizontal translation sub-assembly generally designated 195 to be described are mounted in the housing 42 of the wafer handling station 30 at an acute angle to the horizontal. The several wafers slidably received in the several carriers 50 and in the quartzware 182 (FIGS. 2 and 10) are thereby urged by the component of the gravitational field that acts in the direction of inclination to bias the several wafers against their confronting supports in a known, and precisely controlled spacial position. In this manner, any orientation uncertainty in the position of the wafers that would otherwise arise due to the play of the wafers in the carriers and in the quartzware slots provided therefor is substantially eliminated.
Referring now to FIGS. 10, 12, and 13, the transfer pad sub-assembly 188 includes a quartzware receiving platform generally designated 200 that is hinged at a pivot 202 for rotary motion relative to a fixed support member 203 that is fastened to the housing of the wafer handling station at the same acute angle to the horizontal as described above in connection with the description of FIG. 11. A lift mechanism generally designated 204 is provided between the ends of the members 200, 203 remote from the hinge 202. The lift mechanism 204 includes an articulated arm 206 operatively coupled to a lift actuator 208. The quartzware receiving platform 200 is thereby controllably rotated between a load position, where it is inclined at the same acute angle to the horizontal, and an elevator interface position, where it is generally horizontal. In its inclined condition, the robot arm 192 (FIG. 8) is thereby enabled to controllably move to the biased locations of the wafers out of and into the quartzware for transfer out of and back to the carriers as illustrated in dashed outlines 210, 212 in FIG. 8. Whenever the transfer pad sub-assembly 188 is in its horizontal condition, the elevator 40 (FIG. 1) is therewith enabled to move its tines into the U-shaped members 186 carried by the intermediate carrier 182.
Cross-contamination between outgoing and incoming tube-loads of wafers is eliminated by the provision of separate surfaces in the transfer pad sub-assembly 188 upon which incoming and outgoing quartzware is supported. In the illustrated embodiment, the boats 184 received in the intermediate carrier 182 are supported by pads 212, preferably of quartz, that are fastened to opposed planar surfaces of an inset 214 that is mounted for rotation with a shaft 216 coupled to an actuator generally designated at 218. The pads 212 have longitudinally extending grooves generally designated 220 formed therein that extend along the direction of elongation of the rotatable inset 214 for providing lateral alignment of the bottom rails 221 of the four-rail boats 184 carried by the intermediate carrier 182. Upstanding posts 222, suitably spaced along the opposed surfaces of the rotatable insert 212, have beveled surfaces at their free ends that cooperate with the confronting surfaces of the quartz boats carried by the intermediate carrier 182 for providing longitudinal alignment thereof. It will be appreciated that the provision of separate opposed surfaces on the rotatable inset 214 for outgoing and incoming tube-loads of product wholly eliminates surface contact induced cross-contamination between outgoing and incoming product, and thus helps maintain the desired clean conditions for automated wafer handling. It will further be appreciated that the rotatable inset has four sides defined at right-angles to each other that can each be severally employed to prevent cross-contamination between a plurality of different processing steps using the several surfaces thereof.
The pads 212 are in spaced apart relation along the direction of elongation of the rotatable inset 214. In the innerspaces therebetween, the U-shaped members 186 of the intermediate carrier are received. Axially movable abutments 223 are provided subjacent the two inner U-shaped members 186 for supporting the intermediate carrier 182 on the quartzware receiving platform 200 of the transfer pad sub-assembly 188. The axially movable members 223 are fastened together by an elongated tie 224, and the assembly is mounted as at 226 for linear motion via a rotary motion to linear translation convertor 228, preferably a ROHLIX drive assembly, slidably mounted on a shaft 230 of the actuator 218. The ROHLIX drive 228 translates in response to rotary motion of the shaft 230, and therewith moves different portions of the abutments 223 into supporting relation with the confronting wall of the U-shaped members 186. As will be appreciated, the different axial positions of the abutments 223 as illustrated in solid and dashed outlines thereby further prevents cross-contamination between the outgoing and incoming product.
During transfer between the several carriers and the quartzware, the transfer pad sub-assembly of the elevator-transport access port is in its inclined condition. The robot arm thereby is enabled to precisely transfer wafers from the carriers to the quartzware for providing a tube-load to be processed, and to transfer the wafers individually back to their original carriers in the same order after processing. During processing of each particular tube-load of product, the then empty carriers are stored in their corresponding storage location of the ferriswheel sub-assembly. In the illustrated embodiment, it will be appreciated that up to two (2) tube-loads of product to be coated and up to six (6) tube-loads of empty carriers are readily accommodated in the ferriswheel sub-assembly.
As shown in FIGS. 3 and 8, the output horizontal translation sub-assembly 195 is provided intermediate the vertical transfer station 150 and the inclined pad sub-assembly 188 for controllably moving processed wafers loaded back into their original carriers by the robot into the output elevator queue. In the preferred embodiment, the output translation sub-assembly 195 is constituted as an output walking beam substantially identical to the input walking beam provided for controllably moving the carriers having wafers to be processed into the ferriswheel sub-assembly described above in connection with the description of FIGS. 3, 5, and 6. For the output walking beam sub-assembly 195, the carrier receiving platform is connected to an actuator and linkage shown dashed generally at 232 in FIG. 5 that is operative to pivot the fingers of the platform 70 between an extended operative position shown in solid line and an inner retracted position partially shown dashed at 234. In the outer position, the platform cycles between the lift, X translation, lowering, and reverse X translation movements described above in connection with the description of the operation of the input walking beam for controllably moving carrier pairs two at a time over to the output elevator, which stores the product in the output queue until an operator removes the carriers through the output port 34. In the retracted position 234 of the walking finger platform 70 of the output walking beam, the platform is free from the path of motion of the vertical transfer sub-assembly so that the individual tube-loads of product are able to be transported between their corresponding ferriswheel locations and the vertical transfer position. The output walking beam preferably is in two, separately drivable parts, as shown generally at 235 in FIG. 3, that allows the separate walking-out of an outboard carrier to the output port 34 to allow an analysis thereof from which further process steps on that particular tube-load can be carried out in dependance on the test results.
Referring now to FIG. 14, generally designated at 244 is a pictorial view illustrating a presently preferred air-flow pattern that helps maintain an intended clean condition in the cooperating sub-assemblies of the wafer handling station according to the present invention. An internal air blower is coupled through a conduit containing a HEPA filter 245 that directs clean air through the input queue 246 and downwardly through the input walking beam region 248 into the ferriswheel sub-assembly chamber 250. The air circulates therein and is directed out through a conduit into the output elevator queue 252. A positive pressure is thus maintained in the input queue, the output queue, and in the ferriswheel sub-assembly that prevents external air-borne contaminants from migrating thereinto. A blower is coupled to a conduit in a drive electronics chamber 254 which draws the air therethrough and exhausts it through the floor as shown at 256. A negative pressure is therein created which helps draw particulates from the robot area, the mechanism areas, and the elevator-transport access port area which thereby helps control the air-borne contamination problem in these regions. An internal blower is coupled through a conduit containing a HEPA filter 258 that directs air through the robot area 190 and into the electronics chamber 254 through a manifold provided therefor. This air circulates through the output queue and is coupled back through the floor exhaust 256 through a bonnet schematically illustrated 260 provided at the top of the handler. It should be noted that the air can be directly vented through the ceiling by providing a top exhaust, not shown, rather than the bonnet 260.
In summary, the wafer handling station of the instant invention accepts plural carriers input in the input port and holds them in a plural tube-load input queue. The carriers are transferred in pairs into different tube-loads of product and temporarily stored by the ferriswheel sub-assembly. This sub-assembly maintains in the preferred embodiment two tube-loads of product to be processed and six tube-loads of product carrier during processing. A robot and cooperative vertical transfer sub-assembly are operative to load the carriers into quartzware for a designated furnace processing tube and remove the wafers after processing back to their original carriers and in the same positional order. The output walking beam walks the carriers having processed wafers out into the output queue in two modes. In a test mode, only one carrier need be removed to determine already achieved processing quality so that subsequent processing decisions can be made. In another mode, and usually for single step coating processes, the output beam walks the carriers having processed product into the output queue, which can maintain therein up to two tube-loads of processed product until removal by the operator. It may be noted that the entire system can be fully automated, without requiring an operator to insert and remove carriers, as, for example, can readily be accomplished by providing automatic transport means in communication with the input and output ports for severally adding and removing product thereinto before and after processing.
Many modifications of the presently disclosed invention will become apparent to those skilled in the art without departing from the scope of the instant invention.
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The disclosed wafer handling system includes an input port, an input queue, and output port, and an output queue. The input and output queue each include a vertical elevator assembly capable of storing plural carriers representing multiple tube-loads of wafers input in the input port and into the output queue. A ferriswheel having multiple tube-load storage means is cooperative with an input waling beam and the input queue for arraying the plural carriers therein in multiple tube-loads of wafers each at different intermediate storage locations. A vertical transfer sub-assembly is cooperative with the ferriswheel and with a computer-controlled robot arm for transferring the wafers from each tube-load of carries to quartzware maintained by an inclinable transfer pad defining an elevator-transport access port. An output walking beam is cooperative with the vertical transfer mechanism and the robot for placing processed wafers back in their original tube-load of carriers and for delivering them to the multiple tube-load output queue. The inclinable transfer pad includes movable surfaces for preventing surface contact induced product cross-contamination. Air flow patterns are so produced that positive and negative pressures cooperate to reduce air-borne contamination.
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TECHNICAL FIELD
[0001] The present invention relates to estimation of disasters in infrastructures, such as computer networks.
BACKGROUND
[0002] Risk analysis predicts likelihood of disasters, such as severe failures of an Information Technology (“IT”) infrastructure, that an organization may face, and the consequences of such failures. IT disasters, such as an e-mail server failure or other computer network failure, can impact the organization's ability to operate efficiently.
[0003] Known cindynic theory (science of danger) is applicable in different domains. For example, cindynics has been used to detect industrial risks and can also be used in the area of computer network (including computer hardware and software) risks. According to the modern theory of description, a hazardous situation (cindynic situation) has been defined if the field of the “hazards study” is clearly identified by limits in time (life span), limits in space (boundaries), and limits in the participants' networks involved and by the perspective of the observer studying the system. At this stage of the known development of the sciences of hazards, the perspective can follow five main dimensions.
[0004] A first dimension comprises memory, history and statistics (a space of statistics). The first dimension consists of all the information contained in databases of large institutions constituting feedback from experience (for example, electricity of France power plants, Air France flights incidents, forest fires monitored by the Sophia Antipolis center of the Ecole des Mines de Paris, and claims data gathered by insurers and reinsurers).
[0005] A second dimension comprises representations and models drawn from the facts (a space of models). The second dimension is the scientific body of knowledge that allows computation of possible effects using physical principles, chemical principles, material resistance, propagation, contagion, explosion and geo-cindynic principles (for example, inundation, volcanic eruptions, earthquakes, landslides, tornadoes and hurricanes).
[0006] A third dimension comprises goals & objectives (a space of goals). The third dimension requires a precise definition by all the participants and networks involved in the cindynic situation of their reasons for living, acting and working. It is arduous to clearly express why participants act as they do and what motivates them. For example, there are two common objectives for risk management—“survival” and “continuity of customer (public) service”. These two objectives lead to fundamentally different cindynic attitudes. The organization, or its environment, will have to harmonize these two conflicting goals.
[0007] A fourth dimension comprises norms, laws, rules, standards, deontology, compulsory or voluntary, controls, etc. (a space of rules). The fourth dimension comprises all the normative set of rules that makes life possible in a given society. For example, socient determined a need for a traffic code when there were enough automobiles to make it impossible to rely on courtesy of each individual driver; the code is compulsory and makes driving on the road reasonably safe and predictable. The rules for behaving in society are aimed at reducing the risk of injuring other people and establishing a society. On the other hand, there are situations, in which the codification is not yet clarified. For example, skiers on the same ski-slope may have different skiing techniques and endanger each other. In addition, some skiers use equipment not necessarily compatible with the safety of others (cross country sky and mono-ski, etc.)
[0008] A fifth dimension comprises value systems (a space of values). The fifth dimension is the set of fundamental objectives and values shared by a group of individuals or other collective participants involved in a cindynic situation. For example, protection of a nation from an invader was a fundamental objective and value, and meant protection of the physical resources as well as the shared heritage or values. Protection of such values may lead the population to accept heavy sacrifices.
[0009] A number of general principles, called axioms, have been developed within cindynics. The cindynic axioms explain the emergence of dissonances and deficits.
[0010] CINDYNIC AXIOM 1—RELATIVITY: The perception of danger varies according to each participant's situation.
[0000] Therefore, there is no “objective” measure of danger. This principle is the basis for the concept of situation.
[0011] CINDYNIC AXIOM 2—CONVENTION: The measures of risk (traditionally measured by the vector Frequency-Severity) depend on convention between participants.
[0012] CINDYNIC AXIOM 3—GOALS DEPENDENCY: Goals can directly impact the assessment of risks. The participants may have conflicting perceived objectives. It is essential to try to define and prioritise the goals of the various participants involved in the situation. Insufficient clarification of goals is a current pitfall in complex systems.
[0013] CINDYNIC AXIOM 4—AMBIGUITY: There is usually a lack of clarity in the five dimensions previously mentioned. A major task of prevention is to reduce these ambiguities.
[0014] CINDYNIC AXIOM 5—AMBIGUITY REDUCTION: Accidents and catastrophes are accompanied by brutal transformations in the five dimensions. The reduction of ambiguity (or contradictions) of the content of the five dimensions will happen when they are excessive. This reduction can be involuntary and brutal, resulting in an accident, or voluntary and progressive achieved through a prevention process.
[0015] CINDYNIC AXIOM 6—CRISIS: A crisis results from a tear in the social cloth. This means a dysfunction in the networks of the participants involved in a given situation. Crisis management may comprises an emergency reconstitution of networks.
[0016] CINDYNIC AXIOM 7—AGO-ANTAGONISTIC CONFLICT: Any therapy is inherently dangerous. Human actions and medications are accompanied by inherent dangers. There is always a curing aspect, reducing danger (cindynolitic), and an aggravating factor, creating new danger (cindynogenetic).
[0017] The main utility of these principles is to reduce time lost in unproductive discussions on the following subjects:
How accurate are the quantitative evaluations of catastrophes—Quantitative measures result from conventions, scales or unit of measures (axiom 2); and Negative effects of proposed prevention measures—In any action positive and negative impacts are intertwined (axiom 7).
Consequently, Risk Analysis, viewed by the cindynic theory, takes into account the frequency that the disaster appears (probability), and its real impact on the participant or organization (damage).
[0020] FIG. 1 shows a known “Farmer” curve where disasters are placed on a graph showing the relationship between probability and damage.
[0021] Disaster study is a part of Risk Analysis; its aim is to follow the disaster evolution. Damages are rated in term of cost or rate, with time. Let “d” denote the damage of a given disaster and “If” denote the frequency of such a disaster. From a quantitative point of view, it is common to define a rating “R” of the associated risk as: R=d×f. In practice, often, the perception of risk is such that the relevance given to the damaging consequences “d” is far greater than that given to its probability of occurrence f so that, the given “R=d×f” is slightly modified to: R=d k ×f with k>1. So, numerically larger values of risk are associated with larger consequences.
[0022] Disasters are normally identified by IT infrastructure components. These components follow rules or parameters and may generate log traces. Typically, disaster information is represented in the form of log files. The disaster rating and scale are relative rather than absolute. The scale may be, for example, values between “1” and “10”: “1” being a minor disaster of minimal impact to the disaster data group and “10” being a major disaster having widespread impact. The logging function depends of the needs of monitoring systems and data volumes and, in some cases, delay due to legal obligations.
[0023] The known Risk Analysis uses a simple comparison between values found by the foregoing operations, in order to extract statistics. Also, a full Risk Analysis of a IT infrastructure required a one to one analysis of all the data held on disasters. By comparing each disaster with each of the other disaster it was possible to calculate the likelihood of further disasters. This process is computationally expensive and also requires a significant amount of a computer's Random Access Memory (RAM).
[0024] An object of the present invention is to estimate risk of disaster of an infrastructure.
[0025] Another object of the present invention is to facilitate estimation of risk of disaster of an infrastructure.
SUMMARY OF THE INVENTION
[0026] The present invention is directed to a method, system and computer program for estimating risk of a future disaster of an infrastructure. Times of previous, respective disasters of the infrastructure are identified. Respective severities of the previous disasters are determined. Risk of a future disaster of the infrastructure is estimated by determining a relationship between the previous disasters, their respective severities and their respective times of occurrence.
[0027] In accordance with a feature of the present invention, the risk is estimated by generating a polynomial linking severity and time of occurrence of each of the previous disasters. The polynomial can be generated by approximating a Tchebychev polynomial.
[0028] In accordance with other features of the present invention, the risk is also estimated by modifying the polynomial by extracting peaks in a curve representing the polynomial, regenerating the polynomial using the extracted peaks and repeating the modifying step until a number of extracted peaks is less than or equal to a predetermined value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 illustrates an example of a prior art Farmer's curve.
[0030] FIG. 2 illustrates the result of the Tchebychev's polynomials approximation's use.
[0031] FIG. 3 illustrates two polynomial curves showing the collected disaster information from a first origin and a second origin.
[0032] FIG. 4 illustrates the combining of the polynomial curves of FIG. 3 according to an embodiment of the invention.
[0033] FIG. 5 is a flow diagram, including a flowchart and a block diagram, illustrating a program and system for generating polynomials according to the present invention.
[0034] FIG. 6 illustrates a system according to the present invention for estimating risk of disaster of an infrastructure.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention will now be described in detail with reference to the Figures. A Tchebychev analysis program 500 (shown in FIGS. 5 and 6 ) executing in a risk estimation computer 20 generates a continuous polynomial curve with a corresponding polynomial equation. Program 500 takes derivatives of the polynomial equation. When the derivative of the continuous curve is null, the risk reaches its maximum. The construction of the polynomial equation is shown below.
For i≧1 and j≧1, a Tchebychev polynomial having “n” points is given by:
P n ( x ) = ∑ i = 1 n ( y i ∏ j = 1 n ( x - x j ) ( x i - x j ) )
For example, to calculate the polynomial between two points, Point1 and Point2, having coordinates (x 1 , y 1 ) and (x 2 , y 2 ) respectively in space (x, y), the formula is: n=2,
P 2 ( x ) = y 1 ( x - x 2 ) ( x 1 - x 2 ) + y 2 ( x - x 1 ) ( x 2 - x 1 )
Where P 2 (x 1 )=Y 1 , and P 2 (x 2 )=Y 2 .
To calculate the polynomial between 3 points: Point1(x1, y1), Point2(x2, y2) and Point3(x3, y3), the formula is: n=3,
P 3 ( x ) = y 1 ( x - x 2 ) ( x - x 3 ) ( x 1 - x 2 ) ( x 1 - x 3 ) + y 2 ( x - x 1 ) ( x - x 3 ) ( x 2 - x 1 ) ( x 2 - x 3 ) + y 3 ( x - x 1 ) ( x - x 2 ) ( x 3 - x 1 ) ( x 3 - x 1 )
where P 3 (x 1 )=y 1 , P 3 (x 2 )=y 2 and P 3 (x 3 )=y 3 .
The Tchebychev polynomial is a continuous curve between “n” points.
[0036] Referring to FIG. 5 , Tchebychev analysis program 500 receives identified disasters data 510 from an infrastructure which are then inputted to a Tchebychev approximation module 520 . The Tchebychev module 520 calculates a polynomial from the identified disasters data 510 . The polynomial is inputted to a derivative module 530 . The derivative module 530 identifies peaks and troughs by identifying points which have a null derivative. The peaks having a null derivative are forwarded to a peaks (or tops) module 540 . The peaks module 540 identifies the peaks by studying the sign of the derivative before and after each of the identified points. Where the sign of the derivative is positive before and negative after an identified point, a peak has been found. A new filter module 550 counts the number of identified peaks and compares this to a predetermined maximum. If there are more identified peaks than the maximum, the identified peaks are inputted to the Tchebychev module 520 and the process is repeated. If the number of peaks is less than or equal to the maximum the process stops (step 560 ).
[0037] FIG. 2 illustrates an example of results produced by program 500 . An identified disasters trace 210 plots severity of a disaster against their time of occurrence. Program 500 then generates an approximation of Tchebychev's polynomials to obtain a first polynomial equation represented by a first polynomial curve 220 . Program 500 then takes derivatives of first polynomial equation 220 to identify the points at which the derivative is equal to zero. Null derivative points 230 correspond to peaks and troughs on the polynomial curve. Program 500 identifies peaks by analyzing each null derivative point 230 . If the polynomial values of the polynomial 220 before and after each null derivative point 230 are lower that the peak polynomial value at this point, a peak is identified. In this example, program 500 also identifies the extracted peaks 240 from the polynomial 220 through comparison with the identified disasters trace 210 . Where a null derivative point 230 is identified as a peak, program 500 compares the null derivative point 230 to the value of identified disasters trace 210 before and after the null derivative point 230 . Thus, program 500 identifies the extracted peaks 240 in FIG. 2 . For example, point A is one of extracted peaks 240 , B is the null derivative point 230 preceding A, and C is the null derivative point 230 following A. If the derivative is positive between A and B, and negative between A and C, point A is a peak. Furthermore, the values of the identified disasters trace 210 before and after point A are less than point A. Therefore point A is an extracted peak 240 .
[0038] Program 500 then uses an approximation of Tchebychev's polynomials to create a modified polynomial 250 using points which have been identified as peaks and the start and end point. Program 500 further modifies polynomial 250 by repeating the process described above to identify peaks. In this case, there would be no further improvement but in other cases the process will preserve only the highest peaks.
[0039] Referring now to FIG. 3 , polynomial curves 340 show two collections of disaster information for two organizations (first origin and second origin) with each disaster 310 shown as a point on the polynomial curve 340 . Program 500 identifies represented peaks 320 by the process described above to identify peaks from recovered data points. Each polynomial curve 340 has ends 330 .
[0040] Referring now to FIG. 4 , the polynomial curves 450 represent the two polynomial curves of FIG. 3 ( 340 ). The first origin has disaster points 420 and the second origin has disaster points 430 . Program 500 identifies peaks and ends of each of the polynomial curves 450 and extracts represented peaks. The new ends 440 are the ends from either of the polynomial curves 450 which are of greater gravity or greater extremity of time. Program 500 then uses the represented peaks from each polynomial curve 450 along with the new ends 440 to generate a merged polynomial 460 which represents disaster from the combined information of the first and second origin.
[0041] Referring now to FIG. 6 , a data logger 602 which enables information, typically consisting of logged events, to be collected from a infrastructure network 604 . The information from the data logger 602 is stored in a data storage 606 . A disaster identification program 608 assesses the logged events to determine whether the event is deemed a disaster. For example, if the logged event indicates a failure of system hardware or software it may be logged as a disaster. A disaster gravity program 610 assesses each identified disaster generating disaster data. For example, as described previously, a disaster may be assigned a value between “1” and “10” corresponding to level of impact on the infrastructure 604 . The disaster data is then inputted to Tchebychev analysis program 500 as described previously. The Tchebychev analysis program generates a risk analysis equation or data. Program 500 then analyzes the risk analysis data to identify one or more high risk disaster events. For example, after the Tchebychev analysis program 500 has completed the risk analysis, program 500 typically identifies a number of peaks corresponding to high risk events 612 . These peaks/events can be identified as disasters which generate significant risk to the infrastructure 604 . Measures can then be automatically, or otherwise, taken to minimise further risk. For example, the computer system 20 could instigate additional services on other computers or server of the network 604 to provide additional redundancy to cope with a particular high risk event. The high risk events 612 can also be displayed on a computer screen, or any type of visual display unit, to allow a user to view and obtain more information about the high risk events 612 . In this manner, a disaster of greatest potential risk can be identified automatically.
[0042] The present invention may be embodied in a computer program (including program modules 608 , 610 , 500 and 612 ) comprising instructions which, when executed in computer 20 , perform the functions of the system or method as described above. The computer 20 includes a standard CPU 12 , operating system 14 , RAM 16 and ROM 18 . The program modules 608 , 610 , 500 and 612 can be loaded into computer 20 from a computer readable medium such as a magnetic disk or tape, optical medium, DVD, or network download media (such as including a TCP/IP adapter card 21 ).
[0043] Improvements and modifications may be incorporated without departing from the scope of the present invention.
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Method, system and computer program for estimating risk of a future disaster of an infrastructure. Times of previous, respective disasters of the infrastructure are identified. Respective severities of the previous disasters are determined. Risk of a future disaster of the infrastructure is estimated by determining a relationship between the previous disasters, their respective severities and their respective times of occurrence. The risk can be estimated by generating a polynomial linking severity and time of occurrence of each of the previous disasters. The polynomial can be generated by approximating a Tchebychev polynomial.
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This is a continuation of U.S. patent application Ser. No. 09/049,412, which was filed on Mar. 27, 1998, and issued as U.S. Pat. No. 6,272,187 on Aug. 7, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of electronic communications. In particular, the present invention concerns optimally decoding data encoded with a cyclic code in communications systems where a convolutional code is applied after the cyclic code during the encoding process.
2. Description of the Related Art
In the field of electronic communications, channel coding is used to ensure the accuracy of data transmitted from one point to another. Channel coding refers to a class of signal transformations designed to improve communications performance by enabling the transmitted signals to better withstand the effects of various communications channel impairments, such as noise, fading, and jamming.
One set of channel coding techniques is referred to as linear block codes, which transform a block of k message bits into a longer block of n codeword bits. Binary cyclic codes are an important subclass of linear block codes. The codes are easily implemented with feedback shift registers in integrated circuits, and the underlying algebraic structure of cyclic codes lends itself to efficient decoding methods. Cyclic Redundancy Checks (CRC) are cyclic codes which are commonly used in communications systems, including cellular applications.
Another set of channel coding techniques is referred to as convolutional codes, which are described by three integers, n, k, and K. The integer K is a parameter known as the constraint length; it represents the number of k-tuple stages in the encoding shift register. An important characteristic of convolutional codes, which is not shared by linear block codes, is that the encoder has memory: The n-tuple emitted by the convolutional encoding procedure is not only a function of an input k-tuple, but also of the previous K−1 input k-tuples. Data which has been convolutionally encoded is often decoded using Viterbi decoders, which generally output decoded data in time reversed order.
Convolutional and linear block coding techniques are often combined, for example in wireless cellular communications systems, resulting in significantly improved overall performance. Typical communications systems encode data first with a cyclic code for error detection, and then with a convolution code for error correction. A conventional receiver for such a system first uses a Viterbi decoder to decode the convolutional code and correct as many errors as possible. Then, a different decoder is used to decode the cyclic code and determine whether all of the errors were corrected or not.
In Code-Division Multiple Access (CDMA), Time-Division Multiple Access and most other cellular communications systems, data is divided into a number of “frames” including frame quality indicator bits (sometimes called “CRC bits”) generated using a CRC code. The conventional method of calculating CRC bits is using a circuit provided in TIA Standards Proposal #3384, “Personal Station Base Station Compatibility Requirements for 1.8 to 2.0 GHz Code Division Multiple Access Personal Communications Systems,” and several related TIA Standards. The conventional method requires that the input bits be in normal time order (first bit in first), which is disadvantageous for the following reasons.
In most applications, the CRC bits in a receiver are calculated after a Viterbi decoder. Optimal Viterbi decoding requires a full “traceback” to calculate the input bits, which results in the input bits to the CRC generator being available in time reversed order. If the conventional method of calculating the CRC bits is used, the input bits need to be buffered up and fed into the CRC generator after all of the input bits are generated. It would be preferable to calculate CRC bits from a frame of data that is available in time reversed order (i.e., last bit available first) since this would allow the quality of a frame to be checked simultaneously with the Viterbi decoding, without buffering any bits. This reduces the hardware and other device complexity in implementation.
Therefore, an object of this invention is to provide a circuit which can decode in time reversed order, without buffering any bits, data encoded with a cyclic code in systems where a convolution code is applied after the cyclic code during the encoding process.
SUMMARY OF THE INVENTION
This object is achieved by the present invention, which comprises a device which efficiently decodes data encoded with a cyclic code in communications systems where a convolutional code is applied after the cyclic code during encoding, wherein the device accepts data provided in time reversed order by a Viterbi decoder which decodes the convolutional code. In a preferred version, the device employs linear feedback shift registers having a plurality of feedback paths. A set of multipliers corresponding to a set of coefficients is interposed in the feedback paths such that when data is shifted through the feedback shift registers, the device performs division by x for an input bit equal to 0, and, for an input bit equal to 1, performs division by x and then adds x k+m−1 . The set of multipliers includes a set of weighting multipliers corresponding to coefficients of a weighting polynomial such that addition of x k+m−1 is performed for an input bit equal to 1. In another preferred version, the device compares a known initial state to a final state generated by shifting time reversed data through the linear feedback shift registers such that the final state equals the known initial state if there are no errors.
As a result of this novel configuration, the quality of a data frame can be checked simultaneously with Viterbi decoding, without buffering any bits. This reduces the hardware and other device complexity in implementation. These and other aspects, features, and advantages of the present invention will be apparent to those persons having ordinary skill in the art to which the present invention relates from the foregoing description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a conventional CRC circuit.
FIG. 2 is a block diagram of a preferred version of the CRC circuit of the present invention.
FIG. 3 is a block diagram of another preferred version of the CRC circuit of the present invention.
FIG. 4 is a block diagram of a wireless communications system;
FIG. 5 is a block diagram of the basic architecture of a mobile station.
FIG. 6 is a more detailed block diagram of the basic architecture of a mobile system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A. CRC Characteristics and the Conventional Decoding Method
The conventional method for calculating the CRC is described in the J-STD-008 standard, pages 3-34-36. FIG. 1 shows a conventional circuit for calculating a k-bit CRC. The behavior of this circuit can be analyzed using Galois field theory. The coefficients, g i , can be represented as a polynomial with the following form:
g ( x )= g k x k +g k−1 x k−1 + . . . +g 1 x+g 0 (1)
where the coefficients are taken from GF(2), which is simply the set {0,1}. The state of the shift registers above are defined by a polynomial h(x) with the following form,
h ( x )= h k−1 x k−1 +h k−2 x k−2 . . . +h 0 (2)
where the coefficients are also taken from GF(2). The input bits are represented by a polynomial,
a ( x )= a 0 +a 1 x+a 2 x 2 + . . . +a m−1 x m−1 (3)
where a i represents the input bits, a 0 is the first input bit, and m is the total number of input bits for a frame. The conventional circuit shown in FIG. 1 multiplies the state polynomial h(x) by x, and takes the remainder with respect to the generator polynomial g(x). (Note: The “remainder” of a polynomial with respect to g(x) is the remainder after dividing the polynomial by g(x).) This circuit is similar to circuits commonly used to generate pseudorandom number (PN) sequences. What makes this circuit different from a PN sequence generator is the presence of the input data stream.
For each input bit, if the input bit is a 0, the state polynomial is multiplied by x and the remainder is taken with respect to the generator polynomial g(x). If taking the remainder with respect to g(x) is denoted by < > g(x) , this operation can be expressed as:
h ( x )=< h ( x )* x> g(x) (4)
If the input bit is a 1, the state polynomial is multiplied by x, then x k is added to the polynomial, and then the remainder with respect to g(x) is taken. This can be expressed as:
h ( x )=< h ( x )* x+x k > g(x) (5)
Since the result is the same whether or not the remainder with respect to g(x) is taken at each step or after all of the input bits, the CRC can be represented by the polynomial c(x) given by:
c ( x )=< h ′( x ) x m +x k [a 0 x m−1 +a 1 x m−2 + . . . +a m−1 ]> g(a) (6)
where h′(x) is the initial state of the registers. For J-STD-008, the initial state of the registers is all ones, which can be represented by:
h ′( x )= x k−1 +x k−2 + . . . +x +1 (7)
The problem with the conventional method is that the circuit requires the first input to be the first data bit of the packet. In implementing a standard Viterbi decoder, the output bits are calculated during traceback, which starts at the end of the data packet and moves toward the beginning. The simplest solution is to buffer the input bits and feed them through the CRC generator after the Viterbi decoder traceback is complete. This, however, requires extra complexity in the data flow. A more desirable solution is to derive a circuit that will compute the same CRC, but accept the input bits in time reversed order.
B. Time Reversed Data Implementation
In receivers for many practical communications systems, including J-STD-008, the CRC is calculated after the Viterbi decoder. A Viterbi decoder generally outputs data in time reversed order if a full traceback is done. It is generally desirable to just push CRC input data into the CRC generator circuit as it becomes available instead of buffering up all of the data and taking the extra step to generate the CRC after the Viterbi decoder is finished. What is needed is a circuit that produces the same CRC, given by c(x) above, but accepts the input data in time reversed order.
An approach that will generate the same CRC if the first input bit is a m−1 is now described. In a preferred version of the present invention, the initial state of the registers is:
h ( x )=< h ′( x ) x 2m > g(x) (8)
where h′(x) is the initial state for the standard method. For each input bit, if the input bit is a 0, the state polynomial is divided by x, and then the remainder is taken with respect to g(x), which can be expressed as:
h ( x )=< h ( x )* x −1 > g(x) (9)
If the input bit is a 1, the state polynomial is divided by x, x k+m−1 is added to the result, and then the remainder is taken with respect to g(x). This can be expressed as:
h ( x )=< h ( x )* x −1 +x k+m−1 > g(x) (10)
This yields the same expression for the CRC as the conventional method. The only disadvantage to this method is that the initial state and the polynomial that is added when the input is a 1 are dependent on m, which is the length of the input packet For CDMA systems, this is a minor disadvantage as there are only six different values of m for all of the rates in both rate sets, and these polynomials can be computed ahead of time.
A circuit which implements the time reversed CRC generation is shown in FIG. 2 . The coefficients, g i , represent the generator polynomial and are identical to those of the conventional method described above. The weighting polynomial, w(x), is the polynomial that is added to accomplish the addition by x k+m−1 , and is given by:
w ( x )=w k−1 x k−1 +w k−2 x k−2 . . . +w 0 =<x k+m−1 > g(x) (11)
For J-STD-008, the initial state of the registers is given by:
h ( x )=< x 2m [x k−1 +x k−2 + . . . +x +1]> g(x) (12)
The division by x is performed by reversing the direction of the shift registers and adding the generator polynomial when x 0 is a 1. The input bits are inserted into multiple stages of the shift register sequence, as opposed to just the end for the conventional method.
Another detail needed for implementation is the value of h(x) and w(x) for the six different CRC/packet size combinations. A table for w(x) and h(x) for the CDMA standard is given below:
TABLE 1
Polynomials for Time Reversed CRC Generator
h(x)
w(x)
12 bit - Rate Set 1
0x3B7
0x441
12 bit - Rate Set 2
0xF96
0x43C
10 bit
0x3D2
0x184
8 bit - Rate Set 1
0xC5
0x68
8 bit - Rate Set 2
0x6F
0x83
6 bit
0x2E
0x2F
All of the coefficients are represented as a single hex number where the LSB corresponds to W 0 /h 0 .
C. Alternative Time Reversed Implementation
The goal of generating a CRC is to check if the input frame was decoded correctly. It is desirable to do this with time reversed input data because that is how data is available in certain communications systems such as CDMA systems. An alternative approach is to start with the ending state of the shift register in the conventional method and work backwards to the starting state. If there are no errors in the input sequence, then the final state of the alternative method will equal the initial state of the conventional method.
FIG. 3 shows a circuit which will perform this function. The decision of whether the frame is correct involves comparing the initial state of the standard method to the state of the shift registers after the time reversed data is clocked into the circuit of FIG. 3 . The difference between this method and the previously described methods is that it generates a fixed initial state from the received CRC, instead of generating a CRC from the received data and comparing it to the received CRC.
One advantage of this circuit is that the received CRC is at the end of the received data and can be loaded into the shift registers simply by considering it to be part of the received data that is clocked into the registers. If the CRC is to be loaded in this way, the initial state of the registers must be all zeros. A further advantage of this circuit is that, if the initial state of the registers is all zeros, then any extra zeros at the beginning of the time reversed input data will have no effect on the final state. Therefore, the tail (which by definition is all zeros regardless of the received data), the CRC, and the received packet, which together are the total output of the Viterbi decoder, can be input to the circuit shown in FIG. 3 . If there are no errors in the received packet, the final state of the registers will be the initial state in the standard method. For J-STD-008, the initial state for all of the CRC generators is all ones.
D. Application in Wireless Systems.
By way of example but not of limitation, one possible application of the present invention is in wireless cellular communications systems. As shown in FIG. 4 , a cellular network is comprised of three fundamental parts:
(1) a mobile station 1 (which is carried by the subscriber); (2) a base station subsystem 2 (which controls the radio link with the mobile station); and (3) a network subsystem 3 (which is interfaced to the public fixed network 4 and the base station subsystem). The network subsystem and the base station subsystem communicate across an interface 5 , while the mobile station and the base station subsystem communicate using a radio link 6 .
Mobile Station
The mobile station is the “phone” part of the wireless communication system. The mobile station may be fixed or portable. Fixed mobile stations are permanently installed in a car or a stationary location. Portable units include bag phones and hand-portable phones (commonly called “cell phones”). Hand-portable phones are becoming increasingly popular because they can be carried easily on the person of the subscriber. A mobile station includes an antenna 7 for transmitting and receiving radio signals from the base station subsystem.
Base Station Subsystem
The base station subsystem comprises two fundamental elements, (1) one or more base transceiver stations ( 8 and 9 ) and (2) a base station controller 10 . These components communicate across another interface 11 . A base transceiver station includes radio transceivers that handle radio-link protocols with the mobile station and an antenna 12 for communication with mobile stations.
The base station controller manages the radio resources of the base transceiver stations. It also manages handovers (passing the audio from cell to cell during a call), frequency hopping (changing operating frequency to maintain signal quality) and radio-channel setup.
Network Subsystem
The basic element of the network subsystem is the mobile services switching center (MSC) 13 . The MSC is the interface of the cellular network to the public fixed network and, as such, basically performs the functions of a switching node of the public fixed network The MSC also routes calls from the public fixed network (via the base station controller and the base transceiver station) to the mobile station. The MSC also provides the wireless system with individual information about the various mobile stations and performs the functions of authentication, location updating, and registration. The MSC may operate in conjunction with other functional entities which further comprise a network subsystem, such as registers which hold information regarding current mobile station location and subscriber information.
Radio Link
In conventional wireless communications technology, user data (e.g. speech) is encoded in a radio frequency for transmission and reception between a base station and a mobile unit. Because the number of available radio frequencies, or “channels,” for cellular system is less than the number of all possible users, the system is “trunked.” Trunking is the process whereby users share a limited number of channels in some predetermined manner.
A common form of trunked access is the frequency-division multiple access (FDMA) system. In FDMA, the limited channels are shared by all users as needed. However, once a channel is assigned to a user, the channel is used exclusively by the user until the user no longer needs the channel. This limits the number of concurrent users of each channel to one, and the total number of users of the entire system, at any instant, to the number of available channels.
Another common trunking system is the time-division multiple access (TDMA) system. TDMA is commonly used in telephone networks, especially in cellular telephone systems, in combination with an FDMA structure. In TDMA, data (speech) is digitized and compressed to eliminate redundancy and silent periods, thus decreasing the amount of data which is required to be transmitted and received for the same amount of information. Each of the channels used by the TDMA system is divided into “frames” and each of the users sharing the common channel is assigned a time slot within the frames. The TDMA system appears, to each of the users sharing the channel, to have provided an entire channel to each user.
Code-division multiple access (CDMA), yet another common trunking system, is an application of spread spectrum techniques. The main advantage of CDMA systems as compared to TDMA systems is that all the mobile stations can share the full transmission spectrum asynchronously, that is, there is no need for synchronization among mobile stations (only between a mobile station and a base station).
Mobile Station Architecture
As shown in FIG. 5 , mobile stations generally comprise two basic parts, the RF (radio frequency) part 20 and the digital part (or baseband processing circuitry) 21 . The RF part operates receiving, transmitting, and modulation functions. The digital part handles data processing, control, and signaling functions. As shown, the radio frequency part includes an antenna 27 for receiving and transmitting radio signals. A radio signal received by the radio frequency part is converted to a lower frequency signal and delivered 22 to the digital part. Likewise, a signal generated by the digital part is delivered 23 to the radio frequency part, which in turn converts the signal to a higher frequency signal, and transmits that higher frequency signal.
The digital part is operatively connected to a handset 24 , which has a speaker 25 and a mouthpiece 26 . All or part of the radio frequency part and the digital part can be disposed within the handset, as is the case with cell phones.
Also included in the mobile station architecture (but not shown in FIG. 5 ) is a reference clock, which is used to drive the digital hardware. Clock circuitry may also include tuning circuitry or temperature compensation circuitry to make the reference signal more accurate. A control processor performs the control functions of the mobile station, including, for example, power control and the selection of different channels.
For CDMA systems, mobile stations generally include the following elements. Transmitting circuitry transmits as spread spectrum signals data (e.g. speech) provided by a user, while receiving circuitry receives spread spectrum signals and converts the signals into a form intelligible to the user. Pseudorandom noise (PN) sequence generator circuitry operationally connected to the transmitting circuitry and the receiving circuitry enables the mobile station to transmit and receive spread spectrum signals. Prior to transmission, each data bit is spread into a number of “chips” which can be transmitted in a bandwidth-limited channel along with signals of many other users, who can all share the channel. A chip rate clock, operating at a chip rate, clocks the PN sequence generator circuitry. FIG. 6 shows a more detailed block diagram of a CDMA based mobile system. As shown, a despreader 30 is coupled to a Viterbi decoder 32 , which is coupled to a CRC circuit 34 . The despreader 30 receives data and despreads it. The Viterbi decoder 32 receives the despread data and performs Viterbi decoding. The decoded data is then checked by th CRC circuit 34 .
Although the present invention has been described in detail with regard to the exemplary embodiments and drawings thereof, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. Accordingly, the invention is not limited to the precise embodiment shown in the drawings and described in detail hereinabove. Therefore, it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof as limited solely by the claims appended hereto.
In the following claims, those elements which do not include the words “means for” are intended not to be interpreted under 35 U.S.C. § 112 ¶6.
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A novel device which efficiently decodes data encoded with a cyclic code in communications systems where a convolutional code is applied after the cyclic code during encoding. Specifically, the device accepts data provided in time reversed order by a Viterbi decoder which decodes the convolutional code. In a preferred version, the device employs linear feedback shift registers with multiple feedback paths. A set of multipliers corresponding to a set of coefficients is interposed in the feedback paths such that when data is shifted through the feedback shift registers, the device performs division by x for an input bit equal to 0, and, for an input bit equal to 1, performs division by x and then adds x k+m−1 . The set of multipliers includes a set of weighting multipliers corresponding to coefficients of a weighting polynomial such that addition of x k+m−1 is performed for an input bit equal to 1. In another preferred version, the device compares a known initial state to a final state generated by shifting time reversed data through the linear feedback shift registers such that the final state equals the known initial state if there are no errors.
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FIELD OF THE INVENTION
[0001] The present invention relates to a working method of a card reader, which belongs to field of communication.
PRIOR ART
[0002] At present, communication facilities, such as smart phones and tablets, are becoming more and more popular. However, most of the communication facilities do not have a main interface, or specifications of USB interfaces of the communication facilities are not unified, thus, data communication between a card reader and a communication device is limited.
SUMMARY OF THE INVENTION
[0003] The object of the invention is to provide a working method of a card reader, in which data communication does not still rely on a USB module in the card reader, and the method makes the data communication more compatible and more convenient for users.
[0004] Therefore, according to one aspect of the present invention, there provides a working method of a card reader, which includes:
[0005] Step S 1 , powering on and initializing a card reader, and setting a work mode according to a type of a device which connects to the card reader;
[0006] Step S 2 , determining the work mode, waiting for receiving audio data in the case that the work mode is an audio mode, and executing Step S 3 when the audio data is received; waiting for receiving USB data in the case that the work mode is a USB mode, and executing Step S 5 when the USB data is received;
[0007] Step S 3 , transferring the audio data to digital signals, composing the digital signals to obtain a data package, parsing the data package to obtain a parsing result, determining a type of an instruction according to the parsing result, if the instruction is an operating-card instruction, sending the operating-card instruction to a card, waiting for receiving an operation result returned by the card, and executing Step S 4 ; if the instruction is the other instruction, executing a corresponding operation to obtain an operation result, and executing Step S 4 ;
[0008] Step S 4 , transferring the operation result to an audio data package, sending the audio data package to the connected device, returning to Step S 2 ; and
[0009] Step S 5 , determining a type of the received USB data, if the received USB data is an operating-card instruction, sending the operating-card instruction to a card, waiting for receiving an operation result returned by the card, sending the operation result to a device which connects to the card reader, and returning to Step S 2 ; if the received USB data is the other instruction, executing corresponding operation, and returning an operation result to the device which connects to the card reader, and returning to Step S 2 .
[0010] Preferably, in Step S 1 , setting the work mode according to a type of the device which connects to the card reader, specifically includes:
[0011] determining whether there exists a device which connects to the card reader via a USB module, if yes, setting the work mode as a USB mode; otherwise, setting the work mode as an audio mode; or,
[0012] Step a 1 , determining whether there exists a device which connects to the card reader via an audio module, if yes, setting the work mode as the audio mode; otherwise, executing Step a 2 ;
[0013] Step a 2 , determining whether there exists a device which connects to the card reader via a USB module, if yes, setting the work mode as the USB mode; otherwise, returning to Step a 1 ; or
[0014] Step b 1 , determining whether there exists a device which connects to the card reader via a USB module, if yes, setting the work mode as the USB mode; otherwise, executing Step b 2 ;
[0015] Step b 2 , determining whether there exists a device which connects to the card reader via an audio module, if yes, setting the work mode as the audio mode; otherwise, returning to Step b 1 .
[0016] Preferably, in Step S 5 , returning to Step S 2 further includes:
[0017] Step F 1 , determining whether the card reader connects to a power supply via the USB module, if yes, executing Step F 2 ; otherwise, returning to Step S 2 ; and
[0018] Step F 2 , determining whether quantity of electric charge of a battery reaches a rated value, if yes, prompting over-charging of the battery, and returning to Step S 2 ; otherwise, returning to Step S 2 .
[0019] Preferably, in Step S 2 , waiting for receiving the audio data specifically includes: determining whether the audio data is received via the audio mode in a preset duration, if yes, executing Step S 3 ; otherwise, returning to Step S 2 .
[0020] Preferably, waiting for receiving the USB data specifically includes: determining whether the USB data is received via the USB module in a preset duration, if yes, executing Step S 5 ; otherwise, determining whether the audio data is received via the audio module in the preset duration.
[0021] Preferably, in Step S 1 , initializing the card reader further includes: resetting a USB data transmission flag.
[0022] Preferably, after the work mode is set according to the device which connects to the card reader, the step further includes: turning on a corresponding data communication interrupt according to the work mode, in which the data communication interrupt includes: a USB data communication interrupt and an audio data communication interrupt; when the data communication interrupt is happened, executing Step S 2 .
[0023] Preferably, in Step S 2 , before waiting for receiving the audio data, the step further includes: turning off the USB data communication interrupt.
[0024] Preferably, in Step S 4 , before Step S 2 is returned, the step further includes: turning on the USB data communication interrupt.
[0025] Preferably, before waiting for receiving the USB data, the step further includes: turning off the audio data communication interrupt, determining whether the USB data transmission flag is set, if yes, executing Step S 5 ; otherwise, enabling a USB module connection, performing a USB data enumeration; determining whether the USB data enumeration is finished, setting the USB data transmission flag, and executing Step S 5 in the case that the USB data enumeration is finished; waiting for the data communication interrupt and returning to Step S 2 in the case that the USB data enumeration is not finished.
[0026] Preferably, in Step S 5 , before Step S 2 is returned to, the step further includes: turning on the audio data communication interrupt.
[0027] Preferably, in Step S 5 , turning on the audio data communication interrupt specifically includes: determining whether there exists a device which connects to the card reader via an audio module, if yes, turning on the audio data communication interrupt; otherwise, returning to Step S 2 .
[0028] Preferably, in Step S 5 , after the audio data communication interrupt is turned on, the step further includes: determining whether there exists a device which connects to the card reader via the USB module, if yes, returning to Step S 2 ; otherwise, turning off the USB data communication interrupt, resetting the USB data transmission flag, the card reader setting the work mode according to the type of the device which connects to the card reader, and executing Step S 2 .
[0029] Preferably, in Step S 2 , in the case that the work mode is the audio mode, the step further includes: initializing the audio module.
[0030] Preferably, initializing the audio module specifically includes: turning on a low-power-dissipation timer interrupt, determining whether the audio data is received, if yes, receiving the audio data, resetting a low-power-dissipation timer flag, turning off the low-power-dissipation timer interrupt, sending the audio data to the card reader, and turning on the low-power-dissipation timer interrupt; otherwise, setting the low-power-dissipation timer flag; and
[0031] starting to time when the low-power-dissipation timer interrupt is turned on, entering a low-power-dissipation timer interruption per preset duration, in which, entering the low-power-dissipation timer interruption specifically includes: determining whether the low-power-dissipation timer flag is set, if yes, entering a low-power-dissipation mode; otherwise, exiting from the low-power-dissipation timer interrupt.
[0032] Preferably, in Step S 3 , transferring the audio data to the digital signals specifically includes:
[0033] performing, by the card reader, a filtering process on the audio data to obtain a first processed data, performing a blocking process on the first processed data to obtain alternating component from the first processed data; obtaining a second processed data from the alternating component, transferring the second processed data so as to obtain transferred data, and performing the filtering process on the transferred data to obtain the digital signals.
[0034] Preferably, in Step S 3 , after the digital signals is composed to the data package, and before the data package is parsed, the step further includes: determining whether the data package is legitimate, if yes, parsing the data package; otherwise, waiting for receiving the audio data, and when the audio data is received, returning to Step S 3 .
[0035] Preferably, determining whether the data package is legitimate specifically includes:
[0036] c 1 , obtaining data of four bytes starting from the first byte of the data package, making the data of four bytes as a frame header, determining whether the frame header is a first preset value, if yes, executing c 2 ; otherwise, the data package is illegitimate;
[0037] c 2 , obtaining data at the seventh byte from the data package, making the data as a parameter flag, and determining whether the parameter flag is legitimate, if yes, executing c 3 ; otherwise, the data package is illegitimate;
[0038] c 3 , obtaining data of two bytes starting from the eighth byte of the data package, making the data of two bytes as data-length-value, and executing c 4 ;
[0039] c 4 , obtaining data whose length equals the data-length-value starting from the tenth byte, making the data as a data field, obtaining data of one byte behind the data field, making the data of one byte as a check word, and executing c 5 ; and
[0040] c 5 , calculating the data field via a preset algorithm to obtain a result, comparing the result with the check word, if the result is same as the check word, the data package is legitimate; if the result is not same as the check word, the data package is illegitimate.
[0041] Preferably, determining whether the parameter flag is legitimate in c 2 specifically includes: determining whether the parameter flag is a second preset value or a third preset value, if yes, the parameter flag is legitimate; otherwise, the parameter flag is illegitimate.
[0042] Preferably, when the data package is legitimate, the step further includes: determining the parameter flag, parsing the data package in the case that the parameter flag is the second preset value; waiting for receiving data of a preset length in the case that the parameter flag is the third preset value, and adding the data into the data package, and parsing the current data package.
[0043] Preferably, in Step S 4 , transferring the operation result to the audio data package specifically includes:
[0044] compressing an amplitude voltage of the digital signals of the operation result, transferring the digital signals of the operation result to an analog signal which is similar to a sine wave by a process of charging and discharging slowly, and transferring the analog signal to an audio data package.
[0045] Preferably, in Step S 1 , initializing further includes: setting a card-slot-state flag as a no-card flag; setting the card-slot-state flag as a card-in flag in the case that a card-in-slot pin is a high level; setting the card-slot-state flag as the no-card flag in the case that the card-in-slot pin is a low level.
[0046] Preferably, in Step S 3 , the other instructions includes: an instruction for inquiring card-slot-state, a powering-on instruction, and a powering-off instruction.
[0047] Preferably, in Step S 3 , determining a type of the instruction according to the parsing result, inquiring a state of the card slot according to the card-slot-state flag in the case that the instruction is the instruction for inquiring card-slot-state, setting card-slot-state data, making the card-slot-state data as the operation result, and executing Step S 4 .
[0048] Preferably, in the case that the instruction is the powering-on instruction, determining whether there exists a card in the card slot according to the card-slot-state flag, if yes, powering on the card slot, reading a card-slot-powered-on response, making the card-slot-powered-on response as the operation result, and executing Step S 4 ; otherwise, generating a no-card-in-slot response, making the no-card-in-slot response as the operation result, and executing Step S 4 .
[0049] Preferably, in the case that the instruction is the powering-off instruction, powering off the card slot, reading a card-slot-powered-off response, making the response as the operation result, and executing Step S 4 .
[0050] Preferably, in Step S 5 , the other instruction includes: the instruction for inquiring card-slot-state, the powering-on instruction, and the powering-off instruction.
[0051] Preferably, in Step S 5 , determining the type of instruction according to the parsing result, in the case that the instruction is the instruction for inquiring card-slot-state, inquiring the state of the card slot according to the card-slot-state flag, setting the card-slot-state data, sending the card-slot-state data to a device which connects to the card reader, and returning to Step S 2 .
[0052] Preferably, in the case that the instruction is the powering-on instruction, determining whether there exists a card in the card slot according to the card-slot-state flag, if yes, powering on the card slot, reading a card-slot-powered-on response, sending the card-slot-powered-on response to the device which connects to the card reader, and returning to Step S 2 ; otherwise, generating a no-card-in-slot response, and sending the response to the device which connects to the card reader, and returning to Step S 2 .
[0053] Preferably, in the case that the instruction is the powering-off instruction, powering off the card slot, reading a card-slot-powered-off response, sending the response to the device which connects to the card reader, and returning to Step S 2 .
[0054] According to the other aspect of the present invention, there provides a method of a card reader, which includes:
[0055] Step W 1 , powering on a card reader, and initializing the card reader;
[0056] Step W 2 , waiting for receiving data;
[0057] Step W 3 , setting a work mode as a USB mode, and executing Step W 4 when USB data is received via a USB channel; setting the work mode as an audio mode, and executing Step W 5 when audio data is received via an audio channel;
[0058] Step W 4 , determining an type of the received USB data, if the received USB data is an operating-card instruction, sending the operating-card instruction to the card, waiting for receiving an operation result returned by the card, and executing Step W 6 ; if the received USB data is another instruction, executing corresponding operation to obtain an operation result, and executing Step W 6 ;
[0059] Step W 5 , transferring the audio data to digital signals, composing the digital signals to a data package, parsing the data package to obtain a parsing result, and determining a type of the instruction according to the parsing result, if the instruction is the operating-card instruction, sending the operating-card instruction to the card, waiting for an operation result returned by the card, and executing Step W 6 ; if the instruction is another instruction, executing a corresponding operation to obtain an operation result, and executing Step W 6 ; and
[0060] Step W 6 , determining a work mode, sending the operation result to a device which connects to the card reader, and returning to Step W 2 in the case that the work mode is a USB mode; transferring the operation result to an audio data package, sending the audio data package to the device which connects to the card reader, and returning to Step W 2 in the case that the work mode is an audio mode.
[0061] Preferably, in Step W 6 , before Step W 2 is returned to, the step further includes:
[0062] Step G 1 , determining whether the USB module is connected to a power supply, if yes, executing Step G 2 ; otherwise, returning to Step W 2 ;
[0063] Step G 2 , determining whether quantity of electric charge of the battery reaches a rated value, if yes, executing Step G 3 ; otherwise, returning to Step W 2 ; and
[0064] Step G 3 , prompting over-charging of the battery, returning to Step W 2 .
[0065] Preferably, in Step W 3 , after the USB data is received via a USB channel, and before the work mode is set as the USB mode, the step further includes: turning off an audio data communication interrupt.
[0066] Preferably, in Step W 6 , in the case that the work mode is the USB mode, after the operation result is sent to the device connected to the card reader via a USB channel, and before Step W 2 is returned to, the step further includes: turning on the audio data communication interrupt.
[0067] Preferably, in Step W 3 , after the audio data is received via an audio channel, and before the work mode is set as the audio mode, the step further includes: turning off a USB data communication interrupt.
[0068] Preferably, in Step W 6 , in the case that the woke mode is an audio mode, after the operation result is sent to the device connected to the card reader via the audio channel, and before Step W 2 is returned to, the step further includes: turning on the USB data communication interrupt.
[0069] Preferably, Step W 2 specifically includes: determining whether there exists a device which connects to the card reader via the USB module, if yes, waiting for receiving USB data, and executing Step W 3 ; otherwise, determining whether audio data is received in a preset duration, executing Step W 3 in the case that the audio data is received in the preset duration; entering a low-power-dissipation mode in the case that the audio data is not received in the preset duration.
[0070] Preferably, in Step W 3 , setting the work mode as the audio mode, and executing Step W 5 when the audio data is received via the audio channel specifically includes: determining whether the work mode is a low-power-dissipation mode when the audio data is received via the audio channel, if yes, exiting from the low-power-dissipation mode, and executing Step W 5 ; otherwise, executing Step W 5 .
[0071] Preferably, in Step W 5 , transferring the audio data to digital signals specifically includes:
[0072] performing, by the card reader, a filtering process on the audio data to obtain a first processed data, performing a blocking process on the first processed data to obtain alternating component from the first processed data; obtaining a second processed data from the alternating component, transferring the second processed data so as to obtain transferred data, and performing the filtering process on the transferred data to obtain the digital signals.
[0073] Preferably, in Step W 5 , after composing the digital signals to a data package, and before parsing the data package, the step further includes: determining whether the data package is legitimate.
[0074] Preferably, determining whether the data package is legitimate specifically includes:
[0075] L 1 , obtaining data of four bytes starting from the first byte of the data package, making the data of four bytes as a frame header, determining whether the frame header is a first preset value, if yes, executing L 2 ; otherwise, the data package is illegitimate;
[0076] L 2 , obtaining data at the seventh byte from the data package, making the data as a parameter flag, and determining whether the parameter flag is legitimate, if yes, executing L 3 ; otherwise, the data package is illegitimate;
[0077] L 3 , obtaining data of two bytes starting from the eighth byte of the data package, making the data of two bytes as a data-length-value, and executing L 4 ;
[0078] L 4 , obtaining data whose length equals the data-length-value starting from the tenth byte, making the data as a data field, obtaining data of one byte behind the data field, making the data of one byte as a check word, and executing L 5 ; and
[0079] L 5 , calculating the data field via a preset algorithm to obtain a result, comparing the result with the check word, if the result is same as the check word, the data package is legitimate; if the result is not same as the check word, the data package is illegitimate.
[0080] Preferably, determining whether the parameter is legitimate specifically includes: the parameter flag is legitimate in the case that the parameter flag is the second preset value or the third preset value; the parameter flag is not legitimate in the case that the parameter is other values.
[0081] Preferably, when the data package is legitimate, the step further includes: determining the parameter, parsing the data package in the case that the parameter flag is the second preset value; waiting for receiving data of a preset length, putting the data into the data package, and then parsing the data package in the case that the parameter flag is the third preset value.
[0082] Preferably, in Step W 6 , transferring the operation result to an audio data package specifically includes:
[0083] compressing an amplitude voltage of the digital signals of the operation result, transferring the digital signals of the operation result to an analog signal which is similar to a sine wave through the process of charging or discharging slowly, and transferring the analog signal to an audio data package.
[0084] Preferably, in Step W 1 , initializing further includes: setting a card-slot-state flag as a no-card flag; setting the card-slot-state flag as a card-in flag in the case that a card-in-slot pin is a high level; setting the card-slot-state flag as the no-card flag in the case that the card-in-slot pin is a low level.
[0085] Preferably, in Step W 4 , the other instructions include: an instruction for inquiring card-slot-state, a powering-on instruction, and a powering-off instruction.
[0086] Preferably, in Step W 4 , determining a type of the received USB data, inquiring a state of the card slot according to the card-slot-state flag in the case that the instruction is the instruction for inquiring card-slot-state, setting card-slot-state data, making the card-slot-state data as the operation result, and executing Step W 6 .
[0087] Preferably, in the case that the instruction is the powering-on instruction, determining whether there exists a card in the card slot according to the card-slot-state flag, if yes, powering on the card slot, reading a card-slot-powered-on response, making the card-slot-powered-on response as the operation result, and executing Step W 6 ; otherwise, generating a no-card-in-slot response, making the no-card-in-slot response as the operation result, and executing Step W 6 .
[0088] Preferably, in the case that the instruction is the powering-off instruction, powering off the card slot, reading a card-slot-powered-off response, making the response as the operation result, and executing Step W 6 .
[0089] Preferably, in Step W 5 , the other instructions include: the instruction for inquiring card-slot-state, the powering-on instruction, and the powering-off instruction.
[0090] Preferably, determining the type of instruction according to the parsing result, in the case that the instruction is the instruction for inquiring card-slot-state, inquiring the state of the card slot according to the card-slot-state flag, setting the card-slot-state data, making the card-slot-state data as an operation result, and executing Step W 6 .
[0091] Preferably, in the case that the instruction is the powering-on instruction, determining whether there exists a card in the card slot according to the card-slot-state flag, if yes, powering on the card slot, reading a card-slot-powered-on response, making the card-slot-powered-on response as an operation result, and executing Step W 6 ; otherwise, generating a no-card-in-slot response, and making the no-card-in-slot response as an operation result, and executing Step W 6 .
[0092] Preferably, in the case that the instruction is the powering-off instruction, powering off the card slot, reading a card-slot-powered-off response, making the response as an operation result, and executing Step W 6 .
[0093] As one advantage of the present invention, a card reader communicates with a device via an audio module or a USB module, instead of relying on a USB module in a card reader in prior art, in this way, the card reader is more compatible and convenient for a user.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0094] FIG. 1 is a flow diagram of a working method of a card reader according to Embodiment 1 of the present invention;
[0095] FIG. 2 is a flow diagram of a method for processing an inserting-card-in interrupt according to Embodiment 1 of the present invention;
[0096] FIG. 3 is a flow diagram of a method for processing a pulling-card-out interrupt according to Embodiment 1 of the present invention;
[0097] FIG. 4 is a flow diagram of a working method for initializing an audio module according to Embodiment 1 of the present invention;
[0098] FIG. 5 is a flow diagram of a working method of a low-power-dissipation timer interrupt according to Embodiment 1 of the present invention;
[0099] FIG. 6 is a flow diagram of a working method of a card reader according to Embodiment 2 of the present invention;
[0100] FIG. 7 is a flow diagram of a working method of a card reader according to Embodiment 3 of the present invention;
[0101] FIG. 8 is a flow diagram of a method for processing audio data according to Embodiment 4 of the present invention;
[0102] FIG. 9 is a flow diagram of a method for determining whether a data package is legitimate according to Step 407 in Embodiment 4 of the present invention; and
[0103] FIG. 10 is a flow diagram of a method for processing USB data according to Embodiment 5 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0104] The technical solution in the Embodiments of the present invention is further described more clearly and completely with the drawings in the Embodiments of the present invention. Apparently, Embodiments described are just a few Embodiments of the present invention. On the basis of Embodiments of the invention, all other related Embodiments made by those skilled in the art without inventive work belong to the scope of the invention.
Embodiment 1
[0105] The present Embodiment 1 provides a working method of a card reader, as shown in FIG. 1 , the method specifically includes following steps.
[0106] Step 101 , a card reader is powered on and initialized;
[0107] in the present Embodiment 1, that the card reader is initialized specifically includes: a USB-channel-connect flag is reset, a card-in-slot pin is initialized as a low electric level, a card-slot-state is initialized as no-card flag. After the card reader is initialized, the method further includes: an interrupt is turned on, in which, the interrupt includes inserting-card-in interrupt and pulling-out-card interrupt.
[0108] When the card-in-slot pin of the card reader is high electric level, the inserting-card-in interrupt is entered, as shown in FIG. 2 , which specifically includes:
[0109] Step a 1 , the interrupt is turned off, an inserting-card-in interrupt flag is cleared, a card-slot-state flag is set as a card-in flag;
[0110] preferably, the card-in flag is 0x00;
[0111] Step a 2 , determine whether the USB-channel-connect flag is set, if yes, execute Step a 3 ; otherwise, execute Step a 4 ;
[0112] in Embodiment 1, the USB-channel-connect flag is used for identifying whether the card reader connects to a USB device via a USB module; in the case that the card reader connects to the USB device via a USB module, the USB-channel-connect flag is set by the card reader, the USB module supplies power for the card reader, and the battery is charged by the USB module;
[0113] in the case that the USB module of the card reader does not connect to the USB device, the USB-channel-connect flag is reset by the card reader, the USB module stops supplying power for the card reader;
[0114] Step a 3 , an inserting-card-in response is written into an INT endpoint, and Step a 4 is executed;
[0115] in Embodiment 1, the inserting-card-in response is 5003;
[0116] Step a 4 , determine whether a suspend flag is set, if yes, execute Step a 5 ; otherwise, execute Step a 6 ;
[0117] Step a 5 , the suspend flag is reset, MCU is waken up, and Step a 6 is executed;
[0118] Step a 6 , the interrupt is turned on, and exit from the inserting-card-in interrupt.
[0119] In the case that the card-in-slot pin of the card reader is a lower electric level, the pulling-card-out interrupt is entered, as shown in FIG. 3 , entering the pulling-card-out interrupt specifically includes:
[0120] Step b 1 , the interrupt is turned off, the pulling-card-out interrupt is cleared, the card-slot-state flag is set as no-card flag;
[0121] preferably, the no-card flag is 0X02;
[0122] Step b 2 , determine whether the USB-channel-connect flag is set, if yes, execute Step b 3 ; otherwise, execute Step b 4 ;
[0123] Step b 3 , a pulling-card-out response is written into the INT endpoint, and Step b 4 is executed;
[0124] in Embodiment 1, the pulling-card-out response is 5002 ;
[0125] Step b 4 , the suspend flag is set, MCU is suspended, the interruption is turned on, the pulling-card-out interrupt is exited from.
[0126] Step 102 , a work mode is set according to an IO pin-level state;
[0127] in present Embodiment 1, the work mode is set according to the IO pin-level state, the work mode is an audio mode in the case that the IO pin-level is low electric level; the work mode is set as a USB mode in the case that the IO pin-level is high electric level;
[0128] when the card reader connects to the USB device via a USB module, the IO pin-level is high electric level; when the card reader does not connect to the USB device via a USB module, the IO pin-level is low electric level.
[0129] When the IO pin-level is low electric level, the battery supplies power for the audio module; when the IO pin-level is high electric level, the battery stops supplying power for the audio module.
[0130] Step 103 , the work mode is determined, Step 104 is executed in the case that the work mode is an audio mode; Step 108 is executed in the case that the work mode is a USB mode.
[0131] Step 104 , the audio module is initialized, an audio timer is turned on, and Step 105 is executed;
[0132] in the present Embodiment 1, when the audio module is initialized, an audio-timing flag bit is cleared.
[0133] When the audio module is initialized, as shown in FIG. 4 , the process further includes:
[0134] Step K 1 , a low-power-dissipation timer interrupt is turned on, audio data waits for being received;
[0135] preferably, the low-power-dissipation timer interrupt is entered every 10 seconds.
[0136] Step K 2 , determine whether the audio data is received, if yes, Step K 3 is executed; otherwise, Step K 4 is executed;
[0137] Step K 3 , the audio data is received via the audio module, a low-power-dissipation timer flag is reset, the low-power-dissipation timer interrupt is turned off, the audio data is sent to the card reader, the low-power-dissipation timer interrupt is turned on, the present process is ended; and
[0138] Step K 4 , the low-power-dissipation timer flag is set, the present process is ended; in the present Embodiment 1, a low-power-dissipation timer interrupt is entered when the duration reaches 10 seconds, the low-power-dissipation timer flag is set.
[0139] When the low-power-dissipation timer interrupt is entered, as shown in FIG. 5 , the following steps are executed:
[0140] Step M 1 , the low-power-dissipation timer interrupt is entered;
[0141] Step M 2 , determine whether the low-power-dissipation timer flag is set, if yes, execute Step M 3 ; otherwise, exit from the low-power-dissipation timer interrupt; and
[0142] Step M 3 , a low-power-dissipation mode is entered;
[0143] in the present Embodiment 1, when the audio data is received by the audio module, the low-power-dissipation mode is exited from.
[0144] Step 104 further includes: determine whether the working voltage is lower than the preset value, if yes, prompt that the working voltage is low, and stop supplying power for the card reader after a preset duration; otherwise, execute Step 105 ;
[0145] that the working voltage is low can be prompted by displaying on a screen and/or changing the color of a indicator light and/or buzzing and/or broadcasting; preferably, the preset duration is 30 seconds.
[0146] Step 105 , determine whether an audio-timing flag bit is set, if yes, return to Step 103 ; otherwise, execute Step 106 ;
[0147] in the present Embodiment 1, the audio-timing flag bit is applied for identifying whether data is received by the card reader via the audio module in a preset duration. If the data is not received when the audio-timing flag bit reaches the preset duration, the audio-timing flag bit is set by the card reader.
[0148] Step 106 , determine whether the audio data is received via the audio module, if yes, execute Step 107 ; otherwise, return to Step 105 .
[0149] Step 107 , the audio-timing flag bit is cleared, the audio timer is turned off, the received audio data is processed correspondingly to obtain a processed result, and the processed result is returned to the audio device.
[0150] In present Embodiment 1, more details about the received audio data is processed by the card reader see Embodiment 4.
[0151] Step 108 , the USB module is initialized, a USB timer is turned on;
[0152] in the present Embodiment 1, initializing the USB module further includes: a USB timing flag bit is cleared.
[0153] Step 109 , determine whether the USB timing flag bit is set, if yes, execute Step 104 ; otherwise, execute Step 110 ;
[0154] in the present Embodiment 1, the USB timing flag bit is applied for identifying whether USB data is received by the card reader via the USB module in the preset duration.
[0155] Step 110 , determine whether the USB data is received via the USB module, if yes, execute Step 111 ; otherwise, return to Step 109 .
[0156] Step 111 , the USB timing flag bit is cleared, a USB timer is turned off, the received USB data is processed correspondingly to obtain a processed result, the processed result is returned to the USB device.
[0157] In the present Embodiment 1, more details about processing the USB data, which can be seen in Embodiment 5, are omitted herein.
Embodiment 2
[0158] Embodiment 2 of the present invention provides a working method of a card reader, as shown in FIG. 6 , the method includes following steps.
[0159] Step 201 , the card reader is powered on and initialized;
[0160] the operation of Step 201 is as same as that of Step 101 , besides, Step 201 further includes: a USB data transmission flag is reset.
[0161] In the case that a card-in-slot pin is high electric level, an inserting-card-in interrupt is executed, specific operation is as same as that from Step a 1 to Step a 6 in Embodiment 1, more details will not given herein.
[0162] In the case that the card-in-slot pin is low electric level, pulling-card-out interrupt is executed, specific operation is as same as that from Step b 1 to Step b 4 in Embodiment 1, more details will not given herein.
[0163] Step 202 , determine whether there exists an audio device which connects to the card reader via an audio module, if yes, execute Step 203 ; otherwise, execute Step 204 .
[0164] Step 203 , the work mode is set as the audio mode, an audio data communication interrupt is turned on, Step 206 is executed.
[0165] Step 204 , determine whether there exists a USB device which connects to the card reader via a USB module, if yes, execute Step 205 ; otherwise, execute Step 202 .
[0166] Step 205 , the work mode is set as the USB mode, a USB data communication interrupt is turned on, and Step 206 is executed.
[0167] In the present Embodiment 2, the steps from Step 202 to Step 205 may be replaced with:
[0168] Step 202 ′, determine whether there exists a USB device which connects to the card reader via a USB module, if yes, execute Step 203 ′; otherwise, execute Step 204 ′;
[0169] Step 203 ′, the work mode is set as the USB mode, the USB data communication interrupt is turned on, Step 206 is executed;
[0170] Step 204 ′, determine whether there exists an audio device which connects to the card reader via an audio module, if yes, execute Step 205 ′; otherwise, execute Step 202 ′; and
[0171] Step 205 ′, the work mode is set as the audio mode, the audio data communication interrupt is turned on, Step 206 is executed.
[0172] Step 206 , wait for an interrupt, determine the work mode when the interrupt is happened, execute Step 207 in the case that the work mode is the audio mode; execute Step 211 in the case that the work mode is the USB mode.
[0173] Step 207 , the USB data communication interrupt is turned off, audio data waits for being received, and Step 208 is executed.
[0174] Step 208 , when the audio data is received, the audio data is processed correspondingly to obtain a processed result, the processed result is returned to the audio device, the USB data communication interrupt is turned on;
[0175] in the present Embodiment 2, more details about processing the received audio data by the card reader see Embodiment 4.
[0176] Step 209 , determine whether there exists an audio device which connects to the card reader via an audio module, if yes, return to Step 206 ; otherwise, execute Step 210 .
[0177] Step 210 , the audio data communication interrupt is turned off, and Step 202 is returned to.
[0178] Step 211 , the audio data communication interrupt is turned off, whether the USB data transmission flag is set is determined, if yes, Step 216 is executed; otherwise, Step 212 is executed;
[0179] in the present Embodiment 2, when the USB device is pulled out, the USB data transmission flag is reset.
[0180] Step 212 , a USB module connection is enabled, and Step 213 is executed.
[0181] Step 213 , a USB enumeration is executed.
[0182] Step 214 , determine whether the USB enumeration is finished, if yes, execute Step 215 ; otherwise, return to Step 206 .
[0183] Step 215 , the USB data transmission flag is set, and Step 216 is executed.
[0184] Step 216 , wait for receiving USB data sent by the USB device, when the USB data is received via the USB module, the USB data is processed correspondingly to obtain a processed result, the processed result is returned to the USB device, and Step 217 is executed;
[0185] in the present Embodiment 2, more details about the process of processing the USB data by the card reader see Embodiment 5.
[0186] Step 217 , determine whether there exists an audio device which connects to the card reader via an audio module, if yes, execute Step 218 ; otherwise, return to Step 206 .
[0187] Step 218 , the audio data communication interrupt is turned on, and Step 206 is executed.
Embodiment 3
[0188] The present Embodiment 3 provides a working method of a card reader, as shown in FIG. 7 , the working method includes following steps.
[0189] Step 301 , the card reader is powered on and initialized;
[0190] in the present Embodiment 3, initializing the card reader specifically includes: a USB-channel-connect flag is reset, a card-in-slot pin is initialized as a low electric level, a card-slot-state flag is initialized as a no-card flag. After the card reader is initialized, the step further includes: an interrupt is turned on, in which, the interrupt includes an inserting-card-in interrupt and a pulling-card-out interrupt.
[0191] When the card-in-slot pin of the card reader is a high electric level, the inserting-card-in interrupt is entered, the specific operation is as same as that from Step a 1 to Step a 6 in Embodiment 1, more details will not be given herein.
[0192] When the card-in-slot pin of the card reader is a low electric level, the pulling-card-out interruption is entered, specific operation is as same as that from Step b 1 to Step b 4 in Embodiment 1, more details will not be given herein.
[0193] Step 302 , determine whether there exists an audio device which connects to the card reader via an audio module, if yes, execute Step 303 ; otherwise, execute Step 304 .
[0194] Step 303 , the work mode is set as an audio mode, an audio data communication interrupt is turned on, and Step 306 is executed.
[0195] Step 304 , determine whether there exists a USB device which connects to the card reader via a USB module, if yes, execute Step 305 ; otherwise, return to Step 302 .
[0196] Step 305 , the work mode is set as a USB mode, a USB data communication interrupt is turned on, Step 306 is executed.
[0197] In the present Embodiment 3, steps from Step 302 to Step 305 may be replaced with:
[0198] Step 302 ′, determine whether there exists a USB device which connects to the card reader via the USB module, if yes, execute Step 303 ′; otherwise, execute Step 304 ′;
[0199] Step 303 ′, the work mode is set as the USB mode, the USB data communication interrupt is turned on, and Step 306 is executed;
[0200] Step 304 ′, determine whether there exists an audio device which connects to the card reader via the audio module, if yes, execute Step 305 ′; otherwise, return to Step 302 ′; and
[0201] Step 305 ′, the work mode is set as the audio mode, the audio data communication interrupt is turned on, and Step 306 is executed.
[0202] Step 306 , wait for an interrupt, when the interrupt is happened, determine the work mode, execute Step 307 in the case that the work mode is the audio mode; execute Step 312 in the case that the work mode is the USB mode.
[0203] Step 307 , the USB data communication interrupt is turned off, the audio data waits for being received, and Step 308 is executed.
[0204] Step 308 , when the audio data is received, the audio data is processed correspondingly to obtain a processed result, the processed result is returned to the audio device, and the USB data communication interrupt is turned on;
[0205] in the present Embodiment 3, specific details about the process of processing the received audio data by the card reader, which can be seen in Embodiment 4, are omitted herein.
[0206] Step 309 , determine whether the card reader connects to a power supply via a USB module, if yes, execute Step 310 ; otherwise, return to Step 306 ;
[0207] in the present Embodiment 3, determining whether the card reader connects a power supply via a USB module specifically includes: the card reader determines whether an JO pin is a high electric level and whether there is no communication signal, if yes, the card reader connects to the power supply via the USB module; otherwise, the card reader does not connects to the power supply via the USB module.
[0208] Step 310 , determine whether quantity of electric charge of the battery reaches a rated value, if yes, execute Step 311 ; otherwise, execute Step 306 .
[0209] Step 311 , prompt over-charging of the battery, and return to Step 306 .
[0210] Step 312 , the audio data communication interrupt is turned off, whether the USB data transmission flag is set is determined, if yes, Step 317 is executed; otherwise, Step 313 is executed.
[0211] Step 313 , a USB module connection is enabled.
[0212] Step 314 , a USB enumeration is executed.
[0213] Step 315 , determine whether the USB enumeration is finished, if yes, execute Step 316 ; otherwise, return to Step 306 .
[0214] Step 316 , the USB data transmission flag is set, and Step 317 is executed.
[0215] Step 317 , wait for receiving the USB data sent by the USB device, when the USB data is received via the USB module, the USB data is processed correspondingly to obtain a processed result, the processed result is returned to the USB device, the audio data communication interrupt is turned on;
[0216] in the present Embodiment 3, specific details about the process of processing the USB data by the card reader see Embodiment 5.
[0217] Step 318 , determine whether there exists a USB device which connects to the card reader via the USB module, if yes, return to Step 306 ; otherwise, execute Step 319 .
[0218] Step 319 , the USB data communication interrupt is turned off, the USB data transmission flag is reset, and Step 302 is returned to.
Embodiment 4
[0219] The present Embodiment 4 provides a method for processing audio data, as shown in FIG. 8 , the method specifically includes following steps.
[0220] Step 401 , a card reader waits for receiving audio data.
[0221] Step 402 , when the audio data is received, perform a filtering process on the audio data to obtain a first processed data.
[0222] Specifically, the card reader filters noises from the audio data to obtain clear audio data which is made as the first processed data.
[0223] Step 403 , perform a blocking process on the first processed data to obtain alternating component from the first processed data.
[0224] Step 404 , a second processed data is obtained from the alternating component; specifically, the card reader obtains data whose frequency is higher than a cut-off frequency from the alternating component, and the data is made as the second processed data.
[0225] Step 405 , the second processed data is transferred to digital signals.
[0226] Step 406 , perform the filtering process on the digital signals to obtain processed digital signals.
[0227] Step 407 , the processed digital signals compose a data package, whether the data package is legitimate is determined, if yes, Step 408 is executed; otherwise, Step 401 is executed.
[0228] In the present Embodiment 4, as shown in FIG. 9 , determining whether the data package is legitimate includes:
[0229] c 1 , starting from the first byte of the data package, data of four bytes is obtained, the data of four bytes is made as a frame header, whether the frame header is a first preset value is determined, if yes, c 2 is executed; otherwise, Step 401 is returned to;
[0230] preferably, the first preset value is 0X0ff055aa;
[0231] c 2 , data at a seventh byte is obtained from the data package and made as a parameter flag, whether the parameter flag is legitimate is determined, if yes, c 3 is executed; otherwise, Step 401 is returned to;
[0232] determining whether the parameter is legitimate specifically includes: if the parameter flag is a second preset value or a third preset value, the parameter flag is legitimate; otherwise, the parameter flag is illegitimate; preferably, the second preset value is 0X01; the third preset value is 0X02;
[0233] c 3 , starting from the eighth byte, data of two bytes is obtained from the data package, the data of two bytes is made as data-length-value, and c 4 is executed;
[0234] c 4 , starting from the tenth byte, data whose length equals the data-length-value is obtained and made as a data field, data of one byte behind the data field is made as a check word, c 5 is executed;
[0235] c 5 , the data field is calculated via a preset algorithm to obtain a calculated result, the calculated result is compared with the check word, if the calculated result is as same as the check word, c 6 is executed; if the calculated result is not as same as the check word, Step 401 is returned to; and
[0236] c 6 , the parameter flag is determined, Step 408 is executed in the case that the parameter flag is the second preset value; wait for receiving data of a preset length in the case that the parameter flag is the third preset value, the data of a preset length is added into the data package, Step 408 is executed.
[0237] Preferably, the preset length is ten bytes.
[0238] Step 408 , the data package is parsed, a type of instruction is determined according to a parsing result, Step 409 is executed in the case that the instruction is an instruction for inquiring card-slot-state; Step 413 is executed in the case that the instruction is a powering-on instruction; Step 421 is executed in the case that the instruction is a powering-off instruction; Step 425 is executed in the case that the instruction is an operating-card instruction; execute corresponding operation in the case that the instruction is other instruction, and return to Step 401 ;
[0239] in the present Embodiment 4, determine a type of the instruction according to a first byte of the parsing result;
[0240] if the first byte is 0X65, the instruction is an instruction for inquiring card-slot-state;
[0241] if the first byte is 0X62, the instruction is a powering-on instruction;
[0242] if the first byte is 0X63, the instruction is a powering-off instruction; and
[0243] if the first byte is 0X6f, the instruction is an operating-card instruction.
[0244] Step 409 , a state of the card slot is inquired according to the card-slot-state flag, and card-slot-state data is set;
[0245] in the present Embodiment 4, if the card-slot-state flag is a card-in flag, there is a card is the card slot, and a preset byte of the card-slot-state data is set as 0X00;
[0246] if the card-slot-state flag is a no-card flag, there is no card in the card slot, and the preset byte of the card-slot-state is set as 0X02;
[0247] preferably, the preset byte of the card-slot-state data is the eighth byte of the card-slot-state data.
[0248] Step 410 , an amplitude voltage of the digital signals of the card-slot-state data is processed to obtain a processed card-slot-state data.
[0249] Step 411 , the processed card-slot-state data is transferred to a card-slot-state audio data package;
[0250] specifically, the processed card-slot-state data is transferred to analog signals which are similar as a sine wave through a process of charging or discharging slowly, then, the analog signals are transferred to the card-slot-state audio data package.
[0251] Step 412 , the card-slot-state audio data package is sent to the audio device via an audio module, and Step 401 is returned.
[0252] Step 413 , determine whether there is a card in the card slot according to the card-slot-state flag, if yes, execute Step 414 ; otherwise, execute Step 418 ;
[0253] in the present Embodiment 4, if the card-slot-state flag is the card-in flag, there is a card in the card slot; if the card-slot-state flag is the no-card flag, there is no card in the card slot.
[0254] Step 414 , the card slot is powered on, a card-slot-powered-on response is read; for example, a read card-slot-powered-on response is 800c00000000120000003bf095000081b1fe9a1f0729;
[0255] Step 415 , an amplitude voltage of digital signals of the card-slot-powered-on response is processed to obtain a processed card-slot-powered-on response.
[0256] Step 416 , the processed card-slot-powered-on response is transferred to the card-slot-powered-on response audio data package.
[0257] Specifically, the processed card-slot-powered-on response is transfer to analog signals which are similar to a sine wave through a process of charging and discharging slowly, and the analog signals is transferred into the card-slot-powered-on response audio data package.
[0258] Step 417 , the card-slot-powered-on response audio data package is sent to the audio device via the audio module, and Step 401 is returned to.
[0259] Step 418 , a no-card-in-slot response is generated, an amplitude voltage of digital signals of no-card-in-slot response is processed to obtain a processed no-card-in-slot response.
[0260] Step 419 , the processed no-card-in-slot response is transferred to no-card-in-slot response audio data package;
[0261] specifically, the processed no-card-in-slot response is transferred to an analog signals which are similar to a sine wave through a process of charging and discharging slowly, and the analog signals are transferred to the no-card-in-slot response audio data package.
[0262] Step 420 , the no-card-in-slot response audio data package is sent to the audio device via the audio module, and Step 401 is returned.
[0263] Step 421 , the card slot is powered off, a card-slot-powered-off response is read;
[0264] in the present Embodiment 4, the card slot is powered off by the card reader, the card-slot-powered-off response is read, the first byte of the card-slot-powered-off response is 0X81; for instance, 81000000000004010000.
[0265] Step 422 , an amplitude voltage of digital signals of the card-slot-powered-off response is processed to obtain a processed card-slot-powered-off response.
[0266] Step 423 , the processed card-slot-powered-off response is transferred to a card-slot-powered-off response audio data package;
[0267] specifically, the processed card-slot-powered-off response is transferred to analog signals which are similar to the sine wave through a process of charging and discharging slowly, the analog signals are transferred to the card-slot-powered-off response audio data package.
[0268] Step 424 , the card-slot-powered-off response audio data package is sent to the audio device via the audio module, and Step 401 is returned to.
[0269] Step 425 , the operating-card instruction is sent to the card, an operating-card response returned by the card waits for being received;
[0270] in the present Embodiment 4, after the operating-card instruction is received by the card, the card executes a corresponding operation according to the instruction, and returns a corresponding operating-card response to the card reader.
[0271] Step 427 , the processed operating-card response is transferred into an operating-card response audio data package;
[0272] specifically, the processed operating-card response is transferred to analog signals which similar to the sine wave through the process of charging and discharging slowly, and the analog signals are transferred to the operating-card response audio data package.
[0273] Step 428 , the operating-card response audio data package is sent to the audio device via the audio module, and Step 401 is returned to.
Embodiment 5
[0274] The present Embodiment 5 provides a method for processing USB data, as shown in FIG. 10 , the method specifically includes the following steps.
[0275] Step 501 , the card reader waits for receiving USB data.
[0276] Step 502 , determine a type of the received USB data, execute Step 503 in the case that the received USB data is an instruction for inquiring card-slot-state; execute Step 505 in the case that the received USB data is a powering-on instruction; execute Step 509 in the case that the received USB data is a powering-off instruction; execute Step 511 in the case that the received USB data is an operating-card instruction; execute a corresponding operation in the case that the received USB data is other instruction, and then return to Step 501 ;
[0277] in the present Embodiment 5, the card reader determines the type of the instruction according to a first byte of the USB data;
[0278] specifically, the received USB data is the instruction for inquiring card-slot-state in the case that the first byte is 0X65;
[0279] the received USB data is the powering-on instruction in the case that the first byte is 0X62;
[0280] the received USB data is the powering-off instruction in the case that the first byte is 0X63; and
[0281] the received USB data is the operating-card instruction in the case that the first byte is 0X6f.
[0282] Step 503 , the state of the card slot is inquired according to the card-slot-state flag, and the card-slot-state data is set;
[0283] in the present Embodiment 5, if the card-slot-state flag is a card-in flag, there is a card in the card slot, a preset byte of the card-slot-state data is set as 0X00;
[0284] if the card-slot-state flag is a no-card flag, there is no card in the card slot, the preset byte of the card-slot-state is set as 0X02;
[0285] preferably, the preset byte of the card-slot-state data is the eighth byte of the card-slot-state data.
[0286] Step 504 , the card-slot-state data is sent to the USB device via the USB module, and Step 501 is returned to.
[0287] Step 505 , determine whether there exists a card in the card slot according to the card-slot-state flag, if yes, execute Step 507 ; otherwise, execute Step 506 ;
[0288] in the present Embodiment 5, if the card-slot-state flag is a card-in flag, there is a card in the card slot; if the card-slot-state flag is a no-card flag, there is no card in the card slot.
[0289] Step 506 , a no-card-in-slot response is sent to the USB device via the USB module, Step 501 is returned to.
[0290] Step 507 , the card slot is powered on, a card-slot-powered-on response is read; for instance, the read card-slot-powered-on response is 800c00000000215000003bf095000081b1fe9a1f0729.
[0291] Step 508 , the card-slot-powered-on response is sent to the USB device via the USB module, Step 501 is returned to.
[0292] Step 509 , the card slot is powered on, a card-slot-powered-off response is read; in the present Embodiment 5, the card slot is powered off by the card reader, the card-slot-powered-off response is read, the first byte of the card-slot-powered-off response is 0X81; for instance, 81000000000004010000.
[0293] Step 510 , the card-slot-powered-off response is sent to the USB device via the USB module, Step 501 is returned to.
[0294] Step 511 , the operating-card instruction is sent to the card.
[0295] Step 512 , wait for receiving an operating-card response returned by the card.
[0296] In the present Embodiment 5, after the operating-card instruction is received, execute corresponding operation according to the operating-card instruction, and return a corresponding operating-card response to the card reader. For instance, 8005000000001800000000eA1f010.
[0297] Step 513 , when the operating-card response is received, the operating-card response is sent to the USB device via the USB module, and Step 501 is returned to.
Embodiment 6
[0298] The present Embodiment 6 provides a working method of a card reader, which includes following steps.
[0299] Step 601 , the card reader is powered on and initialized;
[0300] an operational approach of Step 601 is as same as that of Step 101 .
[0301] Step 602 , wait for receiving data.
[0302] Specifically, determine whether there exists a device which connects to the card reader via a USB module, if yes, wait for receiving USB data, and execute Step 603 ; otherwise, determine whether audio data is received in a preset duration, execute Step 603 in the case that the audio data is received in the preset duration; enter a low-power-dissipation mode in the case that the audio data is not received in the preset duration.
[0303] Step 603 , when the USB data is received via a USB channel, an audio data communication interrupt is turned off, a work mode is set as a USB mode, and Step 604 is executed; when the audio data is received via an audio channel, a USB data communication interrupt is turned off, the work mode is set as an audio mode, and Step 605 is executed.
[0304] Specifically, when the audio data is received via the audio channel, determine whether the work mode is the low-power dissipation mode, if yes, exit from the low-power dissipation mode, and execute Step 605 ; otherwise, execute Step 605 .
[0305] Step 604 , determine a type of the received USB data, the operating-card instruction is sent to the card in the case that the USB data is an operating-card instruction, an operation result returned by the card waits for being received, Step 606 is executed; a corresponding operation is executed to obtain an operation result, and Step 606 is executed.
[0306] Step 605 , the audio data is transferred to digital signals, the digital signals compose a data package, the data package is parsed to obtain a parsing result, a type of the instruction is determined according to the parsing result, if the instruction is an operating-card instruction, the operating-card instruction is sent to the card, an operation result returned by the card waits for being received, and Step 606 is executed; if the instruction is other instruction, a corresponding operation is executed to obtain an operation result, and Step 606 is executed;
[0307] the operational approach of Step 605 is as same as that of Embodiment 4, no more details will be given herein.
[0308] Step 606 , determine the work mode, in the case that the work mode is the USB mode, the operation result is sent to the device which connects to the card reader, an audio data communication interrupt is turned on, and Step 607 is executed; in the case that the work mode is the audio mode, the operation result is transferred to an audio data package, the audio data package is sent to the device which connects to the card reader, a USB data communication interrupt is turned on, and Step 607 is executed;
[0309] the operational approach of Step 606 is as same as that of Embodiment 5, more details will not be given herein.
[0310] Step 607 , determine whether the USB module connects a power supply, if yes, execute Step 608 ; otherwise, return to Step 602 .
[0311] Step 608 , determine whether the quantity of electric charge of the battery reaches a rated value, if yes, execute Step 609 ; otherwise, return to Step 602 .
[0312] Step 609 , prompt over-charging of the battery, and return to Step 602 .
[0313] While the preferred Embodiments of the present invention have been shown and described herein, it will be obvious for those skilled in the art that such Embodiments are provided by way of examples only. Any changes and substitutions will be covered by the scope of protection of the present invention. It is intended that the appended claims define the scope of protection of the present invention.
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An operating method for a card reader, comprising: powering on a card reader, and setting an operating mode according to the type of a device connected thereto; judging the operating mode, waiting to receive audio data if the operating mode is an audio mode, converting the received audio data into a digital signal, forming a data packet by the digital signal, parsing the data packet to obtain a parsing result, judging an instruction type according to the parsing result, executing a corresponding operation according to the instruction type, converting the obtained operation result into an audio data packet, and sending the audio data packet to the device connected thereto; and waiting to receive USB data if the operating mode is a USB mode, judging an instruction type of the received USB data, executing a corresponding operation according to the instruction type, and returning the operation result to the device connected thereto. According to the present invention, a card reader conducts data communication with a device through an audio module or a USB module, thereby not depending on the USB module in the existing card reader to conduct data communication any longer, having relatively good compatibility, and improving the user experience.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of priority of U.S. provisional patent application Ser. No. 61/593,913 filed on Feb. 2, 2012, which is incorporated by reference herein.
STATEMENT OF GOVERNMENT INTEREST
The inventions described herein may be manufactured, used and licensed by or for the United States Government.
BACKGROUND OF THE INVENTION
The invention relates in general to cooling systems and in particular to apparatus and methods for evaluating the performance of cooling systems.
Cooling systems help prevent heat stress in humans exposed to extreme climates or work environments. A personal cooling system enables chilled fluid to circulate through tubing placed in garments worn by a person. In some personal cooling systems, the tubing on the person is tethered or connected to heavier components (for example, heat exchangers) that cool the fluid in the tubing. Thus, the heavier components, including power supplies and compressors, are not carried by the person being cooled. Vehicle-mounted personal cooling systems may be mounted in a vehicle, such as an air or ground vehicle, and connected to a person or persons in the vehicle via the fluid tubing. A Microclimate Cooling Unit (MCU) mounted in a vehicle may be used to chill fluid that provides cooling to a vehicle's crew via tubing in garments worn by the crew.
The performance of an MCU can degrade because of normal wear and tear, physical damage, or excessive use. A performance-degraded MCU uses more power and cools less than an MCU that is operating at standard or normal efficiency. In some environments, loss of cooling results causes only personal discomfort. However, in very high temperature environments, such as compartments of armored vehicles deployed in a desert and containing many heat-producing electronic devices, the loss of cooling in the compartment can result in severe heat sickness. Heat sickness adversely affects humans' decision-making abilities, which are critical to survival when engaged with hostile parties or when operating an air or land vehicle.
There exists no simple way to accurately test the performance of an MCU at its point of use. MCUs may be as small as about 6 inches by 6 inches by 14 inches with little space in the interior to access any of the refrigeration components for testing purposes. Also, the MCU housings are not easily opened at the point of use.
An MCU can be shipped from its point of use to another location, such as the manufacturer's facility, for testing with a laboratory testing system. The heat load used to test an MCU in a laboratory test system is generally a multi-gallon capacity heated water reservoir. The manufacturer's testing system is accurate, although it is not portable. The size and weight of the water reservoir and the power need to heat the water in the reservoir preclude ease of portability. So, the MCU must be shipped from its point of use to the laboratory testing system. This process is expensive and time-consuming because all MCUs, whether performance-degraded or not, must be sent to the manufacturer for testing.
An onsite temperature differential test can be used to provide some indication of MCU performance. The temperature differential test includes measuring surface temperature at two locations on a bottom surface of the MCU, using a hand-held infrared temperature sensor. If the difference in temperature between the two locations is greater than 10 degrees F., then the MCU is considered to be performing adequately. While better than no test at all, the temperature differential test does not provide a very accurate indication of the actual cooling performance of an MCU. No heat load is applied to the MCU using the temperature differential test. Thus, properly-performing MCUs may be misdiagnosed as performance-degraded and shipped away for further testing, and performance-degraded MCUs may be misdiagnosed as properly-performing and not shipped for further testing.
In the case of the U.S. Army, over 7,000 MCUs have been deployed in Army aviation and ground vehicles. It is costly and time-consuming to ship this large number of MCUs from their respective points of use to suitable locations for performance testing. A need exists for a more accurate performance testing apparatus that can be used at the point of use of an MCU.
SUMMARY OF INVENTION
One aspect of the invention is an apparatus for measuring cooling power of an electrically-powered Microclimate Cooling Unit (MCU) at a point of use of the MCU. The apparatus includes a fluid supply port connected to a fluid conduit and a flow rate controller disposed in the fluid conduit. The flow rate controller includes an analog flow meter. A fluid heater heats fluid in the fluid conduit downstream of the fluid supply port. A first thermocouple measures supply fluid temperature in the fluid conduit downstream of the fluid supply port and upstream of the fluid heater. A digital flow meter is disposed in the fluid conduit. A fluid return port is connected to the fluid conduit downstream of the fluid heater. A second thermocouple measures return fluid temperature in the fluid conduit downstream of the fluid heater and upstream of the fluid return port.
A power supply is connected to the fluid heater via a relay. At least one cooling fan is connected to the power supply. A housing contains the fluid conduit, the flow rate controller, the first and second thermocouples, the fluid heater, the relay, the digital flow meter, the power supply and the at least one cooling fan. The housing includes an exterior. The exterior has mounted thereon: a) visual displays of the supply temperature measured by the first thermocouple, the return temperature measured by the second thermocouple, and flow rates measured by the digital flow meter; b) a return temperature controller that is connected to the relay; c) the flow rate controller and analog flow meter; d) the fluid supply port and the fluid return port; e) power switches for the fluid heater, the apparatus for measuring cooling power, and the MCU; f) a power supply connection for the MCU; g) a control cable connection for the MCU; and h) a controller for the MCU.
A computer extracts the temperatures measured by the first and the second thermocouples and the flow rates measured by the digital flow meter and computes cooling power in real-time. In one embodiment, the computer is disposed inside the housing and the apparatus includes a visual display of the cooling power, located on the exterior of the housing.
In another embodiment, the computer is disposed external to the housing and the apparatus includes a data acquisition hub on the exterior of the housing. The data acquisition hub and the computer may be connected by a cable. The computer extracts real-time values of the temperatures measured by the first and second thermocouples and flow rates measured by the digital flow meter.
Another aspect of the invention is a method that includes providing an apparatus for measuring cooling power of an electrically-powered Microclimate Cooling Unit (MCU). The MCU is mounted in a vehicle and the point of use of the MCU is in the vehicle. The method includes measuring cooling power of the MCU at the MCU point of use.
The invention will be better understood, and further objects, features and advantages of the invention will become more apparent from the following description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which are not necessarily to scale, like or corresponding parts are denoted by like or corresponding reference numerals.
FIG. 1 is a schematic drawing of an MCU and an MCU tester.
FIG. 2 is a schematic drawing of one embodiment of an MCU tester.
FIG. 3 is a schematic drawing of an exterior of a housing for an MCU tester.
FIG. 4 is a schematic drawing of a computer.
FIG. 5 is a schematic drawing of a microprocessor.
FIG. 6A is a schematic drawing of a ground vehicle with an MCU mounted therein.
FIG. 6B is a schematic drawing of an air vehicle with an MCU mounted therein.
DETAILED DESCRIPTION
FIG. 1 is a schematic drawing of one embodiment of an electrically-powered Microclimate Cooling Unit (MCU) 10 and one embodiment of an MCU cooling performance testing apparatus or tester 12 . Suitable MCUs 10 are available from, for example, Cobham Life Support, 10 Cobham Drive, Orchard Park, N.Y., USA, 14127.
MCU 10 is typically mounted in a vehicle, such as an air or ground vehicle. FIG. 6A is a schematic drawing of a ground vehicle 76 with an MCU 10 mounted therein. FIG. 6B is a schematic drawing of an air vehicle 78 with an MCU 10 mounted therein. Tester 12 is used to determine the cooling power of MCU 10 . For testing purposes, tester 12 is connected to MCU 10 via a fluid supply connection 14 , a fluid return connection 15 , an electrical power cable 16 , and a control cable 18 . Importantly, tester 12 is able to test MCU 10 at the point of use of the MCU 10 .
Fluid cooled by MCU 10 is supplied to tester 12 via fluid supply connection 14 . Fluid heated by tester 12 is returned to MCU 10 via fluid return connection 15 . Fluid connections 14 and 15 may be, for example, insulated hoses. A fluid reservoir (not shown) with a capacity on the order of a pint may be interposed between MCU 10 and tester 12 in either the fluid supply connection 14 or the fluid return connection 15 as a means to purge air from the fluid system. The method of using such a reservoir to purge air is known. Tester 12 supplies power to MCU 10 via power cable 16 . Tester 12 controls the cooling output of MCU 10 via control cable 18 .
FIG. 2 is a schematic drawing of one embodiment of MCU tester 12 . Tester 12 includes a fluid supply port 20 connected to a fluid conduit 22 . A flow rate controller 24 and an analog flow meter 26 are disposed downstream of fluid supply port 20 . A fluid heater 30 heats fluid in fluid conduit 22 downstream of fluid supply port 20 . A thermocouple 28 measures fluid temperature in fluid conduit 22 downstream of fluid supply port 20 and upstream of fluid heater 30 . A power supply 38 supplies power to fluid heater 30 via a relay 39 . At least one cooling fan 40 is powered by power supply 38 . A digital flow meter 32 is disposed in fluid conduit 22 . A fluid return port 34 is connected to fluid conduit 22 downstream of fluid heater 30 . A thermocouple 36 measures fluid temperature in fluid conduit 22 downstream of fluid heater 30 and upstream of fluid return port 34 .
A housing 42 contains fluid conduit 22 , flow rate controller 24 , thermocouples 28 and 36 , fluid heater 30 , digital flow meter 32 , power supply 38 , and cooling fan 40 . Preferably, two fans 40 may be used, an intake fan and an exhaust fan. Housing 42 may be made of a metal and may include a removable lid for easy access to the interior of housing 42 . Housing 42 includes an exterior 44 ( FIG. 3 ). Exterior 44 may include front and side panels. For ease of use, exterior 44 includes fluid and electrical connections for connecting tester 12 to MCU 10 . A variety of visual displays and controls are also located on exterior 44 . Preferably, the connections, visual displays and controls are located on a front panel of exterior 44 .
Referring to FIG. 3 , exterior 44 has mounted thereon a visual display 46 of the supply temperature measured by thermocouple 28 , a visual display 48 of the return temperature measured by thermocouple 36 , a visual display 50 for analog flow meter 26 , and a visual display 52 for digital flow meter 32 . Fluid supply port 20 and fluid return port 34 are mounted on exterior 44 . Controls on exterior 44 include flow rate controller 24 , a power switch 56 for fluid heater 30 , a power switch 58 for tester 12 , a power switch 60 for MCU 10 , and a controller 66 for controlling the cooling output of MCU 10 . Electrical connections on exterior 44 include a control cable connection 64 for connecting control cable 18 to MCU 10 and a power supply connection 62 for connecting power cable 16 to MCU 10 . A data output port 68 on exterior 44 enables temperature and flow data to be extracted from tester 12 . Visual displays 46 , 48 , and 52 may be, for example, liquid crystal displays.
Supply fluid connection 14 ( FIG. 1 ), such as a hose, is connected between fluid supply port 20 on tester 12 and a fluid supply port 120 on MCU 10 . Return fluid connection 15 ( FIG. 1 ), such as a hose, is connected between fluid return port 34 on tester 12 and a return port 134 on MCU 10 . Control cable 18 ( FIG. 1 ), such as a wiring harness, is connected between control cable connector 64 on tester 12 and a control connector 164 on MCU 10 . Control signals from controller 66 on tester 12 are sent via control cable 18 to MCU 10 to vary the cooling output of MCU 10 . Electric power cable 16 ( FIG. 1 ), such as a wiring harness, is connected between power supply connector 62 on tester 12 and a power connector 162 on MCU 10 . Connector 62 is also connected to power supply 38 . Tester 12 supplies power to MCU 10 during performance testing of MCU 10 .
Flow rate controller 24 may include a knob to adjust the flow in fluid conduit 22 . Some performance testing may require a specific flow rate in conduit 22 . The flow rate may be viewed on analog flow meter display 50 . Controller 66 , for example, a knob, controls the cooling output of MCU 10 via control cable 18 . Data output port 68 , such as a USB connection or USB data acquisition hub, enables digital output of real-time values of the temperatures measured by thermocouples 28 and 36 and the flow rate measured by digital flow meter 32 .
In one embodiment, a portable computer 70 ( FIG. 4 ), for example, a notebook or laptop computer, may be connected via cable 71 to data output port 68 to extract and record the temperature and flow rate values. Computer 70 may calculate the cooling power of MCU 10 using known algorithms. The known algorithms calculate cooling power (watts) from the temperatures measured by thermocouples 28 and 36 and the flow rate measured by digital flow meter 32 . The calculated cooling power is then compared to the manufacturer's specifications to determine if the MCU 10 is cooling properly.
In another embodiment, tester 12 may include an internal computer such as a microprocessor 72 ( FIG. 5 ) disposed inside of housing 42 . Microprocessor 72 may extract and record the temperature and flow rate values, perform the cooling power calculations, and display the calculated cooling watts visually on a display 74 on exterior 44 . Microprocessor 72 may include memory to store the temperature, flow rate, and cooling watts data. Data output port 68 may be used to access the information in the memory. Computer 70 may not be needed if microprocessor 72 is used.
To test the cooling performance of MCU 10 , power supply 38 of tester 12 is connected to an external power supply, for example, a 115 volt AC power outlet. Fluid return port 34 of tester 12 is connected via return connection (hose) 15 to return port 134 on MCU 10 . Supply connection (hose) 14 is connected to supply port 120 on MCU 10 and to fluid supply port 20 on tester 12 . Preferably, a small fluid reservoir (not shown) is interposed in a known manner in return or supply fluid connection 15 or 14 to allow air to escape from the fluid system.
Control cable or harness 18 is connected to control connection 64 on tester 12 and to control connection 164 on MCU 10 . Power cable 16 is connected between power connection 62 on tester 12 and power connection 162 on MCU 10 . Computer 70 (if used) is connected to data output port 68 . Main power switch 58 is moved to the on position and then MCU power switch 62 is moved to the on position. MCU controller 66 is moved to the maximum cooling position. The fluid in fluid conduit 22 is cooled by MCU 10 until the supply temperature measured by thermocouple 28 is the same as the return temperature measured by thermocouple 36 . This may take about 30 seconds.
Next, power to heater 30 is enabled using power switch 56 . Incorporated with or separate from return temperature display 48 is a return temperature control 54 for setting a desired return temperature at thermocouple 36 . Control 54 is connected to a relay 39 that is connected to power supply 38 . Relay 39 enables power to heater 30 as needed. Use of relay 39 enables the use of a smaller and less massive power supply 38 . Power to heater 30 may be, for example, 110 volt AC power. The fluid temperature in fluid conduit 22 will increase until the return temperature at thermocouple 36 is the temperature set by temperature control 54 . In some embodiments, the set temperature is about 80 degrees F.
Once the supply temperature at thermocouple 28 is stable, the temperatures at thermocouples 28 and 36 and the flow rate at digital flow meter 32 may be used to calculate the cooling power of MCU 10 . The cooling power of MCU 10 may be calculated by external computer 70 or internal microprocessor 72 . The calculated cooling power is then compared to the manufacturer's specifications to determine if the MTU 10 should be shipped from the point of use for repair or replacement.
Preferably, tester 12 weighs less than fifty pounds. More preferably, tester 12 weighs no more than thirty-one pounds. As defined by the U.S. Dept. of Defense, a “man portable” device weighs no more than thirty-one pounds. The man portable embodiment uses microprocessor 72 disposed in the interior of housing 42 .
While the invention has been described with reference to certain embodiments, numerous changes, alterations and modifications to the described embodiments are possible without departing from the spirit and scope of the invention as defined in the appended claims, and equivalents thereof.
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A testing apparatus measures cooling power of an electrically-powered Microclimate Cooling Unit (MCU) at the point of use of the MCU. The tester includes fluid supply and return ports for fluidly connecting to the MCU. A fluid heater provides a heat load to fluid in the tester. Fluid temperatures upstream and downstream of the heater are measured. The fluid flow rate is adjustable and measurable. A digital processor extracts the temperature and fluid flow rate data and computes cooling watts. The computed cooling watts are compared to the manufacturer's specifications to determine if the MCU is operating properly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/716,437 filed on Nov. 20, 2003 (now abandoned); which is a divisional of U.S. patent application Ser. No. 09/740,937 filed on Dec. 21, 2000 (now U.S. Pat. No. 6,695,847); which claims priority to European Patent Application Serial No. 99830784.7 filed on Dec. 21, 1999.
FIELD OF THE INVENTION
The present invention refers to a surgical device and method for bone surgery. The device is particularly suitable, for example, for orthopedic surgical procedures such as osteotomy, ostectomy, osteoplasty etc. and for oral surgical procedures such as excision of cysts, third molar extraction, preparation of implant sites, creation of an opening into the maxillary sinus and elevation of the endosteum.
BACKGROUND
Bone surgery operations that involve cutting of the bony tissue (osteotomy) and/or modeling thereof (osteoplasty) have hitherto been performed with manual and/or rotary instruments. Manual instruments consist of scalpels and/or chisels operated by hand or with a mallet. Rotary instruments consist of motor-driven milling cutters or disks.
These methods both have serious limitations if they have to be used in difficult situations such as restricted surgical access, anatomically difficult bone conditions and particularly when it is necessary to operate in the vicinity of soft tissue.
The cutting characteristics of the techniques currently in use are unsatisfactory for the following reasons:
the cutting depth is poorly controlled; the mechanical force is often excessive, therefore cutting directionality is lost and/or accidental fractures are caused; and cutting is not selective and can therefore damage the soft tissue (for example the vascular nerve bundles).
SUMMARY
The object of the invention is to eliminate these drawbacks by providing a surgical device for bone surgery that makes it possible to perform surgical procedures with the utmost precision and therefore with less risk.
Another object of the present invention is to provide such a surgical device for bone surgery that is practical and versatile.
Another object of the present invention is to provide such a device for bone surgery that is capable of cutting the mineralized bone tissue without causing cuts and lesions in the soft tissue, and particularly in the neurovascular structures.
Another object of the present invention is to provide a surgical method for bone surgery that is most accurate, efficient and with less risk for the patient.
Preferred embodiments of the invention will be apparent from the claims.
The surgical device for bone surgery according to the invention provides a handpiece comprising a tip capable of operating on bone tissue. For this purpose, according to requirements, various tips such as chisels, compressors, osteotomes, periosteal or endosteal elevators etc. can be mounted on the handpiece.
The handpiece comprises a transducer, which can be piezoceramic, for example, and serves to generate sound waves that set the tip in vibration. The tip is made to vibrate at a frequency within the sonic and ultrasonic range so that when it comes into contact with the mineralized bone tissue an extremely fine and precise cut is made in said tissue. Compression, compaction and displacement of said tissue is also possible according to surgical requirements.
The surgical device according to the invention can be equipped with a console which provides for the electrical and hydraulic supply to the handpiece. The console has a keyboard that can be operated by the operator to control the control electronics of the handpiece.
The control electronics allow the handpiece to be operated with sonic and/or ultrasonic vibrations, modulated or not at low frequency or with low frequency bursts. In this manner the user can modulate the ultrasound pulses to be transmitted to the tip of the handpiece according to the requirements of the surgical procedure.
The surgical device for bone surgery according to the invention has various advantages.
With the surgical device for bone surgery according to the invention, the cutting action on the bone tissue is produced by variable modulation ultrasonic vibrations that are activated only on the cutting end of the tip that comes into contact with the mineralized tissue to be cut. Consequently, the bone tissue surface affected by the action is extremely small. This allows the surgeon to draw the ideal type of procedure that he intends to carry out on the bone tissue with extreme precision. Thus, for example, the actual cut made by the tip will differ minimally from the ideal cut planned beforehand by the surgeon.
Another advantage of the surgical device according to the invention is provided by the fact that, since the cut is extremely fine, the trauma suffered by the bone tissue due to the friction of the cutting instrument and the resulting heat loss will be minimal.
Furthermore, when the vibrating tip encounters soft tissue, such as a neurovascular structure, it loses its cutting capacity. In fact the soft tissue absorbs the vibrations of the tip without being resected and the energy caused by the vibrations of the tip is dissipated in the form of a slight heat. This can be further reduced by the surgeon's promptness in withdrawing the instrument as soon as he feels that it does not vibrate any more. The transmission of heat into soft tissue, such as neurovascular structures, therefore causes no irreparable damage, as might be that caused by injury or cutting of such structures.
Consequently, if during an operation the surgeon touches a neurovascular structure with the tip, he has plenty of time to withdraw the tip without the problem of causing irreparable damage. Thus use of the surgical device according to the invention makes it possible to solve more severe clinical cases of bone surgery in which it is necessary to operate in the vicinity of neurovascular structures.
For example, the device according to the invention can be used in oral surgery for the following types of operations:
bone sampling in anatomically difficult areas, whether for access or because they are near the nerve endings or where there is extremely little bone tissue; excision of cysts and/or of inflammatory or phlogistic tissue of the third branch of the trigeminal nerve; extraction of impacted third molars in the vicinity of the dental alveolus; preparation of an implant site in the vicinity of nerve endings; creation of an opening into the maxillary sinus (Caldwell-Luc) without damaging the sinusal membrane; and elevation of the maxillary sinus by the ethmoidal crest route.
The device according to the invention can also be used in orthopedic and neurological surgery, in operations such as:
osteoplasty; ostectomy; and osteotomy in the vicinity of neurovascular structures as is the case, for example, in vertebral surgery.
Further characteristics of the invention will be made clearer by the detailed description that follows, referring to a purely exemplary and therefore non limiting embodiment thereof, illustrated in the appended drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axonometric view of a surgical device for bone surgery according to the invention, complete with equipment for operation thereof;
FIG. 2 is a block diagram illustrating operation of the surgical device according to the invention;
FIG. 3 is an axial section of the surgical device in FIG. 1 , with a connector element and a tip exploded;
FIG. 4 is a plan view showing five types of osteotomy tips;
FIGS. 5 a , 5 b and 5 c show respectively three different types of chisel insert and each figure shows a side view, a plan view and a view from the other side;
FIG. 6 shows respectively a side view, a plan view and a view from the other side of a compressor tip;
FIGS. 7 a and 7 b show two different types of universal tip and each figure shows a plan view and a view from the right side, respectively;
FIG. 8 shows respectively a side view, a plan view and a view from the other side, of a periosteal elevator;
FIGS. 9 a and 9 b show two different types of endosteal elevator and each figure respectively shows a view from one side, a plan view and a view from the other side;
FIGS. 10 a - 10 f show the various stages of a surgical procedure carried out with the surgical device according to the invention.
DETAILED DESCRIPTION
A surgical device for bone surgery according to the invention, indicated as a whole with reference numeral 1 , is described with the aid of the figures. As shown in FIG. 1 , the surgical device 1 is a handpiece comprising a body 2 , substantially cylindrical in shape so that it can be easily gripped by a surgeon. On the head of the body 2 is mounted a tip 3 having a suitable shape for the various types of bone surgery operations for which the handpiece is intended, as will be described below.
The body 2 of the handpiece is connected to an external connector element 4 . The external connector 4 carries two electrical supply cables 5 and 6 and a first hydraulic supply tube 7 which are wrapped inside a sheath 8 . The connector 4 also carries a second hydraulic supply tube 9 .
The electrical supply cables 5 and 6 are connected to a console 10 that takes its electrical supply from the supply mains or has an independent supply system. The first hydraulic supply tube 7 is connected to a hydraulic supply system, which can be provided in the console 10 or in a separate hydraulic system. The second hydraulic supply tube 9 is connected to a peristaltic pump 11 provided on the console 10 .
The peristaltic pump 11 comprises a rotor 12 with a controlled speed of rotation so as to be able to vary the flow rate of the fluid sent, by means of the second tube 9 , to the handpiece 1 .
The console 10 provides a housing 13 in which the handpiece 1 is positioned and a supporting rod 14 that supports a container 15 , which can be a bottle or a bag, for example, which contains a sterile fluid that must be used during the surgical procedure to bathe the surgically treated area. The tube 9 passes inside the peristaltic pump 11 and is inserted in the container 15 through an outlet 80 . The sterile fluid from the container 15 is sent through the tube 9 to the peristaltic pump 11 which in turn feeds the sterile fluid toward the handpiece 1 . The tube 9 and the outlet 80 of the container 15 can be supplied in sterile disposable packages.
On the console 10 a control keyboard 17 that can be operated by the operator to control the microprocessor control unit 10 provided inside the console 10 . With reference to FIG. 2 , the electrical supply taken from the electrical supply mains 21 is sent to a power supply 22 provided inside the consol 10 . The power supply 22 provides electrical power to the microprocessor unit 20 , to a power stage 23 and to a control unit 24 of the peristaltic pump 11 .
The power stage 23 is able to generate an adequate output current and voltage signal to supply the handpiece 1 . The control unit 24 of the peristaltic pump 11 gives out a control signal to operate the rotor 12 of the peristaltic pump 11 so as to feed the sterile fluid from the container 15 toward the handpiece 1 .
The keyboard 17 generates control signals S 1 toward the input of the microprocessor unit 20 . The microprocessor unit 20 , on the basis of the control signals S 1 received, sends out output control signals S 2 and S 3 respectively toward the power stage 23 and the control unit 24 of the peristaltic pump 11 .
The power stage 23 , on the basis of the control signal S 2 received, sends the electrical supply to the handpiece 1 . The control unit 24 of the peristaltic pump 11 , on the basis of the control signal S 3 received, regulates the speed of the rotor 12 of the peristaltic pump 11 .
With reference to FIG. 3 , the external connector element 4 provides two electrical contacts 30 and 31 connected to respective wires 5 and 6 of the electrical power supply. Furthermore the connector element 4 provides a hydraulic duct 32 connected to the hydraulic supply tube 7 . The tube 9 can be clipped to the sheath 8 by means of a band 33 . The external connector element 4 is destined to be inserted into a complementary connecting element 40 provided in the rear part of the handpiece 1 .
The connector 40 provides two electrical contacts 41 and 42 destined to come into contact with the contacts 30 and 31 of the connector 4 . The connector 40 also provides two ducts 43 and 44 for the hydraulic supply of the handpiece that couple respectively with the duct 32 of the connector 4 and the tube 9 . The duct 43 is stopped and serves to confine any fluid coming from duct 32 of the connector. The handpiece is supplied by the fluid through the tube 9 which is inserted into the connector of the duct 44 .
The electrical contacts 41 and 42 are connected respectively to electrical wires 45 and 46 which carry the electrical supply to a transducer 47 . The transducer 47 is a piezoceramic resonator which must be supplied with alternating voltage and current. The transducer 47 is preferably supplied with a sinusoidal voltage of about 160 V r.m.s. at a frequency ranging between 25 and 30 kHz.
To obtain this type of electrical supply, the console 10 has the power supply 22 and the power stage 23 which act as an electrical transformer, transforming the line voltage from supply mains into a sinusoidal voltage of about 160 r.m.s. at a frequency ranging between 24 kHz and 30 kHz.
The transducer 37 , when it is supplied electrically, acts as a sound wave concentrator and sets a tang 48 provided in the head of the handpiece 1 in vibration at an ultrasonic frequency. The tang 48 has a threaded attachment 39 for engagement in a threaded seat 50 of the tip 3 . Thus the ultrasonic vibrations are transmitted from the tang 48 to the tip 3 .
The microprocessor unit 20 of the console 10 , through the control signal S 2 controls the power stage 23 so as to allow different operating modes for supplying the transducer 47 . In this manner the tip 3 can be set in vibration with ultrasound alone, with ultrasound modulated at low frequency (6-40 Hz), or with a series of low frequency bursts.
This method, which adopts modulation of the vibration of the tip 3 , allows the heat that develops on the soft tissue to be minimized because of the dissipation of energy due to the vibration of the tip.
The method that provides for use of modulated ultrasound in low frequency bursts with a variable duty cycle, makes it possible to have a hammering effect of the tip, combined with the ultrasonic vibration efficiency which produces a clean, precise cut in mineralized tissue.
The microprocessor unit 20 is able to perform various functions:
control of the power stage 23 ; automatic tuning of the ultrasound that acts on the particular tip 3 used; setting of the modulation, that is of the duration and frequency of the bursts; and operation with bursts of increasing or decreasing amplitude.
For these purposes the microprocessor unit 20 has a series of pre-set software programs for use with particular types of tips and in particular clinical setting. These software programs can be updated or other software programs can be stored in the console 10 to make possible applications tested at a later date. Furthermore the user can set operating parameters of his own choice through the control keyboard 17 and store them in the console 10 for subsequent applications.
The hydraulic duct 44 of the connector 40 communicates with a chamber 52 in turn communicating with a duct 53 provided inside the body of the handpiece. The duct 53 is connected to a tube 54 that carries the fluid toward a duct (not shown) inside the tang 48 . From the duct inside the tang 48 the fluid spreads into the seat 50 of the tip 3 and through a duct 55 made in the tip 3 it flows toward the outside. In this manner the fluid can irrigate the tissue on which the tip is working, minimizing the operating temperatures due to friction between the tip and the tissue.
In FIGS. 4-9 various types of tips that can be used in the handpiece according to the invention are shown. In these figures the same reference numerals indicate the same or equivalent parts. Each tip provides a seat 50 able to engage with the threaded attachment 49 provided in the handpiece 1 . The seat 50 is connected to a stem 60 having an axis substantially parallel to the axis of the handpiece 1 . The stem 60 ends in an elbow part 61 connected to the head 62 of the handpiece.
FIG. 4 shows five osteotome tips denoted by the abbreviations OST 1 , OST 2 , OST 3 , OST 4 , and OST 5 . These tips show a head 62 with a very wide blade 63 used for bone resection. The blade 63 must in fact cause a fracture, breaking the continuity of the skeletal segment without causing removal of bone tissue.
FIGS. 5 a - 5 c show three chisel-type tips denoted by the initials T 1 , T 2 and T 3 . The chisel tips have a thinner blade 64 that the blade 63 of the osteotomes. In fact the chisel tip is intended for operations in which a very fine, precise cut in the bone tissue is required. For this purpose the blade 64 of the chisel-type tip can have a diamond surface for greater cutting efficiency.
FIG. 6 shows a compressor-type tip is denoted by the initials CP 1 . This tip has a flattened part 65 in the head to compress the bone tissue.
FIGS. 7 a and 7 b show two universal tips denoted by the initials U 1 and U 2 which can be used for various types of operation.
In FIG. 8 SP 1 denotes a periosteal elevator tip. This tip has a spoon-shaped head 66 to detach the bone from the membrane (periosteum) surrounding it.
FIGS. 9 a and 9 b show two endosteal elevators denoted by the initials SE 1 and SE 2 . These tips have a spoon-shaped head 67 smaller in size than the spoon-shaped head 66 of the periosteal elevator. In fact the endosteal elevator must remove the connective tissue (endosteum) that lines the bone cavities.
A surgical technique using the surgical device 1 according to the invention is described with the aid of FIGS. 10 a - 10 f . By way of example a surgical procedure for implantation on an edentulous ridge is described.
In FIG. 10 a an edentulous ridge 100 is shown at the beginning of the surgical procedure. The thickness of the edentulous ridge 100 , measured with a periodontal probe 101 , ranges from 2.2 to 2.8 mm. For edentulous ridges with such a small thickness an operation with the instruments of the prior art such as cutters or chisels is impossible or extremely difficult.
FIG. 10 b shows a side view of the edentulous ridge 100 of FIG. 1 . This Figure was taken during the surgical operation and shows the type of mucous flap of mixed thickness of the edentulous ridge 100 . FIG. 10 b shows a type T 2 chisel-type tip driven by means of the ultrasound handpiece 1 according to the invention.
FIG. 10 c shows the edentulous ridge 100 after the T 2 chisel tip has drawn a horizontal crestal incision 103 with two releasing incisions, one mesial and the other distal. In this figure it can be seen that the cut made by the T 2 tip is extremely precise and fine.
FIG. 10 d shows the edentulous ridge 100 after passage of a second type of chisel tip, V 2 , again mounted on the handpiece 1 according to the invention and operated by ultrasound. The V 2 tip has a widened point to separate the vestibular cortical bone wall from the palatal one, according to the bone flap surgical technique.
FIG. 10 e shows edentulous ridge 100 after two implant sites 104 with a diameter of 2 mm have been created on the bottom of the horizontal crestal incision 103 . It has been possible to create implant sites 104 with such a small diameter, using an osteotome tip of the OST 1 type described with reference to FIG. 4 . The OST 1 tip has been mounted on the handpiece 1 and operated by ultrasound.
FIG. 10 f shows the edentulous ridge 100 three months after the implant. Two implants 105 are visible which have been placed in the respective implant sites 104 , in the position for grafting bone material between the cortical walls. The perfectly mineralized bone ridge is visible and, after measurement with the probe 101 , it has been possible to detect an increase in the thickness of the bone ridge which has grown from about 2.5 to 5 mm.
The surgical device according to the invention can be used for maxillo-facial and otorhino-laryngol surgical procedures.
The surgical device according to the invention can be used for vertebral laminectomy treatments.
The surgical device according to the invention can be used for hand and foot bone surgery.
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A surgical device ( 1 ) for bone surgery including a body ( 2 ) able to be gripped by the user and a tip ( 3 ) mounted at the head of the body and set in vibration at a modulated ultrasonic frequency to operate on bone tissue, the surgical device ( 1 ) being particularly suitable for oral surgical procedures such as bone sampling, excision of cysts, third molar extraction, preparation of alveolar sites, creation of an opening into the maxillary sinus (Caldwell Luc), elevation of the maxillary sinus by the crestal route and orthopedic and neurosurgical procedures such as osteoplasty, ostectomy and osteotomy.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The contents of this application are related to the provisional patent application, Application No. 60/400,471 filed Aug. 2, 2002, entitled “Digit Light.” The contents of this related provisional patent application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for improving visual feedback by illuminating a field such as a reading area, hobby area or any other field such as a surgical site during a medical procedure, and more particularly, to a finger-mounted light which, in the preferred embodiment, includes at least one light-emitting diode capable of emitting light of selected color.
2. General Background
This invention can be used for many different applications where a beam of light needs to be positioned near a work place. Some examples are the assembly of small components by hobbyists, reaching into dark passages by mechanics, assembly or inspection of electronic components, or surgery. Physicians/surgeons who operate within a patient's body require adequate illumination of the field of operation in order to work most effectively. Numerous methods are being used to provide illumination of the field of operation.
For example, overhead lights equipped with parabolic mirrors and polarizing lenses are being used as a general source of non-glare lighting. However, such overhead lights must often be redirected during dental, medical or other procedures to keep the light directed at the point of interest, and the need to readjust the overhead light creates a distraction and requires additional time. Moreover, when the mechanic, hobbyist, surgeon, or physician must lean over the patient or work area to closely observe the field of operation, the overhead light is blocked. In addition, the light source is so far removed from the work location that it is often not possible to direct the overhead light source deep into the area, such as within the patient's body.
It is also known to support a light source from a headband worn by a physician to illuminate an area being viewed by the physician. For example, within U.S. Pat. No. 4,616,257 to Kloots et al., a medical headlight apparatus is disclosed wherein a fiber optic cable transmits light to a headband worn by the physician. The headband supports a housing including an illuminating lens for directing light transmitted by the fiber optic cable toward the field being viewed by the physician. While being an improvement over the above-described overhead light source, the medical headlight apparatus disclosed by Kloots et al. still does not permit the physician or other user to position the light source closely proximate the patient's mouth or other field of operation, and accordingly, the user's hands may block the light from reaching the desired region within the field of operation.
To overcome these problems, a finger-mounted light, such as the one described in U.S. Pat. No. 5,086,378, may be used for illuminating the area. In that invention, for use by a pilot, a fiber optic finger light includes green and red light-omitting diodes (LED) mounted in a housing adapted for strapping to one hand and operated by a 3-position switch. A lens is mounted forwardly of each of the light-emitting diodes and serves to selectively focus light from the light-emitting diodes on one end of one of a pair of light-transmitting fibers which extend through the housing and project from the housing in a flexible duplex fiber optic cable. The light housing is strapped to the wrist and the fiber optic duplex cable is strapped to a finger, such that red or green light emitted from the LED at the opposite end of the optic fiber by manipulation of the switch, may be focused on charts, instruments check lists and the like, in the aircraft.
However, the problem with this approach is the use of an on-off switch for illuminating the area. Clearly, such devices are aimed at being portable devices, and the need to conserve the battery power is extremely important (especially for critical care situations in medical facilities where it is undesirable to have the battery going dead during surgery).
SUMMARY OF THE INVENTION
Clearly there is a need for a device with an adjustable light output control and a visual means for depicting available battery power so as to adaptively change the settings on the device for conserving battery power.
Accordingly, in one aspect of the invention, a finger light producing a variable intensity light output for mounting on the wrist and finger of a user, comprises (i) a housing; (ii) a wrist strap attached to the housing for removably securing the housing on the wrist; (iii) an electrical cable extending from the housing for energizing a light-emitting diode (LED), the LED residing at a first end of the cable, wherein the first end of the cable is distal to the housing; (iv) finger attachment means for securing said LED to the finger; (v) a power source within the housing for delivering a current to the LED, and (vi) a light intensity control means connected to the housing for controlling the light output from the LED. The LED may be replaced with other types of light emitting devices, such as a bulb, as would be obvious to someone ordinarily skilled in the art. A lens may be placed at the light emitting end of the LED to focus the light output.
In one aspect of the invention, the light intensity control means includes a potentiometer. A knob on the housing may be used to control the light output from the LED. Furthermore, a display is included on the housing for monitoring the current (or voltage) output from the power source (viz., a battery). Thus, the light output may be controlled by the user, via the knob, by visually looking at the power level on the display. Additionally, the potentiometer is connected electrically between the power source and the LED. Moreover, the finger attachment means further comprises one or more finger straps attached to a casing that houses the LED.
The invention is further described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited advantages and objects of the invention are attained, as well as others which will become apparent, more particular description of the invention briefly summarized above may be had by reference to the specific embodiments thereof that are illustrated in the appended drawings. It is to be understood, however, that the appended drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
In the drawings:
FIG. 1 is an isometric view of the finger light with a control knob for controlling light output, and a display means for monitoring battery power;
FIG. 2 is another view of the finger light with a control knob for controlling light output, and a display means for monitoring battery power;
FIG. 3 a is a top view of the finger light with a control knob for controlling light output, and a display means for monitoring battery power;
FIG. 3 b is a side view of the finger light of FIG. 3 a;
FIG. 4 is an exemplary depiction of a circuit diagram for measuring battery level and a means for controlling the light output from the LED.
FIG. 5 is a longitudinal cross section of the casing for holding the LED, with an LED inserted.
FIG. 6 is cross section of the finger attachment mechanism and casing, with the LED removed.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail and by reference characters to the drawings (FIGS. 1 - 6 ), which illustrate several different embodiments of the present invention, therein shown is a finger light with a control knob for controlling light output, and a display means for monitoring battery power. Such a system, as in the preferred embodiment of the present invention, employs circuit elements that allow display of the battery power levels and control of light power output from the LED to conserve battery power.
FIGS. 1-3 show the finger digit light 2 having a housing (generally shown as 18 ) with a cover 26 . The cover may be removed for placing a power source (e.g., a battery) within the housing 18 . The housing also has a wrist strap 4 for securing the housing to a wrist of a person. The circuitry in the housing 18 is connected to a light output device casing 8 by means of an electrical cable 6 . The light output device casing 8 , which is at a distal end from the housing 18 along the cable 6 , houses a light-emitting diode (LED) 20 that is electrically connected by means of an internal connector 22 to the power source in the housing 18 . The internal connector 22 can simply be a pair of conductive wires, as depicted in FIG. 5 . In an alternative embodiment, at the light emitting end of the LED 20 a lens (not shown) can be mounted at opening 10 for focusing the light output from the LED 20 . Attached to the light output device casing 8 is a finger attachment or clip 12 for securing the casing 8 to the finger. In the preferred embodiment, the finger attachment clip 12 is a resilient finger strap attached to the casing 8 . The end 13 of the finger attachment clip 12 is purposely extended to allow the user to easily open the finger attachment clip 12 when inserting or removing a finger.
Additionally, the housing 18 includes a knob 14 for controlling the light output from the LED 20 . Specifically, the knob 14 is used for adjusting the resistance of a light output controlling means (viz., a potentiometer) 34 as shown in FIG. 4 . By turning the knob 14 to the “Lo” position, the resistance introduced by resistor 34 is maximum thereby providing a low intensity light output from the LED 20 . This is useful for conserving battery power in situations where it is desired. By turning the knob 14 to the “Hi” position, the resistance introduced by resistor 34 is minimum thereby providing a high intensity light output from the LED 20 . This is useful for critical applications where a lot of light is desired (e.g., during a surgery). Optionally, an on-off switch 24 may be provided on the housing for switching the LED on or off.
Furthermore, it is possible to monitor the power source's current or voltage levels by means of an indicator 16 located on the housing 18 (FIGS. 1 - 3 ). The indicator 16 can be a series of lights, a pointer or any other simple, inexpensive power level indicator. As can be seen in FIG. 4 , the measurement system 32 measures the current output from the battery and displays it on the display/monitor 16 either via green LEDs or in a numerical manner. Alternatively, as can be seen in FIG. 4 (dotted lines), the alternate measurement system 36 may be used to measure the voltage output from the battery and display it on the display/monitor 16 either via green LEDs or in a numerical manner. The measurement systems are common circuits that are commercially readily available.
As one alternative embodiment, the cable 6 may be replaced with a fiber optic cable, and the LED or other type of light emitter may be placed inside the housing 18 . The light would then be transmitted from the LED in the housing, through the fiber optic cable, and out of opening 10 .
While the specification describes particular embodiments of the present invention, those of ordinary skill can devise variations of the present invention without departing from the inventive concept. For example, any other light output controlling means (e.g., a diode) may be used instead of a potentiometer.
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A finger-mounted light system includes an (LED) mounted in a casing adapted for strapping to one hand and operated by a light output control knob. A housing that includes a power source (e.g., battery) is strapped to the wrist and the LED casing is strapped to a finger, such that light emitted from the LED may be adjusted. A display is included on the housing for displaying the battery level.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an articulated halfshaft particularly suitable for use in an amphibian capable of travel on land and water. More particularly, the articulated halfshaft is suitable for use with at least one retractable wheel or track drive in a high speed amphibian capable of planing on water. The present invention also relates to an amphibian incorporating such an articulated halfshaft.
[0002] It is known, for example from U.S. Pat. No. 5,531,179 of the present applicant, for amphibians to have wheel and suspension assemblies which are retractable, so that the wheels are raised above the water line when the amphibian is operated on water. This reduces hydrodynamic resistance (drag), and allows for increased speed. The amphibian can then operate in a planing mode on water, and not just in a displacement mode only. However, known halfshafts, and in particular those used in automotive applications, have limited ability in terms of the angles of articulation possible. Furthermore, there are servicing and reliability issues when transmitting power and/or rotation at speed at increased angles of articulation.
[0003] Prior art automotive halfshafts generally comprises two constant velocity (hereinafter “CV”) joints arranged in a spaced apart manner, joined by stub and/or intermediate shafts. The resulting driveshaft is commonly known as a halfshaft, axleshaft, CV shaft or CV axle. Whilst the halfshaft may transmit power and provide drive to a supported wheel in the manner of a driveshaft, it may also be used simply to support a wheel and not provide any power transmission or drive.
[0004] The use of CV joints permits limited articulation at two points in the halfshaft such that vertical movement of a wheel is possible, usually supported via a suspension assembly. Splined connection of the stub and/or intermediate shafts or plunging CV joints may be used to accommodate geometry changes on movement of the wheel. Such an arrangement provides for bump and rebound, so as to improve the ride and handling characteristics of a vehicle. It also provides for a substantially constant rotating speed of a shaft over a range of angles between input and output.
[0005] However, the degree of articulation achievable is limited due to the geometrical constraints of known articulating joints (CV joints, Rzeppa joints, tripod joints, Hooke's joints, Thompson CV joints and universal joints) since mechanical resistance to rotation and even geometric lock can occur beyond operational angles. Ultimately, this gives rise to servicing issues and failure of the articulating joint when it is operated at the larger angles of the limited articulation available. Such limitations do not present a problem in automotive applications where the amount of vertical travel of a wheel to be accommodated is limited. Furthermore, in amphibians where the dead rise angle of the hull is low (e.g. 0 to 5 degrees), it is still possible to retract the wheels sufficiently (wheel axle angles generally of between 15 and 45 degrees above the horizontal) to enable planing when the amphibian is operated on the water.
[0006] However, there remains a need to retract wheel and track drives yet further, to achieve wheel or track axle angles of 90 degrees or more above the horizontal. This is of particular benefit in amphibians where the dead rise angle of the hull is more severe (e.g. 10 degrees or more), and/or where there is a need for improved ground clearance which in turn requires a greater height of upright in the suspension assembly.
[0007] This presents significant problems in terms of the degree of articulation required (not to mention also the additional articulation about a vertical axis required for steering), packaging, weight distribution and also in terms of how the resulting power transmission pathways can be realised.
[0008] The present invention seeks to address the aforementioned problems.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention provides, in a first aspect an articulated shaft for an amphibian driveline, the articulated shaft comprising:
[0010] at least two shaft portions; and
[0011] at least three points of articulation, wherein:
[0012] the articulated shaft is movable between a protracted position for use of the amphibian on land and a retracted position for use of the amphibian on water.
[0013] In a second aspect, the present invention provides an amphibian comprising the articulated shaft.
[0014] In a third aspect, the present invention provides a powertrain comprising the articulated shaft.
[0015] These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0017] FIG. 1 is a schematic rear elevation view of a conventional road car transmission to a driven wheel, with the wheel shown at a normal ride height;
[0018] FIG. 2 is a schematic rear elevation view of the conventional road car transmission of FIG. 1 with the wheel shown at a full bump position;
[0019] FIG. 3 is a schematic plan view from above of the conventional road car transmission of FIGS. 1 and 2 with the wheel shown in two extremes of steering position;
[0020] FIG. 4 is a schematic sectional view of a conventional plunging type CV joint;
[0021] FIG. 5 is a schematic elevation view of a first preferred embodiment of halfshaft according to the present invention;
[0022] FIG. 6 is a schematic elevation view of a further preferred embodiment of halfshaft according to the present invention;
[0023] FIG. 7 is a schematic rear elevation view of amphibian transmission to a front steered wheel (optionally driven) incorporating the first preferred embodiment of halfshaft of FIG. 5 according to the present invention, with the wheel shown at a normal ride height;
[0024] FIG. 8 is a schematic rear elevation view of the amphibian transmission of
[0025] FIG. 7 , with the wheel shown semi-retracted;
[0026] FIG. 9 is a schematic rear elevation view of the amphibian transmission of
[0027] FIG. 7 , with the wheel shown fully retracted;
[0028] FIG. 10 is a schematic rear elevation view of amphibian transmission to a rear non-steered wheel (optionally driven) incorporating the further preferred embodiment of halfshaft of FIG. 6 according to the present invention, with the wheel at shown at a normal ride height;
[0029] FIG. 11 is a schematic front elevation view of the amphibian transmission of FIG. 10 , with the wheel shown semi-retracted;
[0030] FIG. 12 is a schematic front elevation view of the amphibian transmission of
[0031] FIG. 11 , with the wheel shown fully retracted; and
[0032] FIG. 13 is a detail schematic view in section of a centering mechanism for use in a halfshaft according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] FIG. 1 shows a simplified schematic view of a known road car transmission to one driven left wheel, in a view taken along the car, looking forwardly from the rear. The transmission can be seen to comprise a differential 1 , a halfshaft generally indicated 5 , and a wheel 9 . An inner joint 3 is provided in the halfshaft 5 , commonly a CV joint. An outer CV joint 7 is also provided. As can be seen from FIG. 1 , the total horizontal articulation angle αR for bump and rebound through which inner CV joint 3 must articulate is about 50 degrees for a typical road suspension (25 degrees above, and 25 degrees below horizontal). As the wheel 9 must remain substantially perpendicular to the road surface, outer CV joint 7 must also articulate through the same angle, but out of phase with the inner joint 3 , as shown in FIG. 2 , where the wheel 9 is at full bump travel.
[0034] Where the wheel 9 is also a steered wheel, the outer CV joint 7 has an additional function, as illustrated in FIG. 3 . FIG. 3 is a simplified plan view from above of the transmission of FIGS. 1 and 2 . As shown, the steered wheel 9 rotates through an angle from position 9 R at full right steering lock to position 9 L (shown in dotted line) at full left lock. Hence, the range of vertical rotation β may be up to 90 degrees. The horizontal angle of rotation αR and the vertical angle of rotation β account for the full range of movement of the outer CV joint 7 (from full bump and right hand steerlog lock, to full rebound and left hand steering lock).
[0035] To maintain a consistent track dimension between the left and right wheels on a given axle, the effective length of the wheel driveshaft must be able to alter as the wheel travels up and down in bump and rebound. This is achieved on a typical road car (e.g. with front wheels which provide drive and steering) by using a plunge type joint as the inner CV joint 3 , and a fixed joint as the outer CV joint 7 . Whilst a plunge joint can provide for changes in the effective length of the driveshaft, a plunge joint can only operate within a more limited range of driveshaft angles, because the driveshaft will contact the outer sleeve when these angles are exceeded, as can be seen from the indicated angle αC in FIG. 4 . A fixed joint can operate through a larger range of angles, and is therefore used as the outer joint 7 to accommodate steering as well as suspension travel. A further reason why the plunge joint is used as an inner joint 3 rather than as an outer joint 7 is because it is bulkier than a fixed joint, so it is more easily packaged adjacent to the differential rather than at the wheel hub, where it would otherwise compete for space with many other components. Furthermore, if fitted to the wheel hub, the heavier plunge joint would add unwanted unsprung weight.
[0036] In view of the foregoing, it will be appreciated that the need to retract wheel and track drives yet further, to wheel or track axle angles of 90 degrees or more above the horizontal, presents significant problems, not least in terms of the angle of articulation desired, packaging and weight.
[0037] Referring next to FIGS. 5 and 7 to 9 , there is shown a first preferred embodiment of halfshaft 10 according to the present invention. FIG. 5 is a schematic elevation view of the halfshaft 10 . In the arrangement shown, the halfshaft 10 is for a front left hand steered wheel 400 , and optionally driven. The front left hand suspension upright 90 (omitted in FIG. 5 for clarity) is mounted on a suspension upright stub shaft 20 of the halfshaft 10 at its left hand end. Drive is transferred from the halfshaft 10 (when driven) to the suspension upright 90 (which includes drop down drive to the wheel 400 by belt drive, gearing, etc.) via a key and keyway 22 . At its right hand end, suspension upright stub shaft 20 is mechanically connected via a shaft pin 23 to a housing plate 24 . In turn, the housing plate 24 is mechanically coupled, for example by way of a bolt or other mechanical fastening (omitted for clarity) to the outer raceway 32 of a first fixed CV joint 30 . The first fixed CV joint 30 forms a first articulated connection with a mid shaft 50 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 32 , CV ball bearings (omitted for clarity), CV cage 34 and CV core 36 , and by way of the splined connection between the CV core 36 and the left hand end of the mid shaft 50 . The mid shaft 50 in fact comprises two parts 52 , 54 each provided with respective male and female splines 56 , 58 for splined connection so as to accommodate changes in the length of the halfshaft 10 during use. The right hand end of the midshaft 50 is connected via splined connection to the CV core 66 of a second fixed CV joint 60 . The second fixed CV joint 60 forms a second articulated connection with the midshaft 50 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 62 , CV ball bearings (omitted for clarity), CV cage 64 and CV core 66 , and by way of the splined connection between the CV core 66 and the midshaft 50 . A third fixed CV joint 70 forms a third articulated connection with a differential stub shaft 80 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 72 , CV ball bearings (omitted for clarity), CV cage 74 and CV core 76 , and by way of a splined connection between the CV core 76 and the differential stub shaft 80 . The respective CV outer raceways 62 , 72 of the second and third fixed CV joints are mechanically coupled, for example by way of a bolt or other mechanical or other fastening method (omitted for clarity) so as to transmit torque. A centering mechanism (omitted from FIG. 5 for clarity, but shown in detail in section in FIG. 13 and described below) is preferably provided between the mid shaft 50 and stub shaft 80 to aid in controlling movement of the shafts in use. The right hand end of the differential stub shaft 80 is received in the differential 95 (omitted from FIG. 5 for clarity), from which drive is received (when driven) via splines 82 . Each fixed CV joint 30 , 60 , 70 , in use, is packed with grease and protected by way of a cover (“boot”) and suitable retaining clips (omitted for clarity).
[0038] The halfshaft 10 is illustrated schematically in protracted, semi-retracted and fully retracted positions in FIGS. 7 , 8 and 9 respectively. First, in FIG. 7 , with front left steered (optionally driven) wheel 400 fully protracted, the first, second and third fixed CV joints 30 , 60 , 70 can be seen to have very shallow angles of articulation between each respective CV core 36 , 66 , 76 and CV outer raceway 32 , 62 , 72 . Next, in FIG. 8 , with the front left steered wheel 400 semi-retracted, the first and second fixed CV joints 30 , 60 can be seen to have very shallow angles of articulation between each respective CV core 36 , 66 and CV outer raceway 32 , 62 , whereas the third fixed CV joint 70 can be seen to have a more developed angle of articulation between its respective CV core 76 and CV outer raceway 72 . Finally, in FIG. 9 , with the front left steered wheel 400 fully retracted, the first CV joint 30 can be seen to have a more developed angle αF 1 (˜20 degrees) of articulation between its respective CV core 36 and CV outer raceway 32 , and the second and third fixed CV joints 60 , 70 can be seen to have very significant angles of articulation αF 2 , αF 3 between each respective CV core 66 , 76 and CV outer raceway 62 , 72 (˜73 degrees collectively).
[0039] Referring next to FIGS. 6 and 10 to 12 , there is shown a further preferred embodiment of halfshaft 100 according to the present invention. FIG. 6 is a schematic elevation view of the halfshaft 100 . In the arrangement shown, the halfshaft 100 is for a rear left hand wheel 600 , and optionally driven. The rear left hand suspension upright 190 (omitted in FIG. 6 for clarity) is mounted on a suspension upright stub shaft 120 at its left hand end. Drive is transferred from the halfshaft 100 (when driven) to the suspension upright 190 (which includes drop down drive to the wheel 600 by belt drive, gearing, etc.) via a key and keyway 122 . At its right hand end, suspension upright stub shaft 120 is mechanically connected via a shaft pin 123 to a stub shaft extension 121 . A first fixed CV joint 130 forms a first articulated connection with the stub shaft extension 121 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 132 , CV ball bearings (omitted for clarity), CV cage 134 and CV core 136 , and by way of a splined connection between the CV core 136 and the right hand end of the stub shaft extension 121 . A second fixed CV joint 160 forms a second articulated connection with a midshaft 150 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 162 , CV ball bearings (omitted for clarity), CV cage 164 and CV core 166 , and by way of a splined connection between the CV core 166 and the midshaft 150 . The respective CV outer raceways 132 , 162 of the first and second fixed CV joints 130 , 160 are mechanically coupled, for example by way of a bolt or other mechanical or other fastening method (omitted for clarity) so as to transmit torque. A centering mechanism (omitted from FIG. 6 for clarity, but shown in detail in section in FIG. 13 and described below) is preferably provided between the mid shaft 150 and stub shaft extension 121 to aid in controlling movement of the shafts in use. The mid shaft 150 in fact comprises two parts 152 , 154 each provided with respective male and female splines 156 , 158 for splined connection so as to accommodate changes in the length of the halfshaft 100 during use. The right hand end of the midshaft 150 is connected via splined connection to the CV core 176 of a third fixed CV joint 170 . The third fixed CV joint 170 forms a third articulated connection with the midshaft 150 , the connection being formed by way of a ball spline connection formed between the CV outer raceway 172 , CV ball bearings (omitted for clarity), CV cage 174 and CV core 176 , and by way of the splined connection between the CV core 176 and the midshaft 150 . In turn, a housing plate 124 is mechanically coupled, for example by way of a bolt or other mechanical fastening (omitted for clarity) to the outer raceway 172 of the third fixed CV joint 170 . The housing plate 124 further comprises a differential stub shaft 180 . The right hand end of the differential stub shaft 180 is received in the differential 195 (omitted from FIG. 6 for clarity), from which drive is received (when driven) via splines 182 . Each fixed CV joint 130 , 160 , 170 , in use, is packed with grease and protected by way of a cover 188 (“boot”) and suitable retaining clips (omitted in FIGS. 6 , 10 and 11 for clarity).
[0040] The halfshaft 100 is illustrated schematically in protracted, semi-retracted and fully retracted positions in FIGS. 10 , 11 and 12 respectively. First, in FIG. 10 , with rear left (optionally driven) wheel 600 fully protracted, the first, second and third fixed CV joints 130 , 160 , 170 can be seen to have very shallow angles of articulation between each respective CV core 136 , 166 , 176 and CV outer raceway 132 , 162 , 172 . Next, in FIG. 11 , with the rear left wheel 600 semi-retracted, the first and second fixed CV joints 130 , 160 can be seen to have very shallow angles of articulation between each respective CV core 136 , 166 and CV outer raceway 132 , 162 , whereas the third fixed CV joint 170 can be seen to have a more developed angle of articulation between its respective CV core 176 and CV outer raceway 172 . Finally, in FIG. 12 , with the rear left wheel fully retracted, the first and second fixed CV joints 130 , 160 can be seen to have very significant angles of articulation αR 1 , αR 2 between each respective CV core 136 , 166 and CV outer raceway 132 , 162 (˜73 degrees collectively), and the third CV joint 170 can be seen to have a developed angle αR 3 (˜12 degrees) of articulation between its respective CV core 176 and CV outer raceway 172 .
[0041] FIG. 13 illustrates, schematically in cross-section, a centering mechanism 800 suitable for use between two adjacently arranged CV joints 910 , 920 and respective shafts 915 , 925 . The CV joints 910 , 920 can be the CV joints 60 , 70 of FIG. 5 , and the shafts 915 , 925 can be the mid shaft 50 and stub shaft 80 of FIG. 5 . Similarly, the CV joints 910 , 920 can be the CV joints 130 , 160 of FIG. 6 , and the shafts 915 , 925 can be the mid shaft 150 and stub shaft extension 121 of FIG. 6 . The centering mechanism 800 can be seen to comprise an integral ball 850 and ball stub shaft 852 , an integral socket 810 and socket stub shaft 812 , and springs 820 , 860 . The spring 820 and socket stub shaft 812 are slidingly received in an aperture 912 provided in shaft 915 , with the spring 820 acting to bias the socket stub shaft 812 against axial movement further into the aperture 912 . Similarly, the spring 860 and ball stub shaft 852 are slidingly received in an aperture 922 provided in shaft 925 , with the spring 860 acting to bias the ball stub shaft 852 against axial movement further into the aperture 922 . The ball 850 and socket 810 are arranged in close proximity, with the ball 850 being received in the socket 810 and free to rotate therein. The respective dimensions of the integral ball 850 and ball stub shaft 852 , integral socket 810 and socket stub shaft 812 , and springs 820 , 860 are such that the ball 850 is urged into contact with the socket 810 under the biasing action of the springs 820 , 860 in all articulations of the CV joints 910 , 920 and shafts 915 , 925 . In use, shaft 915 (acting as an input shaft) can transmit torque to shaft 925 (acting as an output shaft) via the respective external housings 914 , 924 of the CV joints 910 , 920 which are coupled together (e.g. via bolts (not shown) and/or a coupling/cover 980 ). The shaft 915 can pivot relative to the shaft 920 as provided for by the ball 850 and socket 810 . Both the ball 850 and the socket 810 are connected to their respective (input/output) shafts 925 , 915 by their sliding stub shafts 852 , 812 which can slide axially (into and out of) as well as rotate relative to the (input/output) shafts 915 , 925 . The (input/output) shafts 915 , 925 can move relative to the respective external housings 914 , 924 by pivoting around the fixed pivot points P 1 , P 2 . When articulated about the fixed pivot points P 1 , P 2 , the adjacent ends of the (input/output) shafts 915 , 925 must necessarily move away from each other. However, the ball 850 remains in contact with the socket 810 under the biasing action of the springs 860 , 820 , with the stub shafts 852 , 812 sliding axially ‘out’ of the apertures 922 , 912 of shafts 925 , 915 in order to provide for the increased distance. The springs 860 , 820 are preload springs and help overcome friction and permit the ball 850 to remain in the socket 810 . Lubrication (and, optionally, packing with grease around the ball 850 and socket 810 ) may be provided as necessary. The centering mechanism 800 thus aids in controlling movement of the shafts 915 , 925 in use. While a ball and socket arrangement has been described above, this is just one example. A universal joint with adequate angular capability could be beneficially employed in place of the ball and socket, as could any other mechanism which serves the same function.
[0042] It will thus be appreciated that the articulated halfshaft 10 , 100 according to the present invention can provide for significant angles of articulation between input and output. Furthermore, it is also capable of providing steering, drive (transmitting power) and/or a constant speed of rotation between input and output at these significant angles of articulation, yet does so without suffering from the known geometrical problems (mechanical resistance and lockup) of prior art halfshafts.
[0043] Retractable wheel and suspension assemblies (selected parts are omitted from the attached Figures for clarity) as described in the applicant's patents and patent applications are particularly suitable for use with the articulated halfshaft 10 , 100 of the present invention.
[0044] Whilst not shown, it is possible also to provide decouplers separately or integrated in the transmission illustrated. The provision of decouplers allows drive to the wheels or track drives to be disengaged when the amphibian is operated on water. As decouplers should be mounted rigidly to encourage smoothness of operation, it is preferred that decouplers be used on the inner CV joints. The CV joints may also include a synchromesh unit for smooth engagement and disengagement of said decouplers.
[0045] Whilst wheels 400 , 600 have predominantly been referred to throughout for use as the land engaging and/or land propulsion means of the amphibian when operated on land, track drives or individual track drives (i.e. to replace a single wheel) may be used as an alternative or in combination with wheels.
[0046] Furthermore, it will be appreciated that drive (power) may be provided by internal combustion engines, electric motors, hydraulic motors, or hybrid engines in any suitable location (e.g. hydraulic wheel hub motors).
[0047] Although different embodiments of articulated halfshaft 10 , 100 according to the present invention have been described above, any one or more or all of the features described (and/or claimed in the appended claims) may be provided in isolation or in various combinations in any of the embodiments. As such, any one or more these features may be removed, substituted and/or added to any of the feature combinations described and/or claimed. For the avoidance of doubt, any of the features of any embodiment may be combined with any other feature from any of the embodiments.
[0048] Accordingly, whilst preferred embodiments of the present invention have been described above and illustrated in the drawings, these are by way of example only and non-limiting. It will be appreciated by those skilled in the art that many alternatives are possible within the ambit, spirit and scope of the invention, as set out in the appended claims.
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An articulated shaft for an amphibian driveline includes at least two shaft portions and at least three points of articulation, wherein the articulated shaft is movable between a protracted position for use of the amphibian on land and a retracted position for use of the amphibian on water. An amphibian comprising the articulated shaft, and a powertrain comprising the articulated shaft is also provided.
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BACKGROUND OF THE INVENTION
The invention concerns a device to secure the vanes of a turbine on a rotor, with the disk of the rotor carrying at its periphery a plurality of axial grooves into which the roots of the vanes slide.
Numerous devices have been developed to retain vanes and more particularly the roots of vanes, in grooves provided on the rim of a rotor. These devices generally consist of plates which lodge in channels provided in the radial surface of the disk and may be slid in front of the roots of the vanes and secured in place by mechanical deformation.
The devices described above secure the vanes in place satisfactorily, but do not prevent air leaks. In actual fact, each vane is traversed by channels receiving cooling air through the roots. There is an obvious interest in limiting losses to a minimum. It is also of interest to reduce the number of pieces to be handled in assembling the engine. French Pat. No. 1,307,564 partially solved these problems and describes a device comprising an annular plate and keys. The radial surface of the disk has a plurality of channels, with the uppermost channel continuing and extending into the rim of the vanes and the lower channel defining a series of teeth, spaced apart. A number of keys, carrying a small tongue, and retained by it, the annular plate is fastened under the upper channel and comes to rest on the keys so that the notches provided in said plate are placed in front of the tongues of the keys. The tongues are then projected into the notches by deformation, thus locking the annular plate in place against the radial surface of the disk.
SUMMARY OF THE INVENTION
The present invention proceeds from the preceding device and has as its object the elimination of the usual keys or bolts. The device is designed to secure the vanes of a turbine rotor, according to the invention, with the disk of the rotor having a rim on the periphery of which a plurality of axial grooves is arranged, the roots of the vanes being slid into said grooves. At least one annular, axial retaining check plate is coaxial with the disk and fastening and blocking means to maintain the check plate in position on the rim and the invention is characterized by the fact that said fastening means consist of conical projections cooperating, respectively, with the lower edge of the rim and hangers mounted perpendicularly to the plane of the check plate on the lower edge of the check plate, said lower edge of the rim comprising indentations to receive the hangers of the check plate prior to its location by rotation, and said blocking means consist of studs located at the ends of elastic tongues cut radially from the check plate and cooperating with grooves of a corresponding shape, provided in the feet of the vanes.
BRIEF DESCRIPTION OF THE DRAWINGS
The explanation and figures, presented hereafter as examples, will provide an understanding of how the invention may be embodied.
FIG. 1 is a partially sectional view of a turbine disk equipment with a securing device according to the invention;
FIG. 2 is a sectional view according to II--II of FIG. 1; and
FIG. 3 is a perspective, partially in section, of a part of the annular plate along a radial cut forming a tongue.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a part 1 of the rotor disk having at its periphery the axial grooves 2 in the form of fir tree slots, into which slide the vanes 3 of the turbine. According to one embodiment in general use, not shown, the vanes include in their thickness cooling channels, in which air coming from the center of the rotor, circulates. These channels traverse the roots 4 and correspond with passages provided in the disk. It is thus necessary to insure as nearly perfectly tight a seal as possible between the fir tree slot and the root of the vane and to prevent losses through the lateral edges. It is no less necessary to secure the vanes in their grooves and to prevent any slipping along the axis of the disk. To accomplish this, an annular check plate 5 is placed on the sides of the disk and in front of the roots of the vanes. According to the invention, the configuration of the annular check plate is such that said plate is capable of cooperating with the elements of a securing device pertaining to both the disk and the vanes.
The annular check plate 5 is formed at its inner edge with the hangers 10 protruding essentially perpendicularly to the plane of the check plate and toward the disk. Each hanger 10 has a flange turned toward the outside and inclined away from the axis in the direction opposed to the disk. The different faces 12 of the hangers and flange define cone surfaces coaxial with the rotor. Further, as may be seen better in the sectional view of FIG. 2, the inner edge of the rim 1 of the disk defines teeth 7 each of which is cut at a bevel, the face 12' of which slopes toward the inside of the rotor and is inclined to form a conical surface complementary of the faces 12 of the hangers.
According to an important characteristic of the invention, the elastic tongues 13 are formed by cutting radially into the thickness of the annular check plate 5 so as to leave a free end at the side of the outer peripheral edge of the check plate. This tongue 13 carries a projection 11 protruding in the direction of the rim of the disk. Grooves 9 of a corresponding shape are arranged for each of the projections in the feet of the vanes. The expression "the feet of the vanes" signifies the assembly located under the base of the blade of the vane, said assembly generally consisting, in the mode of securing the vanes by means of profiled roots slid into the grooves of the rim, of a vane root 4 surmounted by a platform 8. In the example shown, the grooves 9 are defined by a portion of a slot cut into the axial edges 8' of each platform 8.
The tongues 13, equipped with the projections 11, are provided so that the projections will be located in front of the grooves 9, when a hanger 10 is engaged with the surface 12 of a tooth 7.
According to the example shown, there are as many hangers as there are teeth 7 and one hanger and one tooth are located essentially on a radius of the disk and at the same side of the plate. The projection 11 penetrates into the groove 9, which consists of two parts: one half of the groove consists of the end of a slot provided in the ledge of the vane, parallel to the axis of the disk, the other half is formed by a corresponding and facing slot of an adjacent vane. One projection is thus hooked into two adjacent vanes. Because of the disposition of the projections and the hangers on the annular check plate, the disk may be designed so that the longitudinal plane of symmetry of the fir tree slot is centrally between two teeth 7, upon which the hangers 10 will be placed. In other words, one tooth should be located between two fir tree slots receiving the roots of two adjacent vanes. The part of the check plate between two tongues 13 corresponds to the transverse width of the vane and assures its maintenance in place and its tightness.
A gripping means is provided on the rear face of the tongue 13 carrying the projection 11, in order to make possible the extraction of said projection from its groove 9.
The installation of the securing device takes place as follows: after placing the securing device in the rear (not shown), the vanes are slid into their grooves, the annular plate 5 is then placed against the side of the disk so that the hangers 10 are located in the spaces between the teeth 7. While urging the check plate against the side of the rotor disk 1, it is turned through an angle corresponding to the angle separating a space from a tooth. The hanger 10 and more particularly the face 12 will be located behind the end of a tooth, against which it is blocked in the axial direction. The projections, which up to this time had been flexed outwardly with respect to the face of the check plate in contact with the side of the disk, now flex into the grooves 9, because of the elasticity of the tongue 13, insuring that the annular check plate is locked in place with respect to rotation.
The annular check plate may be removed by using a tool cooperating with the gripping means 14 and effecting the retraction of the projections 11 from their grooves and by then rotating the plate to guide the hangers 10 into the spaces provided between the teeth 7.
According to one embodiment of the annular check plate as shown in FIG. 3, said check plate is machined so as to present an increasing width from its outer edge 15 toward its inner edge 16. On the face 17 and toward the edge 15, an initial ridge is left, which after machining, leaves the projections 11. On the edge 16 a second ridge is likewise left, which can be machined to leave the hangers 10. These ridges are eliminated at least partially on the parts of the check plate corresponding to the free faces of the roots of the vanes. The tongues are then formed by cutting essentially in a radial direction into the check plate. The trapezoidal cross section of the plate serves the purpose of obtaining tongues with an elasticity adequate to maintain the projections in their grooves and hangers sufficiently massive to prevent their deformation under the effect of the centrifugal force.
As an example of the order of magnitude, the thickness of the check plate at the inner edge may be approximately twice the thickness of said check plate at its outer edge. If these thicknesses are, for example, 2 mm and 1 mm, respectively, a width of the tongue of 4 mm may be specified.
The economy in material provided by the device of the present invention will be noted. The elevated rotational velocities of the rotor, also taking into consideration the diameter of the rims of the disk, are the cause of high mechanical stresses; a lightening of the rotating pieces contributes to their reduction.
It will also be noted that the tongues which are part of the securing device according to the invention, participate simultaneously, because they are an integral part of the check plate, in the mechanical securing of said plate, which is important in assuring good functional tightness at the check plate. The invention provides means to secure the device to the side of the disk without requiring the use of classic means, such as bolts or locks with deformable tongues and to assure the proper relation of the roots of the vanes to their environment.
It should be understood that the invention is in no way limited to the embodiments described in the foregoing as examples. Thus, specifically, the number of hangers may be independent of the number of tongues and the number of vanes. Similarly, the grooves for the projections 11 need not overlap two consecutive vanes nor are they necessarily located at the level of the roots of the vanes.
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A device to secure and insure the tightness of vanes of a turbine is an alar plate which carries on the side toward its external edge a plurality of studs and toward its internal edge a plurality of hangers. The disk of the rotor has on its lower edge a series of teeth or indentations, the top of the teeth having a configuration to cooperate with the inner surface of the hangers. The vanes have on their rims a plurality of grooves. Two adjacent vanes form a groove into which the studs enter when the hangers cooperate with the teeth. The studs are borne by tongues cut radially into the annular plate.
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BACKGROUND OF THE INVENTION
This invention relates in general to the extraction of metals from sea water and in particular to a system and method for the continuous extraction of uranium utilizing flexible adsorber sheets which are first deployed in currents of sea water for adsorption of a metal and then recovered for elution of that metal.
The recovery of metals generally from sea water is by no means a novel subject but the costs associated with most techniques have rendered them impractical. It was early recognized that enormous quantities of sea water would be needed for any practical production and that the siting of the extraction facility would have to be carefully chosen to ensure an adequate inflow of fresh sea water and the avoidance of recirculation of depleted sea water through the facility.
Various approaches have been considered. Studies of oceanographic data have indicated that in certain areas of the world a fairly constant current is available to meet certain of the criteria for a practical facility. Tidal schemes have also been proposed where a large area of water may be enclosed in a lagoon for extraction of metals followed by a tidal discharge of the depleted water and tidal refilling of the lagoon. Also, several pumped-water schemes have been proposed. However, a broad range of problems including large capital and operating costs, environmental aspects, energy requirements, availability and characteristics of proposed sites and even political factors have prevented the realization of any of the proposals. It is a major object of this invention to avoid or overcome the problems associated with previous proposals and to provide a practical system and facility for the continuous extraction of metals from sea water.
SUMMARY OF THE INVENTION
Although the extraction of various metals from the ocean is contemplated, the present invention will be described in connection with uranium as a typical metal to which the extraction system and method are applicable.
The world's oceans contain dissolved uranium in the form of the uranyl carbonate ion [UO 2 (CO 3 ) 3 ] -4 in generally uniform concentration of about 3 parts per billion. While this concentration is rather low, the total uranium contained in oceans is enormous and much greater than the economically recoverable land-based resources. The limited nature of land-based resources and the increasing use of uranium in nuclear reactors have awakened renewed interest in the oceans as a source of uranium.
The extraction facility would preferably be on a platform located relatively closely off the shore of the United States with adsorption of uranium to take place on horizontal adsorber sheets floating and stationary in a relatively high-velocity warm current of sea water. The adsorber sheets are made of screen or fabric coated with micron-size adsorber particles and the sheets are continuously deployed and recovered by a conveyer-track system. The sheets are wound on hollow perforated bobbins at the recovery stage and uranium is eluted from the wound adsorber sheets by a flow of elutant from the hollow core of the bobbin uniformly out through the rolled adsorber sheet.
The loaded elutant may be stored in a tank in the platform and periodically the contents of the tank may be transported to an onshore plant for recovery of uranium from the elutant. The elutant from which the uranium has been stripped may then be recycled for further use.
Obviously, for each of the other metals to be extracted, in each case, a specific adsorber and a specific elutant would be chosen.
For a better understanding of the present invention together with other and further objects, features and advantages, reference should be made to the following detailed description of a preferred embodiment of the invention which should be read with reference to the accompanying drawing, in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an offshore facility for extracting uranium from sea water;
FIG. 2 is an enlarged view of a portion of the uranium extraction facility shown in FIG. 1;
FIG. 3 is a perspective view, partially broken away to expose internal details of a portion of a conveyor for vertically transporting bobbins and adsorber sheets;
FIG. 4 is a schematic view of the conveyor systems, the deployment and recovery mechanisms and the elution stages;
FIG. 5 is a process flow chart of the extraction;
FIG. 6 is a view of a preferred form of adsorber sheet; and
FIG. 7 is an enlarged cross-sectional view of a portion of the adsorber sheet shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exhaustive study of oceanographic data indicates that the optimum site in the world for mining metals from sea currents lies off the southeastern Florida coast in the Florida current. Specifically, the flow channel created by the Florida Keys and coast on one side and Cuba and the Bahamas on the other constitutes one of the largest rivers in the world. For example, at a point just south of Miami between Fowey Rocks and Gun Cay, the current is typically in excess of 3 knots at the surface and is in excess of 2 knots to a depth of about 500 feet. Recovery of only a small fraction of the total metals carried by the Florida current would be economically advantageous and recovery of a fraction of uranium alone would provide 100 percent of the uranium required in the U.S. for hundreds of years even with future major utilization of nuclear power. Moreover, insofar as the availability of undepleted sea water is concerned, studies indicate that about half of the volume of the Florida current is derived from the Atlantic Ocean in a circulation pattern which involves waters moving south off the western coast of Africa and forming the north equatorial current. The other half of the Florida current comes from the Guiana current moving from south of the equator and the south equatorial current moving along the eastern coast of South America. Thus, the Florida current comes from well-mixed ocean waters and will serve as a source of metals including uranium for many hundreds of years. Moreover, the sea water in the Florida current is of warm temperature year round, ranging from 24° C. in winter to about 29° C. in summer. With such temperatures, efficient metals extraction by the methods of the present invention is assured year-round.
In FIGS. 1 and 2, a multi-level platform preferably sited in the Florida current is shown. The basic platform structure may be generally similar to those platforms used in offshore oil well drilling having platform decks of the order of 300 ft. by 100 ft.
The legs 10, 11, 12, and 13, which may be interconnected by cross-braces such as those shown at 16 and 19, extend to the ocean bottom where they are encased in concrete footings 17 or other suitable anchoring members to provide stable support for the platform. Alternatively, a platform of the semisubmerisible type may be used.
Beneath a top deck 18 of the platform a conveyer 20 is illustrated. The conveyor 20 operates synchronously with a similar conveyor 20a, and perforated bobbins on which adsorber sheets are wound are carried by opposing elements of the conveyors 20 and 20a. Although a total sheet width of about 240 feet is contemplated, the width of the sheet segment between the conveyers 20 and 20a is approximately 40 feet, as are the other sheet segments. The hollow perforated bobbins are preferably of corrosion-resistant steel tubing and may be about 50 feet in length and about 4 inches in outer diameter. The sheets wound on the bobbins may, for example, be about 200 feet long.
The operation of the two conveyers is identical and the description will be limited to the conveyer 20. Wound upon the bobbins suspended from the conveyer are a plurality of adsorber sheets. The adsorber sheets may be composed of screen or fabric which is coated with micron-size adsorber particles, as is explained in greater detail below.
At the right-hand end of the conveyer 20 the adsorber sheets on the bobbins, having been stripped of adsorbed material and cleaned, are transferred to a second vertically operating conveyer 21 on which they are carried downwardly at relatively high speed. The conveyer 21 may be enclosed in a tube 22 which is slotted to permit engagement of the end of the bobbin by the conveyer 21. Similar structure is provided for a cooperating conveyer 21a. A typical vertically operating conveyor 21 is illustrated in FIG. 3, which also shows a cutaway view of hollow tubular bobbins 33 and the rolled sheets 26 carried thereby. The bobbins 33 include perforations 35 useful in connection with elution of uranium, as is explained in greater detail below.
The bobbins and the adsorber sheets are carried by the second conveyer 21 to a point which may be 20 ft. below the surface of the sea to avoid surface wave action. At that point, a deployment motor 24 spins each bobbin to unroll a sheet such as the sheet 26 from the bobbin. The adsorber sheets are of sufficient density to be approximately neutrally buoyant and they tend to float and stream out in the current of sea water. Each bobbin is then transferred to a third conveyer 27, not visible in FIGS. 1 and 2 but shown in FIG. 4, which may carry the fully deployed sheets downwardly for a predetermined distance--for example, approximately 400 ft. The downward transport is effected at a relatively slow speed so that the sheets are nearly fully loaded with uranium when they reach the end of the 400-foot downward travel. The sheets may be spaced apart typically by a distance of 12 to 24 inches.
At the end of the 400-ft. downward travel on the conveyer 27, which travel may take as long as 4 to 5 hours or longer, the sheets reach a rewind station 28 where the sheets are rewound on the bobbins into rolls by a rewind motor 30. The rolls are there transferred to a fourth conveyer 29, on which they are relatively rapidly carried upwardly to a point 31 above the surface of the water where they are returned to the conveyer 20. The rolls are carried horizontally to the left by the conveyer 20 as shown in FIG. 4 to a fresh-water station 32. At this point, flow connectors are connected to the ends of the bobbins and fresh water is introduced through the hollow centers of the perforated bobbins to flush sea water from the rolls. The flushing action may be enhanced by rotating the bobbins at high speed to cause the fresh water to be forced outwardly through the bobbins and rolls by centrifugal forces. The high speed rotation may also be employed prior to flushing to remove excess sea water from the rolls. Both centrifuging steps assist in minimizing the volume of fresh water required for flushing.
After the water flush, bobbins and rolls are carried to a series of elution stages. Flow connectors again engage the bobbin ends and elution is carried out by introducing 1 M ammonium carbonate solution through the hollow core of the bobbins to pass outwardly through the perforations and the rolled adsorber sheets. Again, the bobbins and rolls may be centrifuged at each stage by rotating the bobbins at high speed. Other elutants such as sodium carbonate or dilute hydrochloric acid may be used as alternatives to ammonium carbonate.
The preferred method of carrying out the elution process is a counter-current continuous operation in which fresh ammonium carbonate solution is introduced at the final elution stage #6, at which point most of the uranium has been extracted from the rolled sheets. The loaded elutant derived from the rolls at elution stage #6 is then pumped to elution stage #5 where the elution is repeated. Again, the loaded elutant from elution stage #5 is then pumped to elution stage #4, the elution being repeated at each elution stage until elution stage #1 is reached. At each stage the concentration of uranium in the elutant increases. Sheets at stage #1 have the maximum loading of uranium as has the elutant. The final concentrated elutant products from stage #1 may be stored for removal to an onshore facility. The sheets leaving elution stage #6 are drained and centrifuged for maximum elutant removal followed by a fresh water wash before they are recycled into the sea.
To minimize blockage of the current of sea water by the bobbins and rolled sheets carried by the conveyors 21 and 29, the bobbin spacings and the speeds of these conveyors must be properly selected relative to those of the conveyor 27. For example, as shown in FIG. 4 (not to scale) the conveyers 21 and 29 which carry the bobbins and rolled sheets vertically may operate at five times the speed of the conveyer 27 which carries the deployed sheets. In this case the spacing of the bobbins of conveyors 21 and 29 is five times the spacing of the bobbins of carrier 27.
In some circumstances, particularly where water temperature is very much lower at greater depths, it is desirable that the deployed sheets be moved upwardly rather than downwardly because the adsorptive capacity of hydrous titania decreases with decreasing temperature. Such a rearrangement is easily made and the result is that fresh adsorber sheets are deployed in the coldest water and the heavily loaded adsorber sheets are in the warmest water nearer the surface thus maximizing the efficiency of adsorption.
In the process flow chart of FIG. 5, the adsorption station is shown at 51, a current of sea water flowing through the station as indicated at 52. The dashed loop 53 indicates adsorption by the hydrous titania elements at 51 followed by the countercurrent elution at 54.
The ammonium carbonate elutant loaded with uranium may be passed to a steam stripping station 55 where the ammonium carbonate is removed (as NH 3 and CO 2 ), the ammonium carbonate then preferably being recycled for further use. From the steam stripping station the uranium solution is passed to the loading station 56 where it is loaded with a suitable anion exchange resin of the type conventionally used in the recovery of uranium from leach liquors. Finally at a stripping station 58 a salt stripping solution is injected to provide an output of uranium in the form of U 3 O 8 at the recovery point 60.
As previously noted, the full width of a typical adsorber sheet may be 240 feet and the length may be 200 feet. About 400 such sheets are used, 200 being deployed in the ocean currents while a second 200 sheets may be going through the elution process.
Some detail on a preferred form of adsorption sheets is shown in FIGS. 6 and 7. Preferably, the sheets comprise a loosely woven fabric or a screen to the surfaces of which micron-sized particles of a uranium-adsorbent material such as hydrous titanium oxide are attached. Hydrous titanium oxide has been shown to be particularly effective in selectively adsorbing uranium from sea water. Use of an adhesive in attaching the particles permits exposure for adsorption of all of the surfaces of the particles except for those in contact with the matrix fabric or sheet. The density of the sheet with its attached particles is adjusted to provide approximately neutral buoyancy in the sea water currents.
Each adsorber sheet segment may be made in the form of a grid of supporting tapes, an end tape 71 being doubled upon itself and laced to cross tapes such as the tape 73, all tapes being further laced to a mesh screen 75. The screen 75 may be a monolayer or two or more layers of mesh to the surfaces of which hydrous titania particles 76 are attached. The filaments of the mesh screen may be fluted to increase surface area and may be about 0.032 inch in diameter. The mesh may be square and the filaments spaced apart by a distance equal to their diameters. With such dimensions 25% of the screen area is open. The hydrous titania particles which coat the filaments of the screen are of a nominal size of about 20 microns.
The sheets with the adhered particles operate adequately, with good mass transfer rates. Mass transfer is aided in part by the tendency of the sheets to ripple in the current, creating turbulence. Mass transfer rate is also aided by the use of a screen rather than a solid, impermeable surface as a support for the adsorbent since the discontinuous surface of the screen serves to break up laminar boundary layers, which increases mass transfer rate.
Other modifications may be useful in increasing turbulence and mixing in the seawater flowing between adjacent sheets. For example, one system of enhancing turbulence illustrated in FIGS. 6 and 7 is the use of flexible self-erecting fingers 77 provided in spaced arrays along the cross-tapes of the grid of adsorber sheets. When the sheets are rewound after deployment, the fingers are flattened against the supporting sheet and serve as spacers to enhance the flow of elutant through the rolls.
In addition to the turbulence fingers, flow diverters 79 may be applied to the adsorber sheets. These diverters are in the form of curved, scoop-like barriers spaced and aligned in such a fashion as to divert seawater flowing between sheets and cause it to surge back and forth through an adsorber sheet.
Reverting to FIGS. 1 and 2, the top deck 18 of the platform may also include a service center 62 for operating personnel, laboratory facilities, and the like. Storage and maintenance quarters 64 may also be provided and hoisting equipment such as the cranes 66 and 68 may also be mounted on the deck 18.
Reference has been made throughout the disclosure to the bobbins which are used. Although cylindrical perforated bobbins may be used, it is also contemplated that perforated bobbins of a flattened shape such as an oval shape may be used. With the flattened bobbins, greater numbers may be carried on the conveyer 21 for travel from the conveyer 20 to the deployment motor 24 and on the conveyor 27, maximizing the number of sheets deployed in the adsorber bed. Finally, after the rolls are wound upon the bobbins at the point 28, the spacing on the conveyer 29 may be closer by use of the generally flattened shape.
Both the tape grid and the mesh screen of the adsorber sheets may be made of a suitable plastic such as polypropylene. The hydrous titania particles are generally of highly irregular shape and therefore provide an exposed surface area considerably greater than the nominal screen area. The particles may be attached to the screen by means of a waterproof elastomeric adhesive such as a solution of nitride rubber dissolved in methyl ethyl ketone. In such circumstances, it is important that the procedure for coating the adsorber sheets with adhesive and attaching the particles not result in coverage of an excessive fraction of the particle surface by the adhesive. The particle attachment procedure may, therefore, include careful monitoring of the viscosity of the coating of adhesive applied to the screen to ensure that the particles thereafter applied sink to only a specified percentage (e.g. 20 percent) of their volume into the adhesive. Another feasible method of attachment is by a spray of hot particles which become attached to the screen by reason of partial melting of the filaments which compose the screen. A screen of cellulose fibers (e.g. cotton) may also be used, in which case a latex adhesive such as a urethane latex would be used.
What has been disclosed constitutes a preferred embodiment of the invention. However, other alternative structures suitable for carrying out the invention will suggest themselves to those skilled in the art. The invention should be limited only by the spirit and scope of the appended claims.
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A method and system for continuously extracting metals from sea water by deploying adsorber sheets in a suitable current of sea water, recovering the adsorber sheets after they become loaded with metal and eluting the metal from the recovered sheets. The system involves the use of hollow, perforated bobbins on which the sheets are rolled as they are recovered and through which elutant is introduced.
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This application is a continuation of U.S. application Ser. No. 09/000,217, filed on Jun. 26, 1998, issued as U.S. Pat. No. 6,521,598; which is a national stage application under 35 U.S.C. §371 of PCT/NL96/00307 filed Jul. 29, 1996. The entire disclosure of the aforementioned patent is incorporated herein by reference.
The invention relates to the field of the immunology, in, particular to the field of cellular immunology.
It is also concerned with the area of organ transplantation, grafting of tissues or cells, especially bone marrow and possible immunological reactions caused by transplantation and/or grafting and bloodtransfusion.
Since the invention concerns a sex-related proteinaceous material, encoded in nature by a sex-related gene, the invention also relates to the areas of sex linked congenital aberrations, of embryonic selection techniques, in vitro fertilization techniques, vaccination and in ovo vaccination.
Bone marrow transplantation (BMT), one of the areas the invention is concerned with and the area from which the present invention originates, finds its application in the treatment of for instance severe aplastic anaemia, leukaemia and immune deficiency diseases.
In the early days of this technique many transplants failed through rejection of the graft by the host. Transplants that did succeed, however often led to an immune response by lymphocytes present in the graft against various tissues of the host (Graft versus Host Disease (GvHD)). It is now known that the GvHD response is mainly due to the presence of major H antigens which present a transplantation barrier. Therefor it is now routine practice to graft only HLA-matched materials (either from siblings or unrelated individuals) resulting in a much improved rate of success in bone marrow transplantation. However, despite this improvement, as well as improvements in pretransplantation chemotherapy or radiotherapy and the availability of potent immunosuppressive drugs, about 20–70% of the treated patients still suffer from GvHD (the percentage is age and bone marrow donor dependent). To avoid GvHD it has been suggested to remove the cells (mature T cells) causing said reaction from the graft. This however often leads to graft failure or to recurrence of the original disease. The cells responsible for GvHD are also the cells which often react against the original aberrant cells in leukaemia (Graft versus Leukaemia response)
.Since BMT is nowadays only carried out with HLA matched grafts, the GvHD which still occurs must be caused by another group of antigens. It is very likely that the group of so called minor H antigens (mHag), which are non-MHC encoded histocompatibility antigens (unlike the major H antigens) are at least partially responsible for the remaining incidence of GvHD.
mHag's have originally been discovered in congeneic strains of mice in tumor rejection and skin rejection studies. In mice, the use of-inbred strains has shown that mHag are encoded by almost 50 different allelically polymorphic loci scattered throughout the genome (24). In humans, mHag have been shown to exist, although their overall number and complexity remains uncertain. One of the better known, though unidentified minor histocompatibility antigens is the H-Y antigen. In the first report of H-Y as a transplantation antigen Eichwald and Silmser observed that within two inbred strains of mice, most of the male-to female skin grafts were rejected, whereas transplants made in other sex combinations nearly always succeeded (1). The term H-Y antigen was introduced by Billingham and Silvers (2) because the male specific antigen can function as a classical transplantation antigen responsible for homograft rejection.
Alloimmunity to human H-Y was first demonstrated in a female patient with aplastic anaemia who was given bone marrow from her HLA-identical brother. After a period of transient chimaerism the graft was rejected. At this time after grafting her lymphocytes showed unambiguously strong MHC restricted cytotoxic T cell (CTL) responses specific for male HLA-A2 positive target cells (3,4). The clinical case not only evidenced that H-Y can function, as a transplantation barrier in man as well, but also that the recognition of the human male specific minor Histocompatibility antigen (mHag) was MHC restricted (4). The clinical relevance of H-Y as alloantigen is demonstrated especially in bone marrow transplantation (BMT) where sex-mismatch is one risk factors associated with rejection (3,4,5) or Graft-versus-Host-Disease (6,7). Sensitization to the H-Y antigen extends to organ transplantation (8–11), bloodtransfusion (12) and pregnancy (13), wherein MHC restricted T cell responses to the mHag H-Y in association with different MHC molecules are observed. To understand the impact of mHag H-Y on the outcome of organ- and bone marrow grafting we earlier studied its tissue distribution. CTL mediated lysis of tissue-derived cell and cultured cell lines of several human tissues demonstrated an ubiquitous expression (11,14,16).
In search for the biological function of the gene encoding the mHag H-Y, our earlier studies analyzing lymphocytes from sex chromosomal abnormalities with our HLA restricted H-Y specific CTL clones revealed that absence of the mHag H-Y correlated with the XO and XX karyotype (17). Subsequent studies combining DNA, and functional expression with our CTL clones analyzing lymphocytes from individuals with Y chromosomal deletions, assigned the H-Y gene encoding the mHag H-Y to a portion of interval 6 (18), to a region covering the proximal segment of the Yq euchromatin, on the long arm of the Y chromosome (19).
Besides the role of H-Y as transplantation antigen, the human Y gene controlling the expression of the mHag H-Y is possibly also functioning as a gene controlling spermatogenesis. Agulnik et al. (20) recently identified a new murine Y chromosome gene, designated Smcy, controlling spermatogenesis as well the expression of the murine male specific mHag H-Y. The Smyc gene appears to be conserved on the Y chromosome in mouse, man and even in marsupials (20). It is notable that recent studies from our laboratories show recognition of the human HA-2 and H-Y peptides on non human primates cells, transfected with human class I genes, by our human HA-2 and H-Y specific class I restricted CTL clones (21).
Until recently, little was known about the molecular nature of the mHag gene products. Recent revealing that the non-sexlinked human mHag HA-2 represents a short peptide originating from a member of the non-filament-forming class I myosin family (22). However, no information exists on the amino-acid sequence nor on the protein of the, male specific mHag H-Y.
Aiming at the identification of the human H-Y peptide, we used the HLA-B7 restricted CTL clone “5W4” (12). Clone 5W4 originates from a female aplastic anemia patient who had received mutiple transfusions (12,23).
Besides the HLA-B7 H-Y specific CTL clone, we earlier characterized HLA-A2 as well as HLA-A1 H-Y specific CTL clones (23).
We used a CD8 positive HLA-A2.1 restricted H-Y specific CTL clone, designated “1R35” (23). Besides, we also previously characterized a CD4 positive HLA-A2.1 restricted H-Y specific cytotoxic as well as proliferative T cell clone, designated as “R416” (41).
We aimed at identification of the human H-Y peptide recognized by the HLA-A2.1 restricted H-Y specific T cell clones IR35 and R416. The, same methodology as applied for the identification of the HLA-B7 restricted H-Y peptide was used.
The invention thus provides a (poly)peptide comprising a T-cell epitope obtainable from the minor Histocompatibility antigen H-Y comprising the sequence SPSVDKARAEL (SEQ ID NO:1) or FIDSYICQV (SEQ ID NO:2) or a derivative of either of these having similar immunological properties.
The two sequences specified are encoded by the SMCY gene. The first sequence is the one found using the HLA-B7 restricted H-Y specific T-cell clone, The second is the one found using the HLA-A2.1 restricted clones.
The way these sequences are obtained is described herein. An important part of this novel method of arriving at said sequences is the purification and the choice of the starting material. Said novel method is therefor also part of the scope of this invention. However, now that the sequence is known, it is of course no longer necessary to follow that method, because the peptides can easily be made synthetically, as is well known in the art. Since routine techniques are available for producing synthetic peptides, it is also within the skill of the art to arrive at analogs or derivatives of the explicitly described peptides, which analogs and/or derivatives may have the same or at least similar properties and or activity. On the other hand analogs which counteract the activity of the explicitly described peptides are also within the skill of the art, given the teaching of the present invention. Therefor derivatives and/or analogs, be it of the same or different length, be it agonist or antagonist, be it peptide like or peptidomimetic, are part of the scope of this invention.
A preferred embodiment of the present invention are the peptides with the sequences SPSVDKARAEL (SEQ ID NO:1) and/or FIDSYICQV (SEQ ID NO:2). This does not imply that other peptides are not suitable. This will for a large part depend on the application and on other properties of the peptides, which were not all testable within the scope of the present invention.
The peptides and other molecules according to the invention find their utility in that they may be used to induce tolerance of the donor immune system in H-Y negative donors, so that residual peripheral blood lymphocytes in the eventually transplanted organ or the bone marrow, as it may be do not respond to host H-Y material in an H-Y positive recipient. In this way GvHD may be prevented. On the other hand tolerance may be induced in H-Y negative recipients in basically the same way, so that upon receipt of an organ or bone marrow from an H-Y positive donor no rejection on the basis of the H-Y material occurs.
For tolerance induction very small doses can be given repeatedly, for instance intravenously, but other routes of administration may very well be suitable too. Another possibility is the repeated oral administration of high doses of the peptides. The peptides may be given alone, or in combination with other peptides, or as part of larger molecules, or coupled to carrier materials in any suitable excipients.
Further applications of the peptide derivatives thereof lie in the prophylactic administration of such to transplanted individuals to prevent GvHD. This can be done with either agonists, possibly in combination with an adjuvant, or with antagonists which may block the responsible cells. This can be done with or without the concomittant administration of cytokines.
Furthermore the peptides or antibodies thereto can be used in so called “magic bullet” applications, whereby the peptide or the antibody is coupled to a toxic substance to eliminate certain subsets of cells.
Diagnostic applications are clearly within the skill of the art. They include, but are not limited to H-Y typing, detection of genetic aberrancies and the like.
Other therapeutical applications of the peptide include the induction of tolerance to H-Y proteins in H-Y related (auto)immune diseases, such as possibly in Rheumatoid arthritis. On the other hand they may be used in vaccines in H-Y related (auto)immune diseases.
For the sake of illustration a number of applications is cited below.
The H-Y peptide or its derivatives can be used to prevent harmful reaction of the recipient towards the donor or vice versa; in all forms of transplantation i.e. organs, tissues and bone marrow. Assuming that residual donor peripheral blood lymphocytes (PBL)'s in the transplanted organ could react with and/or against host PBL's and even could cause GvHD, the H-Y peptide could be used to induce tolerance in living organ (kidney, liver, gut, skin) of H-Y negative donors for H-Y positive patients. In bone marrow transplantation, the H-Y peptide (given alone or in combination with other peptides) can be used to induce tolerance in the living bone marrow donor. The peptide(s) can be given orally, intravenous or otherwise.
In all forms of organ (including cornea), tissue (including heartvalves and skin) and bone marrow transplantation with living or cadaveric donors, the H-Y peptide could be used to induce tolerance in H-Y negative recipients of organ and tissue transplants from H-Y positive donors. In case of bone marrow transplantation, tolerance must be induced in female donors for male recipients. The tolerance induction can be achieved by clinical application of the H-Y peptide systematically, i.v., locally, orally, as eye-drops.
The H-Y peptides could act in a non-allelic restricted manner (thus promiscuous) implicating that its applicability to inducing tolerance is not restricted to the HLA type of the female donors and female recipients and donors
The H-Y peptides or their derivatives can be applied to generate reagents and/or medicine. They can be used as Graft-versus-Host disease and rejection prophylaxis administration to the transplanted individual either with or without adjuvant of
a) a H-Y peptide b) H-Y peptide analogues, including left or right turning peptides c) H-Y peptide antagonists
Usage of the H-Y sequence information to generate, for immunomodulatory purposes:
a) anti-idiotypic T cells b) anti-idiotypic B cells c) human monoclonal antibodies
The H-Y peptides or their derivatives can be used as a marker for sex linked congenital or other diseases.
They can be used for the generation of a genetic probe enabling screening for the congenital sex-linked disorders.
The genetic probe can be used for genetic counseling, population genetics and pre-natal diagnostic.
The defect can be repaired by genetic engineering.
The peptides and other molecules according to the invention can also be used for the production of anti-conceptive drugs.
Furthermore the peptides and other molecules according to the invention can be used for the production of cytotoxic T lymphoctes (CTL) with specificity for the H-Y sequence.
The H-Y specific CTL can be used for selection of male embryos in X linked recessive disorders.
The invented molecules can be applied to generate reagents and/or medicine for
a) determination of foetal erythrocytes in maternal circulation. b) intra uterine diagnostics c) use prior to implantation for in vitro fertilization. d) determination of chimerism.
Veterinary applications include:
a) embryonic selection. b) in vitro fertilization. c) vaccination and in ovo vaccination d) anti-conception.
On the basis of the peptides described herein genetic probes can be produced which can be used to screen for the gene encoding the protein. On the other hand such probes may be useful in detection kits as well. On the basis of the peptides described herein anti-idiotypic B cells and/ or T cells and antibodies can be produced. All these embodiments have been made possible by the present disclosure and therefor are part of the present invention.
The techniques to produce these embodiments are all within the skill of the art.
Dose ranges of peptides and antibodies and/or other molecules according to the invention to be used in the therapeutical applications as described herein before are usually designed on the basis of rising dose studies in the clinic. The doses for peptides may lie between about 0.1 and 1000 μg per kg bodyweight, preferably between 1 and 10 μg per kg bodyweight.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
Reconstitution of the H-Y epitope with HPLC fractionated peptides extracted from HLA-B7 molecules. (A) HLA-B7 molecules were immunoaffinity purified from 2×1010 H-Y positive JY cells. Peptides were eluted from B7 molecules with 10% acetic acid, pH 2.2, filtered through a 10 kD cut-off filter and fractionated on a C18 reverse phase column. Buffer A was 0.1% heptafluorobutyric acid (HFBA); buffer B was 0.1% HFBA in acetonitrile. The gradient consisted of 100% buffer A (0–20 mm), 0 to 12% buffer B (20 to 25 mm), and 12 to 50% buffer B (25 to 80 mm) at a flow rate of 200 μl/min. 60 fractions of 200 μl each were collected from 20 to 80 mm. (B) Fractions 28 and 29 from the separation shown in (A) were rechromatographed with the same acetonitrile gradient, but using trifluoroacetic acid (TFA) instead of HFBA as the organic modifier. For both panels, 3% of each peptide fractions were preincubated with 1,000 51 Cr-labeled T2-B7 cells at room temperature for 2 hours. CTLS were then added at an effector to target ratio of 10 to 1, and further incubated at 37° C. for 4 hours. Background lysis of T2-B7 by the CTL in the absence of any peptides was −3% in (A) and −4% in (B); positive control lysis of JY was 75% in (A) and 74% in (B).
FIG. 2 .
Determination of candidate H-Y peptide by mass spectrometry combined with 51 Cr release assay. HPLC fraction 14 from the separation shown in FIG. 1B was chromatographed with an on-line microcapillary column effluent splitter as previously described (11,13). One-fifth of the effluent was deposited into μl of culture media in microtiter plate wells for analysis with CTLs as in FIG. 1 . The remaining four-fifths of the material were directed into the electrospray ionization source, and mass spectra of the peptides deposited in each well were recorded on a triple-quadruple mass spectrometer (Finnigan-MAT, San Jose, Calif.). (♦), H-Y epitope reconstitution activity measured as percent specific lysis; (▪), abundance of peptide 1171 measured as ion current at m/z 391.
FIG. 3 .
CAD mass spectrum of peptide 1171 after conversion the R residue to ornithine. material from second dimension HPLC fraction 14 shown in FIG. 1B was treated with 70% hydrazine hydrate for 1 hour. The CAD mass spectrum was recorded on the (M+2H)+2 ion at m/z 566.
FIG. 4 .
H-Y epitope reconstitution with synthetic peptides. Synthetic peptides were purified to homogeneity by reverse phase-HPLC on a Vydac C4 column. Purity was established on an analytical RP column and the quantity of each peptide was confirmed by comparing the area of the peak with that of a standard peptide. The identity of the peptides was confirmed by mass spectrometry. 51 Cr release was assayed at an effector to target ratio of 10 to 1 on T2-B7 cells that had been incubated with the indicated concentration of SMCY peptide SPSVDKARAEL (SEQ ID NO:1) (♦), or SMCX peptide SPAVDKAQAEL (SEQ ID NO:3) (▪).
FIG. 5 .
Binding of synthetic peptides to purified HLA-B7. HPLC-purified test peptides were assayed for the ability to inhibit the binding of the iodinated endogenous B7 peptide APRTYVLLL (SEQ ID NO:4) to purified HLA-B7 as previously described (40). (♦), SMCY peptide SPSVDKARAEL (SEQ ID NO:1); (▪) SMCX peptide SPAVDKAQAEL (SEQ ID NO:3); (Δ), APRTLVLLL (SEQ ID NO:5), an endogenous peptide bound to HLA-B7; (x) LLDVPTAAV (SEQ ID NO.6), an endogenous peptide bound to HLA-A2.1 as the negative control.
FIG. 6 .
HLA-A2 molecules were immunoaffinity purified from 10 10 DM cells. Peptides were eluted according to the methodology as described in legend to FIG. 1 .
DESCRIPTION OF THE INVENTION
As with other mHag, the recognition of H-Y by T lymphocytes is MHC-restricted (3,24,25), and it has been shown that some H-Y antigens are peptides derived from cellular proteins that are presented on the cell surface in association with MHC class I molecules (26). We have developed a technique for the identification of individual peptides that are bound to MHC molecules and recognized as antigens by T cells. By combining microcapillary liquid chromatography/electrospray ionization mass spectrometry with T cell epitope reconstitution assays, we previously identified peptide antigens recognized by T cells specific for human melanoma (27), human xenografts (28), and a non-sex-linked human mHag (22). We now report the identification of a peptide antigen recognized by a human cytotoxic T lymphocyte (CTL) clone that is H-Y specific and restricted by the class I MHC molecule HLA-B7, as well as a peptide antigen that is recognized by two HLA-A2.1 restricted CTL clones.,
To isolate endogenously processed H-Y peptides, HLA-B7 molecules were purified by affinity chromatography from the H-Y positive, B lymphoblastoid cell line, JY (29). The associated peptides were extracted in acid and separated from high molecular weight material by ultrafiltration as previously described (31), and subsequently fractionated by reverse-phase high-performance liquid chromatography (HPLC) (27). Aliquots of each fraction were incubated with HLA-B7 positive, H-Y negative T2-B7 target cells in order to assay for the ability to reconstitute the epitope recognized by an HLA-B7-restricted, H-Y specific CTL clone, 5W4 (ref. 12). A single peak of reconstituting activity was observed ( FIG. 1A , fraction 28 and 29), which was rechromatographed using a different organic modifier. Although a single active peak of reconstituting activity was also observed from this separation ( FIG. 1B , fraction 14, 15 and 16), it still contained more than 100 distinct peptide species, as assessed by electrospray ionization tandem mass spectrometry.
To identify active H-Y peptides in this mixture, we, applied each active fraction separately to a microcapillary HPLC column and split the effluent following the separation (11): Four-fifths of the effluent was directed into the mass spectrometer for analysis, while one-fifth was simultaneously directed into a 96-well microtiter plate for a subsequent epitope reconstitution assay. The amount of the H-Y sensitizing activity in each well was correlated to signals observed in the mass spectrum, and therefore to the abundance of different peptide species. By comparing the profile of H-Y activity and the ion abundance data ( FIG. 2 ), we were able to identify an (M+3H)+3 ion at a mass-to-charge ratio (m/z) of 391 (neutral molecular mass=1171), whose abundance correlated with the amount of H-Y epitope reconstituting activity. Further confirmation of the importance of peptide 1171 was provided by the demonstration that a peptide with an identical mass and collision-activated dissociation (CAD) spectrum was also present in HLA-B7 associated peptides extracted from a second H-Y positive B lymphoblastoid line, DM, but absent from a spontaneous H-Y antigen loss variant of this cell, DM(−) (33).
Assignment of a complete amino acid sequence to the 1171 peptide from the CAD mass spectrum recorded at the 20 fmol level proved difficult due to the absence of high mass fragment ions containing the amine terminus (b-type ions). A series of single and/or doubly charged fragment ions containing the amine terminus (b-type ions). A series of single and/or doubly charged fragment ions containing the carboxyl terminus (y-type ions) identified the C-terminal residue as either L or I and the first six amino acids as SPSVDK (SEQ ID NO:7). The difference in molecular mass between this partial sequence and that of the full length peptide suggested the presence of four additional residues, for a total length of 11. Since the candidate peptide existed exclusively in the gas phase as an (M+3H)+3 ion, and underwent mass shifts of 42 and 84 Da on conversion to the corresponding methyl ester and acetylated derivative, respectively, two of the remaining residues were assigned as R and either D or E. Only two combinations of four residues (AREA (SEQ ID NO: 8) and GRDV (SEQ ID NO:9)) meet the above criteria and satisfy the missing mass of 427 Da. CAD spectra recorded on synthetic peptides suggested that R could not be located at either position 7 or 10. Data bases were searched for proteins containing peptides with these characteristics, and a sequence consistent at 9 out of 11 positions was found in residues 909–919 of the protein encoded by a gene called XE169 or SMCX (34), which is located on the X chromosome. A homolog of SMCX, called SMCY, is located on the Y chromosome (20). This protein (35) contains a sequence (residues 902–912) that is consistent at 11 out of 11 positions, and has the expected mass of 1171 Da. A CAD mass spectrum recorded on the naturally processed material after conversion of the R residue to ornithine confirmed that its sequence was identical to that found in SMCY protein ( FIG. 3 ).
In the same manner as described above for the HLA-B7 restricted T-cell clone, the peptide recognized by two HLA-A2.1 T-cell clones was identified. In short the HLA-A2.1 restricted H-Y specific T cell clone R416 recognizes HPLC fraction 34, the HLA-A2.1 restricted H-Y specific T clone 1R35 recognizes HPLC fractions 36 and 39 ( FIG. 6 ). The amino acid sequence analyses and H-Y reconstitution assays demonstrate that both HLA-A2.1 restricted H-Y specific T cell clones recognize peptide sequence FIDSYICQV (SEQ ID NO:2) with a m/z ratio of 544 or the cystinylated form of the same peptide with a m/z ratio of 604.
A synthetic peptide corresponding to the 11 residue SMCY sequence (SPSVDKARAEL (SEQ ID NO:1)) was found to sensitize T2-B7 cells for recognition by the H-Y specific CTL clone. Half-maximal lysis was achieved at a peptide concentration of 10 pM ( FIG. 4 ). The corresponding peptide derived from the sequence of the X chromosomal homolog, SMCX, has substitutions of A for S at position 3 and Q for R at position 8. Although this peptide also was able to sensitize T2-B7 cells for recognition, comparable levels of killing were only achieved by using a 10,000-fold higher peptide concentration. Binding studies showed that the concentration of the SMCY peptide that inhibited the binding of an iodinated standard peptide to purified HLA-B7 by 50% (IC50) was 34 nM, while the IC50 for the SMCX peptide was 140 nM ( FIG. 5 ). Thus, the significant difference in the ability of the SMCY and SMCX peptides to sensitize targets for T cell recognition is almost entirely due to the fine specificity of the T cell receptor, rather than to differences in MHC binding affinities. The SMCX peptide is also present in naturally processed peptide extracts of HLA-B7, although its abundance is only 25% of that of the SMCY peptide (33). Based on all of this information, it is concluded that the peptide epitopes representing the HLA-B7 restricted H-Y antigen is derived from the protein encoded by SMCY, which is also true for the HLA-A2.1 recognized peptide, also encoded by SMCY.
The location of the SMCY gene and the control of its expression fit well with those expected of the H-Y antigen based on previous work. Deletion mapping in humans has placed the HY locus to a portion of interval 6 on the long arm of the human Y chromosome (18), and SMCY maps to this same interval (20). H-Y antigens are expressed ubiquitously in different tissues (5,15), and expression of SMCY has been detected in all male tissues tested (20). One interesting issue is whether the H-Y epitope peptides presented by other MHC molecules will also be derived from SMCY SMCY and SMCX are 85% identical at the amino acid sequence level, and the SMCX gene is expressed ubiquitously from both the active and the inactive X chromosomes in both mice and human (34,36). Therefore, self-tolerance to SMCX will limit the number of SMCY peptides that could give rise to H-Y epitopes in association with different MHC molecules. On the other hand, SMCY contains almost 1500 residues, and the over 200 amino acid sequence differences between it and SMCX are scattered relatively uniformly throughout its length. Thus, there is the potential to generate a large number of distinct SMCY-specific peptides as H-Y epitopes. It is still an open question whether the H-Y epitope peptides presented by other MHC molecules are also derived from SMCY. Genetic mapping of the mouse Y chromosome has suggested at least two and up to five distinct loci encoding H-Y antigens (37). Interestingly, a murine epitope restricted by HL-2Kk has also been shown to be derived from the murine Smcy protein (38). The demonstration that two H-Y epitopes from either mouse or human are derived from the same protein makes SMCY the prime target in searching other H-Y epitopes.
The identification of the protein that gives rise to an H-Y antigen culminates 40 years of uncertainty regarding its origin. However, the function of SMCY, as well as the homologous SMCX, remains unclear. Both proteins share significant sequence homology to retinoblastoma binding protein 2, which has been suggested to be a transcription factor (39). Nonetheless, this and other H-Y specific peptides are candidates for immunomodulatory approaches in bone marrow transplantation. They may also form the basis for genetic probes to be used for prenatal diagnosis in sex-linked congenital abnormalities, as well as for investigating minimal residual disease and chimerism.
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20. A. Agulnik, M. J. Mitchell, J. L. Lerner, D. R. Woods and C. Bishop. A mouse Y chromosome gene encoded by a region essential for spermatogenesis and expression of male specific minor Histocompatibility antigens. Human Molecular Genetics 3: 873–878, 1994.
21. J. M. M. den Haan, J. Pool, N. Sherman, E. Blokland, R. Bontrop, V. H. Engelhard, D. F. Hunt and E. Goulmy. Minor Histocompatibility antigens are conserved between human and non-human primates. Manuscript submitted for publication.
22. J. M. M. den Haan, N. E. Sherman, E. Blokland, E. Huczko, F. Koning, J-W. Drijfhout, J. Skipper, J. Shabanowitz, D. F. Hunt, V. H. Engelhard, E. Goulmy. Identification of graft versus host disease-associated human minor Histocompatibility antigen. Science 268: 1476–1480, 1995.
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38. D. M. Scott et al, unpublished results.
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41. M. de Bueger, A. Bakker, E. Goulmy, Existence of mature human CD4 + T cells with genuine class I restriction, Eur. J. Immunol. 1992, 22: 875–878.
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The present invention relates to a peptide which is immunologically recognizable as a T cell epitope of the minor Histocompatibility antigen H-Y. The peptide comprises amino acid sequence SPSVDKARAEL (SEQ ID NO: 1) or FIDSYICQV (SEQ ID NO: 2). The peptide is obtainable from the minor Histocompatibility antigen H-Y. Providing a toxic moiety to the peptide eliminates T cells having specific binding affinity for the peptide. The peptide induces tolerance for transplantations when administered to H-Y-negative recipients.
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TECHNICAL FIELD OF THE INVENTION
The present invention is directed to a dryer having a wrinkle out cycle for removing wrinkles from fabrics.
BACKGROUND OF THE INVENTION
Electromechanical dryers, such as clothes dryers, typically control the length of a drying cycle using one of two types of control, timer only control and automatic timer/temperature control. The timer only control executes a time controlled cycle that is controlled exclusively by a timer. Prior to starting the drying operation of a dryer implementing timer only control, the user selects a particular time controlled cycle, and the user sets a drying time for that selected time controlled cycle. The user then starts the dryer which runs for the selected amount of time. As the dryer runs, the articles to be dried are continuously tumbled, air is drawn into the dryer, the heater of the dryer is energized to heat the air which is then supplied to the articles to be dried, the heated air picks up moisture from the articles to be dried, and the moisture laden air is then exhausted from the dryer. The heater is controlled by a thermostat that monitors the temperature of the exhaust air. When the thermostat reaches its switching temperature, it opens in order to de-energize the heater. When the temperature of the exhaust air drops sufficiently to cause the thermostat to close, the heater is re-energized. Meanwhile, the timer continuously advances from its original selected timed setting to its heater off position whereat the functioning of the heater is terminated, and the timer advances through a predetermined end of cycle cool down time period of approximately five minutes. At the end of this cool down time period, the operation of the dryer ends.
The automatic timer/temperature control executes a cycle whose length is controlled by both the timer and a temperature sensor of the dryer. The user selects this automatic controlled cycle and starts the dryer. As the dryer runs, the articles to be dried are continuously tumbled, air is drawn into the dryer as before, the heater of the dryer is energized to heat the air which is then supplied to the articles to be dried, the heated air picks up moisture from the articles to be dried, and the moisture laden air is exhausted from the dryer. The heater is controlled by the temperature sensor that monitors the temperature of the exhaust air. However, unlike timer only control, the dryer's timer does not advance while the heater is energized. When the temperature sensor reaches a predetermined temperature, it causes the heater to be de-energized. The timer then advances while the heater is de-energized. When the temperature of the exhaust air drops sufficiently, the heater is re-energized, and the timer stops advancing. This process is repeated until the timer advances to its heater off position whereat the functioning of the heater is terminated, and the timer advances through a predetermined end of cycle cool down time period of approximately five minutes. At the end of this cool down time period, the operation of the dryer ends.
It is also known to use a moisture sensor in order to override the temperature sensor when the moisture sensor is satisfied. Accordingly, the moisture sensor locks out the heater when the moisture sensor is satisfied, and the timer is allowed to time out any remaining time.
Dryers have also included wrinkle out cycles during which articles are continuously tumbled, air is drawn into the dryer, and the heater of the dryer is controlled in response to a temperature sensor to heat the air which is then supplied to the articles in order to release any wrinkles therein. Wrinkle out cycles, however, have heretofore been exclusively time controlled cycles and, thus, have a fixed duration which is typically about fifteen minutes. The problem with a fixed duration wrinkle out cycle is that the amount of time required to heat a load to the proper temperature at which wrinkles are relaxed is dependent upon the size of the load. Larger loads require more time, and smaller loads require less time. Therefore, if the fixed duration of a wrinkle-out cycle is set for smaller loads, the wrinkles of larger loads may not be properly released. On the other hand, if the fixed duration of a wrinkle-out cycle is set for larger loads, too much time is expended on smaller loads, which wastes energy.
The present invention is directed to a dryer having a wrinkle out control which solves one or more of the above noted problems.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, a dryer having first and second automatic cycles comprises a heater, a timer, a temperature sensor, and a circuit. The first automatic cycle is an automatic wrinkle release cycle. The circuit includes the heater, the timer, and the temperature sensor. The circuit is arranged to energize the heater during each of the first and second automatic cycles in response to the temperature sensor, to energize the timer during periods of each of the first and second automatic cycles when the heater is not energized, and to de-energize the timer during periods of each of the first and second automatic cycles when the heater is energized.
According to another aspect of the present invention, a dryer comprises a heater, a timer, a temperature sensor, and a circuit. The circuit includes the heater, the timer, and the temperature sensor. The circuit is responsive to the temperature sensor to alternately energize the heater and the timer during first portions of first and second cycles and to continuously energize the timer during second portions of the first and second cycles. The first cycle is an automatic wrinkle release cycle.
According to yet another aspect of the present invention, a dryer has a circuit which includes a heater and a timer. The circuit is arranged to respond to load in order to alternately energize the heater and the timer during at least a portion of an automatic permanent press cycle, the circuit is arranged to respond to load in order to alternately energize the heater and the timer during at least a portion of an automatic regular cycle, the circuit is arranged to respond to load in order to alternately energize the heater and the timer during at least a portion of an automatic wrinkle release cycle, and the circuit is arranged to continuously energize the timer and to respond to load in order to periodically energize the heater during a time dry cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more apparent from a detailed consideration of the invention when taken in conjunction with the drawings in which:
FIG. 1 is an isometric view of a dryer which incorporates the wrinkle out cycle according to the present invention;
FIG. 2 shows a timer dial which is on the dryer of FIG. 1 and which includes a wrinkle out cycle;
FIG. 3 illustrates cam profiles for a cam stack which is driven by a timer motor of the dryer of FIG. 1 and which provides a wrinkle out cycle; and,
FIG. 4 is a wiring diagram of a dryer control for the dryer of FIG. 1.
DETAILED DESCRIPTION
A dryer 10, such as a clothes dryer, is shown in FIG. 1 and includes a cabinet 12 which houses a drying drum (not shown) into which articles are placed for drying, and which is rotated by a motor so as to tumble the articles to be dried. The cabinet 12 also houses air ducts through which air is drawn into the dryer 10, is passed over the articles to be dried, and is exhausted out of the dryer 10.
A console 14 is suitably attached to the cabinet 12 and supports various buttons, dials, and the like which control the operation of the dryer 10. For example, a timer dial/knob 16, which is supported by the console 14, may be manually operated in order to control the position of a cam stack which is also driven by a timer motor and which controls various operations of the dryer 10. The timer dial/knob 16 has an out position and a pushed in position with respect to the console 14. When the timer dial/knob 16 is pushed in, a start switch is closed in order to start operation of the dryer 10.
In addition to the timer dial/knob 16, a tumble switch 18 may be manually operated by a user if extended tumble of the articles in the dryer 10 is desired. During an extended tumble cycle, the drum within the cabinet 12 of the dryer 10 periodically rotates in order to tumble the articles contained therein. A loudness selector 20 may be included on the console 14 in order to select the loudness of an audible signal. This audible signal is controlled by the cam stack, which is mechanically attached to the timer dial/knob 16 and to the timer, and alerts the user that the dryer 10 has completed a cycle of operation. A fabric selector dial 22 is also included on the console 14 and controls a plurality of switches corresponding to types of fabrics that may be dried by the dryer 10. The cabinet 12 also includes a door 24 which may be opened to permit access to the drum of the dryer 10 into which articles may be inserted for drying.
The timer dial/knob 16 is shown in more detail in FIG. 2. As indicated by the timer dial/knob 16, a user of the dryer 10 may select from among a plurality of cycles by rotating the timer dial/knob 16 with respect to a mark 26 (FIG. 1) on the console 14. These cycles include an automatic regular/delicate cycle, a time dry cycle, an automatic wrinkle out cycle, and an automatic permanent press/knit cycle.
The automatic regular/delicate cycle, whose length of time is determined by both the dryer's timer and the dryer's temperature sensor and which may be used for regular and delicate fabrics, includes a drying portion and a cool down portion. As indicated in FIG. 2, the user may set the dryer's timer to a selected more dry or less dry position by rotating the timer dial/knob 16 so that the selected position is opposite the mark 26 on the console 14. The dryer's timer then advances down from this setting, and the advance of the dryer's timer is interrupted each time the dryer's heater is energized.
The time dry cycle, whose length of time is determined by the dryer's timer and not by the dryer's temperature sensor, includes a drying portion and a cool down portion. The user may set the dryer's timer to a selected number of minutes by rotating the timer dial/knob 16 so that the selected number of minutes is opposite the mark 26 on the console 14. The dryer's timer then advances down from this setting and is not interrupted when the dryer's heater is energized.
The automatic wrinkle out cycle, as will be discussed in more detail hereinafter, has a length of time that is determined by both the dryer's timer and the dryer's temperature sensor, and may be used to release wrinkles in fabrics. The automatic wrinkle out cycle includes a drying portion and a cool down portion. The user may rotate the timer dial/knob 16 to the drying portion of the wrinkle out cycle. The dryer's timer is preset to a minimum amount of time for the wrinkle out cycle. However, this preset minimum amount of time is extendable by the dryer's temperature sensor. That is, the dryer's timer advances down from this preset minimum amount of time but is interrupted each time the dryer's heater is energized.
The automatic permanent press/knit cycle, whose length of time is determined by both the dryer's timer and the dryer's temperature sensor and which may be used for permanent press and knit fabrics, includes a drying portion and a cool down portion. The user may set the dryer's timer to a more dry or less dry position by rotating the timer dial/knob 16 so that the selected position is opposite the mark 26 on the console 14. The dryer's timer then advances down from this setting and is interrupted each time the dryer's heater is energized.
Two extended tumble cycles, one following the automatic regular/delicate cycle and one following the automatic permanent press/knit cycle, may also be provided.
The timer dial/knob 16 is mechanically attached to a cam stack 28 (FIG. 3). The cam stack 28 is housed in the console 14 and is represented by corresponding first, second, third, and fourth cam profiles 30, 32, 34, and 36 which are shown in FIG. 3. The cams of the cam stack 28 corresponding to the first, second, third, and fourth cam profiles 30, 32, 34, and 36 operate corresponding first, second, third, and fourth timer switches 30', 32', 34', and 36' (FIG. 4). Accordingly, the first timer switch 30' is controlled by a cam represented by the first cam profile 30, the second timer switch 32' is controlled by a cam represented by the second cam profile 32, the third timer switch 34' is controlled by a cam represented by the third cam profile 34, and the fourth timer switch 36' is controlled by a cam represented by the fourth cam profile 36. When a cam profile is high, its corresponding switch is closed. Similarly, when a cam profile is low, its corresponding switch is opened. The timer dial/knob 16 and the cam stack 28 are both driven by a timer 38 (FIG. 4).
The first, second, third, and fourth timer switches 30', 32', 34', and 36' control the elements of the dryer 10 as discussed below in connection with FIG. 4. That is, the first timer switch 30' is essentially a timer control switch, the second timer switch 32' is essentially a heater control switch, the third timer switch 34' is essentially a motor control switch, and the fourth timer switch 36' is essentially a signalling control switch.
As shown in FIG. 4, the first timer switch 30' is connected in series with the timer 38. Accordingly, the timer 38 is directly controlled by the first timer switch 30'. The second timer switch 32' is connected to a fabric selector switch 40. The fabric selector switch 40 has first, second, and third fabric selector switches 42, 44, and 46 which are in series with the second timer switch 32'. The first fabric selector switch 42 controls the timer 38. The second fabric selector switch 44, in connection with a temperature sensor 48, controls a heater 50 and the timer 38. The third fabric selector switch 46 controls a thermostat heater 52. When the third fabric selector switch 46 is closed, the thermostat heater 52 is operated in order to add additional heat to a temperature sensing element 54 of the temperature sensor 48 which causes the temperature sensor 48 to be satisfied earlier than would otherwise be the case. Accordingly, the impact of the heater 50 may be reduced for delicate fabrics.
The fabric selector dial 22 determines which of the first, second, and third fabric selector switches 42, 44, and/or 46 are closed. For example, the fabric selector dial 22 may be moved to a fluff position in which the first fabric selector switch 42 is closed, the fabric selector dial 22 may be moved to a regular/permanent press position in which the second fabric selector switch 44 is closed, and the fabric selector dial 22 may be moved to a delicate position in which the second and third fabric selector switches 44 and 46 are closed. The fabric selector dial 22 is arranged with respect to the first, second, and third fabric selector switches 42, 44, and 46 so that at least one of the first, second, and third fabric selector switches 42, 44, and 46 is closed regardless of the position of the fabric selector dial 22. If the fabric selector dial 22 is set to the fluff position so that only the first fabric selector switch 42 is closed, the heater 50 cannot be operated. Therefore, if fabrics are to be fluffed, the drum of the dryer 10 is rotated, and air is supplied to the articles, but the heater 50 is not energized.
The temperature sensor 48 has the temperature sensing element 54 and a switch 56 controlled by the temperature sensing element 54. The switch 56 has a first position (between contacts one and two) and a second position (between contacts one and three). When the switch 56 is in its first position, the timer 38 is energized through the second timer switch 32', the second fabric selector switch 44, and the switch 56. When the switch 56 is in its second position, the heater 50 is energized through the second timer switch 32', the second fabric selector switch 44, the switch 56, a temperature limit switch 58, and a first motor switch 60 of a motor 62. The temperature limit switch 58 is provided in order to de-energize the heater 50 if the temperature inside the dryer 10 exceeds a predetermined limit.
The motor 62, which is essentially controlled by the third timer switch 34', turns the drum of the dryer 10 and also causes air to be circulated into the drum of the dryer 10 and exhausted out of the dryer 10. The motor 62 has a second motor switch 64, a start motor winding 66 which is energized to start operation of the motor 62, and a main motor winding 68 which is energized to run the motor 62. A push-to-start switch 70 is operated by the timer dial/knob 16 when the timer dial/knob 16 is pushed in by the user at the beginning of a dryer operation. A signalling device 72 is controlled by the fourth timer switch 36'. The signalling device 72 may include a repetitive make and break switch in order to periodically provide an audible signal at the end of a cycle. The loudness selector 20 is suitably connected to the signalling device 72 so as to control the loudness of the signal provided by the signalling device 72.
After the user loads the dryer 10 with articles to be dried by the automatic regular/delicate cycle, the user turns the fabric selector dial 22 to its regular/permanent press position which causes the second fabric selector switch 44 to close. The user also turns the timer dial/knob 16 until a desired time on the timer dial/knob 16 within the automatic regular/delicate cycle is opposite the mark 26. The user then pushes in the timer dial/knob 16. When the timer dial/knob 16 is rotated to the automatic regular/delicate cycle, the second timer switch 32' and the third timer switch 34' are closed as indicated by the second and third cam profiles 32 and 34 of FIG. 3. Also, when the user pushes in the timer dial/knob 16, the push-to-start switch 70 closes.
When the push-to-start-switch 70 closes, the start motor winding 66 is energized through a door switch 74, the third timer switch 34', the push-to-start switch 70, and the second motor switch 64. The door switch 74 closes against its normally open contact when the door 24 of the dryer 10 is closed by the user. Energization of the motor start winding 66 causes the first motor switch 60 to close and the second motor switch 64 to operate to its other position so that a main motor winding 68 of the motor 62 is now energized through the door switch 74 and the third timer switch 34'. The drum of the dryer 10 starts turning, and air is circulated through the rotating drum of the dryer 10.
Also, the heater 50 is now energized through the second timer switch 32', the second fabric selector switch 44, and the first motor switch 60 of the motor 62. The heater 50 heats the air circulated through the rotating drum of the dryer 10 by the motor 62. When the temperature of this air at the exhaust of the dryer 10 reaches a predetermined temperature, the temperature sensor 48 opens the circuit to the heater 50 and closes the circuit to the timer 38. The timer 38 turns the cam stack 28. When the temperature of the exhaust air falls sufficiently, the temperature sensor 48 closes the circuit to the heater 50 and opens the circuit to the timer 38. The timer 38 stops turning the cam stack 28. This process repeats until the cam stack 28 closes the first timer switch 30' as indicated by the cam profile 30 of FIG. 3.
Thereafter, the timer 38 continuously turns the cam stack 28 until the end of the automatic regular/delicate cycle. However, the temperature sensor 48 continues to control the heater 50 until the cam stack 28 opens the second timer switch 32' as indicated by the cam profile 32 of FIG. 3, after which the heater 50 is de-energized during a cool down period. Near the end of the cool down period, the cam stack 28 closes the fourth timer switch 36' as indicated by the cam profile 36 of FIG. 3 for a predetermined amount of time in order to energize the signalling device 72 to signal the end of the cycle.
If the user turns the timer dial/knob 16 until a desired time of the time dry cycle on the timer dial/knob 16 is opposite the mark 26 and pushes in the timer dial/knob 16, the first timer switch 30', the second timer switch 32', and the third timer switch 34' are closed as indicated by the first, second, and third cam profiles 30, 32, and 34 of FIG. 3, and the push-to-start switch 70 closes. When the push-to-start-switch 70 closes, the start motor winding 66 is energized through the door switch 74, the third timer switch 34', the push-to-start switch 70, and the second motor switch 64. Energization of the motor start winding 66 causes the first motor switch 60 to close and the second motor switch 64 to operate to its other position so that the main motor winding 68 of the motor 62 is now energized through the door switch 74 and the third timer switch 341. The drum of the dryer 10 starts turning, and air is circulated through the rotating drum of the dryer 10.
Because the first timer switch 30' is closed throughout the time dry cycle as indicated by the first cam profile 30 of FIG. 3, the timer 38 turns the cam stack 28 continuously throughout this cycle. Also, the heater 50 is cycled by the temperature sensor 48 in order to periodically heat the air circulated through the drum of the dryer 10. Near the end of the length of time selected by the user, the cam stack 28 opens the second timer switch 32' as indicated by the cam profile 32 of FIG. 3, after which the heater 50 is de-energized during a cool down period. Near the end of the cool down period, the cam stack 28 closes the fourth timer switch 36' as indicated by the cam profile 36 of FIG. 3 for a predetermined amount of time in order to energize the signalling device 72 to signal the end of the cycle.
If the user turns the timer dial/knob 16 to the wrinkle out cycle and pushes in the timer dial/knob 16, the second timer switch 32' and the third timer switch 34' are closed as indicated by the second and third cam profiles 32 and 34 of FIG. 3, and the push-to-start switch 70 closes. When the push-to-start-switch 70 closes, the start motor winding 66 is energized through the door switch 74, the third timer switch 34', the push-to-start switch 70, and the second motor switch 64. Energization of the motor start winding 66 causes the first motor switch 60 to close and the second motor switch 64 to operate to its other position so that a main motor winding 68 of the motor 62 is now energized through the door switch 74 and the third timer switch 34'. The drum of the dryer 10 starts turning, and air is circulated through the rotating drum of the dryer 10.
Also, the heater 50 is now energized through the first motor switch 60 of the motor 62, the second timer switch 32', and the second fabric selector switch 44. The heater 50 heats the air circulated through the rotating drum of the dryer 10 by the motor 62. When the temperature of this air at the exhaust of the dryer 10 reaches a predetermined temperature, the temperature sensor 48 opens the circuit to the heater 50 and closes the circuit to the timer 38. The timer 38 turns the cam stack 28. When the temperature of the exhaust air falls sufficiently, the temperature sensor 48 closes the circuit to the heater 50 and opens the circuit to the timer 38. The timer 38 stops turning the cam stack 28. This process repeats until the cam stack 28 closes the first timer switch 30' as indicated by the cam profile 30 of FIG. 3.
Thereafter, the timer 38 continuously turns the cam stack 28 until the end of the wrinkle out cycle. However, the temperature sensor 48 continues to control the heater 50 until the cam stack 28 opens the second timer switch 32' as indicated by the cam profile 32 of FIG. 3, after which the heater 50 is de-energized during a cool down period. Near the end of the cool down period, the cam stack 28 closes the fourth timer switch 36' as indicated by the cam profile 36 of FIG. 3 for a predetermined amount of time in order to energize the signalling device 72 to signal the end of the cycle.
If the user turns the timer dial/knob 16 to the automatic permanent press/knit cycle and pushes in the timer dial/knob 16, the second timer switch 321 and the third timer switch 34' are closed as indicated by the second and third cam profiles 32 and 34 of FIG. 3, and the push-to-start switch 70 closes. When the push-to-start-switch 70 closes, the start motor winding 66 is energized through the door switch 74, the third timer switch 34', the push-to-start switch 70, and the second motor switch 64. Energization of the motor start winding 66 causes the first motor switch 60 to close and the second motor switch 64 to operate to its other position so that a main motor winding 68 of the motor 62 is now energized through the door switch 74 and the third timer switch 34'. The drum of the dryer 10 starts turning, and air is circulated through the rotating drum of the dryer 10.
Also, the heater 50 is now energized through the first motor switch 60 of the motor 62, the second timer switch 32', and the second fabric selector switch 44. The heater 50 heats the air circulated through the rotating drum of the dryer 10 by the motor 62. When the temperature of this air at the exhaust of the dryer 10 reaches a predetermined temperature, the temperature sensor 48 opens the circuit to the heater 50 and closes the circuit to the timer 38. The timer 38 turns the cam stack 28. When the temperature of the exhaust air falls sufficiently, the temperature sensor 48 closes the circuit to the heater 50 and opens the circuit to the timer 38. The timer 38 stops turning the cam stack 28. This process repeats until the cam stack 28 closes the first timer switch 30' as indicated by the cam profile 30 of FIG. 3.
Thereafter, the timer 38 continuously turns the cam stack 28 until the end of the automatic permanent press/knit cycle. However, the temperature sensor 48 continues to control the heater 50 until the cam stack 28 opens the second timer switch 32' as indicated by the cam profile 32 of FIG. 3, after which the heater 50 is de-energized during a cool down period. Near the end of the cool down period, the cam stack 28 closes the fourth timer switch 36' as indicated by the cam profile 36 of FIG. 3 for a predetermined amount of time in order to energize the signalling device 72 to signal the end of the cycle.
Certain modifications of the present invention have been discussed above. Other modifications will occur to those practicing in the art of the present invention. For example, as described above, the mechanical timers and/or switches disclosed herein may instead be electronic timers and/or switches. The motor 62 may be configured other than shown in FIG. 4. Also, the cam profiles 30, 32, 34, and 36 shown in FIG. 3 are illustrative only and are not intended to exactly define the timing relationships between, and within, the various operations of the dryer 10.
Accordingly, the description of the present invention is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which are within the scope of the appended claims is reserved.
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In a wrinkle release arrangement for a dryer, a heater heats articles to be wrinkle released, and a timer times the heating of the articles. The timer establishes a wrinkle out cycle. A temperature sensor senses a temperature related to a temperature of the articles. A control circuit substantially alternately energizes the heater and the timer in response to the temperature sensor in order to provide automatic wrinkle release responsive to load.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to smoke and heat barrier structure as used in building construction and, more particularly, but not by way of limitation, it relates to improved fire barrier structure and its utilization with expansion joint assemblies.
2. Description of the Prior Art
The prior art includes various forms of expansion joints and insulative barriers of the type that provides normal thermal insulation, i.e. outside weather conditions versus protected inner heat conditions and the like. No prior patent has been found that is specifically directed to heat resistive materials for use as a high intensity heat and smoke barrier under extreme fire and smoke conditions. U.S. Pat. No. 3,300,913 in the name of Patry is representative of a general form of expansion cover that includes an inner insulating foam that is further contained by an outer elastic strip. U.S. Pat. No. 4,055,925 teaches an expansion joint that is made up of a three-layer structure which includes a layer of woven wire cloth impregnated or coated with asphalt substance at specified points. These types of barrier do not exhibit high intensity heat resistance.
SUMMARY OF THE INVENTION
The present invention relates to an improved construction of a fire barrier that is used in conjunction with structural expansion joint assemblies. The barrier consists of a combination of insulative fabric substances as sealingly disposed to partition or isolate a potential fire and smoke zone. Thus, such barrier structure may be used to seal off an expansion void thereby to coontain a volume of heat and smoke and retard spreading throughout the building structure. More particularly, the fire barrier of the present invention utilizes a primary sheet of a ceramic wool fabric in combination with a closely retained layer of refractory cloth material on one or both sides of the ceramic wool fabric. Further, additional and more loosely draped layers of refractory cloth can be utilized to define dead air spaces as dictated by design criteria.
Therefore, it is an object of the present invention to provide a general purpose, fire-rated heat and smoke barrier structure which may be readily secured to isolate adjoining spaces.
It is further an object of the present invention to provide a fire barrier that is relatively inexpensive yet effective to extremely high heat intensities.
It is still further an object of this invention to provide a smoke and heat barrier that is flexible in design versatility and allows compounding of structure in accordance with the exigencies of the particular design application.
It is also an object of the invention to provide a fire barrier that is readily secured across curtain wall gaps, penetration stops, or shaft stopping between buildings where joint covers cannot be located.
Finally, it is an object of the present invention to provide a relatively simple but reliable smoke and heat barrier which is readily installed in conjunction with various types of building expansion joint assemblies.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in section of a typical form of floor expansion joint assembly in combination with a smoke and heat barrier constructed in accordance with the present invention;
FIG. 2 is a partial sectional view of fire barrier material layers as utilized in FIG. 1; and
FIG. 3 is a view in section of another form of wall expansion joint assembly utilizing smoke and heat barriers as constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a smoke and heat barrier 10 is disposed in sealing and insolating affixture within an expansion space or void designated generally by 12 as bridged by an expansion joint assembly 14. Expansion joint assemblies may be used variously in abridgment of walls, floors, ceilings, external openings and the like, assembly 14 being a floor-type joint. The barrier 10 is disposed to isolate and prevent passage of heat and smoke through the expansion void 12 as from interior expansion space 16 through to expansion space 12 and outward therefrom.
The expansion joint assembly 14 is depicted as bridging between cementitious floor panels 18 and 20 as opposite angle brackets 22 and 24 are secured on opposite sides of expansion void 12 by means of a series of concrete anchor fasteners 26 and 28 respectively. The outer surface adjacent expansion joint assembly 14 is then dressed with such as grout surfaces 30 and 32 therealong.
The expansion joint assembly 14 further consists of opposed guide members 34 and 36 defining respective tube ways 38 and 40 as secured by suitable fasteners to opposite angle brackets 32 and 24. An expansion joint cover plate 42 then covers over the expansion void as opposite sides of cover plate 42 are slidably engaged with the top surfaces 44 and 46 of respective guide members 34 and 36, and the cover plate 42 is maintained in centered relationship by means of pivotally attached guidebar 48 as the opposite end plastic slide balls 50 and 52 move within the respective tube ways 38 and 40. A plurality of such centering bars 48 are located in spaced arrangement along the length of cover plate 42.
In order to provide smoke and heat isolation through the expansion void 12, i.e. from inner expansion space 16 to the void space 12 and outward, the barrier 10 is disposed in loose, relatively draped positioning with opposite sides 54 and 56 sealingly seized between the base plates of opposite angle brackets 22 and 24 and respective shoulder plates 58 and 60 are secured in shoulder facing to panels 18 and 20. The masonry fasteners 26 and 28 maintain all components in rigid sealed engagement. The barrier 10 may be variously constituted of a heavier sheet of ceramic wool or felt 62 as applied with one or more of an inner refractory cloth sheet 64 and an outer refractory cloth sheet 66. Still further, one or more loosely draped sheets of refractory cloth 68 may also be included as it defines a further dead air space 70 within the refractory cloth sheeting.
FIG. 2 represents in section a portion of the barrier that includes an interior ceramic felt sheet 62 sandwiched between refractory cloth sheets 64a and 66a. The ceramic felt sheet 62 is a mat of silicon dioxide and Alumina-Silica ceramic fibers of relatively tight, matted composition having a melting point of about 3100° F. Such ceramic wool or felt material is commercially available from the Carborundum Company, Niagria Falls, N.Y. The outer refractory cloth sheets 64a and 66a may be stitched or bonded using suitable bonding agents to the opposite sides of ceramic felt 62; however, in most applications this would not be necessary since either the weight of gravity or the lay of the fabric will usually maintain the sheets in proper contiguous positioning relative to one another. This is not critical, and as in the case of the spaced refractory cloth sheet 68 defining dead air space 70, the spacing may be specifically effected.
The refractory cloth sheets 64a, 66a, 68 and the like, may be such as silica fiber cloth or alumina silica cloth or other heat resistive fibers from the general class. In a preferred form, the refractory cloth is a high purity silica fiber cloth, that is pre-shrunk as formed from white, vitreous fibers having up to 99% silicon dixode content. Such stock is available in bulk fiber, yarn, etc. but is utilized in the present invention in continuous cloth lengths as sold under the name "REFRASIL", commercially available from Hitco Corporation of Gardena, Calif. Still to be preferred is to impregnate the refractory cloth or silica fiber cloth thoroughly with a self-extinguishing silicone rubber to provide a water resistant coating with still greater barrier efficiency. The silicon rubber impregnated silica fiber cloth is commercially available under the name "METAFLEX" from Metalines, Inc. of Oklahoma City, Okla. The silica fiber cloth has a melting point at about 3100° F. and the impregnating and coating silicone rubber has a melting point upwards of 500° F. with residual cloth sealing properties extending to much higher temperatures. Thus, the Metaflex material provides a flexible yet smoke impervious barrier material that is non-flammable to temperatures far exceeding 500° F.
FIG. 3 illustrates the use of oppositely disposed heat barriers 10 as employed in a wall panel expansion joint with respective opposite wall panel expansion joint assemblies 72 and 74. Thus, the expansion joint void 76 is formed between butt ends of respective adjoining wall panels 78 and 80. The panel 78 consists of one or more opposite panels of gypsum wallboard of the like 82 and 84 are connected by a stud bracket 86 secured by such as screw fasteners 88 and 90. Similarly, adjoining panel 80 is formed by opposite panels 92 and 94 joined by stud bracket 96 as secured by screw fasteners 98 and 100. Expansion joint assembly 72 consists of a cover plate 102 secured along one side by means of screw fastener 88 through a U-shaped channel 104 which tightly engages one side of a barrier member 10 in sealing affixure to the panel 82. The opposite side of the barrier is sealingly secured by a channel 106 secured by fastener 98 as cover plate 102 is slidingly contacting the channel 106. In like manner, the opposite expansion joint assembly 74 consists of the sliding cover plate 108 in contact with channel 110 as the opposite side of cover plate 108 is secured by means of fastener 90 through channel 112.
The opposed barriers 10 consist of the ceramic felt interior portion 62 sandwiched between opposite side refractory cloth sheetings 64 and 66, and sufficient slack material is provided to allow for maximum expansion separation of the adjoining wall panels 78 and 80. In addition, still other combinations of refractory sheet material and/or multiple wallboard layers at various spacings may be utilized to provide particular dead air space configurations within the expansion void space.
The foregoing discloses a novel arrangement of temperature resistive fabrics and woven material as may be utilized for isolating heat and smoke as between interior spaces utilizing expansion joints. The barrier structure provides a relatively inexpensive yet easily applied and long-lasting fire barrier that serves to limit heat and smoke effects up to considerably high temperature levels. The present invention provides yet another degree of security as regards heat and smoke transmission through building walls and surfaces that require expansion spacing.
Changes may be made in combination with arrangement of elements as heretofor set forth in this specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.
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A heat insulative barrier for use in isolating potential fire zones relative to expansion joint voids which comprises the use of a sealed sheet of ceramic felt material secured across an expansion void and including one or more refractory cloth sheets sealingly secured contiguous to the ceramic felt sheet on one or both sides thereof and adjacent to the potential fire zone.
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BACKGROUND OF THE INVENTION
The present invention relates to supervising systems for use in performing piping work in semiconductor manufacturing plants, etc.
Machines for performing piping work, such as welding of pipes and tightening of pipe joints, under predetermined conditions, i.e., automatic welders, automatic tightening machines and like machines are conventionally used, for example, in semiconductor manufacturing plants. The piping work is performed at the actual site and completed at the site, and nothing whatever is known about a method of superposing the piping work including accumulation of data.
The gastightness of the piping system is of extreme importance in semiconductor manufacturing plants wherein hazardous gases are used; a fault in the piping work could lead to an accident. However, after the piping work has been completed, no record is conventionally left as to what particular conditions are employed for the piping work of particular portions of the piping system, consequently entailing the problem that it impossible to realize whether the piping work has been executed properly.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a piping work supervising system which is capable of precluding accidents in piping due to faulty piping work.
The present invention provides a system for supervising piping work comprising a machine for performing piping work such as welding of pipes or tightening of pipe joints under predetermined conditions, check means for checking whether the piping work has been executed properly based on predetermined values of piping work conditions and actual piping work data, a computer for accumulating the predetermined values of piping work conditions, the actual piping work data and the result of checking, and communication means for transmitting the predetermined values of piping work conditions, the actual piping work data and the result of checking.
The supervising system of the invention checks whether the piping work has been executed properly, and accumulates the predetermined values of piping work conditions, the actual piping work data and the result of checking. This precludes accidents in the piping due to faults in the piping work, further making it possible to pick up the main portions to be checked from among the portions of the piping worked on with reference to the actual piping work data when the piping is to be inspected, and to inspect the main portions only which are smaller in number than all the worked-on portions.
Preferably, the communication means is on a spread-spectrum communication system. This system is such that the signal, subjected to usual phase modulation, is then multiplied by a special spreading code at the transmitter side, and multiplied by the same spreading signal at the receiver side to retrieve the original signal. With this system, the signal is spread over a wider frequency range and therefore lower in electric power density, i.e., in electric power per unit frequency. Accordingly, the system has the advantage of being less affected by the noise of the work site.
The piping work chiefly includes welding of pipes and tightening of pipe joints.
Preferably, a piping work supervising system for use in welding pipes comprises an automatic welder for welding the pipe, a welding data output device for outputting predetermined values of welding conditions for the welder and actual welding data, a welding data processor for checking whether output values from the output device are proper and temporarily accumulating the welding data and the result of checking, and a host computer connected to the processor by a local area network (LAN) for accumulating the welding data and the result of checking. This system ensures a proper welding operation, consequently precluding accidents in the piping due to faulty welding. Furthermore, reference to the welding data and the result of checking accumulated in the host computer leads to facilitated supervision for the maintenance of the welded portions.
Preferably, a piping work supervising system for use in tightening up pipe joints comprises a machine for automatically tightening up the pipe joint, a tightening data processor provided in the tightening machine for checking whether tightening data is proper and accumulating predetermined values of tightening conditions, actual tightening data and the result of checking, and a host computer connected to the processor by a local area network (LAN) for accumulating the tightening data and the result of checking. This system ensures a proper tightening operation, consequently precluding accidents in the piping due to faulty tightening. Furthermore, reference to the tightening data and the result of checking accumulated in the host computer leads to facilitated supervision for the maintenance of the pipe joints.
It is desired that the host computer be connected to a plurality of terminal computers by a network. Any of the terminal computers then allows the work supervisor access to the welding or tightening record, while the supervisor can issue a command from the terminal computer to the data processor via the host computer when the work is to be interrupted or the work conditions are to be altered. Thus, the networked system enables the supervisor to recognize reliable execution of the welding or tightening operation at a location remote from the work site.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a first embodiment of piping work supervising system of the invention, i.e., a welding system;
FIG. 2 is a time chart showing the welding conditions for a welder for use in the welding system;
FIG. 3 is a block diagram showing a modification of the welding system;
FIG. 4 is a flow chart showing the main routine of checking portion of the welding system;
FIG. 5 is a block diagram showing another embodiment of piping work supervising system of the invention, i.e., a pipe joint tightening system;
FIG. 6 is a perspective view schematically showing the appearance of a tightening machine for use in the tightening system;
FIG. 7 is a block diagram schematically showing a checking assembly of the tightening machine;
FIG. 8 is a graph showing the tightening conditions to be checked for the tightening machine for use in the tightening system; and
FIG. 9 is a flow chart showing the main routine of the checking assembly of the tightening system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a block diagram showing a piping work supervising system of the invention for use as a pipe welding system. With reference to the drawing, the piping work supervising system for a pipe welding operation comprises an automatic welder 1 for piping, a welding data output device 2 for delivering predetermined values of welding conditions for the welder 1 and actual welding data, a welding data processor 3 for checking whether or not output values from the output unit 2 are proper and accumulating the welding data and the result of checking, and a host computer 4.
The welder 1 is a known one (for example, MODEL 207 of Arc Machine Co.). The welder is set on a pipe at the joint portion thereof to be welded, and the switch is then turned on, whereupon the welder revolves around the pipe one turn to weld the pipe under the predetermined conditions. The welding conditions to be checked for judging whether a proper weld is formed include the welding time, welding current, welding voltage, speed of revolution and pressure of back-shielding gas during welding (pressure during welding). FIG. 2 shows an example of time chart of welding conditions. The welding conditions include a plurality of levels of short duration which are changed over from one to another. The chart shows that the welding current is 35 A for 0.1 second at level 1, 40 A for 0.5 second at level 2, 42 A for 0.5 second at level 3, 40 A for 0.5 second at level 4, 33 A for 0.4 second at level 5, 30 A for 0.3 second at level 6, and 20 A for 0.3 second at level 7, further showing that the speed of revolution is 30 r.p.m. for 2.0 seconds at level 1 through level 5, 26 r.p.m. at level 6 and 15 r.p.m. at level 7.
The welding data output device 2 has a welder power supply incorporated therein, a printer output unit 5 for outputting the predetermined condition values as to the welding time, welding current and speed of revolution for each level as 8-bit parallel data, and a pen recorder output unit 6 for outputting the actual analog values of welding current, welding voltage and speed of revolution during welding.
The welding data processor 3 comprises a parallel/serial converter 7 for converting the predetermined condition values delivered from the output device 2 in the form of 8-bit parallel data to serial data, an A/D converter 8 for converting the actual analog values delivered from the output device 2 to digital data, a check result output unit (I/O unit) 9 for checking whether the welding data is proper and delivering the result, a memory 10 for storing the predetermined values of the welding conditions, the actual welding data and the check result, a wireless LAN transmitter-receiver 11 for transferring data to and from the host computer 4 and a serial interface 12 for delivering welding data to the transmitter-receiver 11.
The host computer 4 is connected to a plurality of terminal computers 13 by a network. The host computer 4 is also provided with a wireless LAN transmitter-receiver 14.
The check result output unit 9 of the welding data processor 3 indicates the check result and actuates an alarm buzzer 15 when the weld is unacceptable.
The memory 10 of the processor 3 temporarily stores data including the welding address, work executor's code, predetermined condition values, welding current, welding voltage, revolution speed, internal pressure during welding, welding date and time and check result. Such data is transmitted to the host computer 4 via the transmitter-receivers 11, 14 and stored in the computer 4.
The wireless LAN transmitter-receivers 11, 14 exchange spread-spectrum wireless communications and can transfer data within the range of up to about 200 m even with use of a feeble current. Other system is of course usable for the transmitter-receivers 11, 14.
A bar code 16 representing a welding address and executor's code is provided for the portion to be welded. These welding address and executor's code are read by a bar code scanner 17 and sent by a bar code reader 18 to the serial interface 12 of the welding data processor 3. The internal pressure of the welder 1 during welding is measured by a pressure sensor 19 and sent to the A/D converter 8 of the processor 3. Instead of providing the bar code 16, the welding address and the executor's code may be input to the processor 3 by the host computer 4.
Since the host computer 4 is connected to the terminal computers 13 by a network, any of the terminal computers 13 allows the work supervisor access to the welding record, while the supervisor can issue a command from the terminal computer 13 to the welding data processor 3 via the host computer 4 when the work is to be discontinued in an emergency or the welding conditions are to be altered. Thus, the networked system enables the supervisor to recognize reliable execution of the welding operation at a location remote from the welding site.
The parallel/serial convertor 7 and the A/D converter 8 of the welding data processor 3, which are intended to conform to the data output mode of the output device 2, can be modified or eliminated in conformity with the data output mode of the device 2. FIG. 3 shows such a modification. Throughout FIGS. 1 and 3 like parts are designated by like reference numerals and will not be described repeatedly.
With reference to FIG. 3, a welding data output device 20 has incorporated therein a power supply for the welder 1. Predetermined condition values as to the welding time, welding current and speed of revolution at each level, and actual values of welding current, welding voltage and speed of revolution during welding are all delivered in the form of digital values through a digital interface 22. In corresponding relation with the device 20, a welding data processor 21 has a digital interface 23 in place of the parallel/serial converter 7 and the A/D converter 8. The digital values are transferred from the output device 20 to the processor 21 by serial and/or parallel signals.
The main routine of the welding data processor 3 will be described next with reference to FIG. 4.
The power supply is turned on (step 1), whereupon the system is initialized (step 2). The start key is then pressed (step 3), whereupon the welding address and executor's code are read from the bar code (step 4). Alternatively, the welding address and the executor's code may be input from the host computer in step 4. The address and the code are compared with the welding address and executer's code stored in the memory (step 5) and checked for a match (step 6). When they do not match the stored data, lack of the corresponding address is displayed on the check result output unit, and the result is output to the host computer, whereupon the sequence returns to step 3 (step 7). If a match is obtained in step 6, the predetermined condition values for each level delivered from the welder are read (step 8), and a welding start signal is output (step 9), whereby a welding operation is started. The actual values of welding current, welding voltage and revolution speed at each level delivered from the welder are read (step 10). These actual values of current, voltage and speed are compared with the respective predetermined condition values read in step 10 (step 11), and checked for matching (step 12). If the read values are found to match the predetermined values, the check result output unit displays "OK" (step 13). If otherwise, the check result output unit shows "BAD" (step 14). Regardless of the check result, the welding address, executor's code, welding date and time, welding data, predetermined welding condition values and check result are fed to the host computer (step 15).
Step 10 through step 15 are repeated for every level of the welding conditions shown in FIG. 2, and an inquiry is made as to whether the welding condition checking for the final level has been completed (step 16). When the inquiry is answered in the affirmative, the sequence returns to step 3. In this way, the welding conditions are checked at every level to ensure a reliable welding operation.
Step 12 also inquires whether the electrode of the welder is to be replaced. If the welder is set at a welding frequency of 50 times until the replacement of the electrode, the number of times the welding operation is conducted following the replacement is automatically counted, and an alarm for the replacement of the electrode is given on completion of the 50th welding operation. This eliminates unacceptable welds due to a fault in the electrode to improve the reliability of welding operation.
FIG. 5 is a block diagram showing a piping work supervising system of the invention for use as a pipe joint tightening system. With reference to the drawing, the piping work supervising system for pipe joint tightening work comprises an automatic tightening machine 24 for piping, a tightening data processor 25 provided for the machine 24, and a host computer 4.
The tightening data processor 25, which is provided in a microcomputer 29 of the tightening machine 24 as will be described later, comprises a controller 26 for checking whether tightening data is proper and outputting the check result, a memory 27 for storing predetermined values of tightening conditions, actual tightening data and check result, and a wireless LAN transmitter-receiver 28.
The host computer 4 is connected to a plurality of terminal computers 13 by a network. The host computer 4 is also provided with a wireless LAN transmitter-receiver 14.
The memory 27 of the tightening data processor 25 temporarily stores the tightening address, executor's code, tightening torque, angle of tightening rotation, tightening date and time, and check result. These items of data are transmitted to the host computer 4 via the wireless LAN transmitter-receivers 28, 14 and stored in the host computer.
The wireless LAN transmitter-receivers 11, 14 exchange spread-spectrum wireless communications and can transfer data within the range of up to about 200 m even with use of a feeble current. Other system is of course usable for the transmitter-receivers 11, 14.
A bar code 16 representing a tightening address and executor's code is provided for the portion to be tightened up. The tightening address and executor's code are read by a bar code scanner 17 and sent by a bar code reader 18 to the tightening data processor 25. Instead of providing the bar code 16, the tightening address and the executor's code may be input to the processor by the host computer 4.
Since the host computer 4 is connected to the terminal computers 13 by a network, any of the terminal computers 13 allows the work supervisor access to the tightening record, while the supervisor can issue a command from the terminal computer 13 to the tightening data processor 25 via the host computer 4 when the work is to be interrupted temporarily or the tightening conditions are to be altered. Thus, the networked system enables the supervisor to recognize reliable execution of the tightening operation at a location remote from the tightening site.
With reference to FIGS. 6 and 7, the tightening machine 24 comprises an upper plate 41 projecting from a body 30, a lower plate 43 disposed under the upper plate 41 in parallel thereto, a nut rotating gear 44 supported by the lower plate 43 so as to be rotatable in a horizontal plane, and a transmission gear 47 disposed inside the body 30 and meshing with the gear 44 for rotating this gear.
The upper plate 41 is provided with a flange holder 42 for fitting therein a flange 35a of an externally threaded member 35 of a pipe joint to prevent the rotation of the member 35. The nut rotating gear 44 is formed with a nut socket 45 for fitting a nut 36 therein.
Provided inside the body 30 are a DC servomotor 46 for rotating the transmission gear 47 by way of a train of gears, the aforementioned microcomputer 29 and a motor driving battery 39. The body 30 is further provided with a start button 31, emergency stop button 32, light-emitting diode 33 and alarm buzzer 34.
The number of revolutions of the transmission gear 47 is counted by a rotational angle sensor 48 and converted to an angle of rotation of the nut. The transmission gear 47 has a shaft 47a, to which a strain gauge is affixed. The amount of strain of the shaft 47a is converted to tightening torque by a tightening torque sensor 49.
The tightening torque detected by the sensor 49 and the angle of rotation detected by the sensor 48 are fed to the microcomputer 29, which checks whether the nut is tightened up properly. The result is output by the light-emitting diode 33 and the alarm buzzer 34. The microcomputer 29 gives the servomotor 46 commands as to the speed of rotation of the nut 36, angle of rotation of the nut 36, change of direction of rotation of the nut 36 and stopping of the nut 36. The battery 39 and the microcomputer 29 are incorporated in the tightening machine, or held to a band 40 as shown in FIG. 6.
FIG. 8 shows the relationship between the angle of rotation of the nut 36 and the tightening torque as established when the nut is tightened up normally or abnormally on the externally threaded member 35 with a wrench. In the normal case, the tightening torque increases in a linear relation (slope (1)) with the angle of rotation of the nut 36 as the nut is tightened through an angle of up to about 80 deg as will be apparent from FIG. 8. The slope alters at an angle of about 80 deg, and the tightening torque thereafter increases in a linear relation (slope (2)) with the angle of rotation of the nut. When the worker forgot to insert a gasket into the pipe joint, the increase in the tightening torque is greater than in the normal case to exhibit a different slope. If the worker forgot to insert both the gasket and thrust bearing, the increase in the tightening torque becomes still greater, showing a slope different from the slope in the absence of the gasket. Accordingly, the tightening torque value relative to the angle of rotation of the nut and the slope of the tightening torque relative to the angle are usable as reference values for checking the tightening. Alternatively, the angle of rotation of the nut can be calculated from the speed of rotation of the motor, and the tightening torque from the current of the motor, so that the speed of rotation of the motor and the current of the motor are usable as tightening conditions for checking whether the nut has been tightened up properly.
The main routine of the tightening data processor 25 will be described with reference to FIG. 9.
When the power supply is turned on (step 1), the system is initialized (step 2), whereupon the start key is pressed (step 3). The tightening address and executor's code are read from the bar code (step 4). Alternatively, the address and the code may be read from the host computer in step 4. The tightening address and the executor's code are compared with the respective tightening address and executor' code stored in the memory (step 5), and checked for a match (step 6). If the read data does not match the stored data, the controller displays "no corresponding tightening address," and feeds the result to the host computer, whereupon the sequence returns to step 3 (step 7). When a match is obtained in step 6, a tightening operation is started (step 8). Before the tightening operation, the nut 36 is manually screwed on the externally threaded member 35, the flange holder 42 of the upper plate 41 is fitted to the flange 35a on the member 35, and the nut 36 is fitted in the nut socket 45 of the nut rotating gear 44. The start button 31 is then pressed. The nut 36 is thereafter automatically tightened up on the externally threaded member 35, and checked as to whether the nut has been tightened up normally to complete the tightening operation (step 9). Regardless of the check result, the tightening address, executor's code, tightening date and time, predetermined values for tightening and check result are output to the host computer (step 10).
Although a proper tightening operation can be assured merely by using the tightening machine 24 which itself has the checking function described, the use of the host computer for accumulating the result of tightening enables the supervisor to preserve and recognize the record of the proper tightening operation conducted by the tightening machine. In addition to the reliable operation of the tightening machine 24 itself, this feature achieves a further improvement in the reliability of the tightening operation.
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A system of the invention for supervising piping work comprises a machine for performing piping work such as welding of pipes or tightening of pipe joints under predetermined conditions, check means for checking whether the piping work has been executed properly based on predetermined values of piping work conditions and actual piping work data, a host computer for accumulating the predetermined values of piping work conditions, the actual piping work data and the result of checking, and communication means for transmitting the predetermined values of piping work conditions, the actual piping work data and the result of checking.
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BACKGROUND
The present invention relates to a transport system for flow line production, especially in the car manufacturing industry, comprising workpieces which are movable along at least two first guides between working stations in transportation direction, at least one working station being configured as a screwing and/or assembling means which particularly comprises a plurality of working tools.
Examples of such workpieces are vehicle components such as engine block, transmission or other vehicle parts that must be worked on before actual installation into the vehicle. Said workpieces are moved along at least two first guides of the transport system between associated working stations. The two first guides can be arranged both horizontally side by side and vertically one below the other. The working stations are separately arranged next to the transport system. Corresponding supply means, separate transportation systems, corresponding installations in the building, or the like are needed for the working stations.
Due to the separate arrangement and configuration of the working stations and the transport systems for the workpieces, the constructional efforts are relatively great on the one hand, which leads to an increased demand for space and also to increased costs. On the other hand, the assignment of working stations and workpiece is made difficult by the separated configuration of working stations and transport system because the transport system for the workpiece and the working stations must be aligned exactly relative to one another to assign working station and workpiece to be worked in a reproducible way relative to one another. This very alignment leads to increased installation efforts, which is also accompanied by additional costs.
It is therefore the object of the present invention to improve a transport system of the above-mentioned type such that with little constructional efforts and at reduced costs the assignment of working station and workpiece to be worked thereby is simplified and made possible in an exact and reproducible manner.
This object is achieved in a transport system where the screwing and/or assembling means is integrated into the transport system and is movable at least over a working path in parallel with the first guides in the transport system.
Thanks to the integration of the working station in the transport system, here above all screwing and/or assembling means, additional and separate guides that are separated from the transport system are not needed. Additional installations, for instance for the supply of power to the working station, are also not needed because the supplies inherent to the transport system can be resorted to in a corresponding way. No longer needed is also a corresponding difficult alignment of the working station relative to the transport system and thus to the workpiece because an alignment is directly carried out on the transport system and not by separate guides, or the like, owing to the integration of the working station in the transport system. The working station is thus movable in a much simplified way with a permanently correct alignment relative to the workpiece.
To prevent a situation where the working station represents a load on the two first guides for the workpiece, the screwing and/or assembling means can be moved along second guides in parallel to the first guides. It is here self-evident that the second guides are integrated into the transport system and are not arranged to be separated therefrom.
The assignment of the first and second guides can be simplified and improved in that the first and second guides are arranged on the same guide stands of the transport system. Depending on the arrangement of the first guides (horizontal, vertical), the second guides are arranged accordingly. When the same guide stands are used, this results, in addition, in a normally reduced number of guide stands because guide stands are not arranged separately for first and second guides in the transport system.
A simple arrangement of the guides with simultaneously simplified orientation of the guides relative to one another can be seen in that the first and second guides are arranged in pairs at opposite sides of the guide stands. The arrangement can be configured again accordingly vertically or horizontally for respectively first and second guides.
To move the working station along the transport system and especially independently of the workpiece in a simple way, first and second guides may each have assigned thereto a drive means for workpiece and screwing and/or assembling means, respectively. The drive means for the screwing and/or assembling means is especially used when after the treatment of the workpiece the working station is returned into its initial position. It is also possible that working station and workpiece are also moved during treatment of the workpiece through a corresponding synchronization of the two drive means.
Electric motors are for instance possible as drive means, the electric motors moving working station and workpiece, respectively, along the corresponding guides by means of corresponding gears, or the like. Such an electric motor may be assigned to each working station and each workpiece, respectively. However, to move a multitude of workpieces by a drive means and also a multitude of working stations by only one drive means, the corresponding drive means may be designed as a rotatable shaft which is acted upon by at least one friction wheel having an adjustable angle of inclination. A friction drive is thereby formed which upon contact of friction wheel and shaft moves workpieces and working stations, respectively, in transportation direction. The speed in the transportation direction can here be varied by changing the angle of inclination of the friction wheel. When such friction wheels are used, it is also possible in a simple way to interrupt the kinetic connection to the drive means by removing the friction wheels from the shaft.
To hold a corresponding workpiece in a simple way and to move it independently of the form and configuration thereof along the transport system, the workpiece may be detachably secured to a workpiece carrier, the friction wheels being arranged on the workpiece carrier. It is also possible to transport different workpieces with the same workpiece carrier.
To standardize, by analogy, the working station with respect to its support on the guides, the screwing and/or assembling means as the working station may comprise a working tool carrier which is movably supported on the second guides and on which the working tools are displaceably supported towards the workpiece. This creates, inter alia, the possibility that with an otherwise identical working tool carrier different working tools are used, depending on the respective requirements, and are moved with the working tool carrier along the second guides.
For reasons of space the working tool carrier and/or workpiece carrier may be substantially plate-shaped and comprise slide rails which project in the direction of the first guides and second guides, respectively, and are displaceable along said guides. For instance, if the first and second guides are each arranged vertically one above the other, a slide rail of each guide moves along an upper side of the lower guide and a further slide rail along an upper side of the upper guide.
To reduce friction between guide and slide rails to a substantial degree, guide rolls may be rotatably supported on the slide rails.
To be able to move all working tools, if possible, in synchronism and with a permanent alignment relative to one another, the working tool carrier may be provided especially at one end with a displacement means for displacing the working tools between ready position and work position. In the work position the working tools are aligned relative to the workpiece such that the latter can be worked. In the ready position the working tools can be displaced to such a degree that they present, for instance, no obstacle for the workpieces to be worked, for workers carrying out other operations, or the like.
It is also possible that the working tools are in principle arranged fixedly in their work position, a corresponding displaceable support by displacement means, or the like, being here omitted.
To obtain a simple displacement means, said means may comprise at least two transverse carriers extending above the first and second guides, along which the working tools are displaceable in a direction transverse to the transportation direction. The working tools can thereby be assigned substantially from above to the workpiece and finally moved to the workpiece for treatment.
The working tools as such can be configured in very different ways, depending on the kind of treatment for the workpiece. Examples of such working tools are drills, thread cutters, polishing means, screwdrivers, assembling devices, or the like. To be able to carry out many screwing or drilling operations in a simple way, the working tools are designed as screwdrivers with telescopically displaceable wrench heads that are displaceably supported between retracted position and operative position, as are e.g. described in DE 201 14 662.2 of the same applicant.
It should here be noted that the working tools are initially arranged in their retracted position e.g. during displacement of the working tools into the operative position and that they are only displaced by corresponding operation of the working tools into their operative position.
The displacement between retracted position and operative position can take place automatically, and after a correct assignment with respect to the workpiece the displacement into the operative position, for instance, and the subsequent treatment of the workpiece take place. The return movement into the retracted position can also take place automatically in a corresponding way after the working of the workpiece has been completed.
In a simple embodiment the working tools can be displaced manually between retracted position and operative position.
It has already been pointed out that the first and second guides may each be arranged horizontally or vertically. With a vertical arrangement, the demand for space is normally reduced.
To move the working tools in a simple way back into the retracted position after a manual displacement of the working tools into the operative position, the working tools may be acted upon by a force towards the retracted position. Actuation by a force may e.g. be carried out by a corresponding spring means or the like.
Especially with a manual assignment of the working tools relative to the workpiece in order to permit an exact alignment between the two, the working tools in their operative position may be aligned relative to the workpiece and optionally detachably fixed in said aligned position. The alignment can take place via a corresponding indexing means, and with an arrangement of the working tools in this correctly aligned position, a fixation by locking or the like can advantageously be carried out between working tools and workpiece or between working tools and workpiece carrier.
Since the assignment of working tools and workpiece takes place in flow line production, it is self-evident that the corresponding assignment and alignment of working tool and workpiece is also maintained during movement in transportation direction. This is simply carried out in that the movements of screwing and/or assembling means are synchronized. The term “synchronization” must here be interpreted such that very different types of kinetic coupling between working station and workpiece are comprised. One type of synchronization can e.g. be performed by a detachable fixation in the aligned position; see the above observations. It is also possible that working tool carrier and workpiece carrier are detachably coupled with one another as long as there is no working of the workpiece. This means, for instance, that the workpiece carrier or the working tool carrier drag along the respectively other member. Another possibility of synchronization is an electrical/electronic synchronization which is e.g. performed via the drive means, a master-slave relationship possibly existing between workpiece carrier and working station. Of course, a corresponding synchronization can also be performed mechanically in that e.g. a kinetic connection is established between screwing and/or assembling means and workpiece or workpiece carrier, respectively.
In flow line production the workpiece moves from one working station to the other one whereas the working stations are only assigned to a specific working area. To be able to work different workpieces one after the other in this area, it must be regarded as an advantage when the screwing and/or assembling means can be returned in a direction opposite to the transportation direction up to and into their initial position automatically after decoupling of workpiece and/or workpiece carrier. In this initial position a new workpiece is then supplied and worked. It is self-evident that a return movement into the initial position can also be carried out manually.
To use working stations, for instance, not only for the return movement into the initial position in the case of a drive means for essentially all working stations, screwing and/or assembling means and drive means assigned thereto may be drivingly connected especially during the return movement. During movement together with the workpiece for the treatment thereof, a corresponding decoupling from the drive means takes place and e.g. a corresponding kinetic connection is established with respect to the workpiece and workpiece carrier, respectively, or optionally also with respect to the drive means of workpiece/workpiece carrier. The kinetic connection can of course also be realized during movement in transportation direction.
To be able to operate all working tools in synchronism and manually, all working tools can be displaced at the same time and especially manually by means of a guide plate into the operative position.
To ensure the supply of the working station during its movement along the working area of the workpiece in a simple way, the screwing and/or assembling means may have assigned thereto a cable towing means.
It is self-evident that the corresponding working tools can be fed to the workpiece in different ways. One feeding possibility is in vertical direction from the top to the bottom. The working tools are arranged accordingly above or below the workpiece in their retracted position and operative position.
However, it is also possible that the working tools are supplied in horizontal direction to the workpiece. In this instance the working tools project substantially vertically from the working tool carrier and pass at least between and through the first guides. This is applicable in case of a vertical arrangement of the guides. With a horizontal arrangement of the guides a horizontal supply of the working tools can of course take place without any projection through the first guides.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantageous embodiments of the invention will now be explained in more detail with reference to the figures which are attached to the drawing, and of which:
FIG. 1 is a perspective front view of a first embodiment of the transport system according to the invention;
FIG. 2 is a partly cut side view of the transport system according to FIG. 1 ;
FIG. 3 is a front view of the transport system according to FIG. 1 ; and
FIG. 4 is a perspective front view according to FIG. 1 of a second embodiment of the transport system of the invention.
DETAILED DESCRIPTION
FIG. 1 is a perspective front view of a first embodiment of the transport system 1 according to the invention. The transport system 1 comprises two pairs of guides 3 , 4 , 10 , 11 . The pair of first guides 3 , 4 serves to guide a substantially plate-shaped workpiece carrier 20 which has a workpiece 2 detachably secured thereto. The workpiece carrier 20 comprises two slide rails 22 , 23 at its back side facing away from the workpiece 2 . The slide rail 22 is movable along an upper side of the lower first guide 4 , the slide rail 23 being movable along a bottom side of the upper first guide 3 .
The workpiece carrier 20 is kinetically connected to a drive means 15 , which is designed as a shaft 17 . The shaft 17 rotates substantially continuously in one direction, the kinetic connection between workpiece carrier 20 and shaft 17 being established via a number of friction wheels 19 , see FIG. 2 . The wheels are supported on the workpiece carrier 20 to be rotatable and adjustable in their angle of inclination relative to the transportation direction 6 and the longitudinal direction of the shaft 17 , respectively.
The first guides 3 , 4 are mounted on a plurality of spaced-apart guide stands 12 , of which only one is shown in FIG. 1 . The first guides 3 , 4 are here mounted at a side 14 of the guide stand 12 . A further pair of second guides 10 , 11 is mounted at the opposite side 13 . Each of the second guides 10 , 11 is arranged in parallel with the first guides 3 , 4 . The second guides 10 , 11 serve to guide and move a working station 5 . In the illustrated embodiment, said station is designed as a screwing and/or assembling means 7 . The working station 5 comprises a substantially plate-shaped working tool carrier 21 whose inner side facing the workpiece carrier 20 has arranged thereon two slide rails 24 , 25 . By analogy with slide rails 22 , 23 , these are in contact with the second guides 10 , 11 ; see also FIG. 2 .
The lower slide rail 23 comprises corresponding friction wheels 19 which are supported thereon to be rotatable and adjustable in their angle of inclination. The friction wheels 19 can be brought into contact with a further shaft 18 as drive means 16 for the working station 5 . The shaft 18 extends in a corresponding manner in parallel with shaft 17 , its direction of rotation, however, being inverse to the direction of rotation of shaft 17 in the illustrated embodiment; see the following description.
At its upper end 26 the working tool carrier 21 comprises two transverse carriers 30 , 31 that are arranged to be perpendicular to said carrier 21 . Said transverse carriers form part of a displacement means 27 . On their insides oriented to each other, the transverse carriers 30 , 31 comprise guide surfaces for a substantially U-shaped bracket 41 . Said bracket is displaceable by means of guide rolls 43 (see also FIGS. 2 and 3 ) along the transverse carriers 30 , 31 .
FIG. 1 shows a ready position 28 in broken line and a work position 29 of the displacement means 27 in unbroken line. At their front ends, the U-legs of the U-bracket 41 have arranged thereon a support plate 42 . Said plate serves to hold a plurality of working tools 8 with corresponding drive means for said working tools. The working tools 8 are here designed as screwdrivers 34 with wrench heads 35 . In FIG. 1 , the screwdrivers 34 and wrench heads 35 , respectively, are arranged in an operative position 33 in which the workpiece 2 is subjected to a corresponding treatment.
All of the screwdrivers 34 and wrench heads 35 , respectively, are jointly displaceable in vertical direction by means of a manually operable guide plate 36 between their operative position 33 and their retracted position 32 ; see also FIG. 2 . On the guide plate 36 , grips 40 are arranged at both ends towards transportation direction 6 so as to be gripped by a worker. The working tools 8 are displaced in vertical direction 47 . The support plate 42 is displaced in horizontal direction 48 perpendicular to transportation direction 6 . The working station 5 is displaced in horizontal direction 46 in parallel with transportation direction 6 , the working station being movable in the area of a working path 9 .
It should here be noted that the configuration of the working station 5 as a screwing and/or assembling means 7 according to FIG. 1 is only by way of example and that other working tools 8 are also possible for the working station 5 .
For the supply of the working station, cable towing means 37 , 38 are arranged that are configured like a chain and allow for adequate clearance with respect to the two horizontal movements 46 and 48 of the working station.
FIG. 2 is a partly cut side view of the transport system 1 according to FIG. 1 . Like reference numerals mark like parts in this figure just as in the remaining figures and are only mentioned in part in connection with a figure.
FIG. 2 shows, in particular, how workpiece carrier 20 and working tool carrier 21 are displaceable by means of their slide rails 22 , 23 and 24 , 25 along the first guides 3 , 4 and the second guides 10 , 11 . The guides 3 , 4 and 10 , 11 are made from one section and guide rolls 39 which are rotatably arranged on the slide rails 22 , 23 and 24 , 25 roll on the outsides thereof. The guide rolls are each arranged in pairs and are inclined relative to one another at an angle of about 90°. Consequently, they roll on guide surfaces of the corresponding guides that are also inclined relative to one another at an angle of 90°.
Corresponding friction wheels 19 (see also FIG. 3 ) can be made out on the insides of workpiece carrier 20 and working tool carrier 21 , respectively, which are oriented towards the shafts 17 , 18 . These wheels are supported on the carriers 20 , 21 to be rotatable and adjustable around their axis of rotation with respect to the adjustment angle. Depending on the inclination of the friction wheels 19 relative to the shaft 17 and 18 , respectively, the speed of workpiece carrier 20 and thus of working tool carrier 21 is variable.
As can particularly be seen in FIG. 2 in addition, the workpiece carrier 20 has assigned thereto a monitoring/controlling means 44 by which the position of the workpiece carrier along the transport system 1 can be detected and optionally corrected.
In FIG. 2 , the working station 5 is shown in its work position 29 with guide plate 36 in the operative position 33 . In these positions the workpiece 2 is worked by the corresponding working tools 8 of the working station 5 . The ready position 28 with respect to support plate 42 and the retracted position 32 with respect to guide plate 36 are also hinted at in FIG. 2 . In the ready position 28 , the working station 5 is displaced in the displacement means 27 to such a degree to the left side in FIG. 2 that the corresponding working tools 8 are essentially arranged above the first and second guides 3 , 4 and 10 , 11 . At the same time, the working tools are displaced by a corresponding vertical displacement of the guide plate 36 into the retracted position 32 , so that ends of the working tools 8 that are assigned to the workpiece 2 are positioned above the guides.
FIG. 3 is a front view of the transport system 1 according to FIG. 1 . The friction wheels 19 which are arranged along shaft 17 , see FIG. 1 , can particularly be seen on the workpiece carrier 20 . The working tools 8 of the working station 5 , which is designed as a screwing and/or assembling means 7 , are arranged in their operative position 33 due to manual operation performed by a worker 45 . The working station 5 is movable by the worker 45 along the working path 9 , see FIG. 1 , in transportation direction 6 , a detachable fixation being normally established between working station 5 and workpiece 2 and workpiece carrier 20 , respectively. In this connection it is also possible to move working station 5 and workpiece 2 automatically and in synchronism with one another in transportation direction 6 . Said synchronous movement can e.g. be performed by electronic synchronization of the drive means or a master-slave relation of the drive means.
As can further be seen in FIG. 3 , the U-webs of the displacement means 7 and 20 , see FIG. 1 , are displaceably supported along guide rolls 43 on transverse carriers 30 , 31 .
FIG. 4 is a perspective front view according to FIG. 1 on a second embodiment of the transport system 1 according to the invention.
This embodiment specifically differs from the first embodiment of FIG. 1 in that the working station 5 is designed without a displacement means 27 , so that the working tools 8 are permanently arranged in the work position 29 . The support plate 42 is fixed relative to the transverse carriers 30 , 31 in a corresponding way. Consequently, since the working station 8 is not movable in horizontal direction perpendicular to the transportation direction 6 , a cable tow member 38 , see FIG. 1 , of the cable towing means can here be omitted.
The other details are identical with those of the embodiment according to the preceding figures.
Operation and function of the transport system according to the invention shall now be explained in a few words with reference to the figures.
According to FIG. 3 a worker first moves the working tools 8 by means of the guide plate 36 in horizontal direction perpendicular to the transportation direction 6 , the drive means 16 being separated from the working station 5 . In this process the working station 5 is entrained by the workpiece carrier 20 in transportation direction 6 . The worker moves the individual working tools 8 by means of the guide plate 36 into the operative position 33 , and the workpiece 2 is subsequently worked. During treatment the working tools are fixed with respect to the workpiece in that they are for instance locked in their operative position 33 . After the workpiece 2 has been worked, the worker returns the working tools into the retracted position 32 and then the displacement means into the ready position 28 ; see embodiment according to FIGS. 1 to 3 . The drive means is then again coupled with the working station, and a return movement is carried out in a direction opposite to the transportation direction into an initial position at an end of the working path 9 at which the treatment of a further workpiece will then start.
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In a transport system for flow line production, especially in the car manufacturing industry, workpieces are movable along at least two first guides between working stations in transportation direction. At least one working station is configured as a screwing and/or assembling means which particularly comprises a plurality of working tools. To improve such a transport system in a way that with little constructional efforts and at reduced costs the assignment of working station and workpiece to be worked thereby is simplified and made possible in an accurate and reproducible manner, the screwing and/or assembling means is integrated into the transport system and is movable at least over a working path in parallel with the first guides in the transport system.
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BACKGROUND OF THE INVENTION
Pools adapted to be moored in a body of water, such as a lake, stream or ocean, are known, the purpose of such pools being to protect swimmers from aquatic life or debris which may be present in the area, or to enable bathing in areas which are otherwise unsuitable due to various adverse conditions such as muddy, rocky or silty bottoms or the presence of dangerous currents. This is especially true of tidal salt waters such as bays, harbors, inlets, channels or marina where ebb and tidal flow prevail, in that dangerous currents and/or poor bottom conditions may prevent the bather from utilizing these otherwise beneficial bodies of salt water. Thus, the purpose of these pools is to allow the bather to take advantage of these otherwise unsuitable natural waterways together with more favorable natural conditions.
These known pools suffer from two disadvantages, namely, the difficulty of construction and disassembly or the absence of a bottom which will provide firm footing for the bather.
SUMMARY OF THE INVENTION
In accordance with the present invention, these difficulties are overcome by providing a floating swimming pool comprising a peripheral pool-enclosing deck composed of a plurality of secured together buoyant sections having a substantially flat upper surface. These buoyant sections are positioned in rows, the deck being constituted by the secured together buoyant sections. These sections are releasably secured together to facilitate assembly, disassembly and storage. The sides and bottom of the pool are formed of a plurality of perforated plates releasably secured together. The upermost plates which form the pool sides are releasably secured to the buoyant sections constituting the deck. The secured together plates forming the pool bottom are rigidly interconnected, thereby providing a relatively rigid bottom for improved footing.
Thus an object of this invention is the provision of a pool structure which is easily fabricated, transported and erected. The entire pool and decking is comprised of modular panels, similar in size and construction for easy assembly. Conversely the structure is easily dismantled and stored. Both these operations may be accomplished by one man.
The relatively rigidly interconnected plates and buoyant sections provide a pool which can be assembled or disassembled and stored with relative ease while providing a pool of any desired size and having a generally rigid construction including a rigid bottom for improved footing, thus overcoming the difficulties of prior known floating pools.
The perforated plates are rigid plates, preferably made of relatively rigid plastic for light weight utilizing a monolithic form of construction for increased rigidity and load bearing capacity. These plates are also preferably formed on a module basis to minimize the number of differently formed plates which are needed. Thus, most of the plates would be of the same size and shape, e.g., rectangular, and some of the plates would have one sloping side to provide a tapered bottom for the pool. The plates are suitably interconnected by the use of nuts and bolts and other fastening devices which join together mating flanges of adjacent plates. The flanges are preferably formed integrally on all four edges of each of the plates to provide enhanced strength and the plates are desirably positioned with the flanges extending outwardly of the pool.
The perforated plates are provided with a plurality of apertures or perforations in such size and number as to not substantially weaken the load bearing capacity of the plates while allowing water in the pool to be constantly circulated and replenished with fresh water either by the natural flow of water in the vicinity of the pool or by the use of a circulatory device such as an outboard motor in areas of static water circulations such as may exist in a lake, or other similar bodies of water.
The use of relatively small perforations in the plates allow the plates to remain rigid, and also allows water circulation therethrough while providing comfortable footing for the bathers.
The buoyant sections are desirably of one piece molded construction block-like in shape, preferably rectangular, and formed to include a sealed hollow air-pocket therein, but the invention is not to be limited to any particular buoyancy expedient. Many of these buoyant sections are secured together to allow ease of assembly or disassembly of the deck or storage of these parts. Also an advantage of using hollow block buoyant sections is that such sections provide increased load bearing capacity for the deck. The hollow-block buoyant sections have a generally flat upper surface for deck use and flange members around the lower periphery thereof to allow these sections to be secured to each other in rows to form a deck for the pool.
If desired, some of these buoyant sections can be joined together in a solid structure to form a raft or dock, which is preferably rectangular but may also be circular or "U" shaped if desired.
To facilitate discussion, the following specific consideration of the present invention is directed to the preferred form of pool structure, namely, a pool of rectangular shape, and to the utilization of rectangular buoyant sections to facilitate construction thereof. However, the present invention is in no way limited to the use of a rectangular pool shape since the present invention may be used to form pools of various geometrical shapes.
Further, the present invention is not limited to the use of rectangular buoyant sections since buoyant sections having circular or polygonal shapes may be used to facilitate construction of pools of geometrical shapes other than rectangular.
Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure.
The invention accordingly consists in the features of construction, combinations of elements, and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scope will be indicated by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic plan view of the swimming pool formed in accordance with the present invention.
FIG. 2 is a side view of the pool of FIG. 1.
FIG. 3 is a vertical sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a partial vertical section taken along line 4--4 of FIG. 3 showing detailed construction of the hollow buoyant sections.
FIG. 5 shows another aspect of the present invention, namely, a water circulation device for the pool of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIGS. 1 and 2, swimming pool 10 is defined by the rectangular buoyant deck 11 and the body of the pool 12 formed to include a generally sloping bottom 13. The pool is provided with the usual appurtenances to a pool such as ladders, diving board, etc. As can be seen generally in FIG. 2, the swimming pool of the present invention is formed by securing together buoyant sections 14 to form the floating deck 11 and by securing to the deck perforated plates 15 which form the body of the pool 12.
The buoyant sections 14 are blocklike in shape as can be seen in FIGS. 1 and 2. Referring to FIG. 3, the buoyant sections 14 are formed to include a sealed hollow air space 16 therein to effect the buoyancy of the section 14. These sections are desirably formed of substantially rigid plastic material resistant to chemical degradation and may be made by molding the plastic in a single operation by methods well known to the art.
The buoyant sections 14 are also formed to include a securing flange 17 which is positioned on the periphery of the section 14, and which allows the buoyant sections 14 to be secured together to form the deck. While any flange element which accomplishes the above stated function may be used, for simplicity of manufacture and assembly, the flange has one face in the same plane as the center line of the buoyant section. Thus, by rotating one section 180° with respect to another section about an axis parallel to the flanges, the flanges of the two sections will be positioned one on top of the other, thereby providing, by securement of the two sections, a flat deck surface without the necessity of providing two different buoyant sections having mating flanges.
If desired, buoyant sections 14 may be formed to omit the flange element on the outer periphery of the outer buoyant sections though this is not necessary. Also the inner buoyant sections may be formed to include on the inner surface thereof a pool connecting flange or some other mechanical fastening means 18 though this expedient is not a requirement of the present invention.
The outer row of buoyant sections are also desirably formed to include mooring means for mooring the pool in a body of water generally indicated at 19 and means for attaching safety ropes 20. These means may be molded into the buoyant sections or attached in any other desirable manner. Preferably, the safety ropes are attached to posts 21 which are of tapered form corresponding to a tapered hole 22 formed in the outer buoyant section as can be seen in FIG. 3, to provide a wedging action.
To further increase the rigidity and load bearing capacity of the deck 11, half size buoyant sections 23 are preferably provided in the corners of the deck which are so arranged that the longitudinal flanged edges of the half sections of the outer row of buoyant sections are perpendicular to the longitudinal flanged edges of the half sections of the inner row. This expedient provides at the juncture of the pool 12 and the deck 11 an increased load bearing capacity of the deck 11.
The bottom and sides of pool 12 are formed by securing together perforated plates 15 which are formed to include securing flanges 24 which extend outwardly of the pool to thereby provide a smooth inner pool surface. These flanges increase the rigidity and load bearing of the plates. The plates 15 are also provided with perforations 25 which allow free circulation of water into the pool to thereby avoid the possibility of the water in the pool becoming stagnant. These perforations are of relatively small size and are arranged in rows so that the load bearing capacity of the plate is not significantly reduced. The upper row of plates forming the pool sides and the plates forming the bottom of the pool are preferably rectangular in shape and of one size to reduce the number of parts needed to construct the pool. The upper row of plates securing flange 18 as described hereinbefore.
In order to provide sloping bottom 13 of the pool, the lower row of said plates are trapezoid in form having three sides at right angles to one another with a sloping surface 26 at the lower edge thereof. The size of these sloping plates are varied so as to provide a sloping bottom which is desirable when the pool is to be used both by small children and adults especially when it is desired to utilize a diving board.
These sloping plates may be conveniently formed by molding relatively rigid plastic material in an adjustable mold. Similarly, the other perforated plates may also be conveniently formed by molding preferably utilizing a relatively rigid plastic material.
The plates 15 and also the buoyant sections 14 are secured together by any convenient securing means such as by nuts and bolts 27. Preferably, plastic nuts and bolts (including plastic coated nuts and bolts) are desirably used so as to prevent freezing of the nuts to the bolts or deterioration thereof due to the chemical action of water and/or salt on the metal.
When the pool is moored in a static body of water such as a lake, the flow of water through the pool is reduced to an undesirable minimum and therefore, means to increase the flow of water through the pool are provided as indicated by 28 in FIG. 1. Any means which will provide the water circulation function are contemplated, such as, gasoline motor or electric motor powered circulatory pumps. Preferably, the circulatory action is provided by a gasoline fueled outboard motor 29 as can be seen in FIG. 5. In order to prevent damage to the motor by debris and injury to the users of the pool, the propeller 30 is desirably encased in a protective T-type duct 31 which not only provides the desired protection but also improves the circulatory flow of water.
The duct is composed of a propeller encasing portion 32 and a water flow section 33 in the shape of an elongated rectangular or circular tube open at both ends. These ends are provided with a protective screening 34 of either metal or plastic to prevent the flow of debris into the duct and also to prevent possible injury to inquisitive children.
By utilizing a T-duct, the rotary movement of the propeller causes an increased flow of water through the duct thus providing a more efficient circulatory device.
From the foregoing it can be seen that the present invention provides a floating pool structure which is easy to construct and which provides the features of the normal swimming pool. It will be understood that various ancillary equipment such as lights and power source or electrical connection means therefor, will also be present and the showing of such ancillary equipment has been minimized herein for clarity. It will also now be appreciated that the instant invention, by its unique air-filled hollow bodies provides a highly rigid, light-weight, noncorrosive, easily erected and dismantled deck, while the perforate plates enhance the rigidity, are also light in weight and noncorrosive. For additional lightness the side and bottom wall panels or plates 15 may be fabricated of plastic foam, or the like.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention.
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A buoyant sectional deck for surrounding a swimming area, perforate side plates depending from the deck and defining a side wall, perforate bottom plates extending across the lower region of the side wall to define the bottom wall, and means securing together the bottom and side plates with the latter secured to the deck sections.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 12/817,100, filed Jun. 16, 2010, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention generally relates to a method and apparatus for treating a heart valve.
BACKGROUND
Referring to FIG. 1 , the heart 2 includes a mitral valve 6 that has a valve annulus 4 . As a result of age, congenital defect or disease, the mitral valve 6 may fail to close completely when it should during a heartbeat. The normal mitral valve 6 opens when the left ventricle 8 relaxes (diastole), allowing blood from the left atrium 10 to fill the decompressed left ventricle 8 . When the left ventricle 8 contracts (systole), the increase in pressure within the left ventricle 8 causes the mitral valve 6 to close, preventing blood from leaking into the left atrium 10 and assuring that all of the blood leaving the left ventricle 8 (the stroke volume) is ejected through the mitral valve 6 into the aorta 12 and then to the body.
Referring to FIG. 2 , the mitral valve 6 has two leaflets. The anterior leaflet 14 has a semicircular shape and attached to approximately two-fifths of the perimeter of the valve annulus 4 . The free edge 15 of the anterior leaflet 14 is typically continuous, without indentations. The posterior leaflet 16 of the mitral valve 6 is attached to approximately three-fifths of the perimeter of the valve annulus 4 . Typically, the posterior leaflet 16 has three segments: the anterior scallop 18 , the middle scallop 20 , and the posterior scallop 22 . The anterior scallop 18 is divided from the middle scallop 20 by a first indentation 24 , and the middle scallop 20 is divided from the posterior scallop 22 by a second indentation 26 . The indentations 24 , 26 aid in posterior leaflet 16 opening during diastole. The free edge 24 of the posterior leaflet 16 contacts the free edge 15 of the anterior leaflet 14 when the mitral valve 6 is closed. The height of the posterior leaflet 16 is typically less than the height of the anterior leaflet 14 ; however, both leaflets 14 , 16 typically have generally similar surface areas.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section view of a human heart.
FIG. 2 is a top view of a mitral valve of the human heart of FIG. 1 .
FIG. 3 is a perspective view of a guide catheter.
FIG. 4 is an end view of the distal end of a first example of the guide catheter of FIG. 3 .
FIG. 5 is an end view of the distal end of a second example of the guide catheter of FIG. 3 .
FIG. 6 is a perspective view of an exemplary sling.
FIG. 7 is a perspective view of an exemplary hook.
FIG. 8 is a perspective view of an exemplary clip applier.
FIG. 9 is a perspective view of an exemplary clip.
FIG. 10 is a perspective view of a step of a method of treating the mitral valve.
FIG. 11 is a perspective view of another step of a method of treating the mitral valve.
FIG. 12 is a perspective view of another step of a method of treating the mitral valve.
FIG. 13 is a perspective view of another step of a method of treating the mitral valve.
FIG. 14 is a perspective view of another step of a method of treating the mitral valve.
FIG. 15 is a perspective view of a treated mitral valve with a clip holding the leaflets thereof.
The use of the same reference symbols in different figures indicates similar or identical items.
DETAILED DESCRIPTION
Structure
Referring to FIGS. 3-4 , an exemplary guide catheter 30 is shown. The guide catheter 30 may be generally cylindrical in shape, and is flexible enough to be advanced through the vasculature of a patient. The surface of the guide catheter 30 is atraumatic, in order to prevent injury to the vasculature of a patient. The guide catheter 30 may be fabricated from any suitable material or combination of materials. The guide catheter 30 may have five channels within. A clip channel 32 may be the largest channel in the guide catheter 30 , and may be substantially concentric within the guide catheter 30 . The clip channel 32 may be generally cylindrical, with a substantially circular cross-section. However, the clip channel 32 may be shaped differently and/or offset from the longitudinal centerline of the guide catheter 30 . Two sling channels 34 may be positioned radially outward from the clip channel 32 , on opposed sides of the clip channel 32 . Two hook channels 36 may be positioned radially outward from the clip channel 32 , on opposed sides of the clip channel 32 . The hook channels 36 may be arranged substantially ninety arcuate degrees away from the sling channels 34 , such that the channels 34 , 36 are substantially evenly spaced around the clip channel 32 . However, the channels 34 , 36 may be positioned at any other suitable angular positions relative to one another; and the channels 32 , 34 , 36 as a group may be arranged in any other suitable manner.
As one example, referring to FIG. 4 , one or more of the channels 32 , 34 , 36 may be lumens defined within a solid or partially solid guide catheter 30 . If so, any such channel may be fabricated within the guide catheter 30 in any suitable manner, such as by drilling, boring, or laser-cutting, or the guide catheter 30 may be fabricated in such a manner that any such channel is devoid of material within throughout the fabrication process. As another example, referring to FIG. 5 , one or more of the channels 32 , 34 , 36 may be individual tubes positioned within the guide catheter 30 . If so, the channels 34 , 36 may be positioned between the outer surface 38 of the clip channel 32 and the inner surface 42 of an outer sheath 40 . In this way, the channels 34 , 36 also may support the clip channel 32 within the lumen 44 of the outer sheath 44 . The channels 32 , 34 , 36 may be connected to the outer sheath 40 in any suitable manner. As another example, the guide catheter 30 may be fabricated in any other suitable manner that results in a suitable number of channels defined therethrough.
Referring to FIG. 6 , at least one sling 50 may be utilized in conjunction with the guide catheter 30 . Each sling 50 may include a broad section 52 and an extension 54 extending proximal to the broad section 52 . The broad section 52 may be substantially D-shaped, as shown in FIG. 6 , or may have any other suitable shape. The broad section 52 may be a closed loop, or may be open at least in party. The broad section 52 may lie in substantially a single plane, but need not do so. The sling 50 may be fabricated from one or more pieces of superelastic wire, such as wire composed of nickel-titanium alloy. However, the sling 50 may be fabricated from spring steel or other metal that is not superelastic, or may be fabricated from any suitable nonmetallic material. The extension 54 is configured to extend through a corresponding sling channel 34 in the guide catheter 30 . The sling 50 is collapsible, such that the sling 50 in its entirety can be held partially or completely within a corresponding sling channel 34 in an initial position, as described in greater detail below.
Referring to FIG. 7 , at least one hook 60 may be utilized in conjunction with the guide catheter 30 . Each hook 60 may be curved or angled at the distal end thereof, such that the free end of the hook 60 is oriented at least partially in the proximal direction. The hook 60 may be J-shaped, or may be shaped in any other suitable manner. The hook 60 may be fabricated from one or more pieces of superelastic wire, such as wire composed of nickel-titanium alloy. However, the hook 60 may be fabricated from spring steel or other metal that is not superelastic, or may be fabricated from any suitable nonmetallic material. The proximal end of the hook 60 is configured to extend through a corresponding hook channel 36 in the guide catheter 30 . The hook 60 is collapsible, such that the hook 60 can be held partially or completely within a corresponding hook channel 36 in an initial position, as described in greater detail below. One or more hooks 60 may include a closing or locking feature at the distal end thereof that can be automatically or remotely actuated to open and close as needed.
A clip applier may be utilized in conjunction with the clip channel 32 . As one example, the clip applier may be substantially as set forth in U.S. Pat. App. Pub. No. 2009/0093826 of Warder-Gabaldon et. al., filed on Oct. 5, 2007 (the “Clip Publication”), which is hereby incorporated by reference in its entirety. Referring to FIG. 8 , the clip applier 70 may be configured to splay and then deploy a clip 72 , as set forth in the Clip Publication. Referring to FIG. 9 , the clip 72 may have four tines 74 arranged in an X configuration. However, the clip 72 may have tines 74 arranged in any other suitable configuration, and/or may include a different number of tines 74 . The clip applier 70 is configured to be held partially or completely with the corresponding clip channel 32 of the guide catheter 30 in an initial position, as described in greater detail below.
Operation
Referring to FIG. 10 , the distal end 31 of the guide catheter 30 is advanced through the left atrium 10 into the left ventricle 8 , through the mitral valve 6 . The guide catheter 30 may be introduced into the left atrium 10 through a transseptal puncture, through the patient's vasculature, or in any other suitable manner that provides access to the left atrium 10 for the guide catheter 30 . The heart 2 advantageously continues to beat during and after introduction of the guide catheter 30 thereinto; however, the heart 2 may be stopped and the patient placed on a heart-lung machine at the discretion of the user.
After the distal end 31 of the guide catheter 30 has been introduced into the left ventricle 8 , then one or more slings 50 are each advanced distally out of the corresponding sling channels 34 in the guide catheter 30 . Such advancement may be performed in any suitable manner, such as by pushing the extension 54 distally either by hand or by application of force through a handle (not shown). The broad section 52 of each sling 50 is initially compressed by and constrained by contact with the interior of the corresponding sling channel 34 such that each sling 50 can be held within the circumference of the guide catheter 30 . As each sling 50 advances distally, its broad section 52 advances out of the corresponding sling channel 34 such that the broad section 52 is no longer constrained by the corresponding sling channel 34 . At that time, the broad section 52 self-expands within the left ventricle 8 . Alternately, the guide catheter 30 actively expands each broad section 52 within the left ventricle 8 . Referring to FIG. 11 , advantageously two slings 50 are deployed from the guide catheter 30 and expanded. The slings 50 expand from the left ventricle 8 through the mitral valve 6 and into the left atrium 10 . In this way, the slings 50 generally center the guide catheter 30 within the mitral valve 6 . The guide catheter 30 may then be retracted such that its distal end 31 is positioned in the left atrium 10 . During that retraction of the guide catheter 30 , the slings 50 substantially remain in position relative to the left ventricle 8 , mitral valve 6 and left atrium 10 due to the outward force exerted by the slings against the inner surfaces of the left ventricle 8 and the left atrium 10 , as well as the lateral ends 82 of the opening 80 of the mitral valve 6 . The guide catheter 30 slides along the extensions 54 of the slings 50 as the broad sections 52 of the slings 50 remain generally in place in the heart 2 . The guide catheter 30 may be retracted using ultrasound, fluoroscopy, or any other suitable imaging method to determine the location of the distal end 31 of the guide catheter 30 .
Next, one or more hooks 60 are each advanced distally out of the corresponding hook channels 34 in the guide catheter 30 . Such advancement may be performed in any suitable manner, such as by pushing each hook 60 distally either by hand or by application of force through a handle (not shown). The distal J-portion 64 of at least one hook 60 may be narrower than the corresponding hook channel 36 in the guide catheter 30 , such that the J-portion 64 of at least one hook 60 is not substantially compressed while that hook 60 is in its initial position within the hook channel 36 in the guide catheter 30 . Alternately, the J-shaped portion 64 of at least one hook 60 may be wider than the corresponding hook channel 36 , such that the J-shaped portion 64 is initially compressed by and constrained by contact with the interior of the corresponding hook channel 36 such that each J-shaped portion 64 can be held within the circumference of the guide catheter 30 . As each hook 60 advances distally, the J-shaped portion 64 of each hook 60 advances out of the corresponding hook channel 36 in the guide catheter 30 . The hook 64 may simply move out of the hook channel 36 without substantially changing its size or shape. Alternately, where the hook channel 36 initially constrained the J-shaped portion 64 of at least one hook 60 , motion of the J-shaped portion 64 of that hook or hooks 60 out of the corresponding hook channel 36 may allow the J-shaped portion 64 to self-expand, and/or frees the J-shaped portion 64 to allow the guide catheter 30 to actively expand it. As the hooks 60 are advanced, they pass through the mitral valve 6 and entire the left ventricle 8 . Because each hook 60 has a J-shaped portion 64 or similarly shaped portion at the distal end thereof, the distal end of each hook 60 is substantially blunt, and thereby passes through the mitral valve 6 without engaging or damaging the tissue of the mitral valve 6 .
Next, the physician retracts one of the hooks 60 , causing each retracted hook 60 to grab the edge of a corresponding leaflet 14 , 16 of the mitral valve 6 . This may require multiple attempts, and may be controlled using ultrasound, fluoroscopy, or any other suitable imaging device or technique. Either leaflet 14 , 16 may be engaged first. For purposes of describing the method, and not to limit the order of engagement, it is assumed in this document that the physician chooses to engage the anterior leaflet 14 first. Once that hook 60 has engaged the anterior leaflet 14 , the hook 60 is retracted toward the guide catheter 30 , moving the edge of the anterior leaflet 14 to its closed position—that is, the position the anterior leaflet 14 would assume during normal closure of the mitral valve 6 . Optionally, the hook 60 may include a locking feature (not shown) that allows the physician to manually lock the J-shaped portion 64 of the hook 60 after it engages the anterior leaflet 14 , or may include an automatic locking feature that automatically locks the J-shaped portion 64 of the hook 60 after it engages the anterior leaflet 14 . Such a locking feature would prevent the leaflet 14 from disengaging from the hook 60 .
Next, the posterior leaflet 16 may be engaged with a second hook 60 in substantially the same manner in which the anterior leaflet 14 was engaged, as described above. The hook 60 is retracted toward the guide catheter 30 , moving the edge of the posterior leaflet 16 to its closed position—that is, the position the posterior leaflet 16 would assume during normal closure of the mitral valve 6 . Alternately, the hooks 60 can be manipulated substantially simultaneously to engage leaflets 14 , 16 at substantially the same time, rather than sequentially as described above. Referring also to FIG. 12 , the hooks 60 thereby hold the leaflets 14 , 16 in a closed position that mimics the position in which the leaflets 14 , 16 would be held by a clip. The physician may utilize ultrasound, fluoroscopy, or any other suitable imaging technique, and/or a nonimaging technique such as flow measurement, to view and/or measure the mitral valve 6 and determine the impact of fixing the leaflets 14 , 16 in substantially the position in which they are held by the hooks 60 . If the imaging and/or measurement does not indicate sufficient reduction of mitral insufficiency, the physician can release the leaflets 14 , 16 from the hooks 60 , such as by moving the hooks 60 distally. The physician may then reorient the guide catheter 30 and capture the leaflets 14 , 16 again, as described above, where the hooks 60 engage different portions of the leaflets 14 , 16 .
Optionally, the slings 50 may stretch the opening 80 of the mitral valve 6 by moving the ends 82 of the opening 80 away from one another. By stretching the mitral valve 6 , the leaflets 14 , 16 may move closer to one another, rendering it easier to capture them with the hooks 60 . The broad sections 52 of the slings 50 may form substantially a single plane, where the sling channels 34 are oriented substantially along a line that includes the centerline of the guide catheter 30 . The hook channels 36 may be oriented along a line that includes the centerline of the guide catheter 30 , where that line is substantially perpendicular to the line formed by the sling channels 34 and the centerline of the guide catheter 30 . In this way, the hook channels 36 and sling channels 34 may be substantially evenly spaced along ninety-degree increments along the circumference of the guide catheter 30 . Further, in this way the hooks 60 may be oriented relative to the opening 80 in the mitral valve 6 in a manner that maximizes the ease of engagement between the hooks 60 and the leaflets 14 , 16 .
Once the physician is satisfied with the alignment of the edges of the leaflets 14 , 16 , the clip applier 70 is advanced distally along the clip channel 32 of the guide catheter 30 , at least partially out of the distal end 31 of the guide catheter 30 . The clip applier 70 is then actuated to splay the clip 72 , as described in the Clip Publication. The distal ends of the tines 74 of the clip 72 each move in a direction having a component of motion away from the longitudinal centerline of the clip 72 . This deformation of the clip 72 may be referred to as “splaying.” Advantageously, the clip 72 is plastically deformed during splaying, such that after splaying the tines 74 of the clip 72 remain in the splayed configuration on their own, without requiring the application of force from the clip applier 70 to maintain the tines 74 in the splayed configuration. Alternately, the clip 72 may be splayed in an elastic or superelastic manner. The splayed clip 72 is still held by the clip applier 70 , and the distal ends of the tines 74 extend radially outward beyond the outer perimeter of the clip applier 70 and of the guide catheter 30 . Next, referring also to FIG. 13 , the leaflets 14 , 16 and the splayed clip 72 are brought into contact with one another. This may be performed by moving the clip applier 70 distally, thereby penetrating the distal ends of at least two tines 74 into the leaflets 14 , 16 . As another example, the hooks 60 may be retracted proximally, bringing the leaflets 14 , 16 into contact with the tines 74 and causing the tines 74 to penetrate the leaflets 14 , 16 . As another example, the clip applier 70 may be moved distally and the hooks 60 may be moved proximally in order to penetrate the tines 74 through the leaflets 14 , 16 . Advantageously, all of the tines 74 penetrate the leaflets 14 , 16 . However, because the clip 72 has multiple tines 74 , it is not necessary for all of the tines 74 to penetrate the leaflets 14 , 16 ; rather, one or more tines 74 may enter the opening 80 in the mitral valve 6 . Alternately, the clip 72 may be configured to have two tines 74 , and the clip applier 70 may be actuated in a manner that ensures that one tine 74 penetrates each leaflet 14 , 16 .
Next, the clip 72 is closed, substantially as described in the Clip Publication. As a result, the leaflets 14 , 16 are firmly and permanently connected together by the clip 72 . Advantageously, the clip 72 engages the leaflets 14 , 16 approximately at the center of the mitral valve 6 . However, the clip 72 may be placed at any location along the leaflets 14 , 16 , at the discretion of the physician. Before the closed clip 72 is released from the clip applier, the physician can retract the clip applier 70 proximally a small amount, to ensure that the clip 72 has penetrated the leaflets 14 , 16 and firmly attached them. Referring also to FIG. 14 , after the physician is satisfied that the clip 72 has closed firmly into the tissue of the leaflets 14 , 16 , the clip applier 70 releases the closed clip 72 , substantially as described in the Clip Publication. The clip applier 70 is then withdrawn proximally, partially or completely into the clip channel 32 in the guide catheter 30 . The hooks 60 are released from the leaflets 14 , 16 in any suitable manner and withdrawn into the hook channels 36 in the guide catheter. Referring also to FIG. 15 , the guide catheter 30 is then withdrawn, leaving the closed clip 72 in the mitral valve 6 . A double orifice mitral valve 6 has thus been created, which is suitable for treating mitral insufficiency.
While the invention has been described in detail, it will be apparent to one skilled in the art that various changes and modifications can be made and equivalents employed, without departing from the present invention. It is to be understood that the invention is not limited to the details of construction, the arrangements of components, and/or the method set forth in the above description or illustrated in the drawings. For example, other heart valves or bodily valves than the mitral valve 6 may be treated with the apparatus and method described above. Statements in the abstract of this document, and any summary statements in this document, are merely exemplary; they are not, and cannot be interpreted as, limiting the scope of the claims. Further, the figures are merely exemplary and not limiting. Topical headings and subheadings are for the convenience of the reader only. They should not and cannot be construed to have any substantive significance, meaning or interpretation, and should not and cannot be deemed to indicate that all of the information relating to any particular topic is to be found under or limited to any particular heading or subheading. Therefore, the invention is not to be restricted or limited except in accordance with the following claims and their legal equivalents.
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An exemplary surgical apparatus may include a guide catheter including a clip channel, at least one hook channel, and at least one sling channel defined therein; a clip applier movable within the clip channel, wherein the clip applier holds at least one clip; at least one hook movable within a corresponding hook channel; and at least one sling movable within a corresponding sling channel. An exemplary surgical method for treating a mitral valve may include providing a guide catheter; a clip applier held by the guide catheter, and a clip held by the clip applier; introducing the distal end of the guide catheter into the left atrium; engaging the anterior and posterior leaflets of the mitral valve with the clip; closing the clip; and disengaging the clip applier from the clip, whereby the clip remains in the mitral valve. Another exemplary surgical method for treating a valve may include providing a guide catheter; a clip applier held by the guide catheter, and at least one clip held by the clip applier; advancing the guide catheter into proximity to the valve; and applying at least one clip substantially in the middle of the valve to create two orifices, one on each side of the clip.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Phase Application of PCT/ES2011/070223, filed Mar. 31, 2011, which claims priority to Spanish Patent Application No. P201031082, filed Jul. 15, 2010, the contents of such applications being incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention refers to a spring rifle of the type described by EP 0655598, which is incorporated herein by reference, the firing of which is effected by electronic means in order to improve the performance it provides to the user as will be explained below.
BACKGROUND OF THE INVENTION
[0003] Rifles which comprise a spring of the type described by EP 0655598 are spring rifles, which unlike those of the PCP (Pre-Charged Pneumatic) type, do not require an external source of compressed gas in order to fire a pellet or any type of ammunition.
[0004] In spring rifles manual compression of air is achieved by means of a spring. Consequently, the action of the trigger (firing) releases a spring which drives a piston. The rapid movement of the piston causes the compression of air in a reservoir. The compressed air contained in the reservoir or caused by the action of the piston is later evacuated through an opening of a smaller diameter than the reservoir, which facilitates the increase in air pressure. Finally, the evacuated compressed air is used to impel a pellet or any other type of ammunition.
[0005] Said rifles have rather lower performance in terms of accuracy compared to PCP type rifles. Principally, the difference in performance is due to the necessity of movement of parts in the firing which causes vibrations and recoil. Nevertheless, spring rifles are an important option owing to their low cost and because few additional accessories, such as pre-compressed gas cylinders, among others, are required.
[0006] At present, spring rifles possess mechanical firing by means of a ratchet mechanism and counter-ratchet which are uncoupled by the action of the trigger, allowing the passage of air, compressed by the spring, through the barrel.
[0007] In order to improve accuracy, it is necessary that the action of the user on the trigger should require the least possible force, as an action of greater force on the trigger causes an undesirable movement in the rifle at the time of firing. Therefore, at present, the coupling between the ratchet mechanism and counter-ratchet is made to have as small a contact area as possible. It is thus guaranteed that the movement required in order to displace the counter-ratchet and therefore fire is small, requiring a force of less magnitude for its operation.
[0008] This type of mechanism to reduce the amount of force necessary to activate the firing means that, when the contact surfaces become very small, any force applied externally, for example an impact, even if not effected direct on the trigger, causes the ratchet mechanism and the counter-ratchet to become uncoupled, causing unintentional firing. Therefore the necessity is observed of having the gentlest possible firing in a weapon which passes the safety tests such as for example the so-called drop test. This test consists of freely dropping the weapon in all possible positions of the rifle, this test is passed if the rifle does not fire in any of the positions.
BRIEF DESCRIPTION OF THE INVENTION
[0009] According to this invention, in order to use the least possible force and maintain a contact surface between ratchet mechanism and counter-ratchet which guarantees safety, an electronic release can be incorporated. By using a release of this type it is no longer necessary to overcome the force of friction between two surfaces, but the philosophy of operation changes, as only the force necessary to operate a switch is used. By an internal mechanism the ratchet mechanism and counter-ratchet are uncoupled, preferably by the action of a solenoid, although any other electromechanical firing mechanism could be used.
[0010] Therefore, it is an objective of the present invention to disclose a rifle with a type of firing which is performed in such a way that the excessive reduction of the contact surfaces between ratchet mechanism and counter-ratchet is not necessary and it guarantees firing by applying the minimum force to the trigger for its operation. Document EP 0081130, which is incorporated herein by reference, makes known a mechanism for the implementation of a solenoid for low-powered pistols.
[0011] A problem known to this document is that its application is valid only for pistols and not for rifles, as the placing of the solenoid in a direction perpendicular to the barrel is useful if a low gas pressure is required. In rifles the pressure is much higher and therefore a solenoid to generate said pressure is of such a size that it would impair the aesthetics and ergonomics of the rifle. Therefore, it is an objective of this invention to find a solution for the use of a solenoid situated in the rifle without having to drastically change the shape and ergonomics presented by this type of devices of a conventional shape.
[0012] Therefore there is a need to find a way of placing the solenoid in a way that is substantially parallel to the barrel.
[0013] To solve this, this invention discloses an electronic firing mechanism by means of an electromechanical actuator, placing the actuator in such a way that it operates in a direction substantially parallel to the barrel. Preferably, said electromechanical actuator is a solenoid.
[0014] To effect a firing in a rifle according to this invention, force must be applied in a direction substantially perpendicular to the direction of the barrel, therefore it is relevant that the position of the solenoid is such that it can be adapted to the conventional shape of rifles and is placed in a direction parallel to said barrel. Consequently, mechanical means must be provided which make it possible to change the direction of the force applied by the solenoid which is in a direction parallel to the barrel, hereinafter referred to as the horizontal direction, to a substantially perpendicular force, hereinafter referred to as the vertical direction. In this invention said piece is a piece in the form of a joint which when activated by a horizontal force from the solenoid exerts a vertical force on the counter-ratchet, causing the firing of the rifle.
[0015] It should be noted that with the presence of said piece, the size of the contact surface between the ratchet mechanism and counter-ratchet does not matter, as the force to uncouple them is not exerted directly on the counter-ratchet as in the prior art, but it is exerted on the piece which requires a much smaller force.
[0016] The spring rifle, according to the present invention, comprises:
a trigger which drives a firing mechanism which operates on an interconnection piece; which exerts a force on a counter-ratchet which releases a spring driving a piston
[0022] in which said firing mechanism is an electronic firing mechanism which comprises an electromechanical actuator and a switch to operate the electromechanical actuator, the electromechanical actuator being arranged in such a way that it exerts a force on the interconnection piece in a direction substantially parallel to the direction of the rifle barrel.
[0023] Said interconnection piece is preferably swivelling and it allows a change of direction of the force generated by the horizontal movement of the electromechanical actuator to a vertical force which uncouples the ratchet mechanism and the counter-ratchet, allowing the operation of the spring and permitting the passage of gas, compressed by the piston, through the barrel. Preferably, said electromechanical actuator comprises a solenoid.
[0024] Said interconnection piece can also comprise a first piece fixed to the body of the rifle and a second piece fixed to the counter-ratchet, in such a way that said first and second pieces are joined by a joint. On this joint the electromechanical actuator will subsequently exert the force, making the piece receive a horizontal force and converting it to a force substantially perpendicular to that received.
[0025] In another preferred embodiment, the rifle has an auxiliary firing mechanism independent of the electronic firing mechanism. This firing mechanism is important because it must permit the use of the rifle in the event that for any reason the electronic firing mechanism should fail. This use, in addition to discharging the rifle, allows it to continue to be fired at targets with a substantially lower accuracy yet maintaining the same firing system (operation of the trigger). That is to say, said independent auxiliary firing mechanism comprises means for discharging the rifle and for firing with substantially lower performance than that provided by the electronic firing mechanism.
[0026] Preferably, the rifle firing mechanism should comprise a trigger locking mechanism, to prevent its movement when the user so wishes, in such a way that accidental firings do not occur, preferably said firing mechanism also comprises a second switch on the current to the solenoid for use as an electrical safety device, so that the solenoid cannot become energised unless this switch is moved to the firing position. Even more preferably, the second switch comprises an activation lever which acts as a locking mechanism for the trigger. Thus both the mechanical and electrical locking of the trigger are achieved by means of a single device.
[0027] Also, to operate the switch, but to maintain the sensation of firing, said firing mechanism comprises a flexible rod to operate the switch. Said flexible rod is mechanically coupled to the trigger and the trigger moves the rod until the rod touches the switch.
[0028] Preferably the firing mechanism also comprises a plate which prevents the action of the electromechanical actuator on other pieces when the trigger is in the rest position and the said plate also comprises a guide for the flexible rod.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention is best understood from the following detailed description when read in connection with the accompanying drawings.
[0030] FIG. 1 shows the prior art in respect of spring rifles.
[0031] FIG. 2 shows an exemplary embodiment of a rifle according to the present invention.
[0032] FIG. 3 shows in detail an electronic firing mechanism according to the present invention.
[0033] FIG. 4 shows a rifle according to the present invention with the trigger in the rest position.
[0034] FIG. 5 shows a rifle according to the present invention with the trigger at the firing point.
[0035] FIG. 6 shows a rifle according to the present invention with the trigger in the final position.
[0036] FIG. 7 shows the solenoid of a rifle according to the present invention in the rest position.
[0037] FIG. 8 shows the solenoid of a rifle according to the present invention in the final position.
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIG. 1 shows a rifle with firing effected exclusively with mechanical means. It has a spring - 1 - and a piston coupled to the said spring, which is held by means of a ratchet mechanism - 10 - in the energy storage position. As firing mechanisms there is a counter-ratchet - 11 - and a trigger - 12 -. It may be observed that between the ratchet mechanism - 10 - and the counter-ratchet - 11 - there is a contact surface, which ideally is the smallest possible, but it must withstand safety tests which guarantee adequate functioning. The smaller the contact surface between the ratchet mechanism - 10 - and the counter-ratchet - 11 -, the less is the force necessary to effect the firing (the ideal situation for the user) but safety is also diminished because a fall of the weapon or the action of any force on this may cause firing.
[0039] The firing action is effected when the trigger - 12 - is rotated anti-clockwise. First, there is a free movement of the trigger - 12 - until the extension - 121 - comes into contact with the counter-ratchet - 11 -. At that moment, the firing point has been reached, as any movement from this point causes the uncoupling between the ratchet mechanism - 10 - and the counter-ratchet - 11 -, that is to say, firing. Furthermore, the rifle must have a safety system to prevent the trigger - 12 - being pressed accidentally. This safety is achieved by means of incorporating a safety catch - 122 - into the trigger. It may be stressed that said safety catch - 122 - only prevents the trigger - 12 - being pressed but a fall of the rifle or an unintentional impact may cause the counter-ratchet - 11 - to move causing uncoupling from the ratchet mechanism - 10 -. Therefore, the contact surface between both must have a distance which provides safety and which is sufficiently smooth to help the accuracy of the shooter. Furthermore, as each shooter has his preferences with regard to the force required to effect firing, rifles according to the prior art possess a screw - 123 - which permits the adjustment which defines the contact surface between the ratchet mechanism - 10 - and the counter-ratchet - 11 -, and consequently the force required to uncouple them.
[0040] FIG. 2 shows a rifle according to the present invention. A rifle with electronic firing comprises a battery - 2 - and a circuit - 3 - to adapt the energy obtained from the battery and take it to an adequate voltage level to have sufficient mechanical force to displace the counter-ratchet - 21 - similar to that known in the state of the art. Continuing with the electrical components, the firing of the rifle according to the present invention is performed when a switch - 225 - is pressed, which permits the passage of electric energy to a solenoid - 5 - which converts this electric energy to mechanical energy to effect a firing.
[0041] In respect of the mechanical components, the present invention comprises a counter-ratchet - 21 - similar to that known in the state of the art, in so far as it possesses a contact area with a ratchet mechanism - 20 - which at the moment of firing is intended to be uncoupled to permit the action of a spring (not shown) which performs a compression and release of air causing the firing of a projectile. In order to effect this uncoupling, the force in the horizontal direction effected by the solenoid - 5 - must be converted into a force in the vertical direction which causes the counter-ratchet - 21 - to rotate, uncoupling it from the ratchet mechanism - 20 -. Said conversion of the direction of the force is obtained thanks to a toggle link - 4 - or swivelling piece, which will be explained subsequently in greater detail. The rifle shown in FIG. 2 also has an auxiliary mechanical firing system, in the event that for any reason the electronic firing mechanism should not operate, there is an auxiliary firing mechanism which is not so accurate nor does it offer the performance of the electronic firing mechanism but even so it permits an acceptable shot which makes it possible, in addition to discharging the weapon, to use it with acceptable accuracy. Said firing mechanism is obtained thanks to the extension - 221 - which causes the counter-ratchet - 21 - to rotate in a manner functionally similar to the extension - 121 - in the prior art, as, once the switch is operated and in the event that this should not function, it is the flexibility of the rod - 224 - which allows the trigger to continue to rotate, allowing the extension - 221 - to move the counter-ratchet - 21 -.
[0042] FIG. 3 shows in detail an electronic firing mechanism. Firing is achieved by causing the counter-ratchet - 21 - to rotate in a similar way to how it is performed in rifles according to the prior art.
[0043] Therefore, in the case of the mechanical firing mechanism it was sufficient to have a device which exerted a force in a vertical direction upon one of the ends of the counter-ratchet to perform a firing, in the case of the firing mechanisms according to the present invention a similar event occurs. The problem which presents itself is that the force must have a not inconsiderable magnitude, and to exert this force in a vertical direction a solenoid - 5 - of a considerable size is used, which if placed vertically would affect the aesthetics and ergonomics of the rifle. Consequently, it is optimal to locate said solenoid - 5 - in the horizontal direction and to use a piece which makes it possible to transform the horizontal direction of the force exerted by the solenoid into a force in a vertical direction which allows the counter-ratchet to be rotated.
[0044] In the present invention said change in the direction of the force is effected through a swivelling piece or toggle link - 4 -. Said toggle link - 4 - comprises a first part - 41 - which is secured to a fixed part of the rifle, as body is, and a second piece - 42 - which is secured to the counter-ratchet and it possesses a joint between the pieces in such a way that it is possible to execute a horizontal movement when exerting a force on the joint. The functioning of the toggle link is such that when it receives a horizontal movement in the joint between both pieces, as the first piece - 41 - is secured to a fixed point in the rifle a force is exerted by the second piece - 42 - in a vertical direction on the counter-ratchet, causing it to rotate and consequently firing the rifle.
[0045] The firing mechanism also comprises a trigger - 22 - with an adjustable position to be set by the shooter, a screw - 223 - for the adjustment of the force required to move the trigger - 22 - a switch - 225 - the function of which is to close the circuit which delivers energy to the solenoid - 5 - activating it and a light emitting diode LED - 226 - which serves to indicate the state of operation of the electronic firing mechanism. In order to execute a firing it is sufficient to press the switch - 225 -. Furthermore the need to have a similar feel to that of rifles with a conventional firing mechanism is an important point to increase the accuracy which a user may have, therefore, the switch - 225 - is operated through a mechanism which we shall call the “flexible rod”. This mechanism is based on the use of a rod - 224 - which at rest has a substantially straight geometry, the trigger is moved until said rod reaches a stop (which may be the switch itself) which simulates the point at which the shooter knows that he is close to activating the spring. Once there, the rod starts to take a substantially more curved geometry until it presses the switch - 225 -.
[0046] FIGS. 4 , 5 and show the operation of the firing mechanism in three different positions of the trigger.
[0047] FIG. 4 shows the firing mechanism when the trigger is in the passive position (without action on the part of the user). It may be noted that the rod - 224 - is in its initial position, separated from the switch, - 225 -. In order to provide greater protection and have a guide for the rod - 224 - using a single device, the rifle according to the present invention has a plate - 227 - which functions, in addition to being a guide for the rod - 224 -, as a barrier to prevent the solenoid (not shown) from activating, the toggle link - 41 -, - 42 without the switch having been pressed (for example, owing to a fall, impact etc.), Said strip comprises a guide - 2271 - to keep the rod on a particular route and a hole - 2272 - which allows the passage of the actuator of the solenoid when the rod - 224 - is in an appropriate position for firing (indicating that the trigger - 22 - has been operated).
[0048] FIG. 5 shows the rod - 224 - when it is in the firing position, it may be observed that the rod - 224 - has already butted up against the switch - 225 - giving the user a warning by easing the necessary resistance to cause the trigger - 22 - to rotate, thus the user knows at what precise moment he is about to fire.
[0049] FIG. 6 shows the rod - 224 - when it activates the switch - 225 - effecting the firing of the rifle, in addition it is observed how through the plate - 227 - the solenoid actuator passes through the hole - 2272 - activating the toggle link - 41 -, - 42 -.
[0050] FIGS. 7 and 8 shove a schematic view to illustrate in detail the operation of the firing mechanism. FIG. 7 shows the rifle in the rest position (without any action on the part of the user) and FIG. 8 shows the rifle in the active position (at the time of firing).
[0051] FIG. 7 shows the toggle link - 4 - in its rest position, that is to say, without exerting force in a vertical direction on the counter-ratchet - 21 -. In addition one may observe the solenoid - 5 -, with its respective actuator - 52 - and its spring - 51 - in the passive position, that is, without receiving electric energy.
[0052] FIG. 8 shows, when the trigger - 22 - is pressed to the final position, the switch (not shown) which supplies electric energy to the solenoid - 5 - is activated causing, by means of its coil - 51 -, an electromechanical force to be exerted in a horizontal direction on the actuator - 52 -, causing this to pass through a plate until it takes the toggle link - 4 - to an active position. At this moment the toggle link exerts a force in a vertical direction which causes the counter-ratchet - 21 - to rotate, uncoupling it from the ratchet mechanism - 20 - and consequently releasing the spring which causes the firing.
[0053] In a particular embodiment, the rifle according to the present invention comprises an electromagnetic safety mechanism which prevents the movement of the trigger and opens the circuit of the switch, making the action, both electrical and mechanical, of the rifle impossible.
[0054] Although the invention has been described with respect to examples of preferred embodiments, these must not be considered to be limiting of the invention, which will be defined by the following claims.
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Air rifle comprising a trigger that actuates a firing mechanism that acts on an interconnection piece; that exerts a force on a counter-pawl that releases a spring for driving a piston, in which said firing mechanism is an electronic firing mechanism with an electromechanical actuator and a switch for actuating the electromechanical actuator, the electromechanical actuator being arranged in such a way that it exerts a force on the interconnection piece in a direction substantially parallel to the direction of the barrel of the gun.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to and claims the benefit of priority under 35 U.S.C. §119 from U.S. Provisional Patent Application Ser. No. 61/247,047 filed Sep. 30, 2009, and titled “Method of Singulating Embryos,” the contents of which are incorporated herein by reference.
BACKGROUND
[0002] Asexual propagation for plants has been shown for some species to yield large numbers of genetically identical embryos, each having the capacity to develop into a normal plant. Such embryos must usually be further cultured under laboratory conditions until they reach an autotrophic “seedling” state characterized by an ability to produce their own food via photosynthesis, resist desiccation, produce roots able to penetrate soil, and fend off soil microorganisms. Some researchers have experimented with the production of artificial seeds, known as manufactured seeds, in which individual plant somatic or zygotic embryos are encapsulated in a seed coat. Examples of such manufactured seeds are disclosed in U.S. Pat. No. 5,701,699, issued to Carlson et al., the disclosure of which is hereby expressly incorporated by reference.
[0003] Typical manufactured seeds include a seed shell, synthetic gametophyte and a plant embryo. A manufactured seed that does not include the plant embryo is known in the art as a “seed blank.” Such a seed blank typically is a cylindrical capsule having a closed end and an open end. Synthetic gametophyte is placed within the seed shell to substantially fill the interior of the seed shell. A longitudinally extending hard porous insert, commonly known as a cotyledon restraint, may be centrally located within the synthetic gametophyte and includes a centrally located cavity extending partially through the length of the cotyledon restraint. The cavity is sized to receive the plant embryo therein. The well-known plant embryo includes a radicle end and a cotyledon end. The plant embryo is deposited within the cavity of the cotyledon restraint cotyledon end first and is sealed within the seed blank by at least one end seal. There is a weakened spot in the end seal to allow the radicle end of the embryo to penetrate the end seal.
[0004] There are automated processes available to mass produce manufactured seeds of the type described above. One such automated process is described in U.S. patent application Ser. No. 10/982,951, entitled System and Method of Embryo Delivery for Manufactured Seeds, and assigned to Weyerhaeuser Company of Federal Way, Wash., the disclosure of which is hereby expressly incorporated by reference.
[0005] Currently, embryos are manually plucked from a growing medium and are physically placed on the plate for retrieval and insertion into a seed blank. Although such manual processes are effective, they are not without their limitations. As a non-limiting example, such manual operations are both labor and time intensive and, therefore, expensive. As part of the process to produce large numbers of somatic embryos available for insertion in manufactured seeds, it is desirable to minimize the manual labor element from the process.
SUMMARY
[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0007] A method of singulating embryos is provided. The method includes providing a plurality of embryos within a system and sensing at least one of the plurality of embryos in a fluid. The method also includes dispensing at least one of the plurality of embryos on a surface.
DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a diagrammatical view of one example of a system using a method of singulating embryos in accordance with one embodiment of the present disclosure;
[0010] FIG. 2A is a flow diagram of a method of singulating embryos in accordance with one embodiment of the present disclosure;
[0011] FIG. 2B is a continuation of the flow diagram of FIG. 2A ;
[0012] FIG. 3A is a flow diagram of a method of singulating embryos in accordance with another embodiment of the present disclosure; and
[0013] FIG. 3B is a continuation of the flow diagram of FIG. 3A .
DETAILED DESCRIPTION
[0014] FIG. 1 diagrammatically depicts an automated system 20 for implementing a method of singulating embryos in accordance with one embodiment of the present disclosure. The system 20 is suitably mounted in conjunction with an assembly for assembling manufactured seeds (not shown) or is remotely located from such an assembly.
[0015] The system 20 includes an embryo storage assembly 22 , a programmable logic controller (PLC) 24 , a placement mechanism 26 , and an embryo deposit assembly 28 . The embryo storage assembly 22 includes a singulation vessel 30 , a lift mechanism 32 , and a sensor 34 . The singulation vessel 30 is suitably a container having a plurality of embryos 40 suspended in a fluid, such as a sterile, Nanopure water. Preferably, the fluid is agitated to a sufficient degree to suspend all embryos 40 . The singulation vessel 30 is mounted on the lift mechanism 32 .
[0016] The lift mechanism 32 includes a base plate 50 coupled to a well-known lift 52 , such as a screw drive or a scissor lift, to assist in maintaining a substantially constant head at the outlet of the singulation vessel 30 . Within the meaning of this disclosure and used in this context, the term “substantially” is intended to include engineering acceptable variations resulting in a nearly constant fluid flow rate.
[0017] Although the use of a lift 52 to assist in maintaining a substantially constant head, other devices known to maintain a substantially head are also acceptable. As a non-limiting example, a pump (not shown) may be placed in fluid communication with the singulation vessel 30 to maintain the substantially constant flow rate. Thus, such devices are acceptable equivalents and are within the scope of the present disclosure. Further, while maintaining a substantially constant head is preferred, a variable head is also within the scope of the present disclosure as described in greater detail below.
[0018] Embryos 40 are transported between the singulation vessel 30 and the placement mechanism 26 by fluid flowing through tubing 60 . The tubing 60 extends between the singulation vessel 30 and the placement mechanism 26 and the sensor 34 is suitably positioned adjacent the tubing 60 to sense and/or detect embryos 40 within the tubing 60 , as described in greater detail below.
[0019] In the illustrated and exemplary embodiment, the flow rate of embryos 40 through the tubing 60 is controlled by the lift 52 . Specifically, and as is well-known, the flow rate within the tubing 60 is proportional to the square root of the vertical distance between the outlet of the tubing 60 at the placement mechanism 26 and the liquid level in the singulation vessel 30 . As the fluid in the singulation vessel 30 is decreased, the height of the singulation vessel 30 is raised by the lift mechanism 32 . The lift 52 raises the singulation vessel 30 at a fixed rate proportional to the flow rate of fluid inside of the tubing 60 to maintain a substantially constant flow rate. In other embodiments, the lift 52 may be raised or lower to increase or decrease, respectively, the flow rate.
[0020] The tubing 60 includes an inner diameter sufficiently large to permit entry of a single embryo 40 to enter the tubing 60 at any given time. Although multiple embryos 40 may be positioned longitudinally within the tubing 60 , it is desirable that only a single embryo may enter the tubing 60 at any given time. It is also preferred that the tubing 60 be of a material, such as silicone, that is transparent or semi-transparent to permit detection of an embryo within the tubing 60 by the sensor 34 .
[0021] The sensor 34 is a well-known, laser-based visual sensor used to detect when an embryo 40 exits the singulation vessel 30 . One such sensor 34 is model No. LV-H300/100 Series, manufactured and sold by Keyence Corporation of Osaka, Japan. The sensor 34 is suitably mounted to the base plate 50 with the tubing 60 operatively disposed between components of the sensor 34 . The sensor 34 , in turn, is in communication with the PLC 24 .
[0022] The system 20 may include a second, well-known sensor (not shown) in communication with the singulation vessel 30 . This second sensor is used to measure the hydrostatic head of the fluid in the singulation vessel 30 . One such sensor is model No. FW-H07, manufactured and sold by Keyence Corp. of Osaka, Japan. Such a sensor uses ultrasonic sound waves to measure distance. Although an ultrasonic sensor is preferred, other types of sensors, including laser and radar based, are within the scope of the present disclosure. The second sensor is in communication with the PLC 24 .
[0023] The well-known PLC 24 suitably has an operator interface to control the singulation process and the raising and lowering of the lift mechanism 32 . One such PLC 24 is a DirectLOGIC 205 Modular Programmable Logic Controller (DL205 PLC), manufactured and sold by Koyo Electronics Industries Co., Ltd. of Tokyo, Japan.
[0024] The PLC 24 is programmable to interface with the lift mechanism 32 , the sensor 34 , the second sensor, and the placement mechanism 26 during operation of the system 20 , as well as to permit the operator to adjust operational parameters. Operational parameters, such as the number of embryos 40 placed on the embryo deposit assembly 28 , the spacing between the embryos 40 , and the location of embryos 40 on the embryo deposit assembly 28 may all be programmed as desired.
[0025] The PLC 24 may be programmed to control the spacing and placement of embryos 40 on the embryo deposit assembly 28 by tracking the embryo as it flows through the tubing 60 . In such an embodiment, the PLC 24 includes a clock or timer and a registry. One such registry is an embryo location registry (“ELR”). The ELR includes binary registers that represent locations along the length of the tubing 60 . As an example, the ELR may segregate the tubing 60 into fifty registers, which represent fifty sequential locations in the tubing 60 . The first register location is suitably located closest to the sensor 34 and the last register is located at the end of the tubing 60 where it connects to the placement mechanism 26 . The ELR tracks and logs as a function of time the path of embryos within the tubing 60 , as described in greater detail below.
[0026] The placement mechanism 26 includes a robotic arm 80 . Motion of the robotic arm 80 is controllable relative to the embryo deposit assembly 28 to position the outlet of the tubing 60 over an open location on the embryo deposit assembly 28 . One suitable robotic arm 80 is an Ultramotion robotic arm, model No. DA25-HT17-8 NO-B/4, manufactured and sold by Ultramotion of Mattituck, N.Y. To achieve the desired motion of the robotic arm 80 , the placement mechanism 26 also includes a well-known stepping motor (not shown), such as model No. PK266-E2.0A, manufactured and sold by Oriental Motor U.S.A. Corp. of Torrance, Calif.
[0027] The robotic arm 80 has two degrees of freedom to provide precise placement of embryos 40 on the embryo deposit assembly 28 . In that regard, it is preferred that the robotic arm 80 translates longitudinally along an axis indicated by the arrow 70 . Further, the robotic arm 80 moves along the axis perpendicular to arrow 70 , i.e., in and out of the page. The outlet of the tubing 60 on the robotic arm 80 is suitably oriented at an angle relative to a vertical axis so that, as the fluid exits from the tubing 60 , it is not perpendicular to the embryo deposit assembly 28 .
[0028] It is also desirable that the robotic arm 80 is controlled by the PLC 24 , in combination with the ELR, sensor 34 , and/or the second sensor. As a non-limiting example, if an embryo 40 is detected by the sensor 34 , it sends a signal to the PLC 24 indicating the presence of the embryo. This signal is entered in the ELR as a “true.” If an embryo 40 is not detected by the sensor 34 , then the register is “false.” A “true” registry is noted as a “1,” while a “false” registry is noted as a “0.”
[0029] The number of registries in the ELR is a function of the length of the tubing 60 . For example, if the tubing 60 is 20 inches long and there are fifty registers, each register represents 0.4 inches of tubing 60 . Further, in this example, the travel time of an embryo from the sensor 34 to the placement mechanism 26 is approximately one second. As a result, each registry of the ELR represents approximately 20 ms of time. The clock updates the registry every 20 ms, such that the registers are shifted forward and each register is updated with a “1” or a “0.” Further, the speed of the robotic arm 80 is also updated every 20 ms and is programmed to match the spacing between the embryos, as desired by the operator to control the spacing of the embryos deposited onto the embryo deposit assembly 28 .
[0030] The embryo deposit assembly 28 includes a singulation frame 82 and a drainage vessel 84 . The singulation frame 82 suitably includes a supporting material that allows fluid to pass through while retaining embryos. The supporting material also preferably provides a color contrast between the supporting material and the embryo such that there is contrast between the embryos and the supporting material. One such supporting material suitable for use with the system 20 is Nitex® nylon, model No. 03-125/45. The drainage vessel 84 suitably supports a vacuum (not shown) for fluid removal and to aid in holding the embryos in a fixed location.
[0031] Operational aspects of the system 20 constructed in accordance with one embodiment of the present disclosure may be best understood by referring to FIGS. 2A-2B . The beginning of the operational sequence is represented by the start block 100 by initiating the system 20 to zero the ELR, indicated by the block 102 . Also, fluid flow through the system 20 is initiated and the lift mechanism 32 raises the singulation vessel 30 at a rate to maintain a substantially constant liquid head throughout the system 20 . This is illustrated by the block 104 .
[0032] The timer is enabled, indicated by block 110 , and the sensor 34 determines whether an embryo 40 is detected in the tubing 60 and indicated by the decision block 106 . If an embryo 40 is detected by the sensor 34 , a “1” is placed in the first registry location of the ELR, indicated by the block 108 . Thereafter, the timer is evaluated to determine whether or not a predetermined period of time, such as 20 ms, has expired, and as indicated by the decision block 112 . If an embryo is not detected by the sensor 34 , the PLC will advance ahead to the block 112 and evaluate whether the timer has timed out.
[0033] If the timer has not timed out, the ELR returns to block 106 to evaluate whether an embryo has been detected. If the timer has timed out, then the ELR shifts the registry by one position forward, indicated by the block 114 . Also, as indicated by the block 116 , the timer is reset.
[0034] As indicated by the block 118 , the PLC evaluates whether there is a “1” in the last ELR registry, indicating the presence of an embryo 40 at the very end of the tube 60 . If there is a “0” in the last registry, indicating that there is no embryo in the last registry, the PLC determines whether every registry of the ELR is a “0,” indicated by the block 120 . If every registry is empty, the robotic arm 80 is turned off, as indicated by the block 122 , and the PLC returns back to block 110 to enable the increment timer and to evaluate whether an embryo is again detected by the sensor 34 , as indicated by block 106 .
[0035] Referring back to the block 118 , if the last registry in the ELR contains a “1,” then the PLC evaluates whether any other registry in the ELR contains a “1,” thereby indicating the presence of another embryo in the tubing 60 . This is indicated by the block 124 . As represented by the block 126 , if no other registry in the ELR contains a “1,” then the speed of the robotic arm 80 is set to a minimum speed. This may be accomplished by an inclusion of a lookup table containing predetermined robotic arm speeds as a function of the number of embryos in the tubing 60 . Such a lookup table is well-known to one of ordinary skill in the art.
[0036] If there is a “1” in any one or more other registry of the ELR, then the PLC sets the robotic arm speed based on the last and next to the last registry positions in the ELR by referring to the lookup table, as noted above. This is indicated by the block 128 .
[0037] Thereafter, as indicated by the block 130 , the output speed is transmitted to the robotic arm 80 .
[0038] Before depositing the embryo onto the singulation frame 82 , the “X” position of the robotic arm 80 relative to the width of the singulation frame 82 is evaluated. Specifically, as indicated by the block 132 , the “X” position of the robotic arm 80 is evaluated to determine whether it has reached the maximum width of the singulation frame 82 . If yes, then the robotic arm 80 is advanced one position forward in the longitudinal direction, or “Y” direction, of the singulation frame 82 and the direction of the robotic arm 80 in the “X” direction is reversed, as indicated by the block 134 .
[0039] After the “X” position of the robotic arm 80 is reversed, the PLC zeroes out the “X” position, indicated by the block 136 . Thereafter, the embryo is deposited on the singulation frame 82 , as indicated by the block 138 . Returning to block 132 , if the “X” position is not reached, the blocks 134 and 136 are bypassed and the embryo is deposited on the singulation frame 82 , as noted in block 138 .
[0040] It is desired that the PLC 24 be programmed to control the robotic arm 80 such that it deposits embryos in a predetermined position on the singulation frame 82 . As a non-limiting example, the PLC 24 may be programmed such that the robotic arm 80 deposits embryos on the singulation frame 82 on their sides. In such a position, both the cotyledon and radical ends contact the supporting material of the singulation frame 82 , or only the cotyledon or radical end contacts the supporting material of the singulation frame 82 . As another non-limiting example, the robotic arm 82 may deposit embryos on the supporting material such that succeeding embryos are spaced from preceding embryos. Accordingly, such predetermined positions, as well as equivalents thereof, are within the scope of the disclosure.
[0041] After the embryo is deposited on the singulation frame 82 , and as indicated by the block 140 , the ELR determines whether a desired number of embryos deposited on the singulation frame 82 have been reached. If “no,” the ELR is returned to block 110 and the evaluation is repeated. If the maximum number of embryos has been deposited on the singulation frame 82 , the process is now complete, as indicated by the block 142 .
[0042] Operation of an alternate method of singulating embryos may be best understood by referring to FIGS. 3A and 3B . It should be noted that components of this alternate embodiment that are the same as those described with respect to the first embodiment of FIGS. 3A and 3B have the same reference number.
[0043] The beginning of the operational sequence is represented by the start block 100 by initiating the system 20 to “0” the ELR, indicated by the block 102 . Simultaneously, fluid flow through the system 20 is initiated and indicated by the block 204 . An increment timer 1 is enabled, indicated by the block 206 , and the singulation rate, or data point, is calculated, as indicated in the block 208 .
[0044] The embryo singulation rate is compared to the set point to determine whether or not the embryo singulation rate is equal to the set point, as indicated by the decision block 210 . The singulation rate is defined as the number of detected embryos per unit time. To calculate it, the number of embryos detected in a moving window of time is divided by the size (in time) of the window, e.g., 50 detections in the last 60 seconds. The window is “moving” forward in time, as the most recent window is always used. If the embryo singulation rate does not equal that set point, the hydrostatic head setpoint is adjusted. If the singulation rate needs to be decreased, the hydrostatic head setpoint is lowered. This is indicated by the block 212 . Then the hydrostatic head of the liquid within the singulation vessel 30 is measured by the second sensor. One such ultrasonic sensor is described above. This is indicated by the block 214 .
[0045] Still referring to FIG. 3A , a comparison of the liquid hydrostatic head is made relative to the set point to determine whether or not the hydrostatic head is equal to the set point, as indicated by the block 216 . If the hydrostatic head is not at the set point, the raise rate of the singulation vessel 30 by the lift mechanism 32 is adjusted, as indicated by the block 218 . In summary, the singulation rate controller adjusts the hydrostatic head setpoint (i.e., the target flow rate of fluid/embryos) and the hydrostatic head controller adjusts the rise rate of the singulation kettle in an attempt to drive the hydrostatic head to its target (aka setpoint). Following adjustment of the hydrostatic head, calculate the length (i.e., number of registers) of the ELR, as indicated by the block 220 . The length of the ELR is calculated based on the distance between the sensor ( 34 ) and the outlet of tubing ( 60 ) and the flow rate of the fluid (i.e., hydrostatic head). As the flow rate (head) increases the velocity of the fluid/embryos increases in tubing ( 60 ), which is turn reduces the time between detection and placement on s-frame ( 82 ). The number of registers required is this time divided by the time of timer 2 in block 220 . Following block 220 , a second increment timer is enabled, as shown in the block 221 .
[0046] The sensor 34 determines whether an embryo 40 is detected in the tubing 60 and indicated by the decision block 106 . If an embryo 40 is detected by the sensor 34 , a “1” is placed in the first registry location of the ELR, indicated by the block 108 . Thereafter, the second increment timer is evaluated to determine whether or not a predetermined period of time, such as 20 milliseconds, has expired, and as indicated by the decision block 222 . If an embryo is not detected by the sensor 34 , the PLC will advance ahead to block 222 to determine whether the second increment timer has timed out.
[0047] If the second increment timer has not timed out, the ELR returns to block 106 to evaluate whether an embryo has been detected. If the second increment timer has timed out, then the ELR shifts the registry by one position forward and places a “1” in the next registry location, indicated by the block 114 . Also, as indicated by the block 116 , the second increment timer is reset.
[0048] As indicated by the decision block 118 , the PLC evaluates whether there is a “1” in the last or “trigger” ELR registry, indicating the presence of an embryo 40 at the very end of the tube 60 . If there is a “0” in the last registry, indicating that there is no embryo in the last or trigger registry, the PLC determines whether the first incremental timer has timed out, indicated by the decision block 224 . If the first incremental timer has not timed out, then the PLC will advance back to enable the second increment timer, indicated by the block 221 . If, however, the first increment timer has timed out, the PLC returns back to enable Timer 1 , as indicated by the block 206 .
[0049] Returning to the decision block 118 , if the last or trigger registry in the ELR contains a “1,” then the PLC deposits an embryo on the singulation frame 82 , as noted in the block 138 . After depositing the embryo onto the singulation frame 82 , the “X” position of the robotic arm relative to the width of the singulation frame 82 is evaluated. Specifically, as indicated by the block 132 , the “X” position of the robotic arm 80 is evaluated to determine whether it has reached the maximum width of the singulation frame 82 . If it has reached the maximum width of the singulation frame 82 , then the robotic arm 80 is advanced one position forward in the longitudinal direction, or “Y” direction, of the singulation frame 82 , and the direction of the robotic arm 80 in the “X” direction is reversed, as indicated by the block 134 . After the “X” position of the robotic arm is reversed, the PLC zeroes out the “X” position, indicated by the block 136 .
[0050] If the “X” position is not reached in block 132 , the robotic arm 80 is moved one position in the “X” axis, as indicated by the block 226 . Doing so moves the robotic arm 80 to the next open position on the singulation frame 82 . Thus, removal of at least one of the plurality of embryos may be synchronized with the data point, such as the hydrostatic head, and the flow rate.
[0051] Thereafter, the PLC determines whether a desired number of embryos deposited on the singulation frame 82 have been reached, as indicated by the block 140 . If the desired number of embryo counts has not been reached, the program returns to block 204 and the process is repeated. If the maximum number of embryos has been deposited on the singulation frame 82 , the process is now complete, as indicated by the block 142 .
[0052] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. As a non-limiting example, the sensor 34 may be positioned at any point along the tubing 60 . In one alternate embodiment, the sensor 34 may be positioned adjacent the robotic arm 80 . In such an alternate embodiment, the PLC 24 may be programmed to actuate the robotic arm 80 to deposit the sensed embryo as soon as it receives an input signal from the sensor 34 . Positioning the sensor 34 adjacent the robotic arm 80 works in a system 20 that has either constant or non-constant fluid flow. Also, the method of the present disclosure may be implemented in a variety of systems and, therefore, the described system for implementing the method is provided for illustration purposes only and is not intended to be limiting.
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A method of singulating embryos is provided. The method includes providing a plurality of embryos ( 40 ) within a system ( 20 ) and sensing ( 34 ) at least one of the plurality of embryos in a fluid. The method also includes dispensing ( 26 ) at least one of the plurality of embryos on a surface ( 28 ).
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FIELD OF THE DISCLOSURE
The present disclosure is directed generally to the use of light sources. More particularly the present disclosure is directed to lighting structures that include reflective and refractive elements that can be used to distribute light from one or more light sources in desired directions.
BACKGROUND OF THE DISCLOSURE
Different strategies have been designed to provide uniform and efficient light distribution over a given area. For example, display cases are commonly used in retail applications, such as the refrigerated cases in supermarkets and convenience stores, to display merchandise and are commonly arranged into banks of shelving displays or showcase displays for holding goods. Typically, such display cases are illuminated by fluorescent light fixtures. While providing certain benefits over incandescent lighting, fluorescent lights themselves have inherent power and maintenance requirements and related costs. Fluorescent lights also contain mercury causing substantial environmental concerns and costs.
Certain techniques have been employed to install alternate sources of lighting in place of fluorescent lights. Such techniques typically require contemporaneous altering of the structural support adjacent to the fluorescent light fixtures, such as by drilling holes. For applications including refrigerated food and beverage displays, such techniques can lead to unnecessary wasted cooling energy, excess labor, and possibly spoiling of the refrigerated items themselves as well as costs related to each.
Light emitting diodes (LEDs) have been used in various applications where incandescent or fluorescent lights have been used. Because individual LEDs are essentially point light sources, as opposed to continuous elements, such as incandescent and fluorescent lights, lighting uniformity has proven challenging to achieve for many applications.
SUMMARY OF THE DISCLOSURE
The present disclosure is directed to lighting structures including refractive and/or reflective structures that can provide or distribute lighting for a given area with high uniformity and efficiency. The lighting structures can include a reflector, configured to reflect light from an adjacent light source, the reflector defining one or more apertures configured to allow light from the light source to pass therethrough. The structures can be used to distribute light from one or more light sources for lighting target areas with a desired light distribution. Other aspects, embodiments, and details of the present disclosure will be apparent from the following description when read together with the accompanying drawings.
The lighting structures can be included in light strips or luminaires. Such light strips or luminaires can be utilized in place of fluorescent lights and can facilitate quick and easy retrofit for previous fluorescent lighting applications. The disclosed techniques and systems (including components and structures) can be particularly useful when employing one or more LEDs or the like as light sources.
Light distribution structures according to the present disclosure can include a refractive element and a reflective element.
An exemplary embodiment can include a luminaire including any of the previously mentioned reflective elements or reflectors may be configured to reflect a first portion of light received from a light source in one or more desired directions and to allow a second portion of light from the light source to pass therethrough in one or more desired directions; and a refractive element configured to receive one or both of the first and second portions of light and transmit both in desired directions.
Another exemplary embodiment can include a luminaire having a light source for emitting light, a reflector having a first side and a second side, the reflector configured and situated such that a first portion of the light emitted by the light source passes through the reflector from the first side to the second side, and a second portion of the light emitted by the light source is reflected by the first side of the reflector. The luminaire can be configured such the first portion of light emitted by the light source passes through an aperture defined in the reflector. The reflector may optionally be generally V-shaped and the luminaire may be configured such that the light source is situated adjacent to the vertex of the V-shaped reflector. The reflector may optionally be generally V-shaped and the luminaire and the first portion of light emitted by the light source may be configured such that the first portion of light passes through an aperture defined approximately at the vertex of the V-shaped reflector. The luminaire may be configured such that a third portion of light emitted by the light source does not pass through the reflector and is not reflected by the first side of the reflector. The luminaire may optionally comprise a second light source wherein a first portion of light emitted by the second light source passes through the aperture defined in the reflector. The luminaire may also optionally comprise a refractor lens having a central lens portion configured to receive at least a portion of the first portion of light emitted by the light source and the central lens portion may optionally be contoured to refract light.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects and embodiments of the present disclosure may be more fully understood from the following description when read together with the accompanying drawings, which are to be regarded as illustrative in nature, and not as limiting. The drawings are not necessarily to scale, emphasis instead being placed on the principles of the disclosure. In the drawings:
FIG. 1 depicts a perspective view of a portion of an example of a luminaire, in accordance with the present disclosure;
FIG. 2 depicts a cross section of another example of a luminaire including light ray traces, in accordance with the present disclosure;
FIG. 3A depicts a cross sectional view of an exemplary embodiment of a luminaire, and FIG. 3B depicts a perspective view of an end of one exemplary embodiment of a luminaire, both in accordance with the present disclosure;
FIG. 4 depicts a cross section view of an example of a luminaire, showing variable design parameters;
FIG. 5 is a cutout view of detail A of FIG. 4 ;
FIG. 6 is a cutout view of detail B of FIG. 4 ;
FIG. 7 depicts a cross sectional view of a further embodiment of a luminaire, in accordance with the present disclosure;
FIG. 8 is a cutout view of detail A of FIG. 7 ; and
FIG. 9 is a cutout view of detail B of FIG. 7 .
The embodiments depicted in the drawing are merely illustrative. Variations of the embodiments shown in the drawings, including embodiments described herein, but not depicted in the drawings, may be envisioned and practiced within the scope of the present disclosure.
DETAILED DESCRIPTION
Aspects and embodiments of the present disclosure provide luminaires and lighting structures. Luminaires according to the present disclosure can be used for new installations or to retro-fit existing lighting assemblies and applications, such as those that utilize fluorescent lighting. Use of such lighting techniques can afford reduced energy and maintenance as well as reduced installation time and costs when compared to existing techniques.
In exemplary embodiments, alternative light sources to fluorescent lights may be utilized. While the preferred embodiment employs LEDs as light sources, other light sources may also be employed or alternatively used within the scope of the present disclosure. By way of example only, other light sources such as plasma light sources may be used. Further, the term “LEDs” is intended to refer to all types of light emitting diodes including organic light emitting diodes or “OLEDs”.
While the luminaire depicted in the Figures is generally applicable to any application that would benefit from strip lighting, it is well-suited, in one example, for application to display cases where the luminaire can be mounted to various of the elongated structural elements of the display case to be hidden from the view of customers viewing items in the display case. One exemplary application is refrigerated food cases such as those commonly found in supermarkets and convenience stores. The depicted luminaire lends itself to application in food cases because its elongated structure facilitates mounting to mullions between doors permitting access to the food case. Such refrigerated cases, can include cases for chilled foods and/or drinks, as well as those used to display frozen foods. Other embodiments may be particularly well-suited for use in display cases for displaying non-food items, e.g., those used to display merchandise goods such as jewelry, watches, and the like. Use in such non-food display cases is advantageous because of the luminaires ability to be mounted to various of the elongated structural components of the display case to illuminate the display case while remaining at least mostly hidden from view of those persons viewing items in the display case. As will be discussed below, the reflector of the present disclosure, while elongated, is applicable to other luminaires such as by using multiple of these reflectors to guide the light from various matrices of light sources.
FIG. 1 depicts a perspective view of a portion of an example of a luminaire 100 , in accordance with the present disclosure. Luminaire 100 may include a reflective element (or reflector) 104 (e.g., a V-shaped element as shown), which has one or more apertures 105 defined at its vertex. The one or more apertures 105 are configured to pass some of the light emitted from one or more light sources 108 (e.g., LEDs) associated therewith. One or more reflector mounting structures 106 (e.g., spring clips) may hold the reflective element 104 relative to the light sources 108 depicted as LEDs mounted or formed on a printed circuit board (“PCB”) 112 supported on a frame 114 . The frame 114 may have any suitable size, shape and cross-sectional configuration. Any suitable materials may be used for the described components. Luminaire 100 may, optionally, be used with or include a lens or refractive element such as that described and/or shown in the figures herein.
In operation while the one or more light sources 108 of the luminaire 100 depicted in FIG. 1 are producing light, a first portion of light from each individual light source 108 passes through an associated aperture 105 and a second portion of light is directed laterally relative to the luminaire 100 ; some of which passes directly as emitted from the light source 108 and some of which is reflected by the reflective element 104 after being emitted from the light source 108 , e.g., as shown and described for FIG. 2 .
FIG. 2 depicts a cross section of another exemplary luminaire in accordance with the present disclosure. Luminaire 200 may include a reflector or reflective element 202 and one or more suitable light sources (e.g., LEDs) 204 . A lens or refractive element 206 may also be included. The reflective element 202 defines one or more apertures 208 that are configured to permit passage of a portion of light from the one or more light sources 204 . One or more reflector mounting structures (e.g., spring clips) 210 hold the reflective element 202 relative to the associated light source 204 mounted on or part of a PCB 212 and the PCB 212 is situated on a frame 214 . FIG. 2 depicts an arbitrary structure 1 to which the luminaire 200 is mounted.
Light emanating from the one or more light sources travels though the refractive element in accordance with Snell's law. For ease of comprehension, light ray traces in the area indicated at reference numeral 3 indicates light passing through the depicted aperture 208 then the lens 206 . Light ray traces in the two areas indicated at reference numeral 2 , indicates light emanating from the one or more light sources 204 and passing laterally through the lens either directly from the light source 204 or after reflecting from the reflective element 202 .
The lens or refractive element 206 may include a portion 206 a that is configured to receive a portion of light from the one or more light sources 204 passing through the one or more apertures 208 .
The reflector mounting structure 210 , comprises the same configuration as the reflector mounting structure 106 shown in FIG. 1 . In the embodiment of the reflector mounting structure 106 , 210 depicted in FIGS. 1 and 2 is comprised of first and second receiving legs 106 a joined at one end to form an inverted V. Each receiving leg 106 a comprises receiving slots 106 b on opposing sides to receive the reflector 104 , 202 as shown. A mounting leg 106 c extends from each of the receiving legs 106 a for standing on the PCB 112 , 212 and allowing the receiving slots 106 b to hold the reflector 104 , 202 apart from the PCB 112 , 212 . Springs clips formed by spring legs 106 d and 106 e extend from each mounting leg 106 c as shown.
Frame 214 may have any desired shape. For example, frame 214 preferably includes one or more arms forming channels ( 214 a , 214 b ) having a partially circular cross-section configured to receive fasteners such as screws, dowels, pins, or the like to assist with assembly or mounting of the luminaire 200 . Frame 214 also preferably includes one or more arms ( 214 c - 214 e ), that are configured to receive and/or contact one or more respective portions of the luminaire 200 . For example, in the embodiment depicted in FIG. 2 , horizontal arm 214 e extends outward from the remaining portions of the frame 214 . Arm 214 c extends upward from arm 214 e and bends inward to define a mounting structure channel 214 f . Each mounting structure channel 214 f receives the spring legs 106 d and 106 e of the reflector mounting structure 106 , 210 to secure the reflector mounting structure 210 to the frame 214 . In one embodiment, the spring legs 106 d and 106 e are flexed to fit the spring clip they form into the mounting structure channel 214 f . Once the spring clip formed by spring legs 106 d and 106 e on each side of the mounting structure 106 , 210 are secured in their respective mounting structure channels 214 f , the mounting structure 106 , 210 is secured in place to the frame 114 , 214 . Furthermore, arm 214 d extends downward from arm 214 e to define a lens mounting channel 214 g to receive a portion of the lens 206 to facilitate securement of the lens 206 to the frame 214 , described in more detail below. In one embodiment, frame 214 is constructed by extrusion to provide the frame 214 with all required rigidity. The frame 214 may be constructed from any suitable material. Examples include, but are not limited to, anodized aluminum, chromed steel, plastic, and the like.
FIG. 3A depicts a cross sectional view of an exemplary embodiment of a luminaire 300 A, in accordance with the present disclosure. Luminaire 300 A may include a refractor, or refractive element, 302 . Refractor 302 may have a central lens portions 303 comprising variable thickness that is configured to distribute or refract light. The central lens portion 303 has a thickness profile and inner surface 303 a to distribute light from a light source (e.g. LED) 308 in a desired distribution pattern. Refractor 302 may also be referred to as a means for refracting or a refractive means. Luminaire 300 A may also include a reflective element or reflector 304 . The refractive element 302 and the reflective element 304 may together or individually be referred to as light distribution means.
Continuing with the description of FIG. 3A , a mounting structure 306 may hold the reflector 304 relative to a frame 314 and the light source 308 mounted thereon. Frame 314 may be any suitable shape and may be made of any suitable material. For exemplary embodiments, frame 314 may be adapted to fit within the footprint of a pre-existing fluorescent light fixture and, optionally, use the same mounting holes or equipment as the pre-existing fluorescent light fixture to facilitate simple replacement of the pre-existing fluorescent light fixture with the light fixture of the present disclosure. One or more light elements or light sources 308 may be present (one is shown in FIG. 3A ). The one or more light sources 308 may be positioned adjacent or on a supporting member, e.g., a PCB 312 . For some applications, the one or more light sources may be enclosed in or disposed on a protective die or a mounting element. If one or more of the light sources are enclosed in a die, then the die may have appropriate sections that are transparent or translucent to allow light from the lights source(s) to pass through.
With further reference to FIG. 3A , the reflector 304 can have one or more apertures 305 for passing light from a light source 308 to refractor 302 . In the embodiment depicted in FIGS. 1 , 2 , 3 A, 4 - 5 and 7 , the reflector 104 (in FIG. 1 ) is configured with a V-shape having first and second arms 304 a spread at a desired included angle α. In exemplary embodiments the included angle, α, may be 100 degrees; of course other included angles may be used as suitable. In the depicted embodiment, the first and second arms are straight, but could be replaced with curved, stepped or other known reflector configurations to facilitate a desired light distribution, Various surface treatments are also contemplated to provide desired reflectance.
Each aperture 305 may be configured (e.g., sized and/or shaped) as desired. For example, a single aperture 305 may be sized to have a length (measured along the vertex of the reflector 304 ) that is or is substantially the length of PCB 312 so as to provide an opening at the vertex of the reflector 304 at each light source along the length of the PCB 312 . In other embodiments, multiple apertures (a plurality of) 305 may be disposed in a desired configuration, e.g., linearly with a constant or varying linear density (e.g., one every foot, one every light source, one every two light sources, etc.). Each individual aperture 305 may have a shape (e.g., of its perimeter) that is selected as desired. For example, an aperture may be elliptical in shape with any degree of eccentricity, circular, rectangular, irregular (any shape) square, triangular, etc.
In exemplary embodiments, the central lens portion 303 of refractor 302 may be positioned to receive light from a light source 308 by way of aperture 305 . The luminaire 300 A may be configured such that all light passing through the aperture 305 passes through the central lens portion 303 . Alternatively, luminaire 300 A may be configured such that only a portion of the light passing through the aperture 305 passes through the central lens portion 303 . In yet a further alternative embodiment, the luminaire may comprise a refractor 302 with no central lens portion 303 , in which case the refractor 302 is of the substantially the same thickness in all portions through which light from the light source 308 travels. Refractor 302 may have one or more lateral faces 307 , as shown, which may have varying thicknesses to direct the light passing therethrough, or be of constant thickness to serve primarily as protection for the elements of the luminaire 300 A. Refractor 302 may optionally have inwardly directed members 318 , as shown. In one embodiment not depicted, optional inwardly directed member 318 may be configured so as to clamp the PCB 312 to the frame 314 when the refractor 302 is connected to the frame 314 as depicted in FIG. 3A . In order to facilitate clamping of the PCB 312 in this manner, the configuration of the optional inwardly directed member 318 must take into consideration no only the configuration of the frame 314 , but also the configuration of the PCB 312 . In yet another alternative embodiment, not depicted, the optional inwardly directed member 318 may be configured so as to clamp down on top of the mounting structure 306 , providing additional stability to the mounting structure 306 and the reflector 304 held by the mounting structure 306 .
Refractor 302 may include a central face 315 in which the central lens portion 303 resided, if a central lens portion 303 is present. Central face 315 may be relatively or substantially flat in some embodiments, though it may comprise one or more curvatures or other shapes. The central face 315 may have a desired width, shown by “a,” and may be of any length suitable for the luminaire 300 A and its application. For example, the length of face 315 may be 3 ft., 6 ft., 9 ft., etc. In some embodiments, central face 315 may have a diffusive surface 316 on the interior or exterior thereof, which may facilitate uniformity of light intensity and distribution. The diffusive surface 316 can span the entirety of central face 315 or portions of central face 315 as needed, e.g., as indicated by width “b” in the FIG. 3A . In exemplary embodiments, diffusive surface 316 can be or include a diffusive acrylic layer approximately 8 mils thick (0.008 in.) covering a desired width of the central face 315 , e.g., 0.7 inch. In one embodiment, the diffusive surface 316 can be provided by co-extruding refractor 302 to comprise a layer of diffusive material (not depicted) at the diffusive surface 316 . In one example, the diffusive layer is 8 mils thick and comprised of an acrylic sold under the trade name Acrylite® 8Ndf23 at the outermost surface of the refractor 302 at the central face 315 . In an alternative embodiment, the diffusive surface 316 can be provided by applying a film of diffusive material to the outside of central face 315 . For example, a length of Scotch tape or other tape may be applied to the outer surface of the central face 315 . In exemplary embodiments, luminaire 300 A may be symmetric with respective to a plane intersecting midline z, as shown.
In operation, light source 308 can produce light, which may emanate from the light source 308 in a three-dimensional distribution pattern, e.g., a hemisphere of 271 steradians of solid angle, or a cone of other given included solid angle, etc. Of the light constituting this distribution, some may travel directly out of the refracting element 302 , for example, through lateral face 307 , as shown by representative rav trace R 1 . Some of the light from the light source 308 may be reflected by reflective element 304 and then pass through refractive element 302 as shown by representative ray trace R 2 . Still, another portion of the light from light source 308 may pass through aperture 305 and then through refractive element 302 , e.g., through contoured portion 303 , as shown by representative ray trace R 3 . Ray traces R 1 -R 3 are merely representative, and other optical paths may occur, e.g., ones including total internal reflection in accordance with Snell's law.
Refractor 302 may be made from any suitable transparent, substantially transparent, and/or translucent material, e.g., glass, Lexan, or acrylic such as sold under the trade name Optix® CA-1000E, or suitable functional equivalent. The material used for the refractor 302 may have any suitable clarity. In exemplary embodiments, the material may be about 85% transmissive, though higher values, e.g., 90% or higher, may be preferred. The diffusive surface 316 or the central face 315 and exemplary materials therefore are discussed above. Any suitable reflective material may be used for reflector 304 . Examples include, but are not limited to, specular aluminum, chromed steel, aluminized or aluminum-coated plastic, painted plastic, and the like. In exemplary embodiments, a specular aluminum sheet is used that is about 95% reflective; of course, other values of reflectivity (e.g., 70%, 85%, 90% or thereabouts) may be used or implemented for a reflective element. Alanod Miro—4400 GP is considered suitable. If the reflector 304 is comprises of a metal, the reflector can be constructed by one or more stamping operations to form the apertures 305 and one or more bending operations to form the desired V-shape. It is further noted that the reflector 304 shape need not be an absolute V. Rather various variations and deviations from the absolute V, such as curved legs extending from the vertex, are contemplated.
In an exemplary embodiment, light source(s) 308 may include one or more LEDs suitable for the light distribution and intensity necessary for the application. The light sources 308 could be LEDs made commercially available by Osram Opto Semiconductor, Model Oslon LUW CP7P-LXLY-7P7E. Other suitable lights sources 308 may include, but are not limited to, Cree XPEWHT-01-0000-00EC, Philips LumiLEDS Rebel LXML-PWN1-0100, or suitable equivalent. The length (e.g., into or out of the plane of FIG. 3A ) of an aperture may be about 0.5 inches in exemplary embodiments. The approximate range of angular rays emanating from the apertures 305 may be 45 degrees, plus or minus five degrees, for exemplary embodiments.
In exemplary embodiments, luminaire 300 A may have a rectangular shape in plan view and may be configured for retrofitting into a lighting application that previously included fluorescent lighting. Of course, luminaire 300 A may have other shapes in plan view, e.g., circular, oval, square, etc.
For use in illuminating a desired area, the luminaires of the present disclosure may be mounted to a structure or surface by any suitable mounting devices, structures, fasteners, or the like.
FIG. 3B depicts a perspective view of a portion of a luminaire 300 B, similar to luminaire 300 A of FIG. 3A , with a mounting bracket 301 for mounting the luminaire to a structure, e.g., an underlying mullion, support structure, or the like. The mounting bracket 301 may be formed from any suitable material, e.g., sheet metal, plastic, or the like. The end cap 301 may include one or more holes or apertures. For example, apertures 330 and 332 may be present for accommodating a power chord. For further example, one or more apertures may be formed in the end cap for use with fasteners, e.g., screws, as shown by 334 and 336 . An end cap 303 may be present to cover the mounting bracket 301 .
For operation, in some applications, a power cable/chord from the luminaire 300 B may be run through a hole (e.g., 332 ) in the mounting bracket 301 out the back and through a hole formed into an underlying structures such as a cooler mullion to which the luminaire 300 B is to be mounted. The other end (not shown) of the luminaire 300 B may optionally include a hole, e.g., a breather hole for venting the interior of the fixture. The cooler mullion can act as a passageway for the power cable and possible mounting location of a related power supply. The luminaire 300 B may be attached (e.g., screwed) into place, e.g., on the cooler mullion, top and bottom. The end cap (e.g., a molded plastic cap) 303 may be snapped over this mounting bracket 301 to hide the screws, cables, etc. The back of the luminaire 300 B and the cap 303 may rest flush against an underlying structure, e.g., cooler mullion. In this way, all potential crevices may be hidden or minimized, e.g., for NSF compliance.
FIG. 4 depicts a cross section view of a further example of a luminaire 400 , showing variable design parameters that may be selected or specified as desired, e.g., for a particular installation or application. As shown, luminaire 400 may include a refractor 402 with a central lens portion 403 having a curved surface 403 a . Luminaire 400 can also include a reflector 404 . Reflector 404 may have one or more lateral reflective faces 404 a . Reflector 404 may have one or more apertures 405 that are configured to allow light to pass through the reflective element 404 . Apertures 405 may be holes, e.g., as drilled or stamped through reflective element 404 , or may be portions of reflective element that are transparent or translucent instead of reflective, for example, portions that are not painted with reflective paint. Reflector 404 may be held by a support member (not depicted in FIG. 4 ). One or more light sources 408 may be present and configured adjacent to aperture 405 , e.g., disposed on support surface or PCB 412 , as shown. The refractor 402 may also have one or more lateral faces 407 , as shown. For some applications, lateral face(s) 407 may have a desired radius of curvature “R.” For example, lateral faces 407 may have a radius of curvature relative to the optical center of one or more light sources 408 . R may have any suitable value (e.g., 0.5 in., 0.590 in., 1.0 in., etc).
For luminaire 400 , a number of design parameters (c-j) are shown, which may be selected as desired for various applications. The design parameters shown include the following: (c)—the distance or height between the top of the refractive element 402 at the central face 415 and the optical center 408 ; (d)—the distance or height between the lowest portion of the curved surface 403 a of the central lens portion 403 ; (e)—the distance or height between the optical center of the light source 408 and the proximal portion of the apex of the reflector 404 at the aperture 405 ; (f)—the thickness of the central face 415 ; (g)—angle between the faces 404 a of the reflector 404 and the horizontal reference plane; (h)—the distance or height between the optical center of the light source 408 and the distal or top portion of the optical source housing, e.g., LED package; (i)—angular range of rays emanating from aperture (either solid angle or 2D angle); (j)—distance or diameter across trench or circle formed by the curved surface 403 a of the central lens portion 403 ; and (k)—distance or length of lateral reflective surface(s) 404 a.
FIG. 5 is a cutout view of detail A of FIG. 4 , while FIG. 6 is a cutout view of detail B of FIG. 4 . FIG. 5 shows the following design parameters: (l)—height between optical center of light source 408 and the aperture 405 , on the distal side, away from light source 408 ; (m)—width of aperture 405 , on the distal side, away from light source 408 ; (n)—half-distance or radius of aperture 405 , on distal side, away from light source 408 ; (o)—radius of curvature of fillet between lateral reflective faces 404 a ; and (p)—thickness of lateral reflective faces 404 a.
FIG. 6 shows the central lens portion 403 with a curved surface 403 a that is symmetrical about a center line. Curved surface 403 a may subtend any suitable angle, “q” for various applications. In exemplary embodiments, the profile of curved surface 403 a may be an elliptical profile, e.g., approximated by the curve y=0.706x 0.664 ; other curves and and/or profiles may of course be used. For the profile of curved surface 403 a , two flats may be angled toward a vertex, e.g., vertex 601 in FIG. 6 finished by a smooth curve or fillet. Of course, any other desired profile may be used for curved surface 403 a , e.g., saw-tooth pattern, sinusoidal, etc.
In an exemplary embodiment, luminaire 400 as shown in FIGS. 4-6 may have the following values for design parameters (c-p):
c
0.450″
d
0.334″
e
0.092″
f
0.050″
g
40°
h
0.062″
i
45°
j
0.240″
k
0.407″
l
0.122″
m
0.048″
n
0.024″
o
R = 0.03″
p
0.020″
q
112°
FIG. 7 depicts a cross sectional view of a further embodiment of a luminaire 700 , in accordance with the present disclosure. FIG. 8 is a cutout view of detail A of FIG. 7 , while FIG. 9 is a cutout view of detail B of FIG. 7 . In operation, luminaire 700 can distribute light similarly to luminaire 400 of FIG. 4 .
As shown, luminaire 700 may include a refractor 702 and a reflector 704 . Refractor 702 may include a central lens portion 703 that has a profiled surface 703 a . Reflector 704 may include one or more lateral reflective faces 704 a . The included angle between the lateral reflective faces 704 a may be selected as desired for the sought light distribution. For example, the angle may be about 100 degrees, about 90 degrees, about 95 degrees, about 110 degrees, 80 degrees, about 105 degrees, etc. Luminaire 700 may also include a frame element 706 with one or more secondary reflective surfaces 706 a , as indicated. Frame element 706 may also have a base 706 b , as shown. Reflective element 704 may include one or more apertures 707 . Aperture(s) 707 may be configured adjacent to, and pass or receive light from, one or more light sources 708 . Light source(s) 708 may be positioned on a support surface 712 , e.g., a PCB.
With continued reference to FIG. 7 , refractor 702 may include a central lens portion 703 having a profiled surface 703 a . The profiled surface 703 a may have any desired surface profile. In exemplary embodiments, the contour or shape of profiled surface 703 a may facilitate even or roughly even light intensity distribution of light outside of the luminaire 700 in a desired area or region. Examples include but are not limited to concentric circles or ovals or ellipses, with a saw tooth or curved profile in cross-section. Refractive element 702 may also include a shaped portion 705 that has a varying thickness in cross section. As shown in FIG. 7 , the shaped portion may 705 facilitate reception of the reflective element 704 by the refractive element 702 .
As further shown in FIG. 7 , refractor 702 may be shaped to provide a viewing angle “r” of desired size or range of sizes. For example, in exemplary embodiments, refractor 702 may have a bend at or near shaped portion 705 such that the viewing angle, r, is 5° or approximately 5°; which may facilitate hiding, or preventing direct viewing of, light source 708 by people in an area or region outside of the luminaire 700 .
In exemplary embodiments, luminaire 700 has a rectangular shape in plan view and may be configured for retrofitting into a lighting application that previously included fluorescent lighting. Of course, luminaire 700 may have other shapes in plan view, e.g., circular, oval, square, etc.
In an exemplary embodiment, the lateral faces 104 a are 0.517 inches long, the viewing angle is 7 degrees, base 706 b is 1.136 inches wide, the secondary reflective surfaces 706 a have a radius of curvature of 1.250 inches, and overall frame width is 2.821 inches, with a height to the top of the frame of 0.490 inches, while the overall height of the luminaire is 0.635 inches.
In another exemplary embodiment, luminaire 700 as shown in FIGS. 7-9 may have the following values for design parameters (r-bb):
R
5°
S
35°
T
32°
U
27°
V
22°
W
15°
X
22°
Y
18°
Z
13°
aa
8°
bb
4°
The LEDs of this exemplary embodiment can be of any kind, color (e.g., emitting any color or white light or mixture of colors and white light as the intended lighting arrangement requires) and luminance capacity or intensity, preferably in the visible spectrum. Color selection can be made as the intended lighting arrangement requires. In accordance with the present disclosure, LEDs can comprise any semiconductor configuration and material or combination (alloy) that produce the intended array of color or colors. The LEDs can have a refractive optic built-in with the LED or placed over the LED, or no refractive optic; and can alternatively, or also, have a surrounding reflector, e.g., that re-directs low-angle and mid-angle LED light outwardly. In one suitable embodiment, the LEDs are white LEDs each comprising a gallium nitride (GaN)-based light emitting semiconductor device coupled to a coating containing one or more phosphors. The GaN-based semiconductor device can emit light in the blue and/or ultraviolet range, and excites the phosphor coating to produce longer wavelength light. The combined light output can approximate a white light output. For example, a GaN-based semiconductor device generating blue light can be combined with a yellow phosphor to produce white light. Alternatively, a GaN-based semiconductor device generating ultraviolet light can be combined with red, green, and blue phosphors in a ratio and arrangement that produces white light (or another desired color). In yet another suitable embodiment, colored LEDs are used, such are phosphide-based semiconductor devices emitting red or green light, in which case the LED assembly produces light of the corresponding color. In still yet another suitable embodiment, the LED light board may include red, green, and blue LEDs distributed on the printed circuit board in a selected pattern to produce light of a selected color using a red-green-blue (RGB) color composition arrangement. In this latter exemplary embodiment, the LED light board can be configured to emit a selectable color by selective operation of the red, green, and blue LEDs at selected optical intensities. Clusters of different kinds and colors of LED is also contemplated to obtain the benefits of blending their output.
Each PCB, e.g., 212 of FIG. 2 , can include an onboard driver to run the light sources, e.g., LEDs, with a desired current. For example, a current suitable for an LED may be used. For example, a representative current range could include, but is not limited to about 250 mA to about 800 mA; one exemplary current is about 350 mA and another is 600 mA. A circuit board can have a bus, e.g., a 24V DC bus, going from one end to the other. Other voltages may of course be used for a bus. Any suitable number of suitable LEDs can be disposed on a light strip board. In one illustrative example, two (2) Rebel LEDs (LUXEON® Rebel LEDs as made commercially available by the Philips Lumileds Lighting Company)—per foot, operational at 80 Lumens minimum may be employed with the luminaire of the present disclosure. Other suitable LEDs or alternative light sources and output values may be used within the scope of the present disclosure.
In exemplary embodiments, a lens or refractive element may be made of an extrusion of polycarbonate or acrylic. Such polycarbonate or other plastic may be selected as desired and may possess a desired degree of transparency (and, therefore, opaqueness) and may have a desired color.
In further embodiments, the formation of at least one support member can include forming a circuit board supporting face in the support member that is configured and arranged to support the circuit board (and attached light sources) in a desired orientation, e.g., as when the related assembly is placed in a retrofit application. A visual cutoff shield may also be mounted to a support member for some applications.
Accordingly, lighting assemblies and luminaires according to the present disclosure can distribute light from one or more light sources in desired ways. Exemplary embodiments of lighting techniques according to the present disclosure can be used to retro-fit existing lighting assemblies and applications that were initially constructed to utilize fluorescent lighting. Such lighting according to the present disclosure can afford reduced energy, maintenance, and installation costs, as well as reduced installation time when compared to existing techniques. As described previously, exemplary embodiments of the present disclosure may utilize LEDs as light sources.
While certain embodiments have been described herein, it will be understood by one skilled in the art that the methods, systems, and apparatus of the present disclosure may be embodied in other specific forms without departing from the spirit thereof. For example, while aspects and embodiments herein have been described in the context of retrofit applications for refrigerated display cases, the present disclosure is not limited to such; for example, embodiments of the present disclosure may be utilized generally for any light distribution applications.
Accordingly, the embodiments described herein, and as claimed in the attached claims, are to be considered in all respects as illustrative of the present disclosure and not restrictive.
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Luminaires are disclosed that include refractive and/or reflective structures that can provide or distribute lighting for a given area with high uniformity and efficiency. The structures can be used to distribute light from one or more light sources for lighting target areas with a desired light distribution. The lighting structures can be included in light strips or luminaires. Such luminaire can be utilized in place of fluorescent lights and can facilitate quick and easy retrofit for previous fluorescent lighting applications. The disclosed techniques and systems (including components and structures) can be particularly useful when employing one or more LEDs as light sources.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a crust used as a base of a pizza pie, a device for production of the crust, and a method of producing same, and in particular, to a method of producing a crust able to be distributed in a dried state, which is not deformed, has a smooth feeling when eaten, and has a good flavor and taste.
2. Description of the Related Art
Pizza pie is a food developed in Italy, and in general, is a kind of pie prepared by adding yeast to wheat flour, kneading and maturing the mixture, spreading the mixture under pressure on a pie dish, placing thereon a topping such as sauce, cheese, etc., and baking the whole. Historically, pizza was developed from a home dish, and is now often supplied by service shops.
The pizza crust is called the pie shell, and in a household and service shop, is prepared by a method comprising the steps of blending raw materials essentially consisting of wheat flour, kneading and maturing the dough, spreading the dough under pressure, and forming and baking the dough in a pie dish.
More particularly, pizza is produced by:
(1) A method in which an uncooked dough is prepared by hand as described in the foregoing, and the dough is cooked;
(2) A method in which the above-described uncooked dough is formed into a crust, and the crust is stored at a cool temperature or by freezing, to be later cooked; or
(3) Recently, a circular, square, etc., bread-like, biscuit-like, or cracker-like pizza crust, which has been baked, or heat-treated so as to be easily cookable, is supplied and cooked. In addition, as described in Japanese Patent Application No. 63-318150, there is also known a bread-like pizza crust.
The pizza crust produced from uncooked dough has remarkable features in that the action of yeast blended with the raw material, enables a pizza pie to be prepared in which the crust and topping are well blended and integrated, having a soft and full state, and a good flavor and good taste. This conventional method however, has a defect in that each stage of the process requires much labor and time, although this depends upon the degree of skill of the cook, that a baking apparatus consuming a large amount of energy, such as gas oven, is required for the final baking, and that the pizza pie does not last long due to the use of an uncooked dough. The afore-mentioned crust prepared in such a way that an uncooked dough is formed into a crust, and the thus obtained crust is stored at a cool temperature or by freezing, can eliminate the defect that the untreated uncooked crust does not last long, but the other afore-mentioned defects remain, and further, a defect exists in that when stored at a cool temperature or by freezing, it is easily broken.
The circular or square shaped backed or heat-treated bread-like pizza crust has a merit in that it can be easily cooked with an apparatus not consuming a large amount of energy, such as oven toaster, etc., and that it will keep. Such a pizza crust, however, has a defect in that, as it is a pizza crust subjected to baking or heat-treatment, there is no yeast action during the cooking thereof, unlike a pizza crust prepared from uncooked dough, and it has a poor flavor and taste, and further, has an important defect in that the pizza crust and the topping to be placed thereon are separated from each other and do not blend well with each other. In addition, such a pizza crust also has a defect in that the topping overflows the crust, because the crust does not possess a flanged portion on the outer circumference thereof, that cooking for a long time is therefore impossible, and it is difficult to brown off the pizza pie. Further, it should be stored in a refrigerator so that it keeps well, because it is a bread-like or biscuit-like product. As described in Japanese Patent Application No. 63-318150, the baked or heat-treated bread-like pizza crust with a flange formed on the outer circumference overcomes the foregoing defect that the topping overflows at the time of cooking, but the other defects have not been overcome.
SUMMARY OF THE INVENTION
The present invention overcomes the above-mentioned various defects of the conventional pizza crusts, and the object of the present invention is to provide a pizza crust which enables an easy cooking of a pizza pie with a good flavor, good crispy feeling when eaten, and a good puffiness and good taste, without requiring a long time and much labor, and which may be cooked with an apparatus not consuming a large amount of energy such as oven toaster, and which keeps well and may be stored for a long time.
More specifically, the present invention provides a pizza crust comprising a top layer of an uncooked dough and a base layer of a dough obtained by subjecting a dough to baking or heat-treatment, the dough having a flanged portion formed on the outer circumference thereof.
The present invention further provides a pizza crust comprising a top layer of an uncooked dough and a base layer of uncooked dough, the dough having a flanged portion formed on the outer circumference thereof.
The present invention also provides a process for the production of a pizza crust, comprising the steps of:
fitting uncooked dough into a base template, placing a first cover template thereover, pressing the first cover template and removing the first cover template to thereby form a base layer; and
supplying uncooked dough onto the formed base layer, placing a second cover template thereover, pressing the second cover template and then removing the second cover template to thereby prepare a top layer.
The present invention still further provides an apparatus for producing a pizza crust, comprising:
a base template defining a shape of a lower surface of a base layer of the pizza crust;
a first cover template defining a shape of an upper surface of the base layer of the pizza crust; and
a second cover template defining the shape of the upper surface of the top layer of the pizza crust, wherein at least one of the first cover template and second cover template has a plurality of needle-like projections having a length corresponding to the thickness of the base layer or surface layer respectively, which needles make holes in the layer.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 represents a sectional view of a pizza crust of the present invention;
FIG. 2 represents a plan view of the pizza crust shown in FIG. 1;
FIG. 3 represents a sectional view of a base template;
FIG. 4 represents a plan view of a base template;
FIG. 5 represents a sectional view of a first cover template;
FIG. 6 represents a plan view of the working surface (which is in contact with the base layer) of the first cover template;
FIG. 7 represents a sectional view of a second cover template;
FIG. 8 represents a plan view of the working surface (which is in contact with the top layer) of the second cover template;
FIG. 9 represents a sectional view wherein a base layer is pressed between a base template and a first cover template;
FIG. 10 represents a sectional view wherein a base layer and a top layer are pressed between a base template and a second cover template.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is further described in detail with reference to the drawings.
FIG. 1 shows a sectional view of the present pizza crust 1 comprising a top layer 2 and a base layer 3, both made of an edible dough. Both layers 2, 3 comprises a plane portion 4 and a flange portion 5, and both layers 2, 3 have a plurality of holes 6 made by needle-like projections provided on the working surface of a second cover template. The working surface of the second cover template means the surface which is in contact with the surface layer of the dough. The flange portion is projected at an angle of, for example, about 135°, relative to the plane portion.
In this embodiment, it is assumed that the pizza crust is circular, and that the diameter thereof is 150 to 310 mm, the thickness 7 of the base layer is, for example, 1 to 3 mm or more, the thickness 8 of the surface layer is, for example, 3 to 6 mm or more, and the size of the flange portion 9 is, for example, 9 to 15 mm.
FIG. 2 represents a plan view of the pizza crust shown in FIG. 1.
A pizza crust of the present invention is provided with a flange portion, whereby a topping such as cheese placed on the crust is prevented from overflowing during the cooking or baking thereof.
Although a circular formed pizza crust is exemplified, any shape such as ellipse, square or the like of a pizza crust can be obtained according to the present invention. Moreover, as the diameter of the pizza crust becomes larger, the thickness 7 of the base layer, the thickness 8 of the top layer, and the size 9 of the flange portion may become larger.
FIG. 3 represents a sectional view of an embodiment of a base template of the present apparatus, and FIG. 4 represents a plan view of the base template shown in FIG. 3. The base template 20 defines the shape of a base layer of a pizza crust, and comprises a plane portion 21 and a flange portion 22. The upper surface 23 of the base template defines the shape of the lower surface of the base layer of dough, and the size and shape of the plane portions 21 and the flange portion 22 correspond to the size and shape of the base layer.
FIG. 5 represents a sectional view of an embodiment of a first cover template, and FIG. 6 represents a plan view of the first cover template shown in FIG. 5. The first cover template 30 comprises a plane portion 31 and a flange portion 32. The working surface 33, which is in contact with the upper surface of the base layer of the dough, and therefore, defines the shape of the upper surface of the base layer, has a plurality of needle-like projection 34. In the use of the apparatus, the tips of the projections 34 are brought into contact with the upper surface 23 of the base template 20 and define a spare between the upper surface 23 of the base template and the working surface (lower surface) 33 of the first cover template, the base layer being sandwiched therebetween. Therefore, the height of the projection 34 defines the thickness of the base layer.
FIG. 7 represents a sectional view of an embodiment of a second cover template 40. The second cover template 40 comprises a plane portion 41 and a flange portion 42, and a working surface 43, which is in contact with the upper surface of the top layer of the dough, and therefore, defines the same of the upper surface of the tap layer, having a plurality of needle-like projections 44. In the use of the apparatus, the tips of the projections 44 are brought into contact with the upper surface 23 of the base template 20 and define a space between the upper surface 23 of the base template 20 and the working surface (lower surface) 43 of the second cover template 40, both the base layer and the top layer being sandwiched therebetween. Therefore, the height of the projection 44 defines the total thickness of the base layer and the top layer.
Note, the projections 44 of the second cover template are always higher than the projections 34 of the first cover template.
Although first and second cover templates are described above, according to the present invention more than two cover templates can be used. For example, a third cover template can be used wherein the needle-shaped projections of the third cover template are longer than the projections 44 of the second cover template. The use of such an apparatus provides a three-layer pizza crust.
The number of projections of the first and second cover templates is not critical and can be from 10 to 30, preferably 15 to 20, for example 18.
Alternatively, the edge 35 formed on the lower surface of the flange portion 32 of the first cover template 30, or the edge 45 formed on the lower surface of the flange portion 42 of the second cover template 40 is brought into contact with the upper surface flange portion 22 of the base template, whereby a space is defined between the base template and the first or second template. In this case, the height of the projections 34 of the first cover template or of the projections 44 of the second cover template need not be the same as the thickness of the base layer, or the total thickness of the base and top layers.
The base template, first template and second template, as well as other templates if any, may be made of a heat resistant material such as metal, for example, iron or stainless steal.
When the production of a pizza crust according to the present invention is carried out, as shown in FIGS. 9 and 10, a pizza dough is placed on the upper surface 23 of the base template 20, and the first cover template is placed thereover and pressed down, whereby the base layer 3 is formed between the base template 20 and the first cover template 30. Next, the first cover template is removed, a dough for the top layer is placed on the base layer 3, and the second cover template is placed thereover and pressed down, to thereby form the top layer between the base layer and the second cover template.
According to one embodiment of the present invention, neither the base layer nor top layer are baked, and in this case, preferably before removing the second cover template, the base layer and top layer are frozen, and the frozen pizza crusts are packaged and shipped. Alternatively, the frozen pizza crusts are lyophilized, and the dried product is shipped.
According to another embodiment of the present invention, the base layer dough is baked prior to placing the top layer dough thereon. The baking is preferably carried out until the color of the surface of the base layer becomes a light brown. In any case, the top layer is not baked, and prior to removing the second cover template, is frozen. The frozen product is then packaged and shipped, or further, is lyophilized and the dried product is packaged and shipped.
Prior to eating, an appropriate amount of water is added to the pizza crust, and after putting the topping such as cheese, cut vegetables or the like, on the pizza crust, it is heated or cooked.
To obtain the baking dough to be used in the pizza crust of the present invention, strong flour, soft flour, cow milk, egg, sugar, salt, olive oil, and water are mixed in a predetermined ratio, the mixture is aged, and the dough is spread under pressure.
To obtain an uncooked dough for the top layer strong flour, soft flour, cow milk, egg, sugar, salt, olive oil, and water are mixed in a predetermined ratio, the mixture is aged, and the thus-obtained dough is used. The pizza crust of the present invention is produced while the top layer thereof is still an uncooked dough. In the case of a dried pizza crust, if the uncooked dough freeze-dried, pizza crusts can be distributed in the market in a dried state without losing their characteristics and properties. That is, the dried pizza crust is rapidly restored to its original uncooked state and can exhibit the properties possessed by the uncooked dough, by heating the crust when it is to be used.
The pizza crust of the present invention can be easily cooked by equipment with a small calorific power such as oven toaster or the like, and as the yeast functions at the time of cooking, there is obtained a soft full and sticky pizza pie, in which the topping and crust are well blended.
The pizza crust of the present invention is characterized in that it can be produced in an optional shape by forming the shape of the concave portion provided on the template for baking not only in a circular shape but also in an elliptic, square or the like, as described above, and forming a cover plate according to the shape of the concave portion, and as mentioned above, it can be produced by constituting the dough for base layer and the dough for surface layer in a flat surface state in two layers, and by cutting the thus obtained two-layer dough.
The pizza crust of the present invention is produced as mentioned above, and because the pizza crust is formed in two or more layers, and is a refrigerated product, and as it may be a baked refrigerated product, its appearance is not lost, and the dried pizza crust has a merit in that it may be transported and stored at a normal temperature, because the dough for the surface layer thereof is a freeze-dried dough.
In addition, because the pizza pie is formed in two or more layers and a flange portion is formed, there is obtained the effect such that a product is supplied which is soft and full and has a good flavor and taste, the crust is well blended with the topping, and is crispy and has good feeling when eaten, the topping does not overflow, scorched lines can be impressed thereon, and it can be easily cooked without much labor and using equipment with a small calorific power such as oven toaster, and it keeps well.
In addition, according to the device and method for the production of a pizza crust according to the present invention, each of the processing means can be disposed along the manufacturing line, so that a large scale production becomes possible, and viewed from the point of construction, it is possible to keep the thickness of the crust constant, and therefore, it is possible to obtain pizza crusts with a constant quality kept.
The pizza crust of the present invention may comprise a top layer of an uncooked dough and a base layer of an uncooked dough or a dough obtained by baking or heat treatment, said layers having an inclined flange portion formed on the outer circumference thereof. Such a multi-layer pizza crust, may further comprise a batter, wafer, oblate and the like between the dough on the top layer and that of the base layer of the pizza crust. The pizza crust of the present invention may be used by laminating the said layers or inserting another edible material therebetween. Alternatively, the pizza crust may be used by placing on the base layer thereof granules prepared by freezing, or freeze-drying, and milling an uncooked dough.
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A process for producing a pizza crust, comprising the steps of: fitting uncooked dough into a base template, placing a first cover template thereover, pressing down the first cover template and removing the first cover template, to thereby form a base layer; and supplying uncooked dough over the formed base layer, placing a second cover template thereover, pressing down the second cover template and removing the second cover template, to thereby prepare a top layer; and a pizza crust produced thereby. Additionally, an apparatus is described for producing a pizza crust comprising: a base template defining a shape of a lower surface of a base layer of the pizza crust; a first cover template defining a shape of an upper surface of the base layer of the pizza crust; and a second cover template defining a shape of an upper surface of a top layer of the pizza crust, wherein at least one of the first cover template and second cover template is provided with a plurality of needle-like projections for making holes in said layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application of U.S. Provisional Applicant No. 62/060,609, filed Oct. 7, 2014, which is herein incorporated by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and method for liquefaction of ethane. More specifically, embodiments of the present invention are related to liquefying a gaseous stream comprised predominantly of ethane by using a mixed refrigerant loop incorporating heavy hydrocarbons (butane, and/or pentane) compression without providing cooling between stages or with limited cooling between stages.
BACKGROUND OF THE INVENTION
[0003] Liquefaction of methane (LNG) is well established, dating back to over 50 years. In certain cases, liquid ethane can also be produced directly from these LNG plants along with other higher hydrocarbon chain components and are called natural gas liquids (NGLs). However, many applications require the independent liquefaction of a gaseous ethane stream from a pipeline.
[0004] FIG. 1 shows a prior art ethane liquefaction process using a cascade refrigerant loop with a pure component such as propane to provide refrigeration at intermediate heat exchange section 15 and warm section 1 , while an ethane flash gas recycle provides cold end 25 and another intermediate level 5 cooling. However, because this process employs large temperature differences between the hot and cold fluids, brazed aluminum heat exchangers cannot be used as the exchangers would be subjected to very high thermal stresses. As such, the process known heretofore suffers several drawbacks, including using multiple, independent shell and tube type exchangers (or the like), suffering high irreversible losses, and having increased power and capital costs.
[0005] Therefore, it would be desirable to have an improved process for liquefaction of a gaseous stream comprised predominantly of ethane that was simple and efficient.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a process that satisfies at least one of these needs. In one embodiment, the process for ethane liquefaction can include using inline compression without interstage cooling (or cooling only after the first compression stages where there is no liquid formation yet) such that the number of liquid recycle loops are reduced or eliminated. The lack of cooling in the compressor slightly reduces the compressor efficiency; however, this is offset by having a more thermodynamically efficient process because the cycles can operate as a mixed refrigerant rather than cascade.
[0007] In one embodiment of the invention, a method is provided for the liquefaction of ethane. The method can include the steps of: (a) providing a stream of gaseous ethane under pressure, wherein the stream of gaseous ethane comprises at least 90% ethane; and (b) condensing the stream of gaseous ethane to produce liquid ethane by exchanging heat with a mixed refrigerant within a heat exchanger, wherein the mixed refrigerant is subjected to a mixed refrigerant refrigeration cycle.
[0008] In one embodiment, the mixed refrigerant refrigeration cycle includes the steps of: compressing the mixed refrigerant in a first compression section to produce a first compressed stream; compressing the first compressed stream in a second compression section to produce a second compressed stream; compressing the second compressed stream in a third compression section to produce a third compressed stream; cooling the third compressed stream to approximately ambient temperature to form a cooled third compressed stream, wherein the cooled third compressed stream is a two phase fluid; separating the cooled third compressed stream into a liquid refrigerant and a gas refrigerant; expanding the gas refrigerant to produce a cooled refrigerant; and introducing the cooled refrigerant to the heat exchanger under conditions effective for absorbing heat from the gaseous ethane such that the gaseous ethane condenses to form the liquid ethane.
[0009] In optional embodiments of the method for liquefaction of ethane:
the mixed refrigerant comprises a heavy hydrocarbon selected from the group consisting of butane, pentane, and combinations thereof; the mixed refrigerant further comprises a hydrocarbon selected from the group consisting of methane, ethane, ethylene, propane, and combinations thereof; the gaseous ethane is at a pressure of at least 15 bara; the method can also include an absence of a cooling step between each of the three compressing steps; the method can also include an absence of a cooling step between the second and third compressing steps; the method can also include the step of cooling the first compressed stream prior to compressing said first compressed stream in the second compression section; during the step of cooling the first compressed stream, the first compressed stream is cooled to a temperature sufficiently warm enough to prevent formation of a liquid phase; and/or the method can also include the step of expanding the liquid refrigerant and combining the expanded liquid refrigerant with the cooled refrigerant prior to the step of introducing the cooled refrigerant to the heat exchanger.
[0018] In another embodiment of the invention, a method is provided for the liquefaction of ethane. The method can include the steps of: (a) providing a stream of gaseous ethane under pressure; and (b) condensing the stream of gaseous ethane to produce liquid ethane by exchanging heat with a mixed refrigerant within a heat exchanger, wherein the mixed refrigerant is subjected to a mixed refrigerant refrigeration cycle.
[0019] In one embodiment, the mixed refrigerant refrigeration cycle can include the steps of: compressing the mixed refrigerant to produce a first compressed stream; compressing the first compressed stream to produce a second compressed stream; compressing the second compressed stream to produce a third compressed stream; cooling the third compressed stream to approximately ambient temperature to form a cooled third compressed stream, wherein the cooled third compressed stream is a two phase fluid; separating the cooled third compressed stream into a liquid refrigerant and a gas refrigerant; expanding the gas refrigerant to produce a cooled refrigerant; and introducing the cooled refrigerant to the heat exchanger under conditions effective for absorbing heat from the gaseous ethane.
[0020] In one embodiment, the mixed refrigerant refrigeration cycle further includes an absence of a formation of a liquid phase of the mixed refrigerant at a point that is located both downstream the first compression step and upstream the final compression step. In another embodiment, there is an absence of a liquid/gas separation subsequent the first compression step and prior to the last compression step.
[0021] In another embodiment of the invention, an apparatus is provided for the liquefaction of ethane. In this embodiment, the apparatus can include: (a) a gaseous ethane source; (b) a heat exchanger configured to condense gaseous ethane received from the gaseous ethane source; (c) a mixed refrigerant refrigeration cycle configured to provide sufficient refrigeration to condense the gaseous ethane in the heat exchanger. In one embodiment, the mixed refrigerant refrigeration cycle further includes: at least two compression stages configured to compress the mixed refrigerant received from a warm end of the heat exchanger; a final cooler in fluid communication with the final compression stage, wherein the final cooler is configured to cool the compressed mixed refrigerant received from the final compression stage to a temperature that is sufficiently low to produce a two phase fluid; a liquid/gas separator in fluid communication with the cooler, wherein the liquid/gas separator is configured to receive the two phase fluid and separate the two phase fluid into a liquid refrigerant and a gas refrigerant; and means for expanding the gas refrigerant and the liquid refrigerant to form a cooled gas refrigerant and a cooled liquid refrigerant; wherein the heat exchanger is configured to receive the cooled gas refrigerant and the cooled liquid refrigerant such that heat from the gaseous ethane is absorbed by the cooled gas refrigerant and the cooled liquid refrigerant within the heat exchanger.
[0022] In optional embodiments of the apparatus for liquefaction of ethane:
the apparatus can also include an absence of a liquid/gas separator subsequent the first compression step and prior to the last compression step; the apparatus can also include an absence of a cooler configured to condense a portion of the mixed refrigerant disposed between the at least two compression stages; the apparatus can also include a first cooler disposed between the at least two compression stages, wherein the first cooler is configured to cool the mixed refrigerant to a temperature that is sufficiently warm enough to prevent a portion of the mixed refrigerant to condense; and/or the mixed refrigerant refrigeration cycle can include an absence of a cascade cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.
[0028] FIG. 1 shows the prior art.
[0029] FIG. 2 shows an embodiment of the present invention.
[0030] FIG. 3 shows an embodiment of the present invention without any intercooling.
[0031] FIG. 4 shows an embodiment of the present invention with one intercooling step.
DETAILED DESCRIPTION
[0032] While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalence as may be included within the spirit and scope of the invention defined by the appended claims.
[0033] To overcome the problems associated with the cascading refrigeration cycle of FIG. 1 , the natural progression of development for one skilled in the art would be to propose using a mixed refrigerant process similar to those used in LNG processes. However, because ethane liquefies at a warmer temperature than methane (i.e., LNG), large quantities of heavier components (e.g., butane and/or pentane) would be the natural choice of the refrigerant. For example, a typical mixed refrigerant composition for LNG production is 30% methane, 38% ethane, 11% propane, 6% butane, 15% pentane
[0034] FIG. 2 provides an example of a thermodynamically optimal solution using a mixed refrigerant refrigeration cycle. However, as the butane and pentane composition increases in the refrigerant mix, which is needed for ethane liquefaction compared to methane liquefaction, the refrigerant stream is partially liquefied by the interstage cooling 63 , 73 , 85 . This occurs because the heavier components liquefy at warmer temperatures than lighter components. The liquid from each stage 64 , 79 , 102 must be removed prior to the next compression stage to prevent mechanical damage to the compressor. This liquid is cooled and flashed to recover refrigeration as shown in FIG. 2 . While the method shown in FIG. 2 yields a thermodynamically optimal solution, it comes at the expense of having to employ a very complex exchanger, and a process that is extremely difficult to control since the quantity of liquid formed at each intercooler is very sensitive to its pressure and temperature at the intercoolers. Consequently, the temperatures at the intercoolers must be precisely controlled to compensate for fluctuations in the cooling medium, which often is related to ambient conditions. If the interstage liquid quantities cannot be precisely controlled, the liquefaction in main exchanger will either not work or be significantly penalized. This is because the design of the main heat exchange is sensitive to controlling these flow rates.
[0035] In FIG. 3 , an ethane feed 2 having a typical composition of 2% methane, 95.5% ethane, 0.5% ethylene, and 2% propane, is compressed in compressor 10 and cooled in aftercooler 20 to near ambient conditions before being further cooled and condensed in the heat exchanger 30 to form the liquid ethane product 32 . The refrigeration for the process is provided by a mixed refrigerant system 140 . In this embodiment, the mixed refrigerant 34 is compressed in a first 60 , second 70 and third stage 80 of a compressor (or in three separate compressors), without any cooling between the various compression steps to avoid liquid formation. The compressed stream 82 is cooled in aftercooler 90 and sent to a liquid/gas separator 100 , wherein the liquid 102 is cooled within the heat exchanger 30 . The gas 104 is partially cooled in the heat exchanger 30 , and then expanded in valve 110 . Following cooling, the liquid 102 and expanded gas 112 can be introduced to a second phase separator 130 , and these streams 132 are used to provide the refrigeration for the system. Those of ordinary skill in the art will recognize that the top gas of second phase separator 130 can be sent to heat exchanger 30 as a separate stream depending on the needs of the system.
[0036] FIG. 4 provides an alternate embodiment to FIG. 3 . While FIG. 3 shows no interstitial cooling, FIG. 4 provides at least one interstitial cooling stage 73 and an optional interstitial cooling stage 63 ; however, the embodiment of FIG. 4 is less complex than that shown in FIG. 2 , and therefore, can provide an advantage in terms capital expenditures and ease of operation. As described above, heat exchanger 30 will only operate (or operate with a reasonable efficiency near its theoretical) if the flow rates to it are stable. Therefore, the process of FIG. 2 must precisely control three intercooler temperatures; however, the embodiment shown in FIG. 4 only needs to control two temperatures (e.g., at separators 75 and 100 ) in order to operate at its highest efficiency.
[0037] In the embodiment shown in FIG. 4 , compressed refrigerant 62 is optionally cooled in interstitial cooling exchanger 63 and then fed to second compression section 70 . This compressed stream is then cooled and partially condensed in cooler 73 and fed to liquid/gas separator 75 . In the embodiment shown in FIG. 4 , top gas 77 is withdrawn and sent to third compression section 80 for further compression, and liquid refrigerant 79 is withdrawn from the bottom of liquid/gas separator 75 and introduced to heat exchanger 30 for partial cooling, before being expanded in valve 111 and combined with stream 132 .
[0038] In the optional embodiment of FIG. 4 using interstitial cooling stage, compressed gas 62 is cooled; however, it is only cooled to a temperature that is sufficiently warm enough to prevent formation of a liquid phase (i.e., it is cooled to a temperature that is still just above the boiling point of the compressed fluid). Depending on the mechanical design of second compression section 70 , justification for this partial cooling without condensation upstream of second stage 70 is based on the efficiency gain of second compression section 70 due to the cooler temperature.
[0039] Table I below provides efficiency data for the various embodiments shown in the Figures.
[0000]
TABLE I
Efficiency Data for Various Embodiments
A
B
C
D
OPEX
FIG. 1
FIG. 2
FIG. 3
FIG. 4
Liquid Ethane
(mt/d)
5412
5412
5412
5412
Production
Total Power
(kW)
80830
67352
79300
69251
Specific Power
(kW-h/mt)
358.4
298.7
351.7
307.1
100.0%
116.7%
101.9%
114.3%
[0040] Table II below provides capital expenditure data, along with the proposed mixed refrigerant composition for each Figure. It is understood that capital expenditures increase with an increase in compression stages, coolers, and refrigeration loops.
[0000]
TABLE II
CAPEX Data for Various Embodiments
A
B
C
D
CAPEX
FIG. 1
FIG. 2
FIG. 3
FIG. 4
Heat Exchangers
(#)
4
1
1
1
compression stages
(#)
8
3
3
3
coolers
(#)
8
3
1
2
refrigeration loops
(#)
3
4
2
3
Components in mixed
(#)
—
4
4
4
refrigerant
MR composition
methane
—
15%
23%
12%
ethane
—
33%
18%
38%
propane
—
10%
15%
10%
butane
—
42%
44%
39%
[0041] It is important to note that efficiency indicated for the process of FIG. 2 (298.7 kW-h/mt) is only theoretical and assumes precise control of the three compressor coolers, which is unlikely to occur during operation.
[0042] The efficiency of cycle in FIG. 3 is only slightly better than prior art of FIG. 1 (Case C efficiency is 1.9% more efficient than Case A). However, as indicated in Table II above, the cycle of FIG. 3 is much simpler (fewer refrigeration loops), and less capital expenditures (fewer compressors, compression stages and coolers), and consequently, provides a significant cost advantage over FIG. 1 and FIG. 2 .
[0043] The cycle of FIG. 4 is slightly more complex than FIG. 3 due to the one additional refrigeration loop (i.e., stream 79 and valve 111 ), which is more difficult to control; however, the additional temperature control of one additional cooler is offset by a significant efficiency gain (1.9% vs 14.3%).
[0044] The number of components in the refrigerant cycle is also a degree of freedom in the balance between complexity (operability) and efficiency. Simulations found that going from four components to five components for FIG. 2 , can increase efficiency by approximately 2.6%
[0045] One side effect of reducing or removing the first and/or second stage cooling steps is a slightly reduced compressor performance. This is due to the warmer temperatures entering the second and third stages. However, this effect is only in the range of 2 to 3% and is more than compensated by the thermal efficiency gain of the main exchanger. Also, if the coolers are removed, the mechanical technology of the compressor can be adjusted to inline type rather than a bull gear type.
[0046] While the invention has been described in conjunction with specific 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 description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. Furthermore, language referring to order, such as first and second, should be understood in an exemplary sense and not in a limiting sense. For example, it can be recognized by those skilled in the art that certain steps or devices can be combined into a single step/device.
[0047] The singular forms “a”, “an”, and “the” include plural referents, unless the context clearly dictates otherwise.
[0048] Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.
[0049] Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.
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The process for ethane liquefaction can include a mixed refrigerant containing heavy hydrocarbons (e.g., butane and/or pentane) using compression without interstage cooling, or cooling only after the first compression stages where there is no liquid formation yet, such that the number of liquid recycle loops are reduced. The lack of cooling in the compressor reduces the compressor's mechanical efficiency; however, this is offset by having a more thermodynamically efficient process cycle because the cycle can operate as a mixed refrigerant rather than cascade.
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BACKGROUND OF THE INVENTION
[0001] The present invention disclosed herein relates to a liquid lipstick container, wherein a liquid lipstick container has a configuration in which an ascending/descending guide member is rotated together when a user rotates a container body while gripping a support body, such that a pumping guide member is lifted up/lowered, thereby performing a pumping operation. Thus, liquid contents are discharged through a simple structure, which improves usability when contents are applied through an applicator at an upper portion of the container.
[0002] Generally, a solid lipstick is configured to lift/lower a solid stick to the outside of a container by rotating a lower portion of the container after opening a cover thereof. For example, when using a lipstick, a user first opens the cover of a container, protrudes the stick out by rotating a lower portion thereof, and lowers the stick to be received into the container after using.
[0003] However, this type of solid lipstick has a problem wherein its ingredients are easily spoiled by contact with outside air.
[0004] In addition, another type of lipstick, which is used by spreading a liquid lipstick onto a brush like spreading a nail polish, also has a problem of hardening easily by contact with outside air.
[0005] To solve the problems as the above, “liquid lipstick container” is disclosed in the registered utility model patent no. 20-0367724 (hereafter called as the registered utility model patent).
[0006] The registered utility model patent relates to a liquid lipstick container, the liquid lipstick container comprising: a liquid lipstick receiving tube ( 10 ) receiving a liquid lipstick; a piston ( 20 ) pressurizing the liquid lipstick received in the liquid lipstick receiving tube; a piston rod ( 30 ) pushing the piston ( 20 ) and pressurizing a liquid lipstick (M); an operation housing ( 40 ) operating the piston rod ( 30 ); a brush supporting cap ( 50 ) supporting a lipstick brush ( 51 ); and a cap ( 20 ) sealing the lipstick brush ( 51 ),
[0007] wherein the liquid lipstick receiving tube ( 10 ) is characterized to be equipped with a pair of elastic leg parts ( 11 ) having a screw part ( 13 ) at an inner side of a lower end thereof and an outward protrusion ( 12 ) at an outer side end thereof, wherein the piston rod ( 30 ) comprises a screw part ( 32 ) screw-coupled to the elastic leg part ( 11 ) and an operating protrusion ( 33 ) at a lower end thereof, wherein the operation housing ( 40 ) is characterized to comprise an operating rib ( 41 ) at an interior so as to push the operating protrusion ( 33 ).
[0008] The registered utility has a structure wherein as a piston rod ( 30 ) ascends by the rotation of the rotation of an operation housing ( 40 ), a piston ( 20 ) coupled with a globular protrusion ( 31 ) at an upper end of a piston rod ( 30 ) moves in an upward direction and discharges liquid contents by squeezing. To squeeze contents out, the lipstick container should be equipped with an operating rib ( 41 ), an operating protrusion ( 33 ), a pair of elastic leg parts ( 11 ); therefore, the structure of the lipstick container becomes complicated, thereby resulting in a problem a complicated assembly process and a high manufacturing cost.
[0009] In addition, a space for the length of a piston rod ( 30 ) should be secured; therefore, the lipstick container gets bigger in size, thereby resulting in a problem of not being easy to carry.
SUMMARY OF THE INVENTION
[0010] The present invention is devised to solve the said problems above, and its goal is to provide a liquid lipstick container, wherein a liquid lipstick container has a configuration in which an ascending/descending guide member rotates together when a user rotates a container body while holding a support body, such that a pumping guide member is lifted/lowered, thereby performing a pumping operation. Thus, liquid contents are discharged through a simple structure, which improves usability when contents are applied through an applicator at an upper portion of the container.
[0011] To solve such problems described in the above, a liquid lipstick container according to the present invention comprises: a container body storing liquid contents therein and having a volume decreased according to use of the contents; an ascending/descending guide member coupled to an upper portion of the container body and rotated along as the container body rotates, wherein at an inner center portion thereof is a content inflow part which equips a first check valve so as to open/close the content inflow hole where contents stored in the container body flow, wherein at an upper portion thereof is equipped an ascending/descending guide protrusion formed alternately upwards and downwards along the perimeter; a pumping guide member which is ascended/descended by a rotation of the ascending/descending guide member, thereby inducing a pumping operation by changing an internal pressure of the content inflow part according to the ascent/descent thereof; a support body which is coupled encasing the ascending/descending guide member and the pumping guide member at an upper portion of the container body, comprising a vertical guide groove which guides a vertical movement of the pumping guide member at an inner circumferential surface; an applicator which is coupled to an upper portion of the support body and applies liquid contents, comprising a discharging hole to discharge the contents.
[0012] Furthermore, it is characterized that the pumping guide member comprises: a pumping guide protrusion which moves along an upper side face of the ascending/descending guide protrusion by a rotation of the ascending/descending guide member and is inserted to the vertical guide groove, thereby ascending/descending; a content suction tube which ascends along as the pumping guide protrusion ascends and sucks the contents stored in the container body by changing an internal pressure of the content inflow part; and a valve installation part forming a space storing contents which moves in a upward direction through the content suction tube and equipping a second check valve which is installed so as to open/close an upper end of the content suction tube.
[0013] Furthermore, it is characterized that a protrusion is formed at both sides of a bottom dead point of the ascending/descending guide protrusion so as to prevent a reverse rotation of the container body.
[0014] Furthermore, it is characterized that a sealing member, whose outer circumferential surface is contacted to the content inflow part, and whose inner circumferential surface is contacted to the content suction tube, is coupled at the content inflow part and seals a space separated between the content inflow part and the content suction tube.
[0015] Furthermore, it is characterized that the content suction tube pressurizes the first check valve in a state of the pumping guide member descending, and prevents the first check valve from being opened.
[0016] Furthermore, it is characterized that at an upper portion of the pumping guide member is coupled a content moving part which connects the pumping guide member and the applicator such that the contents flowing into the valve installation part can move to the applicator.
[0017] Furthermore, it is characterized that at an upper portion of the pumping guide member is equipped a spring which is disposed encasing the content moving part at an outer side of the content moving part and descends the pumping guide member by providing elasticity in a downward direction while the pumping guide protrusion moves from the top dead point of the ascending/descending guide protrusion to the bottom dead point thereof.
[0018] As described above, the present invention has an advantage wherein a liquid lipstick container has a configuration in which an ascending/descending guide member is rotated together when a user rotates a container body while holding a support body, such that a pumping guide member is lifted/lowered, thereby performing a pumping operation. Thus, liquid contents are discharged through a simple structure, which improves usability when contents are applied through an applicator at an upper portion of the container.
[0019] Furthermore, it is possible to prevent air inflow into the inside of the container body by means of a structure of double check valves, and also possible to store the contents discharged into an upper space of the second check valve at each pumping operation, such that it is possible to discharge a fixed amount of contents all the time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an exploded perspective view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention.
[0021] FIG. 2 is an assembled perspective view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention.
[0022] FIG. 3 is a cross-sectional view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention.
[0023] FIGS. 4 to 6 are views illustrating an operational state of a liquid lipstick container according to an exemplary embodiment of the present invention.
[0024] FIG. 7( a ) to FIG. 7( c ) is a view illustrating the process where a pumping guide protrusion is ascended/descended by an ascending/descending guide protrusion according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. The same reference numerals provided in the drawings indicate the same members.
[0026] FIG. 1 is an exploded perspective view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention. FIG. 2 is an assembled perspective view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention. FIG. 3 is a cross-sectional view illustrating a configuration of a liquid lipstick container according to an exemplary embodiment of the present invention.
[0027] Referring to FIGS. 1 to 3 , a liquid lipstick container according to an exemplary embodiment of the present invention may include a container body 100 , an ascending/descending guide member 200 , a pumping guide member 300 , a support body 400 , and an applicator 500 .
[0028] The container body 100 storing liquid contents is configured to have a volume getting reduced according to a use of the contents, and simply saying, the container body 100 may equip a piston 110 which ascends according to a use of the contents inside of the content body 100 . Additionally, it is possible that the container body 100 has a configuration wherein an inner container made of soft material that is absorbed according to a use of contents can be coupled separately inside the container body 100 .
[0029] In the present invention, it is characterized that the container body 100 is configured to be rotated in a state that a support body 400 to be described later is gripped. When a user rotates the container body 100 , a pumping guide member 300 can be ascended/descended by rotating an ascending/descending guide member 200 together which is coupled at an upper portion of the container body 100 .
[0030] Meanwhile, at an upper portion of the container body 100 is coupled an over cap 800 which encases the support body 400 and the applicator 500 so as to prevent the support body 400 and the applicator 500 from being broken by a foreign material flowing through a discharging hole 511 or by an external pressure.
[0031] The ascending/descending guide member 200 , coupled to an upper portion of the container body 100 and rotating together when the container body 100 rotates, is equipped with a content inflow part 210 forming a content inflow hole 211 at an inner center portion thereof such that the contents stored in the container body 100 can flow in. At the content inflow part 210 is equipped a first check valve 212 which is installed at an upper portion of the content inflow hole 211 and opens/closes the content inflow hole 211 according to a pressure change of the content inflow part 210 .
[0032] Furthermore, at the content inflow part 210 is coupled a sealing member 700 which seals a space separated between the content inflow part 210 and a content suction tube 320 to be described later. An outer circumferential surface of the sealing member 700 is closely contacted to the content inflow part 210 and an inner circumferential surface thereof is closely contacted to the content suction tube 320 , such that the sealing member 700 seals the space separated between the content inflow part 210 and the content suction tube 320 .
[0033] In the present invention, it is characterized that at an upper portion of the ascending/descending guide member 200 is equipped an ascending/descending guide protrusion 220 which ascends/descends a pumping guide member 300 to be described later by rotation of the ascending/descending guide member, wherein a pair of ascending/descending guide protrusions 220 are protrusively formed alternately above and below along the perimeter of an upper end of the ascending/descending guide member 200 and guides a movement of a pumping guide protrusion 310 . When the pumping guide protrusion 310 moves form a bottom dead point 312 of the ascending/descending guide protrusion 220 to a top dead point 311 thereof, the pumping guide member 300 ascends, whereas when the pumping guide protrusion 310 moves from a top dead point 311 of the ascending/descending guide protrusion 220 to a bottom dead point 312 thereof, the pumping guide member 300 descends, thereby achieving an ascent/descent of the pumping guide member 300 .
[0034] Meanwhile, it is possible that the ascending/descending guide protrusion 220 can be configured in a way that the container body 100 can be rotated to both directions. However, it is preferable to be rotated to one direction for operational stability e.g. not to easily discharge contents by rotating the content body 100 by an external pressure during the period of storing or not to store contents with a check valve opened. For this purpose, at both sides of the bottom dead point of the ascending/descending guide protrusion 220 is formed a protrusion 221 for preventing a reverse rotation of the container body 100 .
[0035] The pumping guide member 300 ascended/descended by the rotation of the ascending/descending guide member 200 changes an internal pressure of the content inflow part 210 and induces a pumping operation, further comprising a pumping guide protrusion 310 , a content suction tube 320 , and a valve installation part 330 .
[0036] A pair of the pumping guide protrusions 310 protrusively formed at both sides of the pumping guide member 300 are secured at an upper end of the ascending/descending guide protrusion 220 , and move along an upper side face of the ascending/descending guide protrusion 220 when ascending/descending guide member rotates. At this time, the pumping guide protrusion 310 can be inserted to a vertical guide groove 420 formed at an inner side of the support body 400 and move vertically.
[0037] The content suction tube 320 , which ascends together as the pumping guide protrusion 310 ascends and sucks the contents stored in the container body 100 by changing an internal pressure of the content inflow part 210 , has a tube shape with an inner part empty such that contents can move through.
[0038] The content suction tube 320 , which ascends/descends in a state that an outer circumferential surface thereof is closely contacted to the sealing member 700 and makes it possible for a first check valve 212 to open/close a content inflow hole 211 by changing an internal pressure of the content inflow part 210 , pressurizes an upper end of the first check valve 212 in a state that the pumping guide member 300 is descended and thereby prevents the first check valve 212 from being opened.
[0039] The valve installation part 330 forms a space which stores contents moving to an upper portion thereof through the content suction tube 320 and has a second check valve 331 installed so as to open/close an opened upper end of the content suction tube 320 , wherein the second check valve 331 closes the open upper end of the content suction tube 320 when the pumping guide member 300 ascends, whereas the second check valve 331 opens an open upper end of the content suction tube 320 by the pressure of contents when the pumping guide member 300 descends.
[0040] Meanwhile, at an upper portion of the pumping guide member 300 are installed a content moving part 600 which connects the pumping guide member 300 and an applicator 500 such that contents flowing in the valve installation part 330 can move to the applicator 500 . The content moving part 600 comprises a coupling part 610 which is coupled to an upper portion of the pumping guide member 300 , and a content moving tube 620 which extends from the coupling part 610 and is coupled to a discharging tube 520 of the applicator 500 so as to be ascended/descended and forms a space where contents moves.
[0041] The content moving part 600 equips a hollow such that the contents flowing into the valve installation part 330 can move to the applicator 500 .
[0042] Furthermore, at an upper portion of the pumping guide member 300 is equipped a spring (S) which is disposed encasing the content moving part 600 at an outer side of the content moving part 600 , and provides an elastic force to a downward direction during the process when the pumping guide protrusion 310 moves from a top dead point 311 of the ascending/descending guide protrusion 220 to a bottom dead point 312 thereof and causes the pumping guide member 300 to descend. A lower end of the spring (S) is secured to an upper portion of the pumping guide member 300 while an upper end thereof is supported by an upper inner side of the support body 400 , such that the spring (S) contracts when the pumping guide protrusion 310 ascends along an upper side face of the ascending/descending guide protrusion 220 , and stretches when the pumping guide protrusion 310 descends along an upper side surface of the ascending/descending guide protrusion 220 , thereby providing an elastic force to the pumping guide member 300 .
[0043] The support body 400 , which is coupled at an upper portion of the container body 100 , encasing the ascending/descending guide member 200 and the pumping guide member 300 , forms a hollow 410 at an upper portion thereof such that the applicator 500 can be coupled and a vertical guide groove 420 which guides a vertical movement of the pumping guide protrusion 310 .
[0044] The applicator 500 , which is coupled to the hollow 410 of the support body 400 and applies contents to a user's lips, comprises an application surface 510 , wherein the application surface 510 has a discharging hole 511 at a center portion thereof such that contents can be discharged through.
[0045] Furthermore, at an inner upper side of the applicator 500 is equipped a discharging tube 520 which extends to a downward direction such that the content moving tube 620 of the content moving part 600 can be coupled so as to ascend/descend.
[0046] Hereinafter, referring FIGS. 4 to 6 , an operational process of a liquid lipstick container according to an exemplary embodiment of the present invention will be explained. FIGS. 4 to 6 are views illustrating an operational state of a liquid lipstick container according to an exemplary embodiment of the present invention. FIG. 7( a ) to FIG. 7( c ) is a view illustrating a process wherein a pumping guide protrusion is ascended/descended by an ascending/descending guide protrusion according to an exemplary embodiment of the present invention.
[0047] Referring FIG. 4 through FIG. 7( c ) , when a user rotates a container body 100 while gripping a support body 400 , an ascending/descending guide member 200 coupled to an upper portion of the container body 100 rotates together. Due to this, a pumping guide protrusion 310 which is secured at an upper side surface of an ascending/descending guide protrusion 220 of the ascending/descending guide member 200 moves along the upper side surface of the ascending/descending guide protrusion 220 and changes in height, such that the pumping guide member 300 is ascended/descended. As shown in FIG. 7( a ) to FIG. 7( c ) , when the pumping guide protrusion 310 moves form a bottom dead point 312 of the ascending/descending guide protrusion 220 to a top dead point 311 thereof, the pumping guide member 300 ascends, whereas the pumping guide member 300 descends when the pumping guide protrusion 310 moves from the top dead point 311 of the ascending/descending guide protrusion 220 to a bottom dead point 312 thereof; therefore, the pumping guide member 300 is able to perform ascending/descending.
[0048] Meanwhile, shown in FIG. 5 , when the pumping guide member 300 ascends, an internal pressure of the content inflow part 210 is changed by an ascent of the content suction tube 320 and causes a first check valve 212 to open a content inflow hole 211 . This makes the contents stored in the container body 100 flow into the content inflow part 210 through the content inflow hole 211 . At this time, a second check valve 331 installed at a valve installation part 330 keeps an open upper part of the content suction tube 320 closed. As the pumping guide member 300 ascends, part of the contents stored in the valve installation part 330 , a content moving part 600 , and a discharging tube 520 is discharged through a discharging hole 511 of the applicator 500 .
[0049] Next, as shown in FIG. 6 , when the pumping guide member 300 descends, an internal pressure of the content inflow part 210 changes by a descent of the content suction tube 320 , and then causes a first check valve to close the content inflow hole 211 . At this time, a lower end of the content suction tube 320 pressurizes an upper end of the first check valve 212 , prevents the content inflow hole 211 from being opened.
[0050] At this time, the second check valve 331 installed at the valve installation part 330 by a pressure of the contents sucked into the content suction tube 320 opens an open upper portion of the content suction tube 320 , such that the contents sucked into the content suction tube 320 through the open upper portion of the content suction tube 320 move to the valve installation part 330 , the content moving part 600 , and the discharging tube 520 .
[0051] As described in the above, the present invention is configured to discharge contents by a pumping operation according to the ascent/descent of a pumping guide member 300 when a container body 100 rotates and to apply contents to lips by means of an applicator 500 ; thus it is possible to apply liquid contents onto lips and do a lip make-up in the same way of a conventional stick-type lipstick.
[0052] As described above, optimal embodiments have been disclosed in the drawings and the specification. Although specific terms have been used herein, these are only intended to describe the present invention and are not intended to limit the meanings of the terms or to restrict the scope of the present invention as disclosed in the accompanying claims. Therefore, those skilled in the art will appreciate that various modifications and other equivalent embodiments are possible from the above embodiments. Therefore, the scope of the present invention should be defined by the technical spirit of the accompanying claims.
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The present invention relates to a liquid lip stick container having a configuration in which, an ascending/descending guide member is rotated together when a user rotates a container body while holding a support, so that a pumping guide member is lifted up/lowered, thereby performing a pumping operation. Thus, the container can discharge liquid contents through a simple structure, and thus can improve usability when contents are applied through an upper applicator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in part-of U.S. patent application Ser. No. 11/745,25, filed May 7, 2007, a Monday, which claims priority to U.S. Provisional Application No. 60/746,510, filed May 5, 2006, the contents of both of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to systems and methods of broadcasting sporting events and video games and particularly to systems and methods for integrating video games into a broadcast of a sporting event or, alternatively, for integrating a broadcast sporting event into a video game.
BACKGROUND OF THE INVENTION
[0003] Video gaming is a tremendously lucrative and competitive industry around the world. Video-game designers are constantly trying to develop new games, new gaming systems, and new gaming concepts. The Nintendo Wii is but one example of a new video-gaming concept that has been successfully introduced and it is changing the way in which video games are used and developed.
[0004] A major reason for the success of video gaming is the ability and tendency of humans to fantasize. It can begin very early in childhood, as young children play with dolls or action figures. As they get older and begin playing sports, children playing backyard whiffle ball fantasize about coming to bat with the bases loaded in the ninth inning of game 7 of the World Series, or imagine themselves walking up the 18th fairway at Augusta as they play a round of golf or even miniature golf at a local venue. Video games bring this penchant for fantasy to a new level, allowing gamers to select teams based on actual sports players and then play the games by controlling the “virtual players” to make them perform on the virtual playing field.
[0005] While present video games allow the game player to mimic the look and feel of participating in a sporting event, the virtual competitors that they are playing against are computer-generated and the performances of their virtual competitors are computer-generated as well. Unlike reality, in the video game, a virtual Tiger Woods never has a bad round, and there is no connection between the performance of the virtual Tiger Woods and the performance of the actual Tiger Woods on any given day in any given event. To simulate a sporting event in a video game in a more realistic manner, it would be desirable to have a video game system and method whereby a video game player could play against competitors based on the performance of the competitors in an actual event, and preferable one that is occurring essentially simultaneously with the game play.
BRIEF SUMMARY OF THE INVENTION
[0006] Briefly described, the invention provides a system and method of integrating video games into live sporting events, or the converse, in an interactive way.
[0007] In a preferred embodiment of the invention, a viewer watching a broadcast sporting event can elect to become a “phantom participant” in an event. At one or more designated points in the event (e.g., a golf tournament), the viewer's set-top box may switch from feeding the broadcast event to the viewer's television screen to feeding a stream from a video game unit to the same television screen. The video game unit is configured to receive information from the broadcast feed that includes information such as, but not limited to, the event location, the hole being played (in the golf example), the participants, and statistics related to the performance of the participants. This information may be used by the video game unit to present the viewer with the opportunity to “virtually” compete with the participants in the broadcast event. While the viewer is taking his turn in the game, the actual game may be recorded in a digital video recorder (DVR) connected to the set-top box. In this way the set-top box may, after the viewer has had his or her turn, switch back to providing a view of the game from where it was interrupted so that it appears to the viewer that he/she is playing along with the actual event-participants.
[0008] In a further preferred embodiment of the invention, the DVR may record the game while it is being broadcast. When the viewer elects to take his/her turn, in addition to continuing to record the broadcast, the DVR may feed selected footage to a live video insertion unit capable of seamlessly merging images from the game unit with the recorded broadcast material. In this way the game unit may generate images of the viewer taking his/her turn which are inserted into the broadcast footage so that the computer generated output of the video game is made to look as if the viewers' participation is part of the broadcast. If the game unit has been preloaded with actual images of the viewer, the merged output may appear to be the viewer participating in the broadcast event.
[0009] In yet a further preferred embodiment of the invention, the DVR may record the game.
[0010] After the viewer has had his or her turn, the system may switch back to providing a view of the game from where it was interrupted so that it appears to the viewer that he/she is playing along with the actual event-participants. After a few seconds, the system may then fast-forward to once again be showing the game live. This may, for instance, be done at a scene break to make it appear more natural.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 is schematic drawing showing a video game being interstitially incorporated into a live broadcast of a golf game.
[0012] FIG. 2 is a schematic drawing showing a video game being merged with pre-recorded broadcast footage.
[0013] FIG. 3 is a flowchart illustrating the basic operation of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention applies to systems and methods for merging video games with broadcast events, including live broadcast events.
[0015] FIG. 1 is schematic drawing showing a video game being interstitially incorporated into a live broadcast of a golf game. Although a golf game is used for the purposes of illustrating the concepts of the invention, one of ordinary skill in the art will appreciate that the inventive concepts could readily be adapted to apply to most video games, including, but not limited to, football, soccer, basketball, baseball, hockey, horse racing, motor racing and tennis.
[0016] In FIG. 1 , a number of players 14 are participating in a golf event on a golf course 12 . The event is being televised for broadcast by one or more television cameras 16 . In addition, auxiliary personnel, such as caddie 18 , may be carrying additional statistics recording equipment, such as GPS (global positioning system) device 20 . The GPS device 20 feeds back the approximate coordinates at which the ball lands after each player's 14 shot. For example, the caddie carrying the GPS device could stand over the ball and press a button identifying the ball with a particular player. These coordinates may be fed back to a broadcast unit 22 , such as a broadcast truck, to be incorporated into the video feed for broadcast or streaming to an end user's video reception module 26 . The video reception module may, for instance, be a device such as, but not limited to, set-top box or an app operating on a smart phone. The broadcast or streaming may be via a wireless (e.g., standard broadcast; satellite) or wired (e.g., cable) connection 24 . The video feed may additionally or instead be distributed as streaming media, and may be received by a video app operating on a user's cell-phone that may provide the same or similar functions as a conventional set-top box. Other statistical information that may be incorporated into the video feed can include, but is not limited to, the course location, the competitors in the contest, the performance history of each of the competitors in the contest including the location of each of the competitors' balls after each shot, and the weather conditions including lighting and sky conditions.
[0017] The video reception module 26 may feed the video and audio portions of the broadcast through to an end user's video display unit 28 that may, for instance, be television set or video display such as, but not limited to, to smartphone or cellphone screen, so that the end user may watch the broadcast event in the usual way. The additional statistics may be fed by the video app or set-top box 26 to a game unit 34 operatively coupled to the video reception module 26 . The game unit 34 may, for instance, be a well know gaming unit such as a Microsoft Xbox, a Sony
[0018] Game boy, a Nintendo Wii, or some other suitably adapted game device capable of generating graphics for video gaming including, but not limited to, the smartphone on which the video app is operating.
[0019] At a predetermined point in the broadcast contest, such as after or before a particular contestant's turn, the user may be offered a turn to compete. Alternatively, the user could manually select a point themselves by, for example, pressing a button on a game controller or remote control device. At that time, the broadcast video and audio begins recording, via a digital video recorder 32 , the broadcast event, and the video reception module 26 may switch to feeding the output of the game unit 34 to the video display unit 28 instead of feeding the live broadcast to the video display unit. The game unit 34 may make use of the statistics about the broadcast event obtained via the video reception module 26 to generate a game segment set at the same location on the same course in the broadcast event. For instance, the game segment generated may be a three-dimensional rendition of the same location on the golf course as the actual contestants are currently located, with the contestants situated in their approximate positions. Using the remote control 30 or other suitable video game control unit, the user may then take their turn in the contest. This may be done in any of the usual way video game contests participate in simulated sports games such as, but not limited to, using arrow keys to take aim and a swing-timing graphic and a button to determine the strength or length of a shot. The end user's shot is then recorded and compared to the actual contests shots on the actual course. A scoreboard may also, for instance, be generated by the game unit 34 to display a score board with the end user scored relative to the other contestants in the actual game.
[0020] After the end user has taken their turn in the contest, the video receiving module 26 may then resume display of the actual broadcast that was recorded by the digital video recorder 32 , beginning from the point at which the actual broadcast was interrupted to allow the end user to play their ball.
[0021] Using the above described process, a user can not only view a broadcast of a sporting event, but actually feel as though they are actually participating in the event with the other players.
[0022] FIG. 2 is a schematic drawing showing a video game being merged with live and recorded video footage. In this embodiment of the invention, the event may be captured for broadcast in the same way as before. When it is time for the end user's turn, the video receiving module 26 switches to displaying a video feed from a live video insertion system 36 instead of from the live feed of the broadcast event. The live video insertion system 36 is a device such as described in detail in, for instance, U.S. Pat. No. 5,264,933 issued to Rosser et al. on Nov. 23, 1993 entitled “Television displays having selected inserted indicia”, the contents of which are hereby incorporated by reference. The live video insertion system 36 is a software or hardware device, or a combination thereof that allows one or more images generated by the game unit 34 to be seamlessly and realistically combined with broadcast video or with pre-recorded video images sourced from the digital video recorder 32 . The live video insertion system 36 merges images of the end user taking their turn in the contest with prerecorded footage of the golf course (in the golf course example) stored in the digital video recorder 32 . In this way the end user will appear to be competing as part of the broadcast video. At the same time the digital video recorder 32 will be recording the broadcast contest so that at the end of the end user's turn, the event broadcast can continue to be shown from where it left off.
[0023] FIG. 3 is a flowchart illustrating the basic operation of the present invention. At step 302 , a user receives the live broadcast of an event that he or she intends to join as a phantom player. This involves the normal activity of turning on a television set or the display device and selecting the appropriate channel using, for example, a set-top box.
[0024] At step 304 , the live broadcast is displayed on the display device. At step 306 , a determination is made as to whether or not a phantom play signal has been received. If no phantom play has been requested at step 306 , the process continues back to step 304 where the live broadcast is displayed as per normal. However, if at step 306 , a phantom play has been requested, then at step 308 , the video receiving module or game console may begin receiving and logging data from the live broadcast event which may be used during the phantom play. For example, the data pertaining to the scores of the various players participating in the live event, the location of the live event, the location of each player on the playing area of the live event (e.g., at which hole each player is located, etc.) and all other similar data.
[0025] At step 310 , a phantom-player's-turn signal is received. This is simply a signal indicating that the phantom player may now begin gameplay using the game device. As mentioned above, this can be predetermined by the program to occur at a particular time (e.g., after the fourth player in a golfing foursome has taken their shot) or it can be triggered by a signal from the game player who presses a button on their game console, remote control, etc. The phantom-player's-turn signal causes the recording of the live broadcast to begin (or continue if recording has already begun) and the display of the live broadcast on the display device is suspended. At step 314 , the output from the game controller is now displayed on the display device and the user begins play of their game as a phantom player participating in the in-progress event. At step 316 , a determination is made as to whether or not the player's turn is complete. This can be, for example, upon the completion of a stroke in the case of a golf match. If the player's turn is not complete, the process proceeds back to step 314 and continues to display output from the game controller. If play is complete, then the display of the event continues on the display device at step 318 . At step 320 , a determination is made as to whether or not the entire game/event is completed. If it is not completed, the process proceeds back to step 310 where the phantom-player's-turn signal is awaited. If, however, at step 320 it is determined that the game/event is complete, then the process ends at step 322 .
[0026] In yet a further preferred embodiment of the invention, the DVR may record the game.
[0027] After the viewer has had his or her turn, the system may switch back to providing a view of the game from where it was interrupted so that it appears to the viewer that he/she is playing along with the actual event-participants. After a few seconds, the system may then fast-forward to once again be showing the game live. This may, for instance, be done at a scene or advertising break to make it appear more natural. It is usual for instance, for there to be at least one completely black frame before an interstitial advertisement is inserted in a television broadcast in the US. This black frame may, for instance, serve as a trigger for reverting to the live feed.
[0028] An advantage of such an arrangement is that the viewer may stay current with the game or event as it unfolds.
[0029] Although the invention has been described in language specific to structural features and/or methodological acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary forms of implementing the claimed invention. Modifications may readily be devised by those ordinarily skilled in the art without departing from the spirit or scope of the present invention.
[0030] The above-described steps can be implemented using standard well-known programming techniques. The novelty of the above-described embodiment lies not in the specific programming techniques but in the use of the steps described to achieve the described results. Software programming code which embodies the present invention is typically stored in permanent storage. In a client/server environment, such software programming code may be stored with storage associated with a server. The software programming code may be embodied on any of a variety of known media for use with a data processing system, such as a diskette, or hard drive, or CD-ROM. The code may be distributed on such media, or may be distributed to users from the memory or storage of one computer system over a network of some type to other computer systems for use by users of such other systems. The techniques and methods for embodying software program code on physical media and/or distributing software code via networks are well known and will not be further discussed herein.
[0031] It will be understood that each element of the illustrations, and combinations of elements in the illustrations, can be implemented by general and/or special purpose hardware-based systems that perform the specified functions or steps, or by combinations of general and/or special-purpose hardware and computer instructions.
[0032] These program instructions may be provided to a processor to produce a machine, such that the instructions that execute on the processor create means for implementing the functions specified in the illustrations. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer-implemented process such that the instructions that execute on the processor provide steps for implementing the functions specified in the illustrations. Accordingly, the figures support combinations of means for performing the specified functions, combinations of steps for performing the specified functions, and program instruction means for performing the specified functions.
[0033] While there has been described herein the principles of the invention, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation to the scope of the invention. Accordingly, it is intended by the appended claims, to cover all modifications of the invention which fall within the true spirit and scope of the invention.
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This invention provides a system and method of integrating video games into live sporting events, or the converse, in an interactive way. In a preferred embodiment of the invention, a viewer watching a broadcast sporting event can elect to become a “phantom participant” in an event. At one or more designated points in the event (e.g., a golf tournament), the viewer's set-top box will switch from feeding the broadcast event to the viewer's television screen to feeding a stream from a video game unit to the same television screen. The video game unit is configured to receive information from the broadcast feed that includes information such as, but not limited to, the event location, the hole being played (in the golf example), the participants, and statistics related to the performance of the participants. This information may be used by the video game unit to present the viewer with the opportunity to “virtually” compete with the participants in the broadcast event.
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CLAIM OF PRIORITY
The present application is a divisional patent application of previously filed, pending application having Ser. No. 13/080,211 which was filed on Apr. 5, 2011, which is based on and claims priority to a provisional patent application having Ser. No. 61/321,045 and a filing date of Apr. 5, 2010, each of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to a “do-it-yourself” home remodeling kit specifically including a tile assembly which may be specifically, but not exclusively structured to be installed over a kitchen backsplash area in a minimal amount of time. The present invention is also directed to the do-it-yourself method of installation as well as certain structural features of one or more self-adherent tile sheets at least partially defining the tile assembly.
2. Description of the Related Art
A method of installing glass mosaic tile or other tile material pieces by a “do-it-yourself” basis can be complicated, time-consuming, and costly. Typically, one has to obtain not only the tile materials but must frequently visit one or more supply or remodeling stores to buy many of the required installation materials and/or tools associated with the do-it-yourself technique. In addition, the individual must already possess sufficient skill or training to accomplish such an installation in a timely manner, wherein the final product is sufficiently pleasing in appearance and structure to resemble a professional installation. Moreover, if a professional contractor or like individual is not hired to do the installation then the individual involved in the do-it-yourself technique must be skilled in a variety of different techniques, procedures and structures to accomplish a professionally appearing installation.
The installation of various tiles including mosaic glass tiles, ceramic tiles, etc. is conventionally done with a cement or “mastic” applied to the surface being covered. Such cement or mastic may be preformed and purchased separately and applied separately over the entire surface area being covered. Accordingly, the cement or mastic may have a universal composition including a standard viscosity which may secure the tile material directly to the support surface. However, in many cases a standard adhesive composition, in particular such a composition intended for a “do-it-yourself” installation, is not sufficiently strong to maintain the tile being mounted on a substantial permanent basis. Also, the application of the mastic or cement to the surface being covered must be sufficient to distribute the cement or mastic over the area in a somewhat even or at least sufficiently ample basis to maintain the permanent adherence of the tile material to the support surface.
Accordingly, there is a need in this industry for a do-it-yourself installation kit and method of installation which facilitates the application of a tile assembly to the intended surface, such as that of the present invention which incorporates a tile assembly preferably including one or more self-adherent tile sheets. As such, the obtaining, preparing, and applying mastic or cement to the surface to be covered is thereby eliminated resulting in a saving of both time and effort by the individual. As a result, a preferred and proposed kit assembly, installation method and tile assembly should comprise a self-adherent tile assembly including the aforementioned one or more plurality of tile sheets each of which include a composite structure which eliminates many of the procedures and techniques typically included in conventional do-it-yourself tile installation assemblies and methods.
Moreover, a proposed do-it-yourself kit assembly, method of installation and tile assembly incorporating the self adherent feature, should include and utilize installation materials and installation tools cooperatively provided to eliminate the problems as generally set forth above. As a result the time consuming efforts of an individual including the necessity for going to one or more supply stores to obtain a variety of different installation materials, tools, tile materials, mastic, cement, etc., would be eliminated.
SUMMARY OF THE INVENTION
The present invention relates to “do-it-yourself” kit assembly for installing a tile assembly on a support surface such as, but not limited to, a kitchen backsplash area. The present invention is also directed to a “do-it-yourself” method of installation as well as the structural and operative features of one or more tile sheets defining the tile assembly.
More specifically, the do-it-yourself kit assembly of the present invention includes at least one, but more practically a plurality of self-adherent tile sheets each comprising a backing sheet of predetermined configuration and dimension. A plurality of tile pieces are collectively and fixedly secured to an outer face of the backing sheet in spaced relation to one another. In addition, an adhesive layer is secured to a rear face of the backing sheet in opposing relation to the plurality of tile pieces. As such the adhesive layer is disposed and structured to fixedly secure the backing sheet to the support surface on a substantially permanent basis. Also, a cover sheet is removably disposed in overlying, confronting relation to a subsequently exposed surface of the adhesive layer.
In at least one preferred embodiment, the plurality of tile pieces comprises a plurality of mosaic, glass tile pieces which are preferably, but not necessarily, equally dimensioned and configured. Further, each of the tile pieces are disposed in equally spaced relation to next adjacent ones of the plurality of tiled pieces, wherein the spaces between the tiled pieces define grout channels or grout junctions. Other components of the kit assembly include a plurality of containers of grout sufficient in quantity to cover the exterior exposed surfaces of the plurality of the tile pieces, once fixedly secured to the support surface and/or kitchen backsplash. As such, the grout will be sufficient to fill the grout junctions between the plurality of tile pieces as set forth above.
In order to provide an efficient, effective “do-it-yourself” kit assembly, a plurality of installation materials and installation tools are included and are cooperative to facilitate the do-it-yourself method of installation. More specifically, the kit assembly includes at least one but more practically a plurality of tile sheets preferably, but not necessarily, structured and dimensioned to have a 12 inch by 12 inch or one square foot dimension. The installation tools include a pair of gloves to be worn by the user during the installation. Also, a cutting blade is provided so as to form/modify/adjust one or more segments of the one or more tile sheets to correspond to the dimension and configuration of the support surface and/or backsplash area to be covered.
Also, a “grout float” may be utilized to apply the supply of grout over the exposed surface of the plurality of the tile pieces as well as fill the grout junctions between the tile pieces. The grout float is also structured to be manipulated in a manner which applies a sufficient degree of pressure to the exposed surface of the one or more tile sheets. The result of applying a sufficiently greater pressure is to fixedly secure the one or more tile sheets and more specifically the adhesive layer associated therewith in a substantially permanent manner to the support surface. Other installation tools may include a plurality of spacers which may be inserted between adjacent ones of the tile pieces associated with the same tile sheet or adjacent or contiguous ones of the plurality of tile sheets so as to accomplish an accurate and effective alignment thereof.
Informational and/or instructional material, such as a printed brochure, DVD or other viewable media, etc. can also be included in the kit assembly so as to further facilitate the “do-it-yourself” method of mounting or installation. The kit assembly further includes other portions of the tile assembly which may comprise at least one, but preferably a plurality of elongated liner tiles each of which includes a one-piece construction and an adhesive layer on a rear or outer surface thereof. The adhesive layer of the liner tiles, may be the same as that associated with that one or more of the tile sheets, and is sufficient to fixedly secure the liner tiles about the periphery of the installed tile sheets. In addition, a plurality of loose tile pieces are also included in the tile assembly so as to facilitate replacement or repair of damaged or missing tile pieces which would normally be fixedly secured to the backing sheet of the corresponding tile sheet.
The do-it-yourself tile assembly kit and the various components of the kit, as generally described above, facilitate an easy, efficient and quick method of do-it-yourself installation or mounting of the tile assembly in the manner generally set forth hereinafter.
More specifically, the support surface or the backsplash area on which the tile assembly is to be mounted is cleaned at least to the extent of removing any grease, dust or other debris which would affect the installation and/or appearance to the installed tile sheets. Once the affected are of the support surface and/or backsplash has been sufficiently prepared proper measuring is done in order to coordinate the dimension and the configuration of the one or more tile sheets with the area on which the tile sheets are to be mounted. This coordination may include the cutting or severing of portions of the tile sheet to form at least one tile sheet segment which corresponds in dimension and configuration to the portion of the support surface on which it is to be mounted.
A “dry fitting” of the tile sheet is next accomplished by at least partially removing a lower portion of the cover sheet from the adhesive layer thereby exposing a corresponding portion of the adhesive layer. This exposed portion of the adhesive layer is applied to the backsplash area on which the tile sheet is to be mounted by applying only a first predetermined or minimal amount of pressure to the tile sheet. This minimal amount of applied pressure enables the removal and/or adjustment of the adhesive and tile sheet form the support surface. Once accurately aligned and positioned the remainder of the cover sheet may be removed from the adhesive layer thereby exposing the entire adhesive layer and allowing the entirety of adhesive layer to confront the area of the support surface on which it is to be mounted. A second predetermined greater pressure is then applied to the exposed face of the plurality of tile pieces, such as by using the grout float, as will be explained in greater detail hereinafter. The second, greater predetermined amount of pressure is sufficient to fixedly and substantially permanently secure the tile sheet to the backsplash or other area of the support surface.
Subsequently, the grout is applied in overlying, covering relation to the plurality of tile pieces on the sheet or sheets which have been mounted on the support surface. A sufficient amount of time is allowed for the drying or curing of the grout and some of the aforementioned cleaning materials may be used to remove excessive grout from the disposed surface of the plurality of tiles, once a drying of the grout has occurred.
Therefore, the do-it-yourself kit assembly of the present invention may be specifically utilized to cover the kitchen backsplash area and as such the plurality of sheets are sufficient in quantity, dimension, configuration, etc. to cover at least a backsplash area or other support surface area of generally about 15 square feet. Utilizing the kit assembly, preferred method of installation and taking advantage of the structural and operable self-adherent features of the one or more tile sheets, a 15 square foot support surface area can be installed with the aforementioned tile assembly in as little as one hour.
These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of the kit assembly of the present invention.
FIG. 2 is a collective view in perspective of the various installation materials and installation tools accompanying the kit assembly of the embodiment of FIG. 1 .
FIG. 3 is a perspective view of a base portion of a “grout float” used to apply grout as well as pressure to the installed one or more tile sheets accompanying the do-it-yourself kit assembly of the embodiment of FIG. 1 .
FIG. 4 is a perspective view of a handle portion of the grout float.
FIG. 5 is an exploded view of the handle portion and base portions of the grout float in a position to be assembled.
FIG. 6 is a top view of the base portion of the grout float as represented in FIGS. 3 and 5 .
FIG. 7 is a perspective view of a portion of the do-it-yourself method of installation of the kit assembly of the embodiment of FIG. 1 .
FIG. 8 is a perspective view of another portion of the do-it-yourself method of installation of the kit assembly of the embodiment of FIG. 1 .
FIG. 9 is a perspective view of yet another portion of the do-it-yourself method of installation of the tile assembly kit as represented in FIG. 1 .
FIG. 10 is a perspective view of yet another portion of the do-it-yourself method of installation of the kit assembly of the embodiment of FIG. 1 .
FIG. 11 is a transverse sectional view of one of a possible plurality of tile sheets included in the do-it-yourself kit assembly of FIG. 1 .
FIG. 12 is a perspective view of a tile liner piece of the tile assembly of the do-it-yourself 0kit assembly of FIG. 1 .
FIG. 13 is a collective view of a plurality of tile liner pieces included in the do-it-yourself kit assembly of FIG. 1 .
FIG. 14 is a perspective view of one of a plurality of loose tile pieces included in the do-it-yourself kit assembly of FIG. 1 .
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the accompanying Figures, the present invention is directed towards a do-it-yourself mounting or installation kit generally indicated as 10 in FIG. 1 . In addition, the present invention includes the structural and operative details of a tile assembly including one or more tile sheets and the method of installing or mounting the tile assembly in an effective, efficient and time saving manner.
As indicated, the do-it-yourself installation assembly 10 comes in a packaged form utilizing an appropriately sized and structured container 12 . With primary reference to FIG. 2 , the various components of the kit assembly 10 are collectively represented and include at least one but more practically a plurality of tile sheets 14 as well as a plurality of installation materials and installation tools. When combined and used as intended, the installation materials and tools facilitate the do-it-yourself method of installation of the one or more tile sheets 14 on a predetermined area of a support surface 16 , as generally represented in FIGS. 7 and 8 . More specifically, the dimension, configuration and number of tile sheets 14 may be such as to facilitate the mounting or installation of the tile sheets on a predetermined area of the support surface 16 . By way of example only, an intended area for installation of the support surface 16 may be a kitchen backsplash area. As such, the size and quantity of the plurality of tile sheets 14 are sufficient to cover a typical surface area, such as being in the range of 15 square feet. However, it is emphasized that the versatility of the do-it-yourself installation kit 10 , attendant method and structural features of the tile sheets 14 are such that the present invention could be applied a variety of other support surfaces, having a variety of greater or smaller sizes other than the referred to kitchen backsplash area. Accordingly, the support surface 16 being a kitchen backsplash is referred to by way of example only.
Again with primary reference to FIG. 2 , the installation tools included in the kit assembly 10 comprise a grout float 18 , described in greater detail in FIGS. 3-6 ; a cutting blade 20 , a plurality of spacers 22 , a sponge 24 , as well as other cleaning materials; at least one pair of gloves 26 and informational and/or instructional material, such as a printed manual and/or a DVD or other viewable media; generally indicated as 28 . Yet additional installation tools may also include a screwdriver and tape measure. Installation materials included as part of the kit assembly 10 may include a supply of grout 30 , provided in sufficient quantity and in one or more easily accessible containers 32 . Use of the grout supply 30 will be explained with reference to at least FIGS. 9-11 . Moreover, the supply of grout containers 32 are independently accessible so as to deliver the grout contained therein to the grout float 18 as generally indicated in FIG. 9 , and described in greater detail hereinafter.
As also represented in FIG. 2 , the tile assembly includes the one or more tile sheets 14 as well as a plurality of additional tile pieces generally indicated as 34 . The tile pieces may include a plurality of elongated one piece liners 43 dimensioned, configured and structured to be mounted along and at least partially define the peripheral borders of the one or more mounted tile sheets 14 , when installed on the support surface 16 . Structural and operative details of the tile liners will also be discussed in greater detail hereinafter. In addition, the plurality of extra tile pieces 34 may include a plurality of loose, detached tile pieces 45 equivalent in dimension, configuration and coloring to the plurality of individual fixed tile pieces 42 formed on an exposed face or surface of each of the one or more tile sheets 14 , as explained in greater detail with regard to FIGS. 11-14 .
Additional structural features of each of the one or more tile sheets 14 is represented in FIG. 11 . More specifically, each of the tile sheets 14 may be of a predetermined size and configuration based on the size and configuration of the area of the support surface 16 on which the tile assembly is to be installed. By way of example, when the kit assembly 10 is used to cover a kitchen backsplash area of the support surface 16 the plurality of tile sheets 14 may be 15 in number, wherein each sheet has a dimension of 12 inches by 12 inches, or one square foot. As such, each of the plurality of tile sheets 14 include a backing sheet 40 formed of an appropriate material such as, but not limited to, an open mesh material. In addition, the plurality of tile pieces 42 are fixedly secured to an outer surface of the backing sheet 40 in equally spaced relation to one another. In addition, each of the fixed tile pieces 42 may or may not be of an equivalent dimension and configuration. However, each of the tile pieces 42 is appropriately coordinated at least in terms of color, texture, etc. to provide an overall visually pleasing appearance when mounted on the support surface 16 . Moreover, in at least one preferred embodiment of the present invention, the tile pieces 42 , as well as the one or more tile liner pieces 43 and the individual loose tile pieces 45 are formed of a mosaic, glass material. It is emphasized that other materials, such as ceramic material, can be used to form the individual tile pieces 42 as well as the liners 43 and loose tile pieces 45 .
Each of the plurality of tile sheets 14 also includes an adhesive layer 44 extending over the entirety of the corresponding opposed surface of the backing sheet 40 , relative to the placement of the plurality of tile pieces 42 . Finally, a cover sheet 46 is removably disposed in overlying, covering and somewhat protecting relation to the surface 44 ′ of the adhesive layer 44 so as to prevent any inadvertent adherence of the one or more sheets 14 to other objects.
While the composition of the adhesive layer 44 may vary, one preferred embodiment includes the adhesive layer comprising a cross-linked polyethylene foam, double-coated with a rubber based adhesive, composed of organic and synthetic elastomers. As such, the adhesive layer 44 is accurately described as being at least partially “pressure sensitive” as at least partially represented in FIG. 8 . The pressure sensitive characteristics of the adhesive layer 44 is such that during the do-it-yourself method of installation each of the one or more tile sheets 14 may be “dry-fitted” to the support surface 16 in order to accomplish a proper alignment, orientation and/or positioning relative to one another and to the disposed area of the support surface 16 itself. More specifically, the adhesive composition is such that when a first predetermined or minimal pressure is applied to the adhesive layer 44 , it may be disposed in removable confronting engagement with the support surface 16 . This allows adjustment in the alignment or orientation of each of the plurality of sheets 14 . However when proper alignment or orientation has been accomplished, a second predetermined or significantly greater pressure is applied to the exterior or exposed portions of the plurality of tile pieces 42 , thereby fixedly securing the corresponding tile sheet 14 to the support surface 16 in a substantially permanent manner.
Further with regard to FIGS. 12-14 , each of the plurality of liner tiles 43 may be of different lengths but have a solid, one piece construction of the mosaic, glass material corresponding to the material from which the plurality of fixed tile pieces 42 are formed. In addition, an adhesive layer, as at 44 ″, may be secured to the undersurface of each of the plurality of liners 43 so as to facilitate the fixed and substantially permanent positioning thereof about the peripheral borders of the installed tile sheets 14 . Similarly, the individual loose tile pieces 45 may include an adhesive layer backing as at 44 ″. The loose tile pieces 45 are used to replace any damaged or missing fixed tile pieces 42 when such is found necessary. Appropriate liner material may also be associated with the tile liner pieces 43 as well as the loose tile pieces 45 .
Other structural features of the do-it-yourself kit assembly 10 specifically relating to the grout float 18 are represented in FIGS. 3-6 . More specifically, the grout float generally indicated as 18 includes a base 19 and a handle 21 connected to one another by connecting members 21 ′, as demonstrated in the exploded view of FIG. 5 . Moreover, the base 19 is formed of an at least partially flexible material and includes an outer waterproof or water resistant covering 19 ′. One purpose of the grout float 18 is for the spreading and distribution of the grout supply 30 over the exposed surface of the plurality of fixed tile pieces 42 . In distributing the supply of grout 30 it is first delivered to and effectively spread over the exposed surface 19 ′ of the base 19 of the grout float 18 , as represented in FIG. 9 . For convenience, the supply of grout 30 , including that retained within the various grout containers 32 , is in a ready to use form. Once applied to the grout float 18 the grout supply 30 is spread over the exposed surface or faces of the plurality of fixed tiles 42 . To this extent the grout is sufficient in quantity and texture to fill each of the grout junctions or channels 47 extending about the periphery of each of the fixed tile pieces 42 and specifically between adjacent ones of the tile pieces 42 .
Another feature of the grout float 18 is its ability to apply a greater, predetermined pressure to the exposed face of the plurality of tile pieces 42 once properly positioned and secured to the support surface 16 . As set forth above, the second predetermined or greater pressure is applied to the tile sheet 14 by pressing the confronting surface 19 ′ of the base 19 over the exposed face of each of the plurality of fixed tiles 42 to a degree sufficient to fixedly adhere the adhesive layer 44 to the support surface 16 in a substantially permanent manner. Accordingly, the flexibility of the base 19 should be sufficient to be at least partially compressed against the exposed or outer face of the plurality of tiles 42 , without causing damage thereto.
With primary reference to FIGS. 7-10 , the preferred do-it-yourself method of installation of the kit assembly 10 is sequentially represented. More specifically, the area of the support surface 16 to which the one or more tile sheets 14 are to be applied should be thoroughly cleaned so as to remove any grease, dust, debris, particles, etc. which would interfere with the adherence of the tile sheets 14 to the support surface 16 . Cleaning may be accomplished utilizing a plurality of different cleaning solutions to properly prepare the support surface 16 .
Thereafter, as represented in FIG. 7 , the specific area of the support surface 16 is measured and compared with and/or coordinated to a first or subsequent one of the plurality of tile sheets 14 . This coordination may result in a determination of differences in the dimension and configuration of the support surface 16 and that of the tile sheets 14 . Upon such an occurrence, the cutting blade 20 included within the kit assembly 10 can be used to cut through the corresponding tile sheet 14 by directing the blade to pass through the backing sheet 40 , the adhesive layer 44 and the cover sheet 46 . In doing so, the cutting blade 20 may pass into appropriate ones of the grout channels or grout junctions 47 and between adjacently positioned ones of the fixed tile pieces 42 , as desired.
Once the dimension and configuration of the tile sheet 14 and the surface area 16 has been established, there may be a “dry-fitting” of the cover sheet to the surface area 16 as generally represented in FIG. 8 . In doing so, the cover sheet 46 is at least minimally removed from preferably a lower end or periphery of the tile sheet 14 and the tile sheet is bent or folded into an orientation where the adhesive layer 44 may be disposed in confronting relation to the corresponding portion of the support surface 16 . In accomplishing this dry-fitting procedure, only a first predetermined or minimal amount of pressure is applied to the outer or exposed face of the tile sheet 14 . This will allow the adhesive layer 44 to removed from the support surface 16 at least one or two times, such that the corresponding tile sheet 14 can be properly aligned, oriented and positioned. Once the proper alignment has been established, the cover sheet 46 is completely removed thereby exposing the entirety of the adhesive layer 44 and allowing the exposed surface 44 ′ thereof to be disposed in confronting relation to the support surface 16 . Once so positioned, the grout float 18 is applied to the exposed frontal portions of the plurality of fixed tiles 42 in a manner which supplies a second predetermined or greater pressure to the tile sheet 14 . This greater pressure will be sufficient to accomplish a substantially permanent adherence of the tile sheet 14 and adhesive layer 44 to the support surface 16 .
As represented in FIGS. 9 and 10 , the supply of grout 30 is then applied to the surface 19 ′ of the base 19 and spread continuously over the entire surface area of the mounted tile sheets 14 . This is accomplished by a predetermined or preferred directional stroking in a manner which efficiently accomplishes the filling of each of the grout junctions or grout channels 47 with the grout material 30 . A sufficient time of generally about 30 minutes is provided to allow the grout to dry. Thereafter, a moistened sponge 24 is utilized, as well as possibly other cleaning materials, to remove any excessive grout from the face of the fixed tiles 42 . This cleaning of the excessive grout is accomplished in a manner which allows the at least partially dried grout within the grout junctions 47 to remain. Other features demonstrated in FIG. 10 is the removal of any obstacles or objects from the support surface 16 using an included screwdriver, such as the removal of a face plate covering a socket.
Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.
Now that the invention has been described,
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A do-it-yourself kit assembly and installation method for mounting a tile assembly to a predetermined support surface, such as a kitchen backsplash. The kit assembly includes the tile assembly comprised of one or more tile sheets as well as all of the installation materials and installation tools required to accomplish the do-it-yourself installation in a timely manner. Each tile sheet includes a plurality of fixed tile pieces, which may comprise glass mosaic tiles, and a self-adherent adhesive layer, which facilitates the mounting of the tile sheets to virtually any kind of surface. A ready-to-use grout supply makes it easy to apply the optimal quantity of grout onto the mounted tile sheet(s), wherein the installation materials and tools are cooperatively provided to facilitate the installation method.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from Provisional Application Ser. No. 60/434,864 filed Dec. 19, 2002, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to a compact apparatus and methods for generating hydrogen which apparatus and methods provide the capability to respond rapidly to changes in hydrogen demand. More particularly, this invention relates to a compact hydrogen generating apparatus and methods suitable for use in conjunction with a fuel cell.
BACKGROUND OF THE INVENTION
Fuel cells convert hydrogen and oxygen to water, releasing energy as usable electricity without employing combustion as an intermediate step. Unfortunately, the use of fuel cells has been limited especially where a rapid change in electricity demand is required such as in residential applications. The problem is that the rate of hydrogen supply to the fuel cell must rapidly change in order to accommodate varying electrical loads.
One could use a reservoir of hydrogen from which to supply the fuel cell, and the replenishment of hydrogen to the reservoir would therefore not be subjected to accommodating the rapid changes in hydrogen demand. However, such a solution is impractical, especially for residential use, due to difficulties and risks associated with such storage. Moreover, hydrogen storage equipment adds to the size and cost thereby reducing the attractiveness of a fuel cell for residential use. Alternatively, electricity could be stored in batteries, which serve as a buffer between the fuel cell system and the electrical load. Batteries, especially of the volume required to meet the needs of residential units, also add to the cost and size of the fuel cell system. Moreover, batteries have a limited life and must be replaced. Another approach is to store electricity in a super capacitor. While the size and cost of a super capacitor may be attractive, the disadvantage is the limited storage capacity.
Ideally, hydrogen would be generated on-site on an as needed basis for the fuel cell by the reforming (e.g., steam reforming and autothermal reforming) of fuels such as methanol, ethanol, natural gas, propane, butane, gasoline and diesel. Such fuels have high energy storage densities, have conventional storage protocols and have a nationwide supply infrastructure.
Although technology exists for the generation of hydrogen by reforming fuels, the implemented production processes are not able to quickly change the rate of hydrogen generation so as to be useful in a residential fuel cell application. For instance, hydrogen is widely produced for chemical and industrial purposes by converting suitable fuel materials such as hydrocarbons and methanol in a reforming process to produce a synthesis gas. Such chemical and industrial production usually takes place in large facilities that operate under steady-state conditions.
On-site hydrogen supply for fuel cells used in smaller mobile and stationary facilities, including residential-scale facilities, poses substantial problems even without the added complexities of operating at varying production rates. For instance, hydrogen generators for fuel cells must be smaller, simpler and less costly than hydrogen plants for the generation of industrial gases. Furthermore, hydrogen generators for use with fuel cells will need to be integrated with the operation of the fuel cell such that energy storage requirements are minimized. Moreover, the hydrogen generators must in combination with the fuel cells, be economically viable both in terms of purchase cost and cost of operation, and they must be sufficiently compact to meet consumer desires.
The challenge associated with providing smaller scale hydrogen generators is readily apparent from the number of unit operations required to convert fuel to hydrogen suitable for use in a fuel cell. The fuel must be brought to temperatures suitable for reforming which are often in excess of 600° C. The fuel is reformed to produce hydrogen and carbon monoxide, and the reformate is subjected to water gas shift at lower temperatures to convert carbon monoxide and water to hydrogen and carbon dioxide. Residual carbon monoxide is removed from the hydrogen-containing gas. Additionally, pre-treatment operations are generally required to treat the fuel to remove sulfur, a catalyst poison.
These unit operations must be conducted in an energy efficient manner. Consequently, the overall process should be highly heat integrated. As can be readily appreciated, changes in hydrogen production would be expected to take some time as each of the unit operations and heat exchange operations respond. The severity of the problem in changing hydrogen generation rates is exacerbated in that the range of operation of residential units needs to be quite wide, often the turndown ratio must be at least 5:1.
The difficulties in providing a hydrogen generator for use with fuel cells is further exacerbated because carbon monoxide is a poison to fuel cells. The water gas shift reaction is the primary operation used in a hydrogen generator to remove carbon monoxide generated by the reforming of the fuel. Any upset in the operation of the water gas shift reactor can result in an increase in carbon monoxide that must be removed in downstream treatment of the hydrogen-containing gas. While redundant capacity for carbon monoxide removal (e.g., a selective oxidation) may be used in downstream operations to handle spikes in carbon monoxide production, such an approach will incur a penalty in process efficiency and product purity, as well as compactness and cost of the system. Accordingly, the hydrogen generator must be able to accommodate changes in the hydrogen production rate without adversely effecting the water gas shift operation.
Another problem area in the providing hydrogen generators, especially compact hydrogen generators for fuel cell systems, is to cool the reformate to temperatures suitable for the water gas shift reaction. The use of indirect heat exchange has posed problems due to the inherent lag time required when the production rate of hydrogen is changed. Proposals have included cooling by injecting liquid water into the reformate. The injection rate can rapidly respond to a change in the hydrogen production rate and adequate cooling can be obtained with relatively small amounts of liquid water due to the high latent heat of vaporization. Additionally, as the water gas shift reaction is an equilibrium reaction, the additional water has some benefit in shifting the equilibrium to the production of hydrogen.
U.S. Pat. Nos. 6,162,267 and 6,375,924 disclose a reformer and a separate vessel containing a high temperature water gas shift zone and a low temperature water gas shift zone for generating hydrogen with reduced carbon monoxide content. Water is introduced as a spray above each of the shift zones to control temperature.
US Patent Application Publication 2002/0152680 discloses a fuel cell system in which liquid water is injected between the reformer and the water gas shift reactor to cool the reformate. The liquid water is atomized and/or injected on a high surface area material to assist in the cooling.
However, the injection of liquid water poses difficulties in that the water must be essentially completely vaporized prior to contact with the water gas shift catalyst. The presence of liquid water on the water gas shift catalyst can result in deterioration in performance, thereby increasing the potential of carbon monoxide breakthrough to the fuel cell. Additionally, atomization of liquid water and the use of high surface area contact surfaces such as steel wool, ceramic pellets, and honeycomb monoliths which serve to prevent the passage of liquid water to the water gas shift catalyst, pose disadvantages. For instance, atomization nozzles may not be able to perform adequately over the wide range of hydrogen production rates sought for residential units, and atomization nozzles may require maintenance. The use of high surface area structures results in a pressure drop, may not be effective in assuring complete vaporization of the water, and additional energy will have to be consumed in compression of the gases passing through the hydrogen generator.
An unpublished effort known to the inventor used a coiled tube within the passage between the reformer and the water gas shift reactor. Liquid water was introduced into the tube. Indirect heat exchange with the reformate converted the liquid water to steam, and the steam was released at the end of the coil. Difficulties existed in obtaining a uniform temperature reduction across the cross section of the passage and in providing a nozzle at the end of the tube for introducing the steam into the reformate.
US Patent Application Publication 2002/0094310 discloses a compact fuel processor using a plurality of modules stacked end-to-end.
US Patent Application Publication 2001/0002248 discloses a hydrogen generating apparatus having heat integration and the asserted ability to provide a constant hydrogen concentration over a range of hydrogen production rates.
US Patent Application Publication 2001/0014300 discloses a reformer controlling apparatus using downstream detectors to control the fuel to air ratio and the amount of fuel and air.
Apparatus and processes are sought which can handle a wide range of throughputs and overcome the inherently slow thermal response of system components, especially the reformer and water gas shift reactor with associated heat exchangers, without risking undue fluctuations in carbon monoxide production. Moreover, the technology should be economically viable for a compact unit providing hydrogen to a fuel cell and not render the compact unit so complex that it is not sufficiently reliable for residential use.
SUMMARY OF THE INVENTION
In accordance with this invention apparatus and processes are provided for the generation of hydrogen which employ a reformer (e.g., steam or autothermal) and water gas shift reactor. The reformer and water gas shift reactor can be positioned closely to each other. The invention permits the generator to be relatively compact and to respond quickly to changes in hydrogen demand while preventing undue fluctuations in carbon monoxide in the water gas shift reactor effluent. A cooling section between the reformer and the shift reactor uses injected liquid water to cool the reformate by taking advantage of latent and sensible heat of water. The cooling section is operable over a wide range of hydrogen production rates, yet still can rapidly respond to changes in the hydrogen production rate.
The hydrogen generators of this invention comprise a reformer for converting a fuel and either steam or steam and oxygen into a reformate containing hydrogen and carbon oxides; a downstream shift reactor for converting carbon monoxide in the reformate with water to carbon dioxide and hydrogen, said shift reactor having at least one catalyst stage; a conduit from the reformer and encompassing the shift reactor for passing the reformate through the shift reactor; and a heat exchanger/distributor within the conduit for cooling the reformate prior to exiting the conduit, said heat exchanger/distributor comprising:
(a) an indirect heat exchanger adapted to received liquid water and having sufficient surface area to vaporize the received water to steam and adapted to cool the reformate in the conduit, (b) at least one separator in fluid communication with the indirect heat exchanger adapted to receive steam from the indirect heat exchanger and remove substantially all liquid water, and (c) at least one steam distributor in fluid communication with the separator to pass the steam into the reformate.
In the processes of this invention, reformate from a reformer for the conversion of fuel to hydrogen and carbon oxides is subjected to indirect heat exchange with liquid water, said water being provided at a rate sufficient to cool the reformate while being substantially completely converted to steam; separating the steam from the liquid water; and passing the separated steam into the reformate. The indirect heat exchange and the passing of the steam into the reformate in the processes of this invention may occur immediately subsequent to the reformer or during (i.e., between catalyst stages) or after any water gas shift used to treat the reformate.
One of the advantages of the apparatus and processes of this invention is that the cooling of the reformate can be accomplished without the need to introduce liquid water directly into the reformate. Thus, the risk of adversely affecting the performance of shift catalyst is mitigated. Devices to remove entrained water, which would increase pressure drop to the reformate stream, are not necessary as the removal of water is done prior to the introduction of the steam into the reformate. Further, any pressure drop losses occur only with respect to the introduced water, which is a small amount in comparison to the amount the reformate.
Additionally, since all the liquid water being introduced into the heat exchanger/distributor is converted to steam, the mass of liquid water in the heat exchanger/distributor at any given time is relatively small and quickly converted to steam. Because only a minimal mass of liquid water contained in the heat exchanger/distributor, rapid transitions to different hydrogen production rates can be accomplished. Sufficient surface area is provided within the indirect heat exchanger that in operation, the amount of water (liquid and steam) present is less than about 1, preferably less than about 0.5, minute supply.
Heat exchange with the reformate can occur both by indirect heat exchange and by direct heat exchange with the steam passing into the reformate. This feature of the invention further facilitates rapid response.
The apparatus and processes of this invention, because of their inherent broad throughput capabilities, can be used with other heat transfer operations. In one aspect of the invention, the reformate is cooled by indirect heat exchange with another process stream, for example, a stream being preheated for passage to the reformer.
In preferred aspects of this invention, the indirect heat exchanger and distributor are positioned in the conduit to provide adequately uniform cooling of the reformate. For the purposes of this invention, relatively uniform cooling exists where the performance of the shift catalyst is not unduly adversely affected such as by a decrease in carbon monoxide production by 10 percent or more by volume. In another preferred aspect of this invention, a plurality of steam distributors are provided to facilitate the admixing of the steam with the reformate.
The heat exchanger/distributor may be used at one for more of the following locations: between the reformer and the shift reactor; between catalyst stages of the shift reactor if more than one catalyst stage is used; or after the shift reactor to cool the effluent from the shift reactor.
Advantageously, the reformer and the shift reactor are close coupled such that substantially all cooling of the effluent from the reformer is provided by the indirect heat exchange and the introduced steam. By close coupling it is meant that the distance between the reformer and shift reactor is relatively short such that the surface area is available for significant heat loss to the environment. The close coupling is facilitated by the ability of the heat exchanger/distributor to quickly effect cooling. In more preferred aspects, the region of the shell between the reformer and the shift reactor has an external surface area to cross-sectional surface area of between about 1 to 20, say, 2 to 10, and the distance between the units is less than about 50, preferably less than about 30, centimeters. With compact units distance between the units is about 10 to 15 centimeters, and preferably closer to 5 centimeters.
Typically, a controller is provided in fluid communication with the heat exchanger/distributor to adjust the rate of introduction of water to maintain the admixture at a predetermined temperature for entry into the shift unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional schematic representation of an apparatus in accordance with this invention having a high temperature water gas shift unit and a low temperature water gas shift unit.
FIG. 2 is a schematic depiction viewed from the top of a heat exchanger/distributor used in the apparatus of FIG. 1 .
FIG. 3 is a cross-sectional view of the heat exchanger/distributor of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The fuel for the generation of hydrogen is a hydrogen and carbon containing material such as natural gas, liquefied petroleum gas (LPG), butanes, gasoline, oxygenates (e.g., methanol, ethanol, and dimethyl ether), biogas, kerosene or naphtha (a gasoline boiling range material). The invention is particularly useful with natural gas or LPG. Natural gas, LPG and similar hydrocarbons, also generally contain impurities (including odorants) such as sulfur in the form of hydrogen sulfide, mercaptans, organosulfides, and the like which must be removed prior to introducing the feedstock to the steam reforming zone.
Water is used in the hydrogen generating process. In addition for some types of fuel cells, the hydrogen product must be delivered to the fuel cell as a wet gas. This is particularly true with PEM fuel cells, wherein the humidity of the hydrogen product stream is controlled to avoid drying out the PEM membrane in the fuel cell. The water preferably is deionized.
The fuel and steam, for a steam reformer, or fuel, steam and free oxygen, for an autothermal reformer, are fed to the hydrogen generator of this invention. The preparation of this feed, other than to achieve the desired fuel to oxygen and steam to fuel ratios, is not critical to this invention. The feed, or components of the feed, can be heated prior to entry into the hydrogen generator or within the hydrogen generator. In some instances it may be desired to heat the fuel prior to admixing with steam and oxygen, especially if the fuel is a liquid under normal conditions to vaporize it. The source of free oxygen for autothermal reforming may be pure oxygen, enriched air, or most conveniently, air.
Preferably, the ratio of steam to carbon in the feed is between about 1:1 and about 6:1, and more preferably, between about 2:1 and about 4:1, and most preferably, about 3:1. Typically, the amount of steam used is only that amount desired for the reforming reaction to minimize the amount of heat necessary to bring the feed to the reforming unit to reforming temperatures.
The overall partial oxidation and steam reforming reactions for methane are expressed by the formulae:
CH 4 +0.5O 2 →CO+2H 2
CH 4 +H 2 O CO+3H 2
Steam reforming is a catalytic reaction producing hydrogen and carbon oxides (carbon dioxide and carbon monoxide) conducted under steam reforming conditions. Steam reforming conditions usually comprise temperatures in excess of 600° C., e.g., 650° C. to 1300° C., and sometimes 700° C. to 1100° C., and pressures of from about 1 to 25 bar absolute.
Partial oxidation reforming conditions typically comprise a temperature of from about 600° C. to about 1000° C., preferably about 600° C. to 800° C. and a pressure of from about 1 to about 25 bar absolute. The partial oxidation reforming is catalytic. The reformer may comprise two discrete sections, e.g., a first contact layer of oxidation catalyst followed by a second layer of steam reforming catalyst, or may be bifunctional, i.e., oxidation catalyst and steam reforming catalyst are intermixed in a single catalyst bed or are placed on a common support. The partial oxidation reformate comprises hydrogen, nitrogen (if air is used as the source of oxygen), carbon oxides (carbon monoxide and carbon dioxide), steam and some unconverted hydrocarbons.
The reformate, reforming effluent, is a gas and is passed to the shift reactor which contains at least one water gas shift reaction zone. The reformate is typically at temperatures in excess of about 600° C. as it exits the reformer. The reformate is cooled prior to being passed to the shift reactor to water gas shift conditions. In the shift reactor carbon monoxide is exothermically reacted in the presence of a shift catalyst in the presence of an excess amount of water to produce additional amounts of carbon dioxide and hydrogen. The shift reaction is an equilibrium reaction. The reformate thus has a reduced carbon monoxide content.
Although any number of water gas shift reaction zones may be employed to reduce the carbon monoxide level in the hydrogen product, two-zone water shift catalyst stages are often used. The first shift catalyst is for a high temperature shift at high temperature shift conditions comprising temperatures between about 320° C. and about 450° C. The effluent from the high temperature shift zone is fed to a low temperature shift zone operating at low temperature shift conditions. The effluent from the high temperature shift is cooled to temperatures suitable for the low temperature shift. The low temperature shift conditions usually comprise a temperature between about 180° C. and about 300° C.
The water gas shift effluent stream or hydrogen product typically comprises less than about 1, preferably less than about 0.5, mol-% carbon monoxide (on a dry basis). The effluent may be further treated in a suitable manner to remove further carbon monoxide (such as by selective oxidation of carbon monoxide to carbon dioxide) and excess water (as the amount of water required for the cooling of the reforming unit effluent exceeds that required for the shift reaction and for providing a wet gas).
One or more heat exchanger/distributors may be used in the processes and apparatus of the invention. Most frequently, the heat exchanger/distributors are used to cool the reformate prior to entering the water gas shift reactor and/or between shift reactor catalyst stages if two or more catalyst stages are used. If an additional heat exchange is used to cool the reformate, for instance, a heat exchanger used to heat the feed to the reformer, the heat exchanger/distributor usually is positioned further downstream.
Advantageously, the indirect heat exchanger is positioned within the conduit carrying the reformate such that the reformate is relatively uniformly cooled. Often, turbulence, including that induced by the presence of the indirect heat exchanger itself, results in the reformate mixing. Consequently, the configuration of the indirect heat exchanger is not critical and can be determined by the artisan for the given geometry of the cooling section and the reformate flow rates. To a significant extent, the configuration of the heat exchanger will be dictated by the amount of surface area needed to vaporize the water feed and the desire not to cause an undue pressure drop in the conduit.
The indirect heat exchanger provides sufficient surface area that under the range of expected operating conditions, vaporization of essentially all of the liquid water will occur. The determination of the required surface area can readily be determined for a given system, including the composition and range of throughputs for reformate, the temperature of the reformate, the temperature of the liquid water, pressure, and the heat transfer properties and coefficients for the material of the heat exchanger surface. Preferably, the surface area is in excess of that required to vaporize the liquid water.
In fluid communication with the indirect heat exchanger is at least one separator adapted to receive steam from the indirect heat exchanger and remove substantially all liquid water from the steam. The separator may be of any convenient design, including, but not limited to, vane-type separators, demister pads, and the like. It has been found that adequate liquid/vapor separation can be achieved by using a riser where any liquid entrained is either separated by gravity or contacts the surfaces of the riser (which are heated by the reformate) and vaporizes.
The separator is in fluid communication with at least one distributor to permit the steam pass from the heat exchanger/distributor into the reformate passing through the conduit. The number of distributors associated with the heat exchanger/distributor is preferably sufficient to enable a relatively uniform mixture of reformate and steam prior to the mixture contacting a downstream catalyst. Relatively uniform mixing occurs when the peak and minimum temperatures of the gases contacting the downstream catalyst are within about 50° C. Frequently, at least three, more preferably at least four, distributors are used. The distributors may be of any convenient design. The distributors may simply be openings or ports through which the steam passes may be nozzles or porous foam or wire pad structures. The distributors may be integral with the separators, that is, the separator and the distributor are the same structure, or may be separate structures.
DETAILED DESCRIPTION OF THE DRAWINGS
With reference to FIG. 1 , the compact hydrogen generator 100 , comprises cylindrical shell 102 having a first end defining port 104 and a second end defining port 106 . The shell is shown as being continuous; however, it should be apparent that it may be constructed in sections so as to facilitate assembly and replacement of catalyst beds. The cross section of the shell may be in any suitable configuration. Cylindrical shell structures are most often used.
The fuel, steam and oxygen feed enters the compact hydrogen generator through port 104 and the gas flow proceeds through the shell in an axial direction. An optional distribution plate 108 is shown.
The reforming unit 110 comprises a bifunctional monolithic catalyst. The exterior of the shell at the region of the reforming unit 110 is surrounded by insulation 112 . The insulation may extend around all or part of the remaining portions of the shell. Generally, insulation 112 has an R value of at least about 10, preferably at least about 30.
High temperature water gas shift unit 114 is spaced apart from the reforming unit 110 and defines a cooling zone in which the cooling of the reforming unit effluent occurs, steam is generated, and the steam and effluent are admixed. Preferably the units are in a close-coupled relationship, e.g., within about 3, preferably within about 2 shell diameters. For hydrogen generators useful for residential applications, the units are often within about 50, preferably within about 30, centimeters. In some aspects of the invention, the residence time based upon the gas velocity calculated using the inside cross sectional area of shell 102 is less than about 0.5 second. High temperature water gas shift unit 114 contains a monolithic high temperature shift catalyst.
As depicted, a low temperature water gas shift unit 118 is spaced apart from the high temperature water gas shift unit 114 , and this zone 116 is also used for cooling, water vaporization and mixing of steam with the effluent from the high temperature water gas shift unit. Preferably the units are close-coupled as defined above. The low temperature water gas shift unit 118 also contains a monolithic catalyst.
Each of the three units is positioned within the shell such that gases passing therethrough do not by pass the catalysts. The hydrogen-containing effluent exits shell 102 via port 106 .
Returning to the feed to the hydrogen generator, a mixture of fuel and steam is passed via line 120 to controller 122 which receives air via line 124 . Controller 122 meters the amounts of fuel and air to be admixed in order to maintain the effluent from the reforming unit at a predetermined temperature. Controller 122 can also adjust the total amount of fuel being passed to the hydrogen generator. The overall amount of fuel introduced will be dependent upon the demand for hydrogen, and typically the controller is responsive to an indicator of demand, for instance, a sensing of the load on a fuel cell. The ratio of free oxygen to fuel can be based upon an algorithm correlated to hydrogen demand and/or the temperature of the reforming unit.
Water from line 128 is metered by controller 130 for introduction into the cooling zone subsequent to the reforming unit. The metered water passes through line 132 to heat exchanger/distributor 134 described in more detail in FIGS. 2 and 3 .
Controller 130 is responsive to the temperature of the gases entering the high temperature water gas shift unit 114 as determined by thermocouple line 142 .
The water injection system between the high temperature water gas shift unit 114 and the low temperature water gas shift unit 118 is similar to that described above and elements 144 , 146 , 148 , 150 and 152 correspond to elements 128 , 130 , 132 , 134 and 142 , respectively.
Also depicted in FIG. 1 is an indirect heat exchanger 160 which surrounds a conduit of the shell 102 between the reforming unit 110 and heat exchanger/distributor 134 . A fuel and steam mixture is passed via line 162 to heat exchanger 160 . Alternatively, an air and steam mixture could be introduced into heat exchanger 160 . By avoiding the presence of fuel, any coking problems associated with heating a fuel and steam mixture would thus be eliminated. The effluent from heat exchanger 160 is passed via line 120 to controller 122 .
FIGS. 2 and 3 depict a schematic top view and cross-section of the cooling zones between catalyst stages to further illustrate a heat exchanger/distributor in accordance with the invention. For the sake of ease of understanding, the same reference numerals will be used for all three drawings. The depictions will be for the heat exchanger/distributor 134 . The same principles apply to heat exchanger/distributor 150 .
Tube 200 passes from controller 130 into the interior of shell 102 where it is configured as spiral to both provide sufficient heat exchange area to vaporize the water and to aid in the uniform cooling of the effluent gases from the reforming unit. The distal end of tube 200 directs steam into riser 202 . Riser 202 has four arms 204 , with each arm terminated by a distributor 206 . Openings 208 in each distributor allow the steam to enter the effluent from the reforming unit.
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Apparatus and processes are provided for the generation of hydrogen which employ a reformer and water gas shift reactor. The apparatus and processes respond quickly to changes in hydrogen generation. The reformate in a region between the reformer and prior to exiting the water gas shift reactor is cooled by indirect heat exchange with water whereby substantially all the water is vaporized to steam, the steam is separated from liquid water and then introduced into the reformate.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates to an optical modulator provided outside of a light source in order to modulate the light from the light source, in particular to an optical modulator restricting a photorefractive phenomenon in the optical modulator.
[0003] (2) Related Art Statement
[0004] A dense wavelength division multiplexing (DWDM) technology and high speed communication technology have been developed for optical communication systems corresponding to an increase in the demand for high speed, large capacity data communication systems recently. Particularly, although the modulation frequency of an optical modulator is mostly 10 GHz, high speed modulation more than 40 GHz would also be required from now on.
[0005] As the optical modulator which corresponds to high speed modulation, the combination of CW (Continuous Wave) laser and the Mach-Zehnder(MZ) type external optical modulator (hereinafter described as LN optical modulator) using the material with an electro-optic effect, such as lithium niobate(LN), have been proposed and put to practical use.
[0006] Because LN optical modulator has small wavelength dependency, it is suitable for application in DWDM type optical modulator. Also, because there is no modulation bandwidth limit of dielectric loss, it enables extremely high speed modulation.
[0007] Like the optical modulator of 40 GHz, by increasing the light input power inputted into an LN optical modulator for the long distance transmission, degradation of an extinction ratio, increase of an optical loss and fluctuation of the bias point are induced. Especially when the light input power is more than 10 mW, such problems become evident. As a result of studies by the present inventors, they found out that the major factor is that the stray light generated from the input part which inputs laser light to an optical modulator and from an optical waveguide in the optical modulator, and the signal light which passes through the optical waveguide, in particular, interfere mutually, a photorefractive phenomenon is generated, and grating is written at the optical waveguide part by spatial overlap of stray beam and propagating beam.
[0008] Such grating written at the optical waveguide will cause degradation of the extinction ratio by reflecting the signal light that passes through the optical waveguide, in a direction opposite to the traveling direction, or by reflecting it outward from the optical waveguide.
[0009] The photorefractive phenomenon means the phenomenon that exposure to light varies the refractive index of an electro-optic material. In particular, due to the characteristic that a charge transfer is generated in the material by light, when optical distribution causes spatial intensity distribution of light, re-distribution of charge occurs corresponding to said intensity distribution of light, and this uneven distribution of charge varies an internal electric field topically. Because the internal electric field varies the refractive index of the material, refractive index distribution of the material that corresponds to the intensity distribution of light is formed resultantly.
[0010] Further, the photorefractive phenomenon has the characteristic that the refractive index changes little by little when being continuously exposed to light, and a light scattering gets stronger and stronger as time goes by. Therefore, in drive of an optical modulator for many hours, the deterioration of the optical modulator characteristics, especially degradation of the extinction ratio, increase of the optical loss, etc. becomes prominent.
[0011] The present invention intends to solve the above problems, to restrict the photorefractive phenomenon caused by a stray light in the optical modulator, and to provide the optical modulator which improves the characteristics relevant to the extinction ratio or optical loss of a signal light.
[0012] Particularly, the photorefractive phenomenon tends to occur for the optical modulator having a Mach-Zehnder type optical waveguide since there are many opportunities of interference with the stray light due to escaping light from a branching point of the branching optical waveguide and longer optical waveguide active part that allows phase modulation to work on the signal light passing through the optical waveguide. Further, for the optical modulator having so called dual electrode construction which drive controls several optical waveguide active parts by an independent modulating electrode separately, it is necessary to keep enough distance between modulating electrodes for avoiding cross talk between said modulating electrodes. This makes the length of the waveguide after the branching point of the branching optical waveguide longer, which increases the chances of interfering with the stray light and the photorefractive phenomenon tends to occur as a result.
SUMMARY OF THE INVENTION
[0013] In order to solve the above described problems, the invention related to claim 1 provides an optical modulator comprising a substrate consisting of a material having an electro-optic effect, an optical waveguide formed on said substrate, and a modulating electrode for allowing an electric field to work on said optical waveguide, and changing the phase of light passing through said optical waveguide, wherein stray light rejection means are provided on the surface of said substrate.
[0014] In accordance with the invention related to claim 1 , the stray light rejection means avoids a diffusion of the stray light, in particular, that scatters parallel to the surface of the substrate, out of the stray light escaping from the optical waveguide formed on the substrate of the optical modulator. Thus, the stray light doesn't enter another optical waveguide in the substrate, the stray light and a signal light passing through said optical waveguide don't interfere mutually, and accordingly, no interference grating is generated. This provides the possibility of restricting a photorefractive phenomenon.
[0015] In addition, the invention related to claim 2 provides the optical modulator according to claim 1 , wherein said stray light rejection means comprises a stray light rejection groove, at least one part of which is formed adjacent to said optical waveguide.
[0016] In accordance with the invention related to claim 2 , for composing the stray light rejection means of the groove formed on the substrate, known fine processing technologies such as etching, laser beam machining, and cutting works like sand blast can be applied, with which the stray light rejection means can easily formed. Further, because such stray light rejection groove is formed adjacent to the optical waveguide, it is possible, for example, to reject the stray light exiting from the optical waveguide before a diffusion, for the optical waveguide where the stray light exits, and to forestall the interference of the signal light passing through the optical waveguide and the stray light, for the optical waveguide which the stray light enters.
[0017] In addition, the invention related to claim 3 provides the optical modulator according to claim 2 , wherein the distance between said stray light rejection groove and said optical waveguide is 10 to 100 μm at closest.
[0018] In accordance with the invention related to claim 3 , by making the closest distance between the stray light rejection groove and the optical waveguide 10 μm or more, the stray light rejection groove can be formed with good accuracy without damaging the optical waveguide. Especially when the groove is formed by a mechanical processing method, the optical waveguide (or the substrate portion where the optical waveguide is formed) does not have distortion caused by mechanical processing. Therefore, it is possible to maintain the characteristics of the optical waveguide stably. Also, by making the closest distance less than 100 μm, it is possible to reject the diffusion of the stray light from the optical waveguide, or the entrance of the stray light to the optical waveguide effectively, and to restrict the photorefractive phenomenon.
[0019] In addition, the invention related to claim 4 provides the optical modulator according to any of claims 2 and 3 , wherein the depth of said stray light rejection groove is almost the same or more than that of said optical waveguide.
[0020] In accordance with the invention related to claim 4 , because the depth of the stray light rejection groove is almost the same or more than that of the optical waveguide, it provides the possibility of rejecting the stray light effectively in case of the diffusion of the stray light from the deepest part of the optical waveguide, or the entrance of the stray light to the deepest part of the optical waveguide.
[0021] “Almost the same” means the same depth or the depth where the effect, which is substantially no way inferior to the effect obtained from the same depth, can be obtained.
[0022] In addition, the invention related to claim 5 provides the optical modulator according to any of claims 2 to 4 , wherein said stray light rejection groove is filled with a light absorber material.
[0023] In accordance with the invention related to claim 5 , due to the light absorber material filled in the stray light rejection groove, it is possible to obstruct the course of the stray light by said groove itself, as well as to prevent a scattering of the stray light on the surface of the groove with the light absorber material. As a result, the effect of rejecting the stray light improves further.
[0024] In addition, the invention related to claim 6 provides the optical modulator according to any of claims 1 to 5 , wherein said optical waveguide comprises a branching optical waveguide, and at least one part of stray light rejection means is provided adjacent to said branching optical waveguide.
[0025] In accordance with the invention related to claim 6 , for the optical modulator having the branching optical waveguide like a Mach-Zehnder type optical modulator, the stray light rejection means provided adjacent to the branching optical waveguide enables not only the diffusion of an escaping light, the cause of the stray light, from a branching point of the branching optical waveguide to be prevented, but also the scattering light at an input part inputting laser light from the outside of the optical modulator to be restricted not to enter the branching part of the branching optical waveguide and generate an interference grating.
[0026] In addition, the invention related to claim 7 provides the optical modulator according to any of claims 1 to 5 , wherein at least one part of said stray light rejection means is provided between said optical waveguide that the electric field of the modulating electrode works on and the side face of the substrate that is close to said optical waveguide.
[0027] By providing the stray light rejection means between the optical waveguide that the electric field of the modulating electrode works on and the side face of the substrate that is close to said optical waveguide as in the invention related to claim 7 , especially when an active part (hereinafter described as “optical waveguide active part”) of the optical modulator that allows phase modulation to work on the signal light is relatively long compared with the entire optical waveguide as the optical modulator having the Mach-Zehnder type optical waveguide, it is possible to prevent the stray light from entering said optical waveguide active part effectively.
[0028] In addition, the invention related to claim 8 provides an optical modulator comprising a substrate consisting of a material having an electro-optic effect, an optical waveguide formed on said substrate, and a modulating electrode for allowing an electric field to work on said optical waveguide, and changing the phase of light passing through said optical waveguide, wherein a low refractive index area with the refractive index lower than that of said substrate is provided at one portion of the adjacent spaces comprising at least the lower portion and the side portion of said optical waveguide in order to prevent a stray light from entering the optical waveguide.
[0029] In accordance with the invention related to claim 8 , for the stray light, in particular, that scatters in the direction of the reverse face of the substrate, out of the stray light escaping from the optical waveguide formed on the substrate of the optical modulator, the low refractive index area prevents the stray light from reentering the optical waveguide, the stray light and the signal light which passes through the optical waveguide don't interfere mutually, and no interference grating is generated. As a result, it is made possible to restrict the photorefractive phenomenon.
[0030] This is because providing the low refractive index area with the refractive index lower than that of the substrate enables the stray light entering from the material side of the substrate to be reflected at the surface of the low refractive index area (a boundary surface between a substrate material in the substrate and a material forming the low refractive index area). In particular, it is possible to leak out the escaping light from the optical waveguide, to reject only the stray light effectively which is to enter the low refractive index area from the outside of the low refractive index area (opposite to the side where the optical waveguide is formed, the boundary of which is the low refractive index area), and thereby to prevent the stray light from entering the optical waveguide. In order to prevent the stray light from entering from the reverse face side of the substrate more effectively, it is preferable to form the low refractive index area at the lower portion side or side portion side of the optical waveguide.
[0031] In addition, the invention related to claim 9 provides the optical modulator according to claim 8 , wherein said low refractive index area has thickness longer than the depth of said optical waveguide in the thickness direction of the substrate from the surface of said substrate, and the refractive index between the deepest part of said low refractive index area and the reverse face of said substrate is higher than that of said low refractive index area.
[0032] In accordance with the invention related to claim 9 , because the thickness of the low refractive index area has thickness longer than the depth of said optical waveguide in the thickness direction of the substrate from the surface of the substrate, it presents the possibility of preventing the stray light which is to enter the deepest part of the optical waveguide from entering. The possible range of avoiding the stray light with said low refractive index area out of the incidence angle of the stray light entering the optical waveguide depends on the refractive index and location of the low refractive index area. Particularly, it is effective to locate the low refractive index area at the lower portion side. However, it is more preferable to surround the optical waveguide with the low refractive index area entirely. This enables preventing of the stray light entering the optical waveguide effectively.
[0033] Further, by making the whole substrate from its surface to certain depth the low refractive index area, when the low refractive index are is formed, it is possible to form the low refractive index area more easily without making the pattern formation in accordance with the optical waveguide by photolithography etc.
[0034] Also, by making the refractive index between the deepest part of the lower refractive index area and the reverse face of the substrate higher than that of said low refractive index area, it is possible to avoid the stray light at the surface of the substrate, which is reflected at the reverse face of the substrate, or to prevent it from entering the low refractive index area. As a result, it is made possible to prevent the stray light from entering the optical waveguide effectively. Further, for the distribution of the refractive index between the deepest part of the low refractive index area and the reverse face of the substrate, by making the refractive index high in a stable condition, or making it growing into an high refractive index, it is possible to reject the stray light reflected at the reverse face of the substrate more effectively.
[0035] In addition, the invention related to claim 10 provides the optical modulator according to any of claims 8 and 9 , wherein said low refractive index area is formed by diffusion of a low refractive index material with the refractive index lower than that of said substrate over said substrate.
[0036] In accordance with the invention related to claim 10 , a refractive index adjusting means by ionic diffusion, which is frequently used in the production process of the optical modulator, is available. Without adding any special device or complicated process, but only by setting a diffusion process for forming the low refractive index area in the existing production process of the optical modulator, it is possible to produce the optical modulator having the low refractive index area easily.
[0037] In addition, the invention related to claim 11 provides the optical modulator according to any of claims 8 to 10 , wherein said low refractive index area comprises MgO or ZnO as the low refractive index material.
[0038] In accordance with the invention related to claim 11 , in adjusting the refractive index of the substrate by the ionic diffusion, more homogeneous low refractive index area can be formed by applying MgO or ZnO, diffusion of which is easy to adjust. In particular, it can be preferably applied to the low refractive index adjustment of an LN optical modulator, which is predominant currently.
[0039] In addition, the invention related to claim 12 provides an optical modulator comprising a substrate consisting of a material having an electro-optic effect, an optical waveguide formed on said substrate, and a modulating electrode for allowing an electric field to work on said optical waveguide, and changing the phase of light passing through said optical waveguide, wherein a high refractive index area with the refractive index higher than that of said substrate is provided on the reverse face or side face of said substrate.
[0040] The invention related to claim 12 enables reflecting of the stray light, which was reflected at the reverse face or side face of the substrate, at the boundary surface of the substrate material in the substrate and a material forming the high refractive index area, and thereby restricting of the stray light moving toward the surface of the substrate where the optical waveguide is formed.
[0041] In addition, the invention related to claim 13 provides the optical modulator according to any of claims 1 to 12 , wherein antireflection treatment is given on the reverse face or side face of said substrate.
[0042] The invention related to claim 13 makes it possible to prevent the stray light from being reflected at the reverse face or side face of the substrate, and to restrict the stray light not to enter the optical waveguide.
[0043] In addition, the invention related to claim 14 provides the optical modulator according to claims 1 to 13 , wherein the frequency of modulation drive is more than 40 GHz.
[0044] In accordance with the invention related to claim 14 , in driving the optical modulator especially with the frequency of modulation drive more than 40 GHz where the influence of the photorefractive phenomenon becomes significant, it is possible to avoid the degradation of a superior extinction ratio or increase of an optical loss by rejecting the stray light and restricting mutual interference of the signal light passing through the optical waveguide and the stray light.
[0045] In addition, the invention related to claim 15 provides the optical modulator according to any of claims 1 to 14 , wherein the input power of the light that is inputted into said optical modulator is more than 10 mW.
[0046] In accordance with the invention related to claim 15 , in putting the light having an optical input power more than 10 mW especially, where the effect of the photorefractive phenomenon becomes significant, to the optical waveguide, it is possible to avoid the degradation of the superior extinction ratio or increase of the optical loss by rejecting the stray light and restricting mutual interference of the signal light passing through the optical waveguide and the stray light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a diagram showing the generation status of the stray light in an existing optical modulator.
[0048] FIG. 2 is a schematic diagram showing the optical modulator provided with the stray light rejection means of the preset invention.
[0049] FIG. 3 is a diagram showing the positional relation of the optical waveguide and the stray light rejection means.
[0050] FIG. 4 is a diagram showing the generation status of the stray light passing through to the thickness direction of the substrate in the existing optical modulator.
[0051] FIG. 5 is a diagram showing the status where the low refractive index area is formed only around the optical waveguide.
[0052] FIG. 6 is a diagram showing the status where the substrate of the optical modulator, to certain thickness, is made the low refractive index area.
[0053] FIG. 7 is a diagram showing the status where the high refractive index area is formed on the reverse face and side face of the optical modulator.
DETAILED DESCRIPTION OF THE INVENTION
[0054] In the following, the preferred embodiments of the present invention are explained in detail.
[0055] The substrate which configures an optical modulator is made of a material having an electro-optic affect, such as lithium niobate (LiNbO 3 ; hereinafter referred to as LN), lithium tantalite (LiTaO 3 ), or PLZT (lead lanthanum zirconate titanate). In particular, it is preferable to use a LiNbO 3 crystal, a LiTaO 3 crystal, or a solid solution crystal made of LiNbO 3 and LiTaO 3 due to the fact that an optical waveguide device can be easily formed of any of these crystals which have a large anisotropy. The present invention embodiment primarily refers to an example using lithium niobate (LN).
[0056] A method for forming an optical waveguide by thermal diffusion of Ti in an LN substrate, and subsequently forming an electrode directly on the LN substrate without providing a buffer layer over a portion or the entirety of the substrate, and a method for providing a buffer layer, such as SiO 2 which is dielectric, on an LN substrate in order to reduce the propagation loss of light in the optical waveguide and forming a modulating electrode and a grounding electrode having thickness of several tens of μm on top of the buffer layer according to the formation of a Ti. Au electrode pattern, and according to a gold plating method or the like, are cited as methods for manufacturing an optical modulator.
[0057] In general, a plurality of optical modulators are fabricated on one LN wafer, which is cut into individual optical modulators at the last stage and thereby, optical modulators are manufactured.
[0058] FIG. 1 is a diagram showing a skeletal form of an existing LN optical modulator.
[0059] Numeral 1 is the LN substrate, and the waveguide is formed on the surface of the substrate by internally diffusing Ti etc. as above described. 2 is an input waveguide, into which the light from a CW laser source, which is not shown in the diagram, is guided, and which is connected to a fiber 3 having a polarization holding feature.
[0060] The light passing through the waveguide 2 is equally divided at a 3 dB branching optical waveguide 4 , which is a first branching optical waveguide, and respectively put into an optical waveguide active part 5 that configures the arm of a Mach-Zehnder (MZ) type optical waveguide.
[0061] A modulating electrode and a grounding electrode, which are not shown in the diagram, are located adjacent to said optical waveguide active part 5 . The light passing through the optical waveguide active part in accordance with the signal impressed to the modulating electrode receives phase modulation. After the phase modulation, each guided wave is joined together at a second branching optical waveguide 6 , and thereby generates a signal light which is strongly modulated by mutual interference.
[0062] The signal light passes through an output waveguide 7 and then, is taken outside of a module from an output fiber 8 .
[0063] For the existing optical modulator, as shown in FIG. 1 , stray lights a and b escape from the junction of the fiber 3 and the input waveguide 2 of the optical modulator, and further, stray lights c and d escape from the branching point of the first branching optical waveguide 4 . Each stray light enters the first optical waveguide 4 , the optical waveguide active part 5 , the second branching optical waveguide 6 , etc., interferes with the light passing through said optical waveguide and generates an interference grating as a result. This interference grating generates a photorefractive phenomenon, and thereby causes degradation of an extinction ratio of the signal light. Also, in the input waveguide 2 and the output waveguide 7 , the interference grating leads to degradation of an extinction ratio since the light passing through the optical waveguide is likewise scattered.
[0064] In order to eliminate such effect of the stray light, the present invention places stray light rejection means 11 to 22 adjacent to the optical waveguide such that the mutual interference of the stray light and the light passing through the optical waveguide is restricted as shown in FIG. 2 . In particular, each alignment and shape are configured such that the stray light e is rejected with the means 11 , the stray lights f and g, which can not be rejected with the means 11 (or in case there is no means 11 ), are rejected with the means 13 and 14 , the stray light h is rejected with the means 12 and 17 , the stray light i is rejected with the means 18 , and the stray lights j and k are rejected with the means 18 , 19 and 20 .
[0065] The stray light rejection means prevents the stray light from reaching the optical waveguide by forming a groove, depth of which (about 50 μm) is same as that of the optical waveguide, on the surface of the substrate 1 and applying a scattering of the light at the wall surface of the groove.
[0066] As the method for forming the groove, there is one easy method where a substrate material is partly removed by laser beam machining and thereby the groove is formed. Besides, well-known processing techniques in the relevant field such as a chemical processing method where the substrate is grooved by etching, or a chemical cutting method of sand blast, etc. can be also applied.
[0067] As the method for strengthening the features of stray light rejection in the above groove, the stray light which passes through said groove is blocked by filing a light absorber material such as carbon black into said groove.
[0068] Also, in general, as shown in FIG. 3 , the closer the optical waveguide (the input waveguide 2 in the diagram) and the stray light rejection means (the grooves 11 and 12 ) are placed to each other, the higher the rejecting effect becomes. However, there is a technical limit such that the optical waveguide is not damaged but can be formed with accuracy in the production process and it is also necessary to consider reduction of a distortion of the optical waveguide (or the substrate portion where the optical waveguide is formed) in the mechanical process such as a cutting process. The line width of the optical waveguide is normally about 7 μm, and the distance between the edge boundary of the stray light rejection means and the optical waveguide is preferably longer than 10 μm as 15 μm in FIG. 3 .
[0069] On the other hand, if the above distance is longer than 100 μm, the scattering of the stray light from the optical waveguide and incidence of the stray light to the optical waveguide can not be effectively controlled and therefore, it might not be possible to obtain the desirable stray light rejection effect.
[0070] Although the width of the stray light rejection means is set to be 80 μm in FIG. 3 , any width is acceptable as long as the groove is formed therein, basically. The stray light rejection means should be formed taking various points into consideration as described below.
[0071] The alignment and shape of the stray light rejection means such as groove, though various types can be suggested, are decided based mainly on the following points.
1. Preventing primarily the scattering of the stray light (1) One which directly blocks the stray light from the input end of the optical modulator ( 11 , 12 , 13 to 16 in FIG. 1 ) (2) One which directly blocks the stray light from the branching point of the first branching optical waveguide of the optical modulator ( 18 , 19 , 20 in FIG. 1 ) (3) One which blocks the stray light reflecting from the side face of the substrate of the optical modulator ( 13 to 16 , 17 in FIG. 1 )
[0076] Besides, an escaping light could be generated in the second branching optical waveguide or a curve portion of the optical waveguide. It is also necessary to deal with these situations if required.
2. Preventing the stray light from entering the optical waveguide
[0078] One which places the stray light rejection means adjacent to the surrounding area of the optical waveguide where the stray light should be prevented from entering ( 17 , 19 , 20 in FIG. 1 )
3. Consideration of the shape and lead wire of the modulating electrode and the grounding electrode
[0080] It is also possible to adjust the alignment and shape of the stray light rejection means taking into consideration the shape and lead wire of the modulating electrode and the grounding electrode as 11 , 12 , 13 to 16 and 17 in FIG. 1 .
[0081] The second embodiment of the present invention is explained in the following.
[0082] As shown in FIG. 4 , there exist stray lights 1 and m having a vector component in the thickness direction of the substrate for the stray light of the optical modulator, as well as the stray light in parallel with the surface of the substrate.
[0083] The stray light like the stray lights 1 and m that moves in the thickness direction of the substrate reflects at a base 30 or the side face of the substrate, enters the optical waveguide, and possibly interferes with the light passing through the optical waveguide.
[0084] In order to reject such stray light, as shown in FIG. 5 , a low refractive index area 40 is formed such that it surrounds the optical waveguide.
[0085] By making the refractive index of the low refractive index area lower than that of the substrate, stray lights o and h that are released outside of the low refractive index area are reflected at the boundary surface of the substrate and the low refractive index area, and are thereby prevented from entering the optical waveguide that is placed inside of the low refractive index area.
[0086] As the alignment of the low refractive index area against the optical waveguide, besides the one where the low refractive index area surrounds the entire optical waveguide as shown in FIG. 5 , it is possible to configure it to reject only the unnecessary stray lights by selectively placing it on the lower portion side or side portion side of the optical waveguide. Preferably, the low refractive index area is formed in the adjacent spaces of the optical waveguide comprising the lower portion side and side portion side of the optical waveguide.
[0087] In addition, FIG. 5 ( b ) shows a cross-section shape at a dashed line A in FIG. 5 ( a ).
[0088] As the other alignment of the low refractive index area, as shown in FIG. 6 , it is possible to form the low refractive index area over the entire surface of the substrate to certain depth wherein the optical waveguide is comprised. Here, in order to form the low refractive index area in accordance with the shape of the optical waveguide as in FIG. 5 , it is necessary to separately prepare a photomask for forming the low refractive index area (however, it is also possible to use at the same time mask pattern for the optical waveguide as described in the following), and therefore, the production process gets complicated and expensive somewhat. On the other hand, when the low refractive index area is formed over the entire surface of the substrate as shown in FIG. 6 , it is possible to skip such process.
[0089] As the method for forming the low refractive index area, materials such as MgO, ZnO, Na 2 O, Li 2 O, B 2 O 3 , or K 2 O, having lower refractive index than that of an LN substrate material are diffused over said substrate. In addition, Fe 2 O 3 , NiO, or Cu 2 O, are also impurities which decrease the refractive index. However, they are not preferable since they improve optical loss sensitivity of an LN crystal.
[0090] For example, a thermal diffusion method is used as the diffusion method. In particular, the low refractive index material is deposited around an optical waveguide forming area to given thickness by using the mask pattern that is applied in forming the optical waveguide, the substrate is heated to given temperature, and the low refractive index material is thermally diffused in the substrate.
[0091] Such thermal diffusion can be conducted before or after the process for forming the optical waveguide. However, it is preferable to conduct it before the process for forming the optical waveguide such that the optical waveguide that has been already formed do not suffer the bad effect by the thermal diffusion processing of the low refractive index material.
[0092] In addition, the above described mask pattern is not required in forming the low refractive index area as shown in FIG. 6 .
[0093] As for the thickness of the low refractive index area, when the thickness is more than the depth of the optical waveguide from the surface of the substrate to the thickness direction of the substrate, it is possible to prevent the stray light that is to enter toward the deepest part of the optical waveguide from entering.
[0094] Furthermore, the possible range of avoiding the incidence angle with said low refractive index area out of that of the stray light entering the optical waveguide depends on the refractive index and alignment of the low refractive index area. Particularly, it is effective to place the low refractive area at the lower portion side. However, it is preferable to surround the optical waveguide by the low refractive index area entirely as shown in FIG. 5 and FIG. 6 . This enables preventing of the stray light entering the optical waveguide effectively.
[0095] Also, by making the refractive index between the deepest part of the low refractive index area and the reverse face of the substrate higher than that of said low refractive index area, it is possible to prevent the stray light reflected at the reverse face of the substrate, or to prevent the stray light from entering the low refractive index area. The incidence of the stray light to the optical waveguide can be effectively restricted as a result. FIG. 5 and FIG. 6 show the one with the refractive index distribution at a constant state between the deepest part of the low refractive index area and the reverse face of the substrate.
[0096] In addition, it is possible to form said increasing state by doping Ti, Ta, Fe, Ag, La, and Y, which are materials having the high refractive index, from the reverse face of the substrate into the substrate.
[0097] As for the space between the optical waveguide and the low refractive index area, it is preferable to configure it such that said space does not exist by placing the optical waveguide and the low refractive index area adjacent to each other. This is because the stray light escaping from the optical waveguide is reflected at the boundary surface on the side of the optical waveguide of the low refractive index area and thereby generates a problem that the stray light is trapped in the space comprising the optical waveguide in case the optical waveguide and the low refractive index area are formed distantly.
[0098] Subsequently, the third embodiment is explained.
[0099] As shown in FIG. 7 , a high refractive index area 42 is formed on the reverse face (base) or side face of the substrate. As the method for forming the high refractive index area, doping a material having said high refractive index into the substrate by thermal diffusion etc can form the high refractive index area.
[0100] The high refractive index area enables the stray light reflecting at the reverse face or side face of the substrate to be trapped in the high refractive index area, and therefore to be prevented from moving toward the optical waveguide again.
[0101] Further, in order to reject stray light reflection from the base or side face of the substrate of the optical modulator more effectively, antireflection treatment, for example coating these faces with an optical absorber material such as carbon black, or an antireflection coating, can be given.
[0102] Also, combining above described various embodiments if necessary can improve the effectiveness of stray light rejection further.
[0103] As the embodiments of the present invention are described above, the present invention is not limited to the scope of the above embodiments, but comprises the ones where technical configuration is substituted by a technology well know in the art.
[0104] As described above, according to the optical modulator of the present invention, because the escaping light from the optical waveguide is prevented from diffusing and the stray light is restricted not to enter the optical waveguide, the photorefractive phenomenon caused by the stray light in the optical modulator can be restricted and it is possible to provide the optical modulator which improves characteristics relating to extinction ratio or optical loss of the signal light.
[0105] In particular, the photorefractive phenomenon, the cause of degradation of extinction ratio etc. which appears when the optical modulator with the Mach-Zehnder type optical waveguide has more than 40 GHz of drive or more than 10 mW of optical input power.
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An optical modulator restricted in a photorefractive phenomenon caused by a stray light in an optical modulator, and improved in the quenching ratio characteristics of a signal light. The optical modulator comprises a substrate consisting of a material having an electro-optic effect, an optical waveguide formed on the substrate, and a modulating electrode for allowing an electric field to work on the optical waveguide and changing the phase of light passing through the optical waveguide, characterized in that stray light removing means are provided on the surface of the substrate.
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TECHNICAL FIELD
The invention relates to an apparatus for anchoring one structural support member of a building to another structural support member and more particularly to a truss anchor formed from a unitary piece of material having a centralized attachment point and a minimum number of strength reducing deformations in the unitary piece of material for secure anchoring of a roof truss member to an underlying support stud.
BACKGROUND OF THE INVENTION
In the construction of buildings having pitched roofs, truss members are secured to the underlying support structure of the building through the use of a truss anchorage device. Existing truss anchorage devices are fabricated as a unitary band of material, usually a semi-pliable metal, with bends at various locations to form a cap portion, two opposed wing portions, and two opposed attachment flanges.
The cap portion is located in the approximate middle of the unitary band and extends over the distal end of the top chord of the truss member. The two opposed wing portions extend horizontally downwardly from the cap portion at ninety degree (90°) angles to the cap portion on opposite sides of the truss member and are bent vertically at a ninety degree (90°) angle relative to the planar surface of the cap to extend at a spaced apart interval within the same plane and adjacent to the surface of an exterior edge of an underlying horizontally extending wall support frame member, thereby functioning as a retaining surface relative to positioning of the truss in relation to the exterior surface of the wall support frame. Extending downwardly from each wing portion is an attachment flange, bent at a ninety degree (90°) angle relative to the planar surface of the wing portion, to allow attachment of the truss anchorage to opposed surfaces of the underlying vertically extending support stud. Thus, the unitary band of material in existing truss anchorage devices is subjected to at least six areas of deformation to create the ninety degree (90°) angles to form the cap portion, the two wing portions, and the two attachment flanges, thus creating six potential areas of weakness or possible failure of the truss anchorage device.
In other existing truss anchorage devices, two separate unitary band of material are used, deleting the cap portion, and thereby deleting two of the ninety degree angles (90°) of deformation in the device. Although deletion of the cap portion reduces the number of deformations in the band of material forming the anchorage device, it also reduces the degree of stability realized through use of a single unitary band of material including the cap portion extending over the distal end of the top chord of the truss member.
In addition to weakness created by the multiple bends or deformations in the surface of the unitary bands of material, the same number of fasteners, such as nails or screws, must be used in each of the opposed attachment flanges for anchoring the truss anchorage device to the opposed sides of the underlying support stud. Thus, the total number of fasteners used is split in half for the two opposed attachment locations, thereby limiting the strength at any one attachment location to half of the total strength provided by the fasteners should they be placed in a single location.
SUMMARY OF THE INVENTION
The preferred embodiment truss anchorage device of the present invention overcomes the foregoing problems by eliminating two of the ninety degree (90°) angle deformations, without deleting the cap portion, and creating a single attachment surface for both of the attachment flanges, thereby reducing the potential weak or failure areas in the unitary band of material and concentrating the total number of fasteners, such as nails or screws, necessary for attachment of the truss anchorage device to the underlying support stud to a single location on one surface of the stud to strengthen the attachment to the stud. Furthermore, the positioning of the single attachment location of the anchorage device of the present invention allows repairs to be made to a damaged roof truss, in conformance with new building codes and federal guidlines, without having to tear out and replace insulation or structural bracing between adjacent wall studs. This advantage is especially beneficial in areas susceptible to hurricane or tornado damage.
In the preferred embodiment truss anchorage device, the ninety degree (90°) angle bends between the planar surfaces of the wing portions and the attachment flanges is omitted, deleting two potential failure sites present at the crucial attachment point in existing anchorage devices. Deletion of the potential failure sites creates the stronger truss anchorage device of the present invention.
When the ninety degree (90°) angle bends between the planar surfaces of the wing portions and the attachment flanges is omitted, the attachment flanges extend adjacent one another instead of opposite one another as in existing truss anchorage devices, and are attached to a single outwardly facing surface of the underlying support stud. When attaching the flanges to the support stud, the flanges may be positioned adjacent one another or one on top of the other with openings in the flanges, for receiving the fasteners therein, in positional alignment. Inclusion of adjacent attachment flanges concentrates in one location the total number of fasteners needed to attach the anchorage device to the underlying support stud, thereby strengthening the attachment point.
Other embodiments of the invention may include the use of two separate bands of material, deleting the cap portion, but also deleting the two ninety degree (90°) angle bends between the planar surfaces of the wing portions and the attachment flanges, thereby reducing the number of potential failure sites of existing two part truss anchorage devices. Similarly, other embodiments of the invention may include the use of different materials of construction, other than metal.
Further advantages of the truss anchorage device of the present invention will become apparent from the following Detailed Description and accompanying Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings, wherein:
FIG. 1 is a perspective view of a truss anchorage device incorporating a first embodiment of the present invention;
FIG. 2 is a perspective view illustrating the overlap of the attachment flanges of the truss anchorage device of FIG. 1;
FIG. 3 is a perspective view of a truss anchorage device incorporating a second embodiment of the present invention;
FIG. 4 is a perspective view of a truss anchorage device incorporating a third embodiment of the present invention;
FIG. 5 is a perspective view of a prior art truss anchorage device; and
FIG. 6 is a perspective view of a second embodiment of a prior art truss anchorage device.
DETAILED DESCRIPTION
Referring now to the Drawings, and in particular to FIG. 1, there is shown a perspective view of a truss anchor 10 incorporating the preferred embodiment of the present invention. The truss anchor 10 is fabricated from a unitary band of material 12 having a first planar surface 14 and a second planar surface 16.
The band 12 is positioned to extend transversely over the top chord 18 of a truss member 20 near the distal end 22 of the top chord 18, as used in interior zones of a building. Following the shape of the top chord 18, the band 12 is bent transversely at a ninety degree (90°) or right angle at a first location 24 and at a second location 26 to form the top 28 and two sides 30 of a first section or cap portion 32 of the truss anchor 10. At least one aperture 34 extends through the top 28 of the cap portion 32 for receiving a fastener 36, such as a nail or screw, therethrough for fixedly attaching the cap portion 32 of the truss anchor 10 to the top chord 18 of the truss member 20.
To form two second sections or wing portions 38 of the truss anchor 10, the band 12 is bent at ninety degree (90°) angles longitudinally at third and forth locations 40 and 42 (not shown), respectively. The first planar surface 14 of the band 12 in the second sections or wing portions 38 extends adjacent to and in contact with the distal end 44 of the bottom chord 46 of the truss member 20 and perpendicular to and in contact with the outwardly facing surface 48 of a horizontally extending wall frame member 50. The wing portions 38 extend at a spaced apart interval from one another within the same vertical plane to retain the truss member 20 in position relative to the outward surface of the wall frame 51.
Referring now to FIGS. 1 and 6, in prior art truss anchorage devices 52, as shown in FIG. 6, the band 54 is bent in fitch and sixth locations 56 and 58, respectively to form attachment flanges 60 wherein the first planar surface 62 of the band 54 in the region of the flanges 60 extends in the same vertical plane as the first planar surface 62 of the band 54 in the region of the sides 64 of the cap portion 66 and perpendicular to the vertical plane in which the planar surfaces 62 and 68 of the wing portions 70 extend. The truss anchor 10, as shown in FIG. 1, does not contain fifth and sixth bends corresponding to the bends at the fifth and sixth location 56 and 58 along the band 54 of the prior art truss anchorage device 52. Two third sections or attachment flanges 72 of the truss anchor 10 extend downwardly from the wings 38, with the second planar surface 16 of the band 12 extending in the same vertical plane in the region of the wings 38 and in the region of the attachment flanges 72, avoiding the introduction of weakness or possible failure by deleting the fifth and sixth bends 56 and 58, respectively, of prior art truss anchorage devices 52.
Referring now to FIGS. 1 and 2, the attachment flanges 72 have at least four apertures 74 therein for receiving fasteners 36 therethrough for attachment of the truss anchor 10 to an underlying, vertically extending support stud 76. Because the attachment flanges 72 extend adjacent one another and in the same vertical plane, they are attached to the support stud 76 on a single, normally outwardly extending, surface 78 of the stud 76, thereby concentrating in one location the total number of fasteners 36 required to secure the truss anchor 10 to the stud 76. As shown in FIG. 2, the attachment flanges 72 may be positioned one on top of the other, with the apertures 74 positionally aligned such that all of the necessary fasteners 36 extend through the apertures 74 in both of the two attachment flanges 72 to secure the truss anchor 10 to the underlying stud 76.
Referring now to FIG. 3, there is shown a truss anchor 80 incorporating a second embodiment of the present invention. Many of the elements of the truss anchor 80 are similar to those of the truss anchor 10 and will be given the same reference numerals with the elements of the truss anchor 80 being differentiated by a prime (') designation. The top 28' of the cap portion 32' of the truss anchor 80 extends transversely over the top chord 18' of a double truss member 82 near the distal end 22' of the top chord 18', as used at the end zones or at roof openings of a building. At least two apertures 34' extend through the top 28' of the cap portion 32' for receiving fasteners 36' therethrough for attachment of the truss anchor 80 to the top chord 18' of the double truss member 82.
Referring still to FIG. 3, each attachment flange 72' has at least four apertures 74' for receiving fasteners 36' therethrough for fixed attachment of the truss anchor 80 to the outwardly extending surface 78' of the underlying stud 76'. As with the truss anchor 10 shown in FIG. 2, the attachment flanges 72' of the truss anchor 80 may be attached to the surface 78' of the stud 76' adjacent one another, or one on top of the other with the apertures 74' in positional alignment for receiving all of the necessary fasteners 36' through the apertures 74' of both of the flanges 72', thereby increasing the strength of the attachment of the truss anchor 80 to the underlying stud 76'.
Referring now to FIG. 4, there is shown a truss anchor 90 incorporating a third embodiment of the present invention. Many of the elements of the truss anchor 80 are similar to those of the truss anchor 10 and will be given the same reference numerals with the elements of the truss anchor 80 being differentiated by a double prime(") designation.
Referring still to FIG. 4, the truss anchor 90 is fabricated from two separate, but individually unitary bands 92. Unlike the truss anchors 10 and 80, the cap portion 94 of the truss anchor 90 has no top 28 nor 28'. Instead, at least one aperture 96 extends through each side 30" of the cap portion 94 for receiving a fastener 36" therethrough for attachment of the truss anchor 90 to opposed sides 98 of the top chord 18" of a truss member 20" near the distal end 22" of the top chord 18".
Referring still to FIG. 4, as with the truss anchor 10 shown in FIG. 2, the attachment flanges 72" of the truss anchor 90 may be attached to the surface 78" of the stud 76" adjacent one another, or one on top of the other with the apertures 74" in positional alignment for receiving all of the necessary fasteners 36" through the apertures 74" of both of the flanges 72", thereby increasing the strength of the attachment of the truss anchor 90 to the underlying stud 76". Unlike the prior art truss anchorage device 100 shown in FIG. 5, the truss anchor 90 avoids the introduction of weakness or possible failure near the attachment point of the attachment flanges 72" to the underlying stud 76' and concentrates the strength of all the fasteners 36" in one location by deleting the second and third bends 102 and 104, respectively, of the prior art truss anchorage device 100.
While it is understood that in the preferred embodiment of the truss anchors 10, 80 and 90 are formed to the desired shape shown and described from a single thin sheet of semi-pliable or workable metal or composite material, any of a number of other materials readily available in commerce having similar workability and sufficient strength qualities may be utilized in constructing the truss anchors 10, 80, and 90. It is further understood that the degree of the angle created by bending the bands 12, 12' and 92 may be any appropriate degree of angularity necessary to conform to the relevant contours of the subject truss member or support member. Although the invention is described as using nails or screws for fasteners, it is understood that other readily available fasteners such staples, rivets, or suitable adhesives may be used without departing from the spirit of the invention.
Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed but is capable of numerous rearrangements and modifications of parts and elements without departing from the spirit of the invention.
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A truss anchor for securely attaching a truss member to an underlying support wall includes at least one unitary band having a cap portion for partially surrounding the truss member, and a wing portion extending downwardly from the cap portion and in angular relation to the cap portion as defined by a longitudinally extending bend in the unitary band. An attachment flange extends downwardly from the wing portion, and in the same vertical plane occupied by the wing portion, for attachment of the anchor to a stud of the underlying support wall. The attachment flange is attached individually or is stacked with a second, adjacent attachment flange for attachment to the stud. Suitable fasteners are used to attach the flanges to the stud.
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FIELD
[0001] The invention relates to a method for operating a safety system with temporary participants and to a safety system provided to carry out said method, and to an elevator system having said safety system.
BACKGROUND
[0002] Elevator systems are provided with safety systems for safe operation. Said safety systems typically consist of safety elements connected in series. Said safety elements can for example monitor the condition of shaft doors or elevator car doors. Electromechanical safety circuits or else bus-based safety circuits are known for this. The safe operation of such bus-based safety circuits is checked regularly. The structure and testing methods of such bus-based safety circuits are known for example from EP 1159218 A1, WO 2010/097404 A1 or WO 2013/020806 A1. However, it is not clear from this prior art whether or to what extent safety is ensured when temporary participants, such as a manual control device for controlling the elevator system during maintenance or an input device in which configuration settings of the safety system can be set, are connected and disconnected.
SUMMARY
[0003] An object of the invention is therefore to specify a method, a safety system and an elevator system having such a safety system, with which safe disconnection of a temporary participant from the safety system is ensured.
[0004] The safety system of the elevator system comprises a control unit, a bus, a plurality of bus nodes, which are connected to the control unit via the bus, and a plurality of participants, which are connected to the control unit via a bus node.
[0005] A control unit in this case means a unit that at least has a microprocessor, a working memory and a non-volatile memory. Such a control unit is therefore designed to execute computer-supported programs. The control unit is in this case configured as a safety control unit that monitors safety-relevant conditions of the elevator system and, if an unsafe condition occurs, returns the elevator system to a safe condition. This includes for example monitoring the shaft door conditions, the elevator system being stopped if a shaft door is open.
[0006] Participants in this case mean sensors, switch contacts, operating elements or actuators, which on the one hand monitor a condition of the elevator system and on the other hand can influence the safe operation of the elevator system. These include position sensors, speed sensors or acceleration sensors, which monitor a movement condition of an elevator car, and also switch contacts, which monitor the condition of a shaft door or elevator car door or the passing of a predefined end position by the elevator car. A safety system can also comprise operating elements, by means of which control commands for controlling the safety system or the elevator system, for configuring the safety system or for selecting an operating mode can be input, such as a button, an input screen or a manual control device. Actuators mean all components that can be actuated by the control unit to return an elevator system to a safe condition after an impermissible condition has been established, such as a drive motor, a holding brake or a safety brake. This list of the above-mentioned participants is only by way of example and is not exhaustive.
[0007] The safety system can have at least one participant that is designed as a temporary participant. A temporary participant in this case means a participant that is connected to the safety system or the control unit via a bus node only temporarily. Such temporary participants can be designed for example as operating elements, governor elements or bridging elements, which are connected or should be connected to the safety system only in a certain operating mode, such as a normal operating mode, a maintenance mode or a configuration mode.
[0008] Manual control device in this case means a device for controlling the elevator system that is operated by a maintenance technician during maintenance work. This manual control device preferably comprises four control elements, namely a button for executing a downwardly or upwardly directed movement, a button for triggering an emergency stop, and a switch for activating and deactivating the maintenance mode.
[0009] The temporary participant is preferably logged out of the safety system by A) giving notice of a disconnection of the temporary participant from the safety system by means of a manipulation of the safety system, and B) disconnecting the temporary participant from the safety system.
[0010] By means of the manipulation of the safety system, an expectation is created in the control unit, which expectation can be used for monitoring the logging out process of a corresponding temporary participant. This manipulation can take place for example via a switch element of a manual control device or via a touch-sensitive screen of an input device.
[0011] The manipulation preferably takes place by inputting a control command at an input point provided therefor or by operating a switch. The input point or the switch are each connected to the safety system.
[0012] The safety system is preferably set to a fault mode by the control unit if the temporary participant is not disconnected from the safety system until after a predefined time after the manipulation of the safety system. This ensures that the logging out process of the temporary participant is an action carried out deliberately.
[0013] Fault mode in this case means a mode in which the elevator system can be operated only to a limited extent or not at all. When in fault mode, the elevator system is generally stopped so that a potentially dangerous situation cannot arise. At most, it would be possible in fault mode to permit a last movement of the elevator car to the nearest floor to avoid trapping passengers in the elevator car. The elevator system can then be put back into operation when the situation that resulted in the fault mode has been rectified. If, for example, the temporary participant is not disconnected from the safety system until after a predefined time, the temporary participant must be connected to the safety system again.
[0014] A target list of the participants is preferably implemented on the control unit, which list includes at least data on an identification number of each participant, and the temporary participant is logged out of the control unit by the control unit changing an entry of the temporary participant in the target list from an active status to an inactive status.
[0015] The identification number is a number by means of which a participant connected to the safety system can be identified; in particular, said number can be an identification number that is unique for each participant or an identification number that states a type of the participant. The identification number can be stored on a storage medium of the participant. Such an identification number can also be stored in advance on the target list. The target list defines an expectation of the control unit of which participants should be connected to the safety system. Accordingly, there is an entry in the target list for each participant that can be connected to the safety system. If the temporary participant is disconnected from the safety system, said participant is set to inactive in the target list or in the entry thereof by the control unit.
[0016] An actual list of the participants is preferably implemented on the control unit, said list forming an image of the participants connected to the safety system, and operation of the elevator system is only enabled if the control unit establishes a correspondence in a comparison between the participants activated in the target list and the participants entered in the actual list.
[0017] The actual list is a list of all the participants connected to the safety system at a certain point in time. All the detected participants are preferably listed in the actual list using their identification numbers. The comparison between the participants listed in the actual list and the participants stored in the target list, in particular those that have an active status for a certain operating mode, is preferably performed on the basis of the identification numbers listed in the two lists. This comparison ensures that all the participants provided for a certain operating mode are connected to the safety system before a corresponding operating mode is enabled.
[0018] In the event of a power failure, a system condition of the safety system is preferably stored in a non-volatile memory of the control unit; in particular the system condition is stored using a target list.
[0019] When the safety system is put back into operation after the power failure, the stored system condition is preferably compared with the current system condition by the control unit; in particular the stored target list is compared with an updated actual list and the safety system is set by the control unit to a fault mode if a temporary participant is found to be missing from the actual list on the basis of the comparison.
[0020] A further aspect of the invention relates to a device for carrying out the method and an elevator system having said device.
DESCRIPTION OF THE DRAWINGS
[0021] The invention is described in more detail below using exemplary embodiments. In the figures:
[0022] FIG. 1 schematically shows an exemplary arrangement of an elevator system according to the invention;
[0023] FIG. 2 shows an exemplary embodiment of a target list that is implemented on the control unit of the safety system; and
[0024] FIG. 3 shows a flow chart of an exemplary sequence of a logging out process of a temporary participant in the safety system.
DETAILED DESCRIPTION
[0025] The elevator system 1 shown schematically in FIG. 1 comprises a control unit 2 , which is connected to a plurality of bus nodes 41 to 49 via a bus 3 . The control unit 2 can be arranged in a separate drive room 8 , as shown in FIG. 1 . In a preferred embodiment, the control unit 2 can also be arranged in a shaft 6 .
[0026] Reference sign 6 schematically indicates a shaft 6 of a building in which the elevator system 1 is installed. The building has, by way of example, three floors, each floor being equipped with a shaft door 61 , 62 and 63 , respectively. The bus node 41 is assigned the shaft door 61 , the bus node 42 is assigned the shaft door 62 and the bus node 43 is assigned the shaft door 63 .
[0027] The respective bus node 41 , 42 , or 43 is assigned a participant, in this case for example a switch contact 61 a, 62 a, 63 a, which detects information relating to the condition of the associated shaft door 61 , 62 or 63 (open, closed, locked) and can generate a fault signal for the control unit 2 if necessary.
[0028] The elevator system 1 also has an elevator car 7 . The elevator car 7 is equipped with an elevator door 74 , which is likewise assigned to a bus node 44 . The bus node 44 is assigned a further participant, for example a further switch contact 74 a , which determines information relating to the condition of the associated elevator door 74 (open, closed, locked) and can generate a fault signal for the control unit 2 if necessary.
[0029] The elevator system 1 can also have a bus node 45 and a bus node 46 , which are assigned further participants, namely a safety brake 75 arranged on the elevator car 7 and an emergency switch 76 , respectively. The safety brake 75 is used for safety-braking the elevator car 7 , for example if said car reaches an excessive speed. The elevator system 1 can be brought to an immediate standstill in an emergency situation by operating the emergency switch 76 .
[0030] Also, a drive unit is arranged in a drive room 8 , which drive unit is equipped with two further participants, namely with an emergency brake 87 and with a rotation speed sensor 88 , which are assigned a bus node 47 and 48 respectively. In a preferred embodiment, the drive unit can be arranged in the shaft 6 , omitting a separate drive room.
[0031] Furthermore, a bus node 49 is provided, which is arranged in the region of the shaft 6 and is designed to receive a temporary participant, namely a manual control device 89 . The bus node 49 can be arranged in particular on the roof of the car 7 or in the bottom of the shaft 1 or at one of the doors 61 - 63 , depending on the point of the elevator system 1 at which maintenance work that requires the elevator car 7 to be moved is to be carried out. The temporary participant 89 is therefore connected to the bus 3 or the control unit 2 via the bus node 49 .
[0032] In the example shown, the temporary participant 89 can be connected to the bus 3 at a slot of the corresponding bus node 49 . Alternatively, the temporary participant 89 can also be connected to bus 3 wirelessly, for example via a WLAN, Bluetooth or other type of radio connection.
[0033] The manual control device 89 is designed to control the elevator system 1 and the elevator car 7 during a maintenance mode and comprises for example four control elements, namely a button for executing an upwardly or downwardly directed movement, a button for triggering an emergency stop and a switch for activating and deactivating a maintenance mode.
[0034] The control unit 2 has a target list 5 a, which defines an expectation of the control unit 2 . The target list 5 a comprises e.g. a list of which of the participants 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 should be connected to the bus 3 at a certain point in time. In addition, the control unit 2 has an actual list 5 b, which is a list of all the participants 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 currently connected to the bus 3 .
[0035] The target list 5 a is explained in more detail using FIG. 2 . The target list 5 a comprises an entry for each participant contained therein. This entry corresponds to one row of the table. In a first column is stored a bus address ADD of a bus node 41 to 49 at which the respective participant 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 is connected. The control unit 2 can communicate with a bus node 41 to 49 and a participant 61 a - 63 a , 74 a, 75 , 76 , 87 , 88 , 89 connected thereto via the bus address ADD. The control unit 2 can correspondingly address control signals to a corresponding participant, for example to the safety brake 75 via the bus address ADD, 45 , or request conditions of the switch contact 61 a in a targeted manner from the bus address ADD, 41 .
[0036] In a second column is stored a first identification number ID 1 of a participant 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 . This first identification number ID 1 is dependent on the type of participant. For instance, the participants 61 a to 63 a all have the same first identification number ID 1 with the value SS, since all three participants are in the form of switch contacts 61 a to 63 a of identical type, which monitor the condition of an associated shaft door 61 to 63 . A safety brake 75 , however, has a different first identification number ID 1 with the value UU.
[0037] The participants can also be identified by means of a second identification number ID 2 . This second identification number ID 2 is for example a number AAA to JJJ for each participant 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 , which number permits unambiguous identification of each participant 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 .
[0038] Finally, an activation value A or I is stored for each participant in the target list 5 a, the activation value A representing an active status of a participant and the activation value I representing an inactive status. The target list 5 a shown has activation values A, I for two different operating modes of the elevator system 1 , namely for a normal operating mode N and for a maintenance mode W. For instance, in the entry for the temporary participant 89 or the manual control device, an activation value A is given for a maintenance mode W and an activation value I is given for a normal operating mode N. The manual control device 89 is therefore assigned an active status in the maintenance mode W and an inactive status in the normal operating mode N.
[0039] After maintenance work has finished, the manual control device 89 is logged out of the control unit 2 by, in a first step A according to FIG. 3 , notifying the control unit 2 of a disconnection of the manual control device 89 from the bus 3 by resetting the activation switch on the manual control device. After the activation switch has been reset, the manual control device 89 can be disconnected from the bus 3 in a second step B. By resetting the activation switch, an expectation is created in the control unit 2 , which expectation can be used for monitoring the logging out process of the manual control device 89 .
[0040] In this case, the elevator system 1 is preferably set to a fault mode by the control unit 2 if the temporary participant 89 is not disconnected from the bus 3 until after a predefined time after the activation switch is reset.
[0041] Alternatively, notice can be given of the disconnection of the temporary participant 89 by means of a manipulation on the control unit 2 . The notification can be made by inputting a control command at an input point provided therefor, which is connected to the bus 3 via a bus node or is arranged directly on the control unit 2 . A further possible way of giving notice of the disconnection is by operating a switch. This switch can likewise be connected to the bus 3 via a bus node or be arranged directly on the control unit 2 .
[0042] When the manual control device 89 is logged out, its entry in the target list 5 a is set by the control unit 2 from an active status A to an inactive status I. In correspondence with the operating mode W, N stored for the inactive status I for the manual control device 89 in the entry in the target list 5 a, the control unit 2 can automatically put the elevator system 1 into a normal operating mode N.
[0043] In addition, an actual list 5 b of the participants 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 is implemented on the control unit 2 , which list forms an image of the participants 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 connected to the safety system at a certain point in time. The actual list 5 b has a very similar structure to the target list 5 a and comprises substantially the first four columns of the target list 5 a. The control unit 2 therefore reads out the participant 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 connected to the respective bus node 41 to 49 for each bus node 41 to 49 present or the address ADD thereof and the identification numbers ID 1 , ID 2 . Operation of the elevator system 1 is only enabled by the control unit 2 if the control unit 2 establishes a correspondence in a comparison between the identification numbers ID 1 , ID 2 , in particular the identification numbers ID 1 , ID 2 of the entries in the target list 5 a for which an active status is stored in a respective operating mode N, W, and those of the actual list 5 b.
[0044] In the event of a power failure, the system condition of the elevator system 1 is stored in a non-volatile memory of the control unit 2 . In particular, the target list 5 a is stored in the non-volatile memory, since the target list 5 a represents such a system condition. This is because all the participants 61 a - 63 a, 74 a, 75 , 76 , 87 , 88 , 89 that should have an active status at a certain point in time are listed in the target list 5 a.
[0045] When the elevator system 1 is put into operation again after the power failure, the stored target list 5 a acts as a check-list. The stored target list 5 a is compared with the current actual list 5 b to establish whether all the temporary participants 89 present before the power failure are still connected to the bus 3 . If the control unit 2 finds on the basis of the comparison that a temporary participant 89 is missing from the actual list, the control unit sets the elevator system 1 to a fault mode.
[0046] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A method for operating a safety system having a control unit, a bus, a plurality of bus nodes connected to the control unit via the bus, and a plurality of participants connected to the control unit via the bus nodes, wherein at least one participant is designated as a temporary participant. The method includes the step of logging the temporary participant out of the safety system by giving notice of a disconnection of the temporary participant from the safety system by a manipulation and disconnecting the temporary participant from the safety system. The safety system can be used with an elevator system for carrying out the method.
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[0001] The invention relates to a retainer for a welding wire container and to a welding wire container.
BACKGROUND OF THE INVENTION
[0002] The use of bulk polygonal packs or round drums containing large quantities of reverse wound aluminium welding wire (in some cases up to as much as 500 kgs) is becoming increasingly popular since it offers the advantage of great savings thanks to a reduced pack changeover downtime and a higher productivity. The ability to avoid unwanted weld interruptions in some applications like the production of vehicle components and automotive parts, is extremely important because stoppages in the middle of the automated weld process can cause cracks, weld defects, mechanical failures with consequent costly aftermarket product liability issues. A good weld with no defects or imperfections is absolutely necessary in order to prevent subsequent equipment failures.
[0003] Unwanted production interruptions can offset the advantages of the so-called “lean manufacturing process” that relies on the optimization of the supply flow in sequential steps of production.
[0004] The industry today, and in particular the automotive industry, is increasingly using aluminium welding wires for many applications, since aluminium has the advantage of being a resistant, fairly strong, corrosion-free metal but also much lighter (approximately three times lighter) than steel; vehicles with less weight bring relevant fuel savings.
[0005] More and more manufacturers are choosing bulk containers with large quantities of twist-free reverse wound welding wire in combination with high performing low friction guiding liners with rolling elements inside.
[0006] Aluminium wires are however very soft and can easily be deformed by friction or attrition in particular when the wire during payout is forced to scratch against the inner edge of the wire retainer. Deformed wires can cause serious weld defects that would either require repair where possible, or in the worst case scenario, the inevitable scrapping of valued parts because of their non conformance to the desired quality standards.
[0007] This problem has been known for a while and several prior art attempts have been made to solve it.
[0008] Barton and Carroscia in U.S. Pat. No. 7,398,881 propose a rigid retainer ring with embedded pockets of different shape and density in order to help reduce the overall retainer weight. The attempt to generate some weight relief is obvious but notwithstanding the pockets the retainer maintains its rigidity, and this could still deform soft aluminium wires (like, but not limited to, the grade AWS 4043) in the commonly used thin wire diameters like for example 1.20 mm.
[0009] Again Carroscia in U.S. Pat. No. 7,410,111 describes, as a possible solution, the cut out of entire retainer sections in order to decrease the retainer plate weight by as much as 50% of its overall weight. This plate however is rigid and it can still deform the wire during payout; additionally this particular embodiment comes with the risk that the wire coil under the retainer can become excessively exposed to air contamination and oxydation.
[0010] Edelmann and Zoller in EP 2 354 039 also try to address the problem of the possible impact of a heavy retainer on the wire coil and disclose a retainer exerting a contact pressure on the wire spool for maintaining the spirals of the spool which is between 10 and 25 N/m 2 . This retainer with a claimed thickness of up to 15 mm has a significant degree of rigidity.
[0011] Gelmetti and Fagnani in EP 2 168 706 propose a flexible rubber retainer to smoothly control the wire payout but their retainer is quite expensive to build as it requires an outer periferical support frame and it is not designed to control aluminium welding wire since it features a plurality of flexible flaps which are freely hanging and pushed downwardly by the force of gravity into the middle of the pack. A soft aluminium wire would have to overcome the resistance of these flaps to be paid out, and that would also inevitably contribute to cause wire deformation. The flaps, in this invention, seem to be aimed at preventing possible tangles caused by the simultaneous feeding of multiple wire strands.
[0012] While the first two prior art documents are expressly directed to resolve the problem of the wire deformation, the latter two attempt to rather address the issue of wire tangling during payout from the bulk container.
[0013] Gelmetti in U.S. patent application Ser. No. 13/330,314 and International Patent Application PCT/EP2012/076081 teaches of a dynamic retainer to pay wires out of a bulk container such retainer being composed by the assembly of several individual “tiles” connected together but independently raising at the passage of wire. Notwithstanding the dynamic interaction of this retainer with the wire the tiles are rigid pieces and testing has demonstrated that deformation of softer aluminium wires can in fact still occur.
[0014] There is a need for a retainer which allows a smooth pay-out of soft, deformable welding wire such as aluminum welding wire.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The invention provides a retainer for exerting a braking effect on wire provided as a spool in a container. The retainer has a plate-like elastic element with a contact surface adapted for resting on the wire, an outer circumference adapted for being guided in the container, and an inner circumference adapted for allowing the wire to pass through. The plate-like elastic element has an elasticity such that one of the inner and outer circumferences sags down, under the proper weight of the retainer, by a distance of at least 10 mm when the retainer is supported at the other of the inner and outer circumference. The invention is based on the recognition that a comparatively elastic retainer is particularly suitable for controlling pay-out of the welding wire as it on the one hand allows the wire to lift the retainer at the inner circumference, thereby locally adapting the shape and curvature of the retainer to the shape of the welding wire in the portion which is currently withdrawn from the upper surface of the welding wire coil, and on the other hand ensures that the remainder of the retainer remains flat on the upper surface of the wire coil, thereby exerting its braking effect on the upper windings of the welding wire coil.
[0016] Preferably, the distance by which the inner or outer circumference sags down is at least 20 mm and not more than 50 mm.
[0017] The invention also provides a retainer for exerting a braking effect on wire provided as a spool in a container, which has a plate-like elastic element with a contact surface adapted for resting on the wire, an outer circumference adapted for being guided in the container, and an inner circumference adapted for allowing the wire to pass through. The plate-like elastic element has an elasticity such that when the retainer is supported along a diameter, opposite sides of the retainer sag down, under the proper weight of the retainer, by a distance which is more than 5% of said diameter of the retainer. The elasticity which allows this deformation of the retainer also allows controlling pay-out of the welding wire in an advantageous manner as it on the one hand allows the wire to lift the retainer at the inner circumference, thereby locally adapting the shape and curvature of the retainer to the shape of the welding wire in the portion which is currently withdrawn from the upper surface of the welding wire coil, and on the other hand ensures that the remainder of the retainer remains flat on the upper surface of the wire coil, thereby exerting its braking effect on the upper windings of the welding wire coil.
[0018] Preferably, the distance by which opposite sides of the retainer sag downwardly when the retainer is being supported centrally along a diameter is at least 10% of the diameter of the retainer and more preferably 15% of the diameter.
[0019] In order to ensure that the retainer has a strength and rigidity which prevents the retainer from collapsing and falling into the interior of the welding wire coil, the distance by which opposite sides of the retainer sag downwardly when the retainer is being supported centrally along a diameter is not more than 40% of the diameter of the retainer.
[0020] Preferably, the plate-like elastic element consists of plastic. This allows manufacturing the retainer at low costs with the desired elasticity.
[0021] Polycarbonate is particularly advantageous as its properties, in particular the elasticity, can easily be controlled to be within desired values.
[0022] According to a preferred embodiment of the invention, the retainer is transparent. This allows visually checking the welding wire coil which is being covered by the retainer.
[0023] The plate-like elastic element of the retainer preferably has a thickness which is in a range of 0.3 mm to 12 mm. These values allow combining the desired elasticity with a low weight and a sufficient rigidity.
[0024] According to an embodiment of the invention, the plate-like elastic element of the retainer is provided with a reinforcement ring which extends along said outer circumference. This allows using a very pliant and yielding plate-like elastic element, e.g. a rubber sheet, which is being conferred the necessary rigidity for staying on top of the welding wire coil by the frame-like reinforcement ring.
[0025] Preferably, the retainer has a contact surface with a roughness which is different from a roughness of a surface which is opposite the contact surface. In other words, the two surfaces of the plate-like elastic element are manufactured with different surface roughnesses. If a higher braking effect of the retainer is desired, the retainer is employed such that the surface with the higher roughness acts as the contact surface. If a lower braking effect is desired, the retainer is reversed and the smoother surface is being used as contact surface. The different roughnesses can be achieved by molding the plate-like elastic element in a mould which has a polished and a non-polished or even roughened surface, or by a suitable surface treatment of the plate-like elastic element of the retainer.
[0026] The invention also provides a welding wire container having a bottom, circumferential walls extending upwardly from the bottom, a welding wire coil formed from a plurality of windings of welding wire, and a retainer which rests on an upper surface of the coil. The retainer has a plate-like elastic element with a contact surface adapted for resting on the wire, an outer circumference adapted for being guided in the container, and an inner circumference adapted for allowing the wire to pass through. The plate-like elastic element has an elasticity E which is in a range of 0.05 to 0.4, with the elasticity E being determined by the following formula:
[0000]
E
=
0.2
%
yieldlimit
specificweight
*
B
[0000] with:
the 0.2% yield limit of the welding wire in N/mm 2 ; the specific weight of the welding wire in g/cm 3 ; B being the widths of the retainer from the inner to the outer circumference in mm;
[0030] Preferably, the elasticity E as determined by the above formula is within a range of 0.08 to 0.14.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will now be described with reference to the enclosed drawings. In the drawings,
[0032] FIG. 1 shows a prior art container with retainer in a cross section;
[0033] FIG. 2 shows the elastic behavior of the prior art retainer when tested in a first type of set-up;
[0034] FIG. 3 shows a perspective view of a container according to the invention with a retainer according to a first embodiment of the invention;
[0035] FIG. 4 shows a perspective view of a container according to the invention with a retainer according to a second embodiment of the invention;
[0036] FIG. 5 shows the first type of set-up for determining the appropriate elasticity of a retainer according to the invention, and two embodiments of the retainer according to the invention;
[0037] FIG. 6 shows a second type of set-up for determining the appropriate elasticity of a retainer according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] A welding wire container 10 with a welding wire retainer 12 as known from the prior art is shown in FIGS. 1 to 3 . The container 10 has a rectangular inner cross section (e.g. octagonal), side walls 14 (two side walls are shown), a bottom 16 and a lid 18 .
[0039] In the interior of the container 10 , a welding wire coil 20 is accommodated. The welding wire coil 20 consists of a certain amount of welding wire 22 which is coiled so as to form a hollow body with a ring-shaped cross section. The portion of the welding wire which is currently being withdrawn from the container is designated with reference numeral 24 .
[0040] On the upper side of the welding wire coil 20 , the retainer 12 is provided. The retainer 12 has a plate-like body with a central opening 28 which is delimited by an inner circumference 30 . An outer circumference 32 of retainer 12 serves for guiding the retainer within the container, in particular between the side walls 14 .
[0041] The retainer 12 lies on the upper side of the welding wire coil 20 , the retainer 12 being always generally parallel to lid 18 .
[0042] Conventional prior art retainer are made from a thick plastic element which is generally rigid. This will be explained with reference to FIG. 2 . If the retainer as used in the container of FIG. 1 is supported along its outer circumference 32 by means of a support 40 which follows the outer contour of retainer 12 and has a small width x (e.g. not more than 10 mm), then the inner circumference 30 of the prior art retainer 12 sags downwardly by a distance s which is not more than 10 mm. This is due to the fact that the plate-like retainer is essentially rigid.
[0043] The result of retainer 12 being rigid can be seen in FIG. 1 .
[0044] Retainer 12 exerts, owing to its weight and the friction between the retainer 12 and the welding wire 24 , a braking effect on the welding wire 24 when the welding wire is withdrawn from container 10 . This braking effect results in a certain traction force which is necessary for pulling the wire from the coil 20 . The traction force however results in the welding wire 24 being bent in a region B where it passes around the inner circumference 30 of retainer 12 .
[0045] In order to avoid the welding wire 24 from being bent when passing around the inner circumference 30 of retainer 12 , the invention provides a retainer 12 which is elastic. A first embodiment of the retainer is shown in FIG. 3 , where the same reference numerals are being used as in FIG. 1 .
[0046] Retainer 12 is as a plate-like elastic element 13 which can simply be cut out from a thin sheet made of elastic material. As elastic material, plastic with the necessary elasticity is preferred, in particular polycarbonate. The inherent elasticity of the plate-like elastic element allows deforming the plate-like element which however returns to its original position as soon as the pressure is released.
[0047] The behavior of the retainer can be seen in FIG. 3 . Retainer 12 bends and deforms only at the very point (and closely adjacent thereto) where it is engaged by the wire 24 being paid out while the remaining portion of retainer 12 , not engaged, remains still and undeformed to control the remaining strands and the rest of the wire coil 20 .
[0048] As soon as the wire h 24 as passed the engaged point of plate-like elastic element 13 , the deformed portion returns to its original undeformed condition. This provides a dynamic controlling action that actively follows the movement of the wire strand being paid out, adapting itself to the wire 24 without deforming it.
[0049] It can be seen that due to the particular elasticity of the plate-like elastic element which forms retainer 12 , the inner contour of the retainer adjacent inner circumference 30 is deformed by the wire such that the retainer is locally curved upwardly, thereby preventing any sharp bending of the welding wire.
[0050] A second embodiment of the retainer is shown in FIG. 4 . The difference between the first and second embodiment is that the second embodiment uses a reinforcement ring 50 which defines the outer contour of retainer 12 . The majority M of the width B of the annular retainer 12 is however not covered by reinforcement ring 50 so that the plate-like elastic element 13 is exposed. The advantage of the second embodiment over the first embodiment is that a very thin and thereby flexible plate-like elastic element 13 can be used with the second embodiment without there being any risk that the stability and rigidity of the entire retainer 13 is not sufficient for securely keeping it on top of the welding wire coil. The plate-like elastic element can here be formed of a very thin, flexible material like rubber or silicon, with the reinforcement ring 50 acting as a rigid, supportive frame.
[0051] For both embodiments, the outer contour of retainer 12 , defined by outer circumference 32 , matches the contour of the inside of container 10 , with a slight play being provided between the inner contour of the container 10 and the outer contour of the retainer 12 . This play allows retainer 12 to freely descend in the interior of container 10 when the height of the welding wire coil 20 decreases.
[0052] Further, the diameter of the opening 28 defined by the inner circumference 30 of the retainer 12 is slightly larger than the inner diameter of welding wire coil 20 so that no area of the top of the wire coil 20 is exposed to air contamination. In other words, the retainer plate completely covers the top side of the coil.
[0053] The inner contour 30 of plate-like elastic element 12 has a uniform, uninterrupted edge, without there being any additional flaps, fingers or dents.
[0054] The optimal thickness to obtain a sufficient level of elasticity of the retainer varies and is in relation with the dimensions of the retainer itself: the larger the plate, the thicker it must be, and vice versa. In general, the elasticity of the retainer must not be excessively high as this could result in a deformation of the entire retainer such that it drops into the interior of the welding wire coil, resulting in a jamming of the whole system. At the same time, the elasticity of the retainer must be sufficient for allowing the plate-like elastic element to yield under the traction forces acting on the welding wire such that the welding wire is not deformed.
[0055] The suitable elasticity of the retainer can very easily be determined with the set-up as shown in FIG. 5 . The set-up is the same as already shown in FIG. 2 , namely a support 40 which is narrow (with a thickness x of no more than 10 mm) and which supports the outer circumference 32 of the retainer.
[0056] The retainer 12 as shown in FIG. 4 is shown in continuous lines in FIG. 5 . It can be seen that the outer circumference 32 remains basically undeformed due to reinforcement ring 50 . The inner circumference 30 sags down by a distance s which is at least 10 mm and preferably at least 20 mm.
[0057] The retainer of FIG. 3 is shown in dashed lines. Here again, the inner circumference 30 sags down by a distance s which is at least 10 mm and preferably at least 20 mm. Owing to the desired stability of the retainer, the inner circumference 30 of retainer 12 will not sag down more than 50 mm.
[0058] A retainer 12 according to the invention will exhibit the same behavior or the set-up is reversed such that it supports the retainer along the inner circumference 30 rather than along the outer circumference 32 .
[0059] A different set up for choosing the correct elasticity of retainer 12 is shown in FIG. 6 . Here, a narrow support (again having a width x of not more than 10 mm) is used which supports the retainer centrally along a diameter. A conventional, rigid retainer will, when supported by a narrow support 50 which extends along a diameter of the retainer, deform under its proper weight such that opposite sides sag down by a distance s which is not more than 5% of the diameter of the retainer. An inventive retainer 12 will show a larger deformation. Opposite ends of a retainer 12 according to the invention will sag down by a distance s which is more than 5% of the diameter of the retainer, in particular more than 15%. In order to guarantee a sufficient proper stability of the retainer, the elasticity is chosen such that opposite sides of the retainer do not sag down more than 40% of the diameter of the retainer.
[0060] It has been determined that the 0.2% yield limit of the welding wire in the container and also the specific weight of the welding wire are decisive factors for determining a suitable elasticity of retainer 12 . Taking further into account the dimensions of the retainer, it has been found out that an elasticity factor E can be determined with the following formula:
[0000]
E
=
0.2
%
yieldlimit
specificweight
*
B
[0000] with:
the 0.2% yield limit of the welding wire in N/mm 2 ; the specific weight of the welding wire in g/cm 3 ; B being the widths of the retainer from said inner to said outer circumference in mm;
[0064] The best results were achieved with an elasticity E in a range of 0.05 to 0.4, in particular well within the range of 0.08 to 0.14.
[0065] If a transparent material like thin polycarbonate is used to produce the retainer, it is also possible to visually inspect the complete wire movements and layers behavior.
[0066] It also possible to use, for cutting the retainer out, plastic sheets which have a polished and therefore more slippery surface on one side and a milled and therefore rougher surface on the opposite side, so that the retainer can conveniently be turned upside down as needed, in order to increase or decrease the retainer strands controlling action, for example depending on the wire diameter, the wire hardness or the wire surface finish.
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A retainer is described for exerting a braking effect on wire provided as a spool in a container. The retainer has a plate-like elastic element with a contact surface adapted for resting on the wire, an outer circumference adapted for being guided in the container, and an inner circumference adapted for allowing the wire to pass through. The plate-like elastic element has an elasticity such that one of the inner and outer circumferences sags down, under the proper weight of the retainer, by a distance of at least 10 mm when the retainer is supported at the other of the inner and outer circumference.
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BACKGROUND
[0001] This invention relates generally to bath items, and more particularly to bath sets and floating candles.
[0002] Personal bathing is a common experience, an experience which is treated as a chore by many. For others, however, bathing is a luxuriant experience, made more enjoyable by employing a variety of aesthetic fragrances and visual queues.
[0003] Fragrances, and bath items themselves, may be provided in liquid or solid form. Liquids are often provided in bottles or the like, and solids, such as bath salts may also be so provided. Loose bottles, however, do not necessarily lend themselves for pleasing storage when not in use, and containers for such bottles may be soiled or damaged by excess water on the outer surface of the bottles.
[0004] The use of visual bath queues also poses potential problems. For example, floating candles may be viewed by some as enhancing the bath experience. Such candles, however, when in a bathtub may also pose an inconvenience, and the lighting provided by such candles may be less than ideal.
SUMMARY OF THE INVENTION
[0005] The invention provides, in some aspects, a container for a bath set. The invention also provides, in some aspects, a container for a floating candle. In some aspects the invention provides a container for both storage of a bath set and for use with a floating candle.
[0006] In some aspects the invention provides a bath set, comprising a container with an open top, the open top being dimensioned so as to receive a floating candle, the container adapted to contain water, internal dimensions of the container sized so as to receive a floating candle therein when water is held by the container; a floating candle at least partially within the container.
[0007] In other aspects the invention provides a floating candle apparatus, comprising a container of a largely water impervious material, the container having an open top; a liquid within the container; a floating candle floating on the liquid within the container; wherein the open top of the container has dimensions slightly larger than dimensions of the floating candle.
[0008] These and other aspects of the invention are more readily comprehended upon review of the following description and accompanying figures, in which common reference numerals indicate like features throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of the bath set;
[0010] FIG. 2 is a front view of the bath set of FIG. 1 ;
[0011] FIG. 3 is a side view of the bath set of FIG. 1 ;
[0012] FIG. 4 is a rear view of the bath set of FIG. 1 ;
[0013] FIG. 5 is a further side view of the bath set of FIG. 1 ;
[0014] FIG. 6 is a top view of the bath set of FIG. 1 ;
[0015] FIG. 7 is a bottom view of the bath set of FIG. 1 ; and
[0016] FIG. 8 illustrates the gift set emptied of its contents, other than a single floating candle
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 illustrates a perspective view of a bath set. The bath set includes a container 11 . Preferably the container is made of a wax such as a candle wax. As with many candle waxes, the wax may be colored in a variety of patterns and/or shades. For example, in one embodiment the container is an orange candle wax.
[0018] Preferably the container is substantially impermeable to water, and has an open top 13 . As illustrated, the container is in the shape of a cube with an open top. In other embodiments the container has a variety of shapes, generally shapes forming a container with an open top.
[0019] Disposed within the container are a number of bottles 15 . Preferably the bottles contain bath items such as bath salts, various bath oils, and soaps and fragrances. As illustrated, the gift set includes three bottles leaning at an angle against a side of the container, with the side being denoted as the rear side of the container.
[0020] Floating wax candles 17 are also provided within the container. The floating wax candles are positioned upon a filler 19 provided in the container. The filler, which may be wrapping paper or the like, allows the floating candles to be positioned near the top of the container and preferably facing forward approximate the open top of the container to provide a more pleasing look to the gift set.
[0021] Floating candles are relatively well-known, and the floating candles illustrated are in the shape of a flower having petals. The floating candles may be placed on the surface of water, such as in a bathtub, and provide a stunning visual effect when lighted and floating in the bath.
[0022] Transparent plastic wrap 21 encases the set, and assists in maintaining position of items in the set. In some embodiments, the container is additionally provided a wrapping bow wound from across the front, side, and rear of the container. The wrapping bow may include a decorative bow, for example, across the front of the container.
[0023] FIG. 2 shows a front view of the gift set. As may be seen in FIG. 2 , the bottles extend well beyond the open top of the container. The floating candles are towards the top and front of the container, and, leaning forward, provide a soothing visual effect.
[0024] Further details of the gift set may be seen in the side views of the FIGS. 3 and 5 . As may be seen in FIGS. 3 and 5 , bottles lean rearwardly from within the container, and towards and past the rear edge of the container. Filler, which-may be gift paper or wrapping paper, is crumpled forward of the bottles, and assists in maintaining position of the bottles within the container. On top of the paper, and facing at an angle upwardly forward, are floating candles. A translucent plastic wrap maintains the items in the gift set in their predetermined positions.
[0025] FIG. 4 illustrates a rear view of the gift set, and more fully shows the bottles approximate the rear of the container.
[0026] FIG. 6 illustrates a top view of the gift set, and more fully shows the floating candles facing upwardly and forward, and also positioned so as to slightly overlap the edges of the container. From FIG. 6 it can also be seen that the floating candles are sized smaller than the opening of the top of the container.
[0027] FIG. 7 is a bottom view of the gift set, and is illustrated for completeness. The view of FIG. 7 would not normally be seen by consumers and others as the container would generally be positioned on an opaque surface, or even a translucent surface under which one does not normally crawl.
[0028] FIG. 8 illustrates the gift set with the container 11 emptied of its contents, other than a single floating candle 17 . As previously mentioned, the container is largely impervious to water. This allows the container to be filled with water. As illustrated in FIG. 8 , the container is partially filled with water 23 . The floating candle is placed on the surface of the water within the container, and when lit, provides a stunning visual effect. The visual effect can be enhanced if the container is only partially full of water, allowing for reflection of the flame within the container.
[0029] In some embodiments the wax is semi-transparent, allowing illumination within the container to be transmitted through, at least partially, the walls of the container. A further beneficial aspect of the use of the container to positioning of the floating candle is that the benefits of a floating candle can be obtained without the floating candle interfering with other use of a bath tub, for example.
[0030] A bath set is generally described. The bath set has certain visual appealing characteristics, as well as a utility indicated in aspects in the claims below.
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A bath set including a container for storage of bath related items and for use with a floating candle.
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BACKGROUND OF THE INVENTION
[0001] A. Field of Invention
[0002] This invention pertains to an optimization circuit in a cochlear implant system and more particularly to a circuit which monitors one or more parameters within the implant such as the internal power supply level and the compliance of the stimulation signals applied by the implant. If an undesirable condition is indicated by these parameters, the circuit generates control signals to correct the condition by adjusting the coupling between the internal and external components of the system.
[0003] B. Description of the Prior Art
[0004] Certain patients suffer from a hearing disability in the inner ear which cannot be satisfactorily assisted by normal hearing aids. However, if the aural nerve is intact, the patient may have some aural functions restored with a cochlear implant system. A typical cochlear implant system presently available includes an external component or processor and an internal component often called the implanted stimulator. The external component includes a microphone for receiving ambient sounds and converting them into electrical signals, a processor for processing said electrical signals into encoded signals and a transmitter transmitting said encoded signals to the internal component.
[0005] The internal component includes a receiver receiving the encoded signals, a decoder for decoding said signals into stimulation signals and an electrode array including both intracochlear electrodes extending into the patient's cochlear and optionally one or more extra-cochlear electrodes. The stimulation signals are applied in the form of pulses having durations and waveshapes determined by the processor.
[0006] Because the internal component of the cochlear implant system is relatively small, it is not normally provided with its own permanent power supply. Instead, the internal component is energized transcutaneously by RF signals received from the external component with the use of two inductively coupled coils, one provided in the external component and the other being provided within the internal component. The external component sends data to the internal component, by first encoding the data into the RF signals and then transmitting it across the transcutaneous link. The internal component decodes the data from the received RF signals and also stores the received RF energy in a capacitor to power its electronics. In order to achieve efficient power transfer across the transcutaneous link, both coils are tuned to resonate, at or close to the operating frequency of the transmitter and are held in axial alignment with the aid of a magnetic coupling.
[0007] The amount of energy being transferred to the internal component depends mainly on the amount of inductive coupling between the two coils as well as the resonance frequency of the respective coils. The former is dependent on the thickness of the tissue separating the two coils, which thickness varies over the patient population. Hence, for identical cochlear implant systems the efficiency of energy transfer varies from one patient to another.
[0008] The required amount of energy varies with the patient, (due to the electrode-tissue interface impedance being patient specific) the system programming, and the sound environment. Therefore, every cochlear implant system must be designed so that adequate power is delivered to the internal component for all patients under all conditions. Hence, there is an excess energy transfer across the link for patients with relatively smaller separation between the coils, or a low electrode-tissue interface impedance, resulting in a shorter battery life, than optimally desired.
[0009] Attempts have been made by others to resolve this problem but they have not been entirely satisfactory. For example, U.S. Patent No. 5,603,726 discloses a multichannel cochlear implant system in which the implantable section generates signals to a wearable processor indicative of the status of the implantable section, such as its power level and stimulation voltages. The information is used by the wearable processor to modify the characteristics of the signals transmitted. More particularly, the implantable section has an internal power supply capable of producing several outputs having different nominal DC levels. Additionally, the implantable section is also capable of providing unipolar or bipolar stimulation pulses between various intercochlear electrodes as well as an indifferent electrode. A telemetry transmitter is used to send data to the wearable processor, the data being indicative of the voltage levels of the power supply outputs, the amplitudes of the stimulation signals and other parameters. The wearable processor uses the power level signals to adjust the amplitude (and therefore the power) of the RF signals transmitted to the implantable section. However, this approach is disadvantageous because it requires an RF transmitter having a variable programmable amplitude, and utilizes a fixed tuning of the transmit coil, therefore making no attempt to modulate the voltage on the tank capacitors to track the voltage required to maintain system compliance. Obviously such a transmitter is expensive to make and more complex then a standard RF transmitter having a preset amplitude. Moreover, sending information from the implantable section about the amplitude of the stimulation pulses after these pulses have already been applied is ineffective because, if one of these pulses is out of compliance, the external section can do nothing about it, except crank up the power to insure that future pulses are compliant. However, merely cranking the power without any further intelligence wastes energy.
[0010] Commonly assigned application Ser. No. 09/244,345 filed Feb. 4, 1999 entitled HIGH COMPLIANCE OUTPUT STAGE FOR A TISSUE STIMULATOR, incorporated herein by reference, describes a cochlear implant system wherein the generation of stimulation pulses is monitored, (i.e. the compliance of the stimulation generation circuit) and a voltage multiplier is used if necessary to ensure that the stimulation pulses are of the desired intensity. This application essentially deals with a system of improving the internal power supply in order to eliminate stimulation pulses, and as such, there is no provision in this application for transmission of data back to the external section.
OBJECTIVES AND SUMMARY OF THE INVENTION
[0011] In view of the above disadvantages of the prior art, it is an objective of the present invention to provide a power control circuit for a cochlear implant which is constructed and arranged to automatically and dynamically optimize the power transferred to the internal component based on one or more preselected criteria by adjusting an inductive coupling therebetween.
[0012] A further objective is to provide a power control circuit for a cochlear implant which is constructed and arranged to automatically and dynamically regulate the inductive coupling with the internal component thereof to insure that power is not wasted, thereby increasing the life of the external component battery.
[0013] A further objective is to provide a cochlear implant system wherein the external and internal systems are coupled inductively, wherein the voltage of the internal supply is monitored and the frequency of this coupling is tuned to obtain optimal power transfer using the voltage as a feedback signal.
[0014] Yet another objective is to provide a cochlear implant system wherein the compliance of the stimulation signals is monitored and used as a feedback signal to optimize the power transfer to the internal component.
[0015] Yet a further objective is to provide a cochlear implant with a compliance monitor arranged and constructed to sense a possible out of compliance condition before the respective stimulation pulse is completed and to adjust the power transferred to the internal section in such a manner that the out of compliance condition is averted.
[0016] Other objectives and advantages of the invention shall become apparent from the following description.
[0017] Briefly, a cochlear implant system constructed in accordance with this invention includes an external speech processor and an implantable stimulator having electronic circuitry, the two components being coupled to each other inductively by respective coils. Each coil is part of a tank circuit. The external speech processor transmits RF signals through the coupling. The implantable stimulator uses these signals for two purposes. First, the energy of the signals is stored in a storage element such as a capacitor and used to power the electronic circuitry. Second, the signals are decoded and used to derive the stimulation signals applied to the aural nerve.
[0018] In one embodiment of the invention, a parameter indicative of the voltage of the storage element is monitored and sent back to the speech processor via a secondary channel. The external speech processor then adjusts the frequency of its tank circuit to regulate the power transferred to the internal component to optimize it.
[0019] Additionally, or alternatively, the compliance of the stimulation signals is monitored and used as a feedback signal to control the frequency of the tank circuit to optimize power transfer to the internal component. This adjustment can be done either based on statistical basis, or in response to an individual and specific out of compliance condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a schematic diagram of a cochlear system constructed in accordance with the present invention;
[0021] FIG. 2 shows a schematic diagram of the external component of the cochlear system of FIG. 1 ;
[0022] FIG. 3 shows a schematic diagram of the internal component of the cochlear system of FIG. 1 ;
[0023] FIGS. 4A, 4B and 4 C show the power control signals transmitted from the internal to the external components respectively to indicate the power level induced within the internal component;
[0024] FIG. 5A and 5B show flow charts for the operation of internal and external components of FIGS. 1-3 , respectively; and
[0025] FIG. 6 shows two sets of typical biphasic stimulation signals defined by the speech processor;
[0026] FIG. 7 shows the current pulses required to produce the stimulation pulses of FIG. 6 ; and
[0027] FIG. 8 shows the corresponding waveforms across the current source.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring first to FIG. 1 , a cochlear implant system 10 constructed in accordance with this invention includes an external component 12 and an internal component 14 . The external component includes a speech processor 12 A and is associated with a microphone 16 for sensing ambient sounds and generating corresponding electrical signals. These signals are sent to the speech processor 12 A which processes the signals and generates corresponding encoded signals. The encoded signals are provided to a transmitter (including a transmit coil 20 ) for transmission to the internal component 14 .
[0029] The internal component 14 (which may also be referred to as an implantable stimulator) receives the power and data via a receive coil 22 . The RF power signal is stored by a power supply 24 (See FIG. 3 ) which provides power for the internal component 14 . The data signals control the operation of the internal component 14 so as to generate the required stimulation pulses which are applied to the auditory nerve of the patient via an electrode array 28 .
[0030] The structure of the external speech processor 12 A is shown in more detail in FIG. 2 . First, the audio signals received from microphone 16 are fed to a signal processor 30 . This signal processor 30 maps the audio signals into excitation signals in accordance with one or more mapping algorithms stored in a map memory 31 . These excitation signals are encoded by a digital data encoder 34 . The encoder data is combined with an RF signal in the data and power transmitter 36 , and passed to the transmit coil 20 via a tuneable tank circuit 38 .
[0031] In accordance with the present invention, encoded telemetry data is received back from the internal component 14 via coil 20 , and is decoded by telemetry decoder 52 . The decoder telemetry data is passed to the tuning adjuster and power controller 40 , which uses the telemetry data to generate a tuning adjustment signal. The tuneable tank circuit 38 adjusts the tuning of the transmit coil 20 according to the tuning adjustment signal as described in more detail below. This can be achieved, for example, by using an electrically controlled variable capacitor in conjunction with a series tuning capacitor, or by any of various similar means known to the art. Power to the whole system 10 is provided by a power supply 50 which typically includes a battery.
[0032] Referring now to FIG. 3 , the internal component 14 includes a housing (not shown) which is hermetically sealed. The component 14 also includes a receiver tank circuit 32 having the receive coil 22 and a capacitor 66 . Signals received through this tank circuit are fed to a power supply 24 generating an output voltage Vdd. The power supply is represented in FIG. 3 by a diode 68 charging a capacitor 70 . The power supply 24 uses the energy of the received RF signals to charge up the capacitor 70 .
[0033] The RF signals are also fed to a data decoder 60 . The data decoder 60 derives from the RF signal the digital excitation signals generated by the data encoder 34 and generates corresponding stimulation control signals. These signals are fed to a programmable current source 62 and a switching control circuit 64 . These two circuits cooperate in response to the signals from data decoder 60 to apply the cochlear stimulation signals to predetermined electrodes of electrode array 28 in a known manner which is beyond the scope of this invention.
[0034] Implant 14 further includes a compliance monitor 66 which generates an output that is fed to a telemetry encoder 80 as discussed more fully below; and a power supply monitor 82 which is used to monitor the voltage Vdd generated by power supply 24 and which provides a voltage condition signal to telemetry encoder 80 .
[0035] The compliance monitor 66 and power supply monitor 82 each sense certain specific functions of the internal component and transmit them to the telemetry encoder 80 . The telemetry encoder 80 then transmits this information to the telemetry decoder 52 . The data is decoded and used to adjust the power transmit between the coils, if necessary.
[0036] An exemplary mode of operation indicating the voltage monitoring made is now described in conjunction with FIGS. 4A , B and C and 5 A and 5 B. At predetermined intervals, for example, every 100 ms, or alternatively after every stimulation pulse, the telemetry encoder 80 generates a first pulse F. (Step 100 ). This pulse may have a duration of about 1 ms. This pulse F indicates to the external speech processor 12 A that the implantable stimulator 14 is sending data.
[0037] Next, the power supply monitor 82 compares the power supply output voltage Vdd to a threshold value Vt and sends the result to the telemetry encoder 80 . More specifically, starting with step 102 , the power supply monitor 82 first determines if Vdd>Vt. If it is, then in step 104 , a parameter pw (pulse width) is set to a predetermined value A, of for example, 2 ms by the telemetry encoder 80 .
[0038] If in step 102 Vdd is not larger than Vt then in step 106 a check is performed to determine if Vdd is approximately equal to Vt. If it is, then in step 108 parameter pw is set to zero. If it is not then, Vdd must be smaller than Vt and in step 110 the parameter pw is set to a predetermined value B of, for example, 1 ms.
[0039] Next, in step 112 a pulse D is generated having a pulse width A or B, or no pulse is generated, depending on the outcome of the decisions 102 and 106 . The pulse D (if present) is generated a period T after pulse F. T may be about 1 ms. The results of this step are seen in FIGS. 4A, 4B , 4 C.
[0040] For FIG. 4A it has been determined that Vdd>Vt, and hence pulse D with a pulse width A is sent about 1 ms after pulse F.
[0041] In FIG. 4B , Vdd has been found to be about equal to Vt and hence no pulse D is present.
[0042] In FIG. 4C , Vdd is found to be smaller that Vt and hence pulse D having a pulse width B is sent about 1 ms after period F, pulse width B being generally shorter than pulse width A. For example, pulse width A may be 2 ms and pulse width B may be about 1 ms.
[0043] Pulse F and, if present, pulse D are then sent to the tank circuit 32 . As a result, a corresponding signal appears on the transmit coil 20 , which is then decoded by the telemetry decoder 52 .
[0044] The operation of the telemetry decoder 52 is now described in conjunction with FIG. 5B . Starting with step 120 , a pulse F is first detected which indicates that the power supply monitor 82 is sending information about the status of the power supply 24 . Next in step 122 a check is made to determine if a pulse D is present following pulse F. If this pulse is not detected, then in step 130 the previous operations are continued with no change.
[0045] If in step 122 , a pulse D is detected then in step 124 a determination is made as to whether this pulse D has a pulse width A or a pulse width B. A telemetry pulse D having a relatively long pulse width, in a range corresponding to the pulse width A (for example if pulse D exceeds 1.5 ms), indicates that the implant supply voltage is high (i.e. Vdd>Vt). In step 126 , the tuning adjuster and power controller 40 therefore adjusts the tunable tank circuit 38 to reduce the power transferred to the implant. A preferred method to accomplish this effect is to reduce the resonance frequency of the tank circuit.
[0046] If the telemetry pulse is less than 1.5 ms, (indicating a pulse width B and that the power supply Vdd<Vt) then in step 128 the tuning adjuster and power controller 40 adjusts the tunable tank circuit 38 to increase the transferred power.
[0047] The tunable tank circuit 38 is adjusted by the tuning adjuster and power controller 40 via means of a tuning capacitor (not shown) which is preferably a voltage dependent capacitor. It should be appreciated that the tunable tank circuit 38 could also be tuned by other known means as would be understood by one skilled in the art.
[0048] Similarly, the above mentioned operation may be performed in respect of the compliance monitor signal, as described in more detail below.
[0049] Briefly, referring to FIG. 3 ; under the control of commands from data decoder 60 , the programmable current source 62 generates current pulses which are applied to the electrodes by switching control circuit 64 . FIG. 6 depicts two typical stimulation current waveforms 70 and 73 which may be requested by the signal processor 30 . It can be seen that each-waveform, is biphasic, consisting of two current pulses of equal amplitude and opposite polarity. Thus, lower amplitude biphasic current waveform 70 consists of positive and negative pulses 71 and 72 respectively, and higher amplitude current waveform 73 consists of positive and negative pulses 74 and 75 .
[0050] Next, FIG. 7 depicts the corresponding current waveforms that must be generated by the programmable current source 62 to produce the desired stimulation current waveforms 70 and 73 . That is, the programmable current source 62 must generate two lower amplitude square waves 76 and 77 to generate stimulus pulses 71 and 72 respectively, and two larger amplitude square waves 78 and 79 to generate the stimulus pulses 74 and 75 . Pulses 77 and 79 are reversed by the switching control circuit 64 . However, if the current pulses 78 and 79 exceed the capability of the power supply 24 , an out of compliance condition occurs. This problem is resolved in the present invention as follows.
[0051] Referring to FIG. 8 the voltage waveform 80 represents the voltage Vn at the output of the programmable current source 62 . It can be seen from the shape of the voltage waveform 80 that the load contains a capacitive component. The level Vc marks the minimum voltage across the programmable current source 62 at which compliance with the desired current waveforms of FIG. 7 can be maintained. The voltage Vca is a little higher than Vc as shown and is selected to provide a safety margin. As seen in FIG. 8 , pulse 83 required to generate pulses 78 and 74 of FIGS. 7 and 6 respectively, starts off at a level above Vca but decreases linearly toward a minimum value (P) which is substantially below level Vc and therefore is not attainable. When this pulse reaches Vca (at point 85 ), the compliance monitor 66 generates a compliance monitor signal indicating an out of compliance condition. The signal is encoded by the telemetry encoder 80 and transmitted to the external processor. The signal may be the same signal as when VDD drops below VT as discussed above, or it may be a different signal, as would be appreciated by one skilled in the art. In response, the tuning adjuster and power controller commands the tunable tank circuit 38 to increase the voltage transmitted to the internal section.
[0052] The adjustment of the link tuning or RF power generated can be performed for every instance of a compliance monitor signal being received from the implant and may be maintained at a high level for a predetermined time, after which the RF power can be dropped to a previous level.
[0053] Alternatively, the frequency of the compliance monitor signal may be monitored by the tuning adjuster and power controller 40 . The link tuning or RF power generated could then be adjusted to maintain a desired ratio of compliance monitor signals to stimulation signals. For example, the link tuning or RF power generated could be adjusted to keep the ratio of compliance monitor signals to stimulation pulses to a desired target of for example 5%, i.e. For this purpose, the tuning adjuster and power controller 40 includes a counter which counts every instance of non-compliance. After a predetermined number of stimulation pulses, for example a thousand, the counter is checked to determine the number of non-compliant instances. If the counter shows a number over the desired target (i.e. 50 for a 5% target) then the tuning adjuster and power controller 40 adjusts the tank circuit 38 to increase its power level. On the other hand for a number of non-compliant instances below the target, the power level is increased. Of course, this determination could also be made within the implant by the compliance monitor itself, as would be evident to one skilled in the art.
[0054] Obviously numerous modifications can be made to the invention without departing from its scope as defined in the appended claims.
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In a cochlear implant system, the implantable stimulator includes a monitor which monitors parameters associated with the stimulation signals and/or the power stored in an energy storage element which stores energy transmitted from the processor. This parameter or parameters is/are analyzed and one or more feedback signals are generated and transmitted back to the processor. The processor uses the feedback signal to insure that power is transmitted to the stimulator optimally and that the stimulation signals are compliant.
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RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 60/168,056, filed Nov. 30, 1999.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for isolating desired chemical products of reactions conducted in aqueous fermentation broths. The invention further relates to isolation of pravastatin, compactin and lovastatin from a fermentation broth and in particular to isolation of pravastatin made by fermentation of compactin.
BACKGROUND OF THE INVENTION
[0003] Complications of cardiovascular disease, such as myocardial infarction, stroke, and peripheral vascular disease account for half of the deaths in the United States. A high level of low density lipoprotein (LDL) in the bloodstream has been linked to the formation of coronary lesions which obstruct the flow of blood and can rupture and promote thrombosis. Goodman and Gilman, The Pharmacological Basis of Therapeutics 879 (9th ed. 1996). Reducing plasma LDL levels has been shown to reduce the risk of clinical events in patients with cardiovascular disease and in patients who are free of cardiovascular disease but who have hypercholesterolemia. Scandinavian Simvastatin Survival Study Group, 1994; Lipid Research Clinics Program, 1984a, 1984b.
[0004] Statin drugs are currently the most therapeutically effective drugs available for reducing the level of LDL in the blood stream of a patient at risk for cardiovascular disease. This class of drugs includes, inter alia, compactin, lovastatin, simvastatin, pravastatin and fluvastatin. The mechanism of action of statin drugs has been elucidated in some detail. They disrupt the synthesis of cholesterol and other sterols in the liver by competitively inhibiting the 3-hydroxy-3-methyl-glutaryl-coenzyme A reductase enzyme (“HMG-CoA reductase”). HMG-CoA reductase catalyzes the conversion of HMG-CoA to mevalonate, which is the rate determining step in the biosynthesis of cholesterol. Consequently, its inhibition leads to a reduction in the rate of formation of cholesterol in the liver.
[0005] Pravastatin is the common medicinal name of the chemical compound [1S-[1α(β*,δ*)2α,6α,8β(R*),8aα]]-1,2,6,7,8,8a-hexahydro-β,δ,6-trihydroxy-2-methyl-8-(2-methyl-1-oxobutoxy)-1-naphthalene-heptanoic acid. (CAS Registry No. 81093-370.) The molecular structure of pravastatin in free acid form is represented by Formula (Ia) where R=OH. The lactone form is represented by Formula (Ib), with atoms labeled to indicate numbering of the atoms.
[0006] Pravastatin, compactin (Formula Ib, R=H), lovastatin (Formula Ib, R=CH 3 ), simvastatin, and fluvastatin each possess an alkyl chain that is terminated by a carboxylic acid group closed in a lactone and that bears two hydroxyl groups at the β and δ positions with respect to the carboxylic acid group. This alkyl chain is the portion of the molecule that binds to HMG-CoA reductase. The carboxylic acid group and the hydroxyl group at the δ position are prone to lactonize as shown in formula (Ib). Lactonizable compounds like the statins may exist in the free acid form or the lactone form or as an equilibrium mixture of both forms. Lactonization causes processing difficulties in the manufacture of statin drugs because the free acid and the lactone forms of the compounds have different polarities. A method of purifying one form is likely to remove the other form along with the impurities resulting in a lower yield. Consequently, great care must ordinarily be exercised when handling lactonizable compounds in order to isolate them in high yield.
[0007] Pravastatin exhibits an important therapeutic advantage over other statins. Pravastatin selectively inhibits cholesterol synthesis in the liver and small intestine but leaves cholesterol synthesis in the peripheral cells substantially unaffected. Koga, T. et al. Biochim. Biophys. Acta , 1990, 1045, 115-120. This selectivity appears to be due, in part, to the presence of a hydroxyl group at the C-6 position of the hexahydronaphthalene nucleus. The C-6 position is occupied by a hydrogen atom in compactin and a methyl group in lovastatin. Pravastatin is less able to permeate the lipophilic membranes of peripheral cells than the other more lipophilic congeners, Serajuddin et al., J. Pharm. Sci ., 1991, 80, 830-34, and the limited mobility of pravastatin is thought to account for its more localized action in the liver and intestine.
[0008] According to U.S. Pat. No. 4,346,227, incorporated herein by reference, pravastatin is reported as having been first isolated as a metabolite of compactin by M. Tanaka et al. during a study of compactin metabolism. According to the '227 patent, pravastatin can be obtained by fermentation of compactin using a variety of microorganisms: Absidia coerulea IFO 4423 spores, Cunninghamella echinulata IFO 4445 , Streptomyces rosochromogenus NRRL 1233 , Syncephalastrum racemosum IFO 4814 and Syncephalastrum racemosum IFO 4828. After fermentation, pravastatin was separated from the fermentation broth by acidifying the broth to a pH of 3 and extracting pravastatin and other non-hydrophilic organics with ethyl acetate, followed by washing with brine. The pravastatin free acid was lactonized by addition of a catalytic amount of trifluoroacetic acid, then neutralized with dilute sodium bicarbonate, dried over sodium sulfate and evaporated to dryness. The residue was purified by preparative reverse-phase high performance liquid chromatography (“HPLC”). One skilled in the art will appreciate that reverse-phase HPLC is not an economical method of purification for large-scale preparation of a chemical compound.
[0009] U.S. Pat. No. 5,942,423 relates to the microbial hydroxylation of compactin to pravastatin using a strain of Actinomadura. The only isolation method presented in the examples is the isolation of minute quantities attendant to analytical scale HPLC analysis of the fermentation broth. According to a more general discussion about isolating pravastatin from the broth, the preferred method of isolation is HPLC.
[0010] Commonly-assigned, co-pending PCT Application Serial No. PCT/US00/19384 relates to the microbial hydroxylation of compactin to pravastatin using a strain of Micromonospora maculata that is unusually resistant to the antifungal effects of compactin.
[0011] U.S. Pat. No. 5,202,029 relates to a process of purifying HMG-CoA reductase inhibitors using HPLC. Following separation of the impurities on the HPLC column, the HMG-CoA reductase inhibitor elutes from the HPLC column as a solute dissolved in the eluent. The eluent is partially evaporated and then water is added to induce crystallization of the HMG-CoA reductase inhibitor.
[0012] U.S. Pat. No. 5,616,595 relates to a continuous process for recovering water-insoluble compounds from a fermentation broth by tangential filtration. The fermentation broth is cycled past a filter. The broth becomes increasingly concentrated with each cycle because of loss of water through the filter. Once a desired concentration is reached, the concentrated broth is then slurried with a solvent in which the desired compound is soluble. The slurry is then cycled past the filter. The solution of the desired compound is collected as the filtrate and the desired compound is then isolated from the filtrate and optionally subjected to further purification. The method is said to be applicable to a wide variety of compounds including lovastatin, pravastatin and simvastatin.
[0013] A process for isolating lovastatin in the lactone form is described in U.S. Pat. No. 5,712,130. In this process, lovastatin is extracted from a fermentation broth with butyl acetate. The resulting solution is then centrifuged and an aqueous phase that separates out is discarded. The organic phase is vacuum distilled at above 40° C., which, in addition to concentrating the solution, promotes lactonization by removal of water. Crystals of lovastatin lactone crystallize upon cooling and are recrystallized to a purity of 90% or greater. Those of skill in the art will appreciate that this method is ill-suited to isolation of the free carboxylic acid or a carboxylate salt form of a statin.
[0014] Presently, the most economically feasible method of making pravastatin is by enzymatic hydroxylation of compactin at the C-6 position. However, the known methods of isolating a statin from a fermentation broth are ill-suited for isolating pravastatin as its sodium salt, do not achieve a pharmaceutically acceptable level of purity, or require chromatographic separation to achieve high purity. The present invention meets a need in the art for an efficient method of isolating pravastatin from a fermentation broth in high purity, in high yield, on a preparative scale and without the need for chromatographic purification.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide an efficient method of isolating a statin compound from an aqueous fermentation broth. In particular, the present invention provides an industrial preparative scale method for purifying pravastatin, compactin and lovastatin without a need for chromatographic separation.
[0016] It is a further object of the invention to obtain pravastatin in a highly pure form and in high yield so that the remarkable stereoselectivity and regioselectivity of microbial transformations may attain, as well, a higher yield and greater economy. The pravastatin is separated from the broth with a minimum consumption of solvent, purified in high yield, and transformed to its pharmaceutically acceptable sodium salt.
[0017] The process involves extraction of pravastatin from an aqueous fermentation broth into an organic solvent, back-extraction of pravastatin into a basic aqueous solution and, optionally, a re-extraction into an organic solvent or concentration of the aqueous solution, resulting in either an aqueous or organic solution that is enriched in pravastatin relative to the initial concentration of pravastatin in the fermentation broth. The pravastatin is obtained from the enriched solution by precipitation of its metal or ammonium salt and then purified by recrystallization of the pravastatin salt. The recrystallized salt is then trans-salified to form pravastatin sodium salt and any excess sodium ions are scavenged with an ion exchange resin. The sodium salt of pravastatin may then be isolated from solution by recrystallization, lyophilization or other means.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention is a process for isolating pravastatin, compactin and lovastatin from an aqueous fermentation broth. The invention is illustrated by isolation of pravastatin sodium from a fermentation broth. However, it will be understood that the process can be used to purify other compounds made by a microbial or an enzymatic process.
[0019] Enzymatic Hydroxylation of Compactin
[0020] Pravastatin sodium is synthesized by enzymatic hydroxylation of compactin such as described in U.S. Pat. Nos. 5,942,423 and 4,346,227. The hydroxylation broth from which pravastatin is to be isolated can be any of the aqueous broths known for industrial scale fermentation of compactin. If the broth is neutral or basic upon completion of the fermentation, then an acid is added to it to bring the broth to a pH of between about 1 and 6, preferably between 1 and 5.5 and more preferably between 2 and 4. Acids that may be used include hydrochloric acid, sulfuric acid, trifluoroacetic acid or any other protic acid, preferably one having a pH of less than 1 as a 1M solution in water. Acidification of the fermentation broth converts any pravastatin carboxylate salts in the broth to the free acid and/or lactone.
[0021] Isolation of Pravastatin Sodium
[0022] The process of the present invention involves the steps of forming an enriched solution of pravastatin, obtaining a salt of pravastatin from the enriched solution, purifying the pravastatin salt, trans-salifying the pravastatin salt to the pravastatin sodium salt and isolating the pravastatin sodium salt.
[0023] In the first step, pravastatin is obtained from an aqueous fermentation broth at a relatively highly concentrated solution by a sequence of extraction, back-extraction operations. Fermentation is typically conducted at very high dilution. Through dilution, the broth attains a higher maximum enzyme potential. A disadvantage of high dilution is that a large volume of fermentation media must be manipulated until the desired product is obtained in a more enriched form. The large volume also places stringent requirements upon the method of isolation. Chromatographic methods are generally impractical for separation of such large volumes, particularly where the solvent is water. If the isolation is conducted by extraction, the organic extraction solvent must have sufficient polarity to compete with water for favorable partitioning of the product yet not be so polar as to be substantially soluble in water. If the extraction is inefficient, large volumes of organic solvent are required to isolate the desired product in high yield, with attendant risks to the health and safety of personnel in and around the fermentation facility.
[0024] We have found that C 2 -C 4 alkyl formates and C 1 -C 4 alkyl esters of C 2 -C 4 carboxylic acids are capable of highly efficient extraction of pravastatin from an aqueous fermentation broth. The partition coefficient of the pravastatin lactone typically is 1000:1 or higher and the partition coefficient of the free acid typically is 10:1 or higher. The alkyl group may be linear, branched or cyclic. Preferred esters include ethyl formate, n-propyl formate, i-propyl formate, n-butyl formate, s-butyl formate, i-butyl formate, t-butyl formate, methyl acetate, ethyl acetate, n-propyl acetate, i-propyl acetate, n-butyl acetate, s-butyl acetate, i-butyl acetate, t-butyl acetate, methyl propionate, ethyl propionate, n-propyl propionate, i-propyl propionate, butyl propionate, methyl butyrate, ethyl butyrate, n-propyl butyrate, i-propyl butyrate, butyl butyrates, methyl isobutyrate, ethyl isobutyrate, propyl isobutyrates and butyl isobutyrates. Of these preferred organic solvents we have found that ethyl acetate, i-butyl acetate, propyl acetate and ethyl formate are especially well suited. The most preferred extraction solvent is i-butyl acetate. Other organic solvents may be substituted for the esters. Halogenated halocarbons, aromatic compounds, ketones and ethers may be used, such as dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, benzene, butyl methyl ketone, diethyl ether and methyl t-butyl ether.
[0025] In the enrichment step of our invention, an organic extract is formed by contacting an organic extraction solvent, preferably selected from the list above, with the fermentation broth. The pH of the fermentation broth is between about pH 1 to about pH 6. Preferably, the pH is between about pH 2 to about pH 4.
[0026] Any equipment adapted for mixing large volumes of liquid in either a batch or continuous process may be used. Since fermentation is typically conducted as a batch process, a batchwise isolation process is a natural choice. Accordingly, conventional high volume mixers and settling tanks or equipment adapted for both mixing and phase separation may be used. In the preferred mode of this aspect of the invention a minor portion, preferably less than 50% (v/v), of the extraction solvent is contacted with the fermentation broth, preferably with mild mechanical agitation. After contacting and phase separation, the extraction solvent containing pravastatin is separated from the pravastatin-depleted fermentation broth. The broth may then be contacted with organic extraction solvent one or more times and each of the resulting organic extracts may be combined. The volume of the resulting organic extract of pravastatin may be either greater or less than the volume of the fermentation broth.
[0027] The second operation toward forming an enriched solution of pravastatin is back-extraction of the pravastatin into a basic aqueous solution. Back-extraction removes some or all non-polar organic impurities and, if pravastatin lactone is present, promotes reopening of the pravastatin lactone ring. Although not intending to be limited in any way by a particular chemical theory or mechanism, according to well-established chemical theory pravastatin is in carboxylate anion form in the basic aqueous extract. Back-extraction may be used to concentrate the pravastatin by using a volume of aqueous base that is less than the volume of the organic extract. The base is preferably NaOH, NH 4 OH or KOH, most preferably NH 4 0 H or NaOH, and the basic aqueous solution preferably has a pH of between about 7.0 and about 13.7, more preferably between about 7 and about 13, most preferably between about 7.5 and about 11. The extraction solvent is contacted with the basic aqueous solution until the amount of pravastatin in the organic phase has been substantially depleted as determined by thin layer chromatography or any other method including the subjective judgment that sufficient contacting has occurred for complete extraction. Multiple back-extractions may be performed for optimal recovery. However, a single back-extraction is highly efficient when the organic phase is butyl acetate. Preferably, the back-extraction is conducted with a volume of basic aqueous solution that is less than one third of the volume of the organic extract, more preferably less than one fourth and most preferably, about one fifth of the volume of the organic extract. The preferred concentration range of the enriched aqueous solution from which pravastatin is obtained later in the process is from about 2 to about 50 g/L, more preferably from about 5 to about 15 g/L.
[0028] The aqueous extract may be further concentrated by distillation, preferably vacuum distillation, to increase the concentration of the solution. Before further concentrating the aqueous extract by distillation the pH should be adjusted between about pH 7 to about pH 13.7, preferably to between about pH 7.5 and about pH 11 and more preferably to between about pH 8 and about pH 10. Vacuum distillation may be done by heating the aqueous extract from about 30° C. to about 80° C. under 5-120 mm Hg absolute pressure. The choice of other vacuum distillation conditions is well within the capabilities of those skilled in arts to which this process relates.
[0029] As an alternative to obtaining pravastatin from an enriched aqueous solution later in the process, pravastatin may be obtained from an enriched organic solution. The enriched organic solution of pravastatin is formed by re-extracting the pravastatin into an organic solvent after the aqueous extract has been reacidified with an acid, preferably trifluoroacetic acid, hydrochloric acid, sulfuric acid, acetic acid, or phosphoric acid, more preferably sulfuric or phosphoric acid, to a pH of about 1.0 to about 6.5, more preferably about 2.0 to about 4.0. Depending upon conditions, the pravastatin carboxylate anion may be protonated to the pravastatin free acid, which is less polar than the carboxylate or lactonized to a yet less polar form.
[0030] Pravastatin is re-extracted into a re-extraction solvent selected from the organic solvents previously described as suitable for extracting pravastatin from the fermentation broth. The organic solvent may be, but need not be, the same solvent used to extract pravastatin from the fermentation broth. In this re-extraction, further enrichment of pravastatin is accomplished by re-extracting into an amount of organic solvent that is preferably less than about 50% (v/v) of the aqueous extract, more preferably from about 33% (v/v) to about 20% (v/v) and still more preferably about 25% (v/v) the volume of the aqueous extract. Accordingly, as further exemplified in Example 1, pravastatin may be concentrated from 100 L of fermentation broth to 8 L of enriched organic solution in 89% yield from the initial organic extract. It will be appreciated by those skilled in the art that a higher yield of purified pravastatin may be attained by performing multiple extractions where only a single extraction has been described in this preferred mode for practicing the invention. This preferred mode achieves a balance of solvent economy and high product yield. Deviations from this preferred mode which further enhance the yield by repeated extractions where only one has been described above do not necessarily depart from the spirit of the invention. Before proceeding to obtain pravastatin from the enriched organic solution by “salting out,” the enriched organic solution is preferably dried, which may be done using a conventional drying agent such as MgSO 4 , Na 2 SO 4 , CaSO 4 , silica, perlite and the like, and optionally decolorized with activated carbon. A dried and/or decolorized enriched organic solution is then separated conventionally, as for instance by filtration or decanting.
[0031] In the next step of our process, a salt of pravastatin is obtained from the enriched aqueous or organic solution, as the case may be. The salt is obtained by precipitation from the enriched solution. Precipitation is induced by adding to the enriched solution a metal salt, ammonia, an amine, a salt of ammonia or a salt of an amine.
[0032] Metal salts that may be used include hydroxides, alkoxides, halides, carbonates, borates, phosphates, thiocyanates, acetates, nitrates, sulfates, thiosulfates and any other salts that have a high solubility in water. The metals of the metal salts include lithium, sodium, potassium, calcium, magnesium, copper, iron, nickel, manganese, tin, zinc and aluminum. Preferred salts are salts of the following metal cations: Li + , Na + , K + , Ca 2+ , Mg 2+ , Cu 2+ , Fe 2+ , Fe 3+ , Ni 2+ , Mn 2+ , Sn 2+ , Zn 2+ and Al 3+ . The most preferred metal cations of salts for inducing precipitation of a pravastatin metal salt are Na + and K + .
[0033] Pravastatin may also be precipitated as an ammonium or amine salt by adding ammonia or an amine. The amine may be a primary, secondary or tertiary amine. Any alkyl or aryl amine that is not so hindered as to prevent ionic interaction between the amine nitrogen and the carboxyl group of pravastatin may be used. The amines include, but are not limited to, methyl, dimethyl, trimethyl, ethyl, diethyl, triethyl and other C 1 -C 6 primary, secondary and tertiary amines; and further include morpholine, N-methylmorpholine, isopropyl cyclohexyl amine, piperidine and the like. Regardless of the absence, presence or multiplicity of substitution on nitrogen, a salt formed by reaction of ammonia or an amine is hereafter referred to as an ammonium salt. Its meaning is intended to encompass salts of amines as well as a salt of ammonia.
[0034] Precipitation of the ammonium salt of pravastatin may also be induced by addition of an ammonium salt either alone or in combination with ammonia, an amine or a metal salt. The preferred ammonium salts are the following salts of ammonia: NH 4 Cl, NH 4 Br, NH 4 I, (NH 4 ) 2 SO 4 , NH 4 NO 3 , (NH 4 ) 3 PO 4 , (NH 4 ) 2 S 2 O 4 , NH 4 OAc and NH 4 SCN, the most preferred being NH 4 Cl.
[0035] Metal salts, ammonium salts and high boiling liquid and solid amines may be added by conventional means, preferably in an area with good ventilation, either as solids, neat liquids or solutions in aqueous or organic solvent. Addition of gaseous ammonia requires special equipment for handling caustic gases. Such equipment, including pressure vessels, regulators, valves and lines are widely available. The ammonia may be introduced into the headspace above the enriched solution at ambient pressure or if a pressure vessel is used, at elevated pressure. Alternatively, the ammonia may be bubbled through the solution, which is preferably stirred to reduce clogging of the inlet tube by precipitated pravastatin ammonium salt.
[0036] In a preferred embodiment of the inventive process, pravastatin is obtained from the enriched solution as an ammonium salt by addition of ammonia or an amine. In a more preferred embodiment, pravastatin is obtained from the enriched solution as the pravastatin salt of ammonia by addition of gaseous ammonia to the enriched solution. Ammonia yields a highly polar ammonium salt of pravastatin which is easily precipitated in high yield from antisolvent. In the most preferred embodiment, pravastatin is obtained as the pravastatin salt of ammonia by addition of gaseous ammonia and an ammonium salt. The most preferred ammonium salt is NH 4 Cl, which has the advantage of forming a concentrated aqueous ammonium chloride solution in the case of incomplete drying of the enriched organic solution.
[0037] The temperature at which the metal salt, ammonia, amine and/or ammonium salt should be added can be determined by routine experimentation by conducting the reaction on a small scale and monitoring the exothermicity of the reaction. Preferably, the solution temperature is not allowed to exceed 40° C. Although temperatures as high as 80° C. may be experienced without significant decomposition of pravastatin, many organic solvents of this invention will boil at a lower temperature. When ammonia is used, the preferred temperature range is from about −10° C. to about 40° C.
[0038] Once precipitation appears to cease or once consumption of pravastatin is determined to be substantially complete by other means, the addition should be ceased. When ammonia or a volatile amine is used, the vessel should be vented to disperse excess fumes. The crystals are then isolated by filtration, decantation of the solvent, evaporation of the solvent or other such method, preferably filtration.
[0039] After optionally washing the precipitated crystals, the pravastatin salt is purified by one or more recrystallizations. To purify the pravastatin salt, the salt is first dissolved in water. Preferably a minimum amount of water is used. Dissolution will generally require more water if an amine salt, instead of metal salt or salt of ammonia has been obtained. Once the pravastatin salt has completely dissolved, the polarity of the solution is decreased by addition of an anti-solvent. The anti-solvent is a water-soluble organic solvent or solvent mixture in which the pravastatin salt is poorly soluble. Suitable water-soluble organic solvents include acetone, acetonitrile, alkyl acetates, i-butanol and ethanol.
[0040] The pravastatin salt may be allowed to recrystallize spontaneously, or may be induced to recrystallize by taking further steps such as adding a common ion, cooling or adding a seed crystal. To further induce recrystallization by adding a common ion, a salt having the same metal or ammonium ion as the pravastatin salt is added to the mixture. Suitable salts for inducing recrystallization of the pravastatin salts are the same metal and ammonium salts as may be used to precipitate the pravastatin salt from the enriched solution. According to the preferred process wherein pravastatin is obtained as an ammonium salt, the chloride salt of ammonia or the amine previously used to obtain the pravastatin salt is added to induce recrystallization of the pravastatin salt. In the most preferred embodiment wherein the pravastatin salt of ammonia is obtained the added salt is most preferably NH 4 Cl.
[0041] The recrystallization may be performed at between about −10° C. and about 60° C., preferably between about 0° C. and about 50° C. and most preferably between about 0° C. and about 40° C. After the pravastatin salt has been substantially recrystallized from the solution, the crystals are isolated and may be washed, for example with a 1:1 mixture of i-butyl acetate and acetone and then dried. Drying may be conducted at ambient temperature but is preferably conducted at mildly elevated temperature of less than 45° C. and preferably about 40° C. The recrystallization may optionally be repeated to good effect as shown in Examples 7 and 8. Each repetition occurs in about 92-96% yield.
[0042] Even after recrystallization, the pravastatin contains an organic impurity which has a relative retention time. (RRT) of 0.9 on HPLC. The organic impurity is estimated to be about 0.2% of the total composition based upon the HPLC chromatogram obtained with UV detection. The organic impurity can be removed as follows.
[0043] The pravastatin salt is dissolved in water, preferably a minimum or about 6 ml g −1 and about 0.2% (v/v) isobutanol is then added. The pH is raised to from about pH 8 to about pH 14, preferably about pH 10 to about pH 13.7 by addition of sodium hydroxide and the mixture is maintained at a temperature of about 10° C. to about 50° C. for 10-200 minutes, preferably at a temperature of about 20° C. to about 30° C. for 60-100 minutes. The solution is then reacidified with a mineral or organic acid, preferably, hydrochloric acid or sulfuric acid to a pH of about pH 4 to about pH 9, more preferably about pH 5 to about pH 9 most preferably about pH 6 to about pH 7.5. After adjusting the pH, ammonium chloride is then added to the solution to salt out the pravastatin salt. If the amount of water used is about 6 ml g −1 , then use of about 2.0-2.3 g of ammonium chloride per gram of pravastatin salt is recommended. Preferrably the ammonium chloride is added portionwise over four to six hours.
[0044] After adding ammonium chloride, the pravastatin ammonium salt may crystallize spontaneously. Otherwise, recrystallization may be induced by cooling, seeding or other conventional means. While recrystallization is preferably induced via addition of a common ion, for example by adding ammonium chloride, recrystallization also may be induced by dilution with an anti-solvent as is preferably done in the recrystallization step previously described. However, in this operation care must be taken not to inadvertently precipitate pravastatin salts. As shown in more detail in Example 1, the amount of organic impurity with an RRT=0.9 was reduced beyond detectable limit and pravastatin ammonium was obtained in about 99.3% purity, approaching the level of purity that is acceptable for pharmaceutical use. At this stage of the inventive process, a pravastatin ammonia salt may be obtained with less than about 0.70% (w/w) organic impurities.
[0045] After removal of the organic impurities by recrystallization, the pravastatin salt is trans-salified to pravastatin sodium. Trans-salifying as it is used herein, refers to any process whereby the cation of an organic salt molecule is exchanged with another cation. In the trans-salification, pravastatin is first liberated from its metal or ammonium salt by dissolving the salt in an aqueous solvent, adding any protic acid such as hydrochloric, sulfuric, phosphoric trifluoroacetic or acetic acid to the aqueous solution and extracting pravastatin from the aqueous solution with an organic solvent. The protic acid is added to the aqueous solution in an amount that neutralizes or acidifies it, preferably acidifies it to a pH of about 1 to about 6, more preferably about 2 to about 4. Either before or after adding the protic acid to the aqueous solution, the aqueous solution is contacted with a water-immiscible organic solvent such as i-butyl acetate or any other water-immiscible organic solvent. After the aqueous solution has been contacted with a water-immiscible organic solvent and treated with the protic acid, the resulting organic phase containing pravastatin is then separated from the aqueous phase and, after optionally washing with water to remove ammonium residues, the pravastatin is back-extracted with aqueous sodium hydroxide. It is preferable to use an amount of NaOH that is only a modest molar excess over the amount pravastatin, preferably less than 1.1 equivalents thereof, more preferably less than 1.02 equivalents thereof.
[0046] After extraction into aqueous sodium hydroxide, excess sodium cations are scavenged to attain a near 1:1 equivalence of sodium cation and pravastatin. Scavenging is accomplished using water insoluble ionic exchange resins. Suitable ion exchange resins are the cationic and chelate type resins, the preferred being strong and weak acid exchange resins.
[0047] Among the strong acid cationic exchange resins which may be used are those having sulfonic acid (SO 3 − H + ) groups. These include the commercial products Amberlite® IR-118, IR-120, 252H; Amberlyst® 15, 36; Amberjet® 1200(H) (Rohm and Haas) Dowex® 50WX series, Dowex® HCR-W2, Dowex® 650C, Dowex® Marathon C, Dowex® DR-2030, and Dowex® HCR-S, ion exchange resins (Dow Chemical Co.); Diaion® SK 102 to 116 resin series (Mitsubishi Chemical Corp.) and Lewatit SP 120 (Bayer). The preferred strong acid cationic exchange resins are Amberlite® 120, Dowex® 50WX and Diaion® SK series.
[0048] Weak acid cationic exchange resins include those which have pendant carboxylic acid groups. Weak acid cationic exchange resins include the commercial products Amberlite® CG-50, IRP-64, IRC 50 and C67, Dowex® CCR series, Lewatit® CNP series and Diaion® WK series, of these, the most preferred are Amberlite® IRC56, Lewatit® CNP 80 and Diaion® WK 10. Less preferred are the chelate type exchange resins. Some of the commercial varieties that are available include Duolite® C-718, and C467 (Rohm & Haas).
[0049] The solution containing pravastatin sodium salt and excess sodium cations may be contacted with the ion exchange resin by any method known to the art, including passage of the solution through a column or bed of the resin or by stirring a sufficient quantity of the resin in a flask with the solution. The mode of contact is not critical. After scavenging of the excess sodium ion, the pH of a pravastatin sodium solution should be in the range of about of 6.5 to about 10, preferably about 7.4 to about 7.8, although the pH will vary with dilution. Reduction in the pH of the pravastatin sodium solution from a higher pH to a lower pH and then leveling off of the pH at the lower level is an indication of substantial completion of scavenging excess Na + ions. After scavenging is complete, the pravastatin sodium solution is separated from the resin in a conventional manner. It may either be collected as the eluent from a column or bed or may be separated by filtration, decantation and the like.
[0050] Pravastatin sodium may be isolated from the pravastatin sodium solution by crystallization. Efficient crystallization may first require partial removal of the water, which can be conducted by vacuum distillation or nano-filtration. Preferably, the aqueous pravastatin sodium salt solution is concentrated from about 20 to about 50 w/v % before crystallizing. If necessary, after concentration the aqueous pravastatin sodium solution can be adjusted to a pH of between about 7 and about 10 with an ion exchange resin in H + form.
[0051] Addition of a water soluble organic solvent or organic solvent mixture to the pravastatin sodium solution will assist the crystallization. In particular, there may be mentioned acetone and acetone/acetonitrile, ethanol/acetonitrile and ethanol/ethyl acetate mixtures. One of the most preferred solvent system for crystallizing pravastatin sodium is a 1/3/12 water/acetone/acetonitrile mixture formed by concentrating the pravastatin sodium solution to about 30 w/v % and then adding an appropriate volume of 1/4 acetone/acetonitrile mixture. The other most preferred crystallization solvent mixture is water-acetone (1:15).
[0052] Pravastatin sodium also may be isolated by lyophilization of the aqueous pravastatin sodium solution.
[0053] Whether isolated by crystallization or other means that improves the purity of the product, the pravastatin sodium that is isolated in the practice of the present inventive process is substantially free of pravastatin lactone. As demonstrated in the examples that follow, pravastatin sodium may be isolated with less than 0.5% (w/w) total impurity content. Further, pravastatin sodium may be isolated with 0.2% (w/w) or less total impurity content by adhering to the preferred embodiments of the invention, two of which are exemplified in Examples 1 and 15. Major impurities which are part of the total impurity content include epipravastatin sodium, 3′-OH compactin sodium, 6-hydroxy isocompactin sodium and pravastatin lactone.
[0054] Although, the following examples illustrate the practice of the present invention in some of its embodiments. The examples should not be construed as limiting the scope of the invention. Other embodiments will be apparent to one skilled in the art from consideration of the specification and examples. It is intended that the specification, including the examples, is considered exemplary only, with the scope and spirit of the invention being indicated by the claims which follow.
EXAMPLES
Example 1
[0055] Purification of Pravastatin
[0056] The fermentation broth (100 L) was acidified to a pH from about 2.5 to about 5.0 by addition of sulfuric acid. The acidified fermentation broth was extracted with i-butyl acetate (3×50 L). The yield of i-butyl acetate extraction was found to be 95% by HPLC analysis calibrated to the internal standard in the broth. HPLC Conditions (Reverse phase): column: C 18 , particle size 5 μm, length 150 mm, diameter 4.6 mm; mobile phase: 45% methanol/water, 0.1% Et 3 N, 0.1% glacial acetic acid; flow rate 1.3 ml min. −1 ; column temperature 25° C.; injection volume 10 μl; internal standard ethyl parahydroxybenzoate; detection: UV λ=238 nm.
[0057] The combined i-butyl acetate phases were then extracted with water (35 L) at about pH 7.5 to about pH 11.0 by addition of concentrated ammonium hydroxide. The resulting aqueous pravastatin solution was then reacidified to a pH of about 2.0 to about 4.0 by addition of 5M sulfuric acid and back-extracted with i-butyl acetate (8 L). The resulting solution of pravastatin in i-butyl acetate was partially dried over Perlite and Na 2 SO 4 . The pravastatin solution was decanted and then filtered from the drying agents and decolorized over activated charcoal (1.7 g). The solution was then filtered to remove the charcoal and transferred to a flask equipped with a gas inlet.
[0058] Ammonia gas was then introduced into the headspace above the solution at 15-25° C. with rapid stirring. After further precipitation appeared to cease, the ammonia was turned off and ammonium chloride was added to the mixture to ease filtration. The precipitated crystals of ammonium pravastatin carboxylate salt were collected by filtration and washed with i-butyl acetate and then acetone which yielded pravastatin ammonium salt in about 94% purity as determined by HPLC with UV detection at λ=238 nm.
[0059] The pravastatin ammonium salt was further purified by crystallization from a saturated ammonium chloride solution as follows. The pravastatin salt containing 162 g of active substance was dissolved in water (960 ml) and diluted with acetone (96 ml) and i-butyl acetate (96 ml) at about 35-40° C. The solution was cooled to about 30-32° C. and pravastatin ammonium was induced to crystallize by addition of solid NH 4 Cl until further addition resulted in no apparent increase in crystal formation. After adding ammonium chloride, the solution was cooled to about 0-26° C. The pravastatin ammonium crystals were collected by filtration and washed with i-butyl acetate and acetone, as before, and then dried at about 40° C. The resulting pravastatin ammonium salt crystals (155.5 g) were obtained in about 98% purity as determined by HPLC employing the afore-mentioned conditions.
[0060] The pravastatin ammonium salt was further purified by another crystallization as follows. The pravastatin ammonium salt (155.5 g of active substance) was dissolved in water (900 ml). Isobutanol (2 ml) was added and then the pH was raised to about pH 10 to about pH 13.7 by addition of a concentrated solution of sodium hydroxide and the solution was stirred for 75 min. at ambient temperature. The solution was neutralized to a pH of about 7 by addition of sulfuric acid and crystallization of pravastatin ammonium was induced by addition of solid NH 4 Cl. The crystals (150 g) were collected by filtration and washed with acetone. Pravastatin ammonium was found to be about 99.3% pure by HPLC detection using the above-described conditions.
[0061] The pravastatin ammonium was then trans-salified to the sodium salt as follows. The pravastatin ammonium salt crystals were dissolved in water (1800 ml). i-Butyl acetate (10.5 L) was added. The solution was then acidified to a pH of between from about pH 2 to about pH 4, by addition of sulfuric acid, which converted pravastatin back to its free acid. The i-butyl acetate phase, containing pravastatin, was washed with water (5×300ml). Pravastatin was then converted to its sodium salt and back-extracted into another aqueous phase by swirling the i-butyl acetate solution over water (900-2700 ml) with intermittent addition of 8m NaOH until a pH of between about pH 7.4 to about pH 13 was reached.
[0062] The pravastatin sodium salt solution was then treated with an ion exchange resin to scavenge excess sodium cations. After separation, the aqueous phase was stirred over Amberlite® IRC 50 exchange resin in the H + form for 30 min. at ambient temperature. Stirring was continued until a pH of about pH 7.4 to about pH 7.8 was reached.
[0063] The solution was then filtered to remove the resin and partially concentrated to a weight of 508 g. under vacuum. The solution was then diluted with acetonitrile (480 ml), giving a solvent 1.4:1 acetonitrile:water solvent mixture. The solution was stirred over activated carbon (5 g) to decolorize. After filtering of the activated carbon, pravastatin sodium was obtained as crystals by crystallization in 90% yield after further addition of acetone and acetonitrile to form a 1/3/12 mixture of water/acetone/acetonitrile (5.9 L) with cooling to about −10 to about 0° C. Pravastatin sodium was obtained in an overall yield of 65% in about 99.3% purity from the starting fermented active substance as measured by HPLC using the above-described conditions.
Example 2
[0064] Following the procedure in Example 1, but omitting the recrystallization from the water/acetone/acetonitrile mixture, pravastatin sodium was obtained by lyophilization of the concentrated solution of pravastatin sodium in water in about 99% purity and about 72% yield. Comparison of the ultimate purity of this example with Example 1 demonstrates that recrystallization of pravastatin sodium rather than lyophilization yields a somewhat purer product.
Example 3-6
[0065] Following the procedure in Example 1, pravastatin sodium was isolated from a fermentation broth in the yield and purity shown in Table 1, when the corresponding organic solvent was used in the trans-salification process.
TABLE 1 Example Yield Purity No. Organic Solvent (%) (%) 3 CH 2 Cl 2 63 96.6 4 ethyl acetate 58 99.5 5 ethyl formate 51 99.6 6 butyl methyl ketone 61 99.5
Example 7
[0066] Following the procedure of Example 1, but further purifying the pravastatin ammonium salt by once repeating the crystallization of the pravastatin ammonium salt, pravastatin sodium was obtained in about 99.6% purity and 58.4% yield.
Example 8
[0067] Following the procedure of Example 1, but further purifying the pravastatin ammonium salt by twice repeating the crystallization of the pravastatin ammonium salt, pravastatin sodium was obtained in about 99.8% purity and 53% yield.
Example 9
[0068] Following the procedure of Example 1, the fermentation broth (100 L) was acidified to pH from about 2.5 to about 5.0. by addition of sulfuric acid. The acidified fermentation broth was extracted with i-butyl acetate (3×50 L). The combined i-butyl acetate phases were then extracted with water (35 L) having been basified to a pH of about pH 7.5 to about pH 11.0 by addition of concentrated ammonium hydroxide.
[0069] Instead of reacidifying the aqueous extract and extracting with i-butyl acetate to obtain a further enriched organic solution as was done in Example 1, the aqueous extract was concentrated to 140 g/L under vacuum. The resulting concentrated solution had a pH of about pH 4.0 to about pH 8. Excess ammonia was removed by evaporation.
[0070] Ammonium chloride crystals (405 g.) were then slowly added to the concentrated solution portionwise over four hours and the pravastatin ammonium salt was allowed to crystallize at ambient temperature. The crystals were then isolated by filtration and washed with a saturated solution of ammonium chloride. The crystals were then added to water (IL) at 40° C. After dissolution, the temperature was reduced to 30° C. and ammonium chloride (330 g.) was added to the solution portionwise over two hours. The solution was then stirred for 15 h at ambient temperature and crystals of pravastatin ammonium salt were recovered by filtration and washed with i-butyl acetate and after that with acetone and dried. The resulting crystals were then further purified by recrystallization transposed to the sodium salt and isolated as described in Example 1. Pravastatin sodium was obtained in about 99.6% purity and 64.7% yield.
Example 10
[0071] Following the procedure of Example 1, but the pravastatin sodium salt was crystallized from 1/15 mixture of water/acetone in an overall yield from the starting fermented active substance of 64% and in 99.6% purity as measured by HPLC.
Example 11
[0072] Following the method of Example 9, first two paragraphs, a concentrated aqueous extract (140 g. L −1 ) was obtained. The concentrated aqueous extract was divided into three equal parts. The resulting concentrated solution was then acidified to a pH of about pH 4.0 to about pH 8.0 by addition of 1M HCl. Following the method of Example 9, third paragraph, but substituting the salts in Table 2 for ammonium chloride, a pravastatin salt was precipitated from each of the portions and transposed to the sodium salt.
TABLE 2 Purity Yield Salts (%) (%) KCl 99.3 42 NaCl 99.4 38 LiCl 99.1 34
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A novel process for recovering a compound from a fermentation broth that includes the stages of forming an enriched solution of the compound by extraction, obtaining a salt of the compound from the enriched solution, purifying a salt of the compound and trans-salifying the salt of the compound to a metal salt of the compound is disclosed.
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The present application is a national stage application claiming priority to International Application Serial Number PCT/SE2011/050556, filed May 3, 2011, which claims priority to U.S. Provisional patent application Ser. No. 61/333,817, filed May 12, 2010, and Swedish National Patent Application Serial Number 1050458-7, filed May 7, 2010.
TECHNICAL FIELD
The present invention relates generally to a helmet comprising an energy absorbing layer, with or without any outer shell, and a sliding facilitator being provided inside of the energy absorbing layer.
BACKGROUND ART
In order to prevent or reduce skull and brain injuries many activities requires helmets. Most helmets consist of a hard outer shell, often made of a plastic or a composite material, and an energy absorbing layer called a liner. Nowadays, a protective helmet has to be designed so as to satisfy certain legal requirements which relate to inter alia the maximum acceleration that may occur in the center of gravity of the brain at a specified load. Typically, tests are performed, in which what is known as a dummy skull equipped with a helmet is subjected to a radial blow towards the head. This has resulted in modem helmets having good energy-absorption capacity in the case of blows radially against the skull while the energy absorption for other load directions is not as optimal.
In the case of a radial impact the head will be accelerated in a translational motion resulting in a linear acceleration. The translational acceleration can result in fractures of the skull and/or pressure or abrasion injuries of the brain tissue. However, according to injury statistics, pure radial impacts are rare.
On the other hand, a pure tangential hit that results in a pure angular acceleration to the head are rare, too.
The most common type of impact is oblique impact that is a combination of a radial and a tangential force acting at the same time to the head, causing for example concussion of the brain. The oblique impact results in both translational acceleration and rotational acceleration of the brain. Rotational acceleration causes the brain to rotate within the skull creating injuries on bodily elements connecting the brain to the skull and also to the brain itself.
Examples of rotational injuries are on the one hand subdural haematomas, SDH, bleeding as a consequence of blood vessels rupturing, and on the other hand diffuse axonal injuries, DAI, which can be summarized as nerve fibers being over stretched as a consequence of high shear deformations in the brain tissue. Depending on the characteristics of the rotational force, such as the duration, amplitude and rate of increase, either SDH or DAI occur, or a combination of these is suffered. Generally speaking, SDH occur in the case of short duration and great amplitude, while DAI occur in the case of longer and more widespread acceleration loads. It is important that these phenomena are taken into account so as to make it possible to provide good protection for the skull and brain.
The head has natural protective systems that try to dampen these forces using the scalp, the hard skull and the cerebrospinal fluid beneath it. During an impact, the scalp and the cerebro spinal fluid acts as rotational shock absorber by both compressing and sliding over the skull. Most helmets used today provide no protection against rotational injury.
Important features of for example bicycle, equestrian and ski helmets are that they are well ventilated and have an aerodynamic shape. Modern bicycle helmets are usually of the type in-mould shell manufactured by incorporating a thin, rigid shell during the molding process. This technology allows more complex shapes than hard shell helmets and also the creation of larger vents.
SUMMARY
A helmet comprising an energy absorbing layer and a sliding facilitator being provided inside of the energy absorbing layer is disclosed.
According to one embodiment, the helmet comprises an attachment device for attachment of the helmet to a wearer's head. The attachment device is aimed to be in at least partly contact with the top portion of the head or skull. It may additionally have tightening means for adjustment of the size and grade of attachment to the top portion of the wearer's head. Chin straps or the like are not attachment devices according to the present embodiments of helmets.
The sliding facilitator could be fixated to the attachment device and/or to the inside of the energy absorbing layer for providing slidability between the energy absorbing layer and the attachment device.
Preferably an outer shell is provided outside of the energy absorbing layer. A helmet designed accordingly could be manufactured using in-mould technology, although it is possible to use the disclosed idea in helmets of all types, for example helmets of hard shell type such as motorcycle helmets.
According to yet another embodiment the attachment device is fixated to the energy absorbing layer and/or the outer shell by means of at least one fixation member, which could be adapted to absorb energy and forces by deforming in an elastic, semi-elastic or plastic way. During an impact, the energy absorbing layer acts as an impact absorber by compressing the energy absorbing layer and if an outer shell is used, it will spread out the impact energy over the shell. The sliding facilitator will allow sliding between the attachment device and the energy absorbing layer allowing for a controlled way to absorb the rotational energy otherwise transmitted to the brain. The rotational energy can be absorbed by friction heat, energy absorbing layer deformation or, deformation or displacement of the at least one fixation member. The absorbed rotational energy will reduce the amount of rotational acceleration affecting the brain, thus reducing the rotation of the brain within the skull.
The fixation member could comprise at least one suspension member, having a first and second portion. The first portion of the suspension member could be adapted to be fixated to the energy absorbing layer, and the second portion of the suspension member could be adapted to be fixated to the attachment device.
The sliding facilitator gives the helmet a function (slidability) and can be provided in many different ways. For example it could be a low friction material provided on or integrated with the attachment device on its surface facing the energy absorbing layer and/or provided on or integrated in the inside surface of the energy absorbing layer facing the attachment device.
A method of manufacturing a helmet comprising a sliding facilitator is further provided. The method comprising the steps of: providing a mould, providing an energy absorbing layer in the mould, and providing a sliding facilitator contacting the energy absorbing layer. According to one embodiment, the method could further comprise the step of fixating an attachment device to at least one of: the shell, the energy absorbing layer and the sliding facilitator using at least one fixation member.
The sliding facilitator provides the possibility of sliding movement in any direction. It is not restricted to movements around certain axes.
Please note that any embodiment or part of embodiment as well as any method or part of method could be combined in any way.
BRIEF DESCRIPTION OF DRAWINGS
The invention is now described, by way of example, with reference to the accompanying drawings, in which;
FIG. 1 shows a helmet, according to one embodiment, in a sectional view,
FIG. 2 shows a helmet, according to one embodiment, in a sectional view, when placed on a wearers head,
FIG. 3 shows a helmet placed on a wearers head, when receiving a frontal impact,
FIG. 4 shows the helmet placed on a wearers head, when receiving a frontal impact,
FIG. 5 shows an attachment device in further detail,
FIG. 6 shows an alternative embodiment of a fixation member,
FIG. 7 shows an alternative embodiment of a fixation member,
FIG. 8 shows an alternative embodiment of a fixation member,
FIG. 9 shows an alternative embodiment of a fixation member,
FIG. 10 shows an alternative embodiment of a fixation member,
FIG. 11 shows an alternative embodiment of a fixation member,
FIG. 12 shows an alternative embodiment of a fixation member,
FIG. 13 shows an alternative embodiment of a fixation member,
FIG. 14 shows an alternative embodiment of a fixation member,
FIG. 15 shows an alternative embodiment of a fixation member,
FIG. 16 shows a table of test results,
FIG. 17 shows a graph of test results, and
FIG. 18 shows a graph of test results.
DETAILED DESCRIPTION
In the following a detailed description of embodiments will be given. It will be appreciated that the figures are for illustration only and are not in any way restricting the scope. Thus, any references to direction, such as “up” or “down”, are only referring to the directions shown in the figures.
One embodiment of a protective helmet comprises an energy absorbing layer, and a sliding facilitator being provided inside of the energy absorbing layer. According to one embodiment an in-mold helmet suitable for bicycling is provided. The helmet comprises an outer preferably thin, rigid shell made of a polymer material such as polycarbonate, ABS, PVC, glassfiber, Aramid, Twaron, carbonfibre or Kevlar. It is also conceivable to leave out the outer shell. On the inside of the shell an energy absorbing layer is provided which could be a polymer foam material such as EPS (expanded poly styrene), EPP (expanded polypropylene), EPU (expanded polyurethane) or other structures like honeycomb for example. A sliding facilitator is provided inside of the energy absorbing layer and is adapted to slide against the energy absorbing layer or against an attachment device which is provided for attaching the helmet to a wearer's head. The attachment device is fixated to the energy absorbing layer and/or the shell by means of fixation members adapted to absorb impact energy and forces.
The sliding facilitator could be a material having a low coefficient of friction or be coated with a low friction material: Examples of conceivable materials are PTFE, ABS, PVC, PC, Nylon, fabric materials. It is furthermore conceivable that the sliding is enabled by the structure of the material, for example by the material having a fiber structure such that the fibers slide against each other.
During an impact, the energy absorbing layer acts as an impact absorber by compressing the energy absorbing layer and if an outer shell is used, it will spread out the impact energy over the energy absorbing layer. The sliding facilitator will allow sliding between the attachment device and the energy absorbing layer allowing for a controlled way to absorb the rotational energy otherwise transmitted to the brain. The rotational energy can be absorbed by friction heat, energy absorbing layer deformation or deformation or displacement of the at least one fixation member. The absorbed rotational energy will reduce the amount of rotational acceleration affecting the brain, thus reducing the rotation of the brain within the skull. The risk of rotational injuries such as subdural haematomas, SDH, blood vessel rupturing, concussions and DAI is thereby reduced.
FIG. 1 shows a helmet according to one embodiment in which the helmet comprises an energy absorbing layer 2 . The outer surface 1 of the energy absorbing layer 2 may be provided from the same material as the energy absorbing layer 2 or it is also conceivable that the outer surface 1 could be a rigid shell 1 made from a different material than the energy absorbing layer 2 . A sliding facilitator 5 is provided inside of the energy absorbing layer 2 in relation to an attachment device 3 provided for attachment of the helmet to a wearer's head. According to the embodiment shown in FIG. 1 the sliding facilitator 5 is fixated to or integrated in the energy absorbing layer 2 , however it is equally conceivable that the sliding facilitator 5 is provided on or integrated with the attachment device 3 , for the same purpose of providing slidability between the energy absorbing layer 2 and the attachment device 3 . The helmet of FIG. 1 has a plurality of vents 17 allowing airflow through the helmet.
The attachment device 3 is fixated to the energy absorbing layer 2 and/or the outer shell 1 by means of four fixation members 4 a , 4 b , 4 c and 4 d adapted to absorb energy by deforming in an elastic, semi-elastic or plastic way. Energy could also be absorbed through friction creating heat and/or deformation of the attachment device, or any other part of the helmet. According to the embodiment shown in FIG. 1 the four fixation members 4 a , 4 b , 4 c and 4 d are suspension members 4 a , 4 b , 4 c , 4 d , having first and second portions 8 , 9 , wherein the first portions 8 of the suspension members 4 a , 4 b , 4 c , 4 d are adapted to be fixated to the attachment device 3 , and the second portions 9 of the suspension members 4 a , 4 b , 4 c , 4 d are adapted to be fixated to the energy absorbing layer 2 .
The sliding facilitator 5 may be a low friction material, which in the embodiment shown is provided on outside of the attachment device 3 facing the energy absorbing layer 2 , however, in other embodiments, it is equally conceivable that the sliding facilitator 5 is provided on the inside of the energy absorbing layer 2 . The low friction material could be a waxy polymer, such as PTFE, PFA, FEP, PE and UHMW PE, or a powder material which could be infused with a lubricant. This low friction material could be applied to either one, or both of the sliding facilitator and the energy absorbing layer, in some embodiments the energy absorbing layer itself is adapted to act as sliding facilitator and may comprise a low friction material.
The attachment device could be made of an elastic or semi-elastic polymer material, such as PC, ABS, PVC or PTFE, or a natural fiber material such as cotton cloth. For example, a cap of textile or a net could be forming an attachment device. The cap could be provided with sliding facilitators, like patches of low friction material. In some embodiments the attachment device itself is adapted to act as a sliding facilitator and may comprise a low friction material. FIG. 1 further discloses an adjustment device 6 for adjusting the diameter of the head band for the particular wearer. In other embodiments the head band could be an elastic head band in which case the adjustment device 6 could be excluded.
FIG. 2 shows an embodiment of a helmet similar to the helmet in FIG. 1 , when placed on a wearers head. However, in FIG. 2 the attachment device 3 is fixated to the energy absorbing layer by means of only two fixation members 4 a, b , adapted to absorb energy and forces elastically, semi-elastically or plastically. The embodiment of FIG. 2 comprises a hard outer shell 1 made from a different material than the energy absorbing layer 2 .
FIG. 3 shows the helmet according to the embodiment of FIG. 2 when receiving a frontal oblique impact I creating a rotational force to the helmet causing the energy absorbing layer 2 to slide in relation to the attachment device 3 . The attachment device 3 is fixated to the energy absorbing layer 2 by means of the fixation members 4 a , 4 b . The fixation absorbs the rotational forces by deforming elastically or semi-elastically.
FIG. 4 shows the helmet according to the embodiment of FIG. 2 when receiving a frontal oblique impact I creating a rotational force to the helmet causing the energy absorbing layer 2 to slide in relation to the attachment device 3 . The attachment device 3 is fixated to the energy absorbing layer by means of rupturing fixation members 4 a , 4 b which absorbs the rotational energy by deforming plastically and thus needs to be replaced after impact. A combination of the embodiments of FIG. 3 and FIG. 4 is highly conceivable, i.e. a portion of the fixation members ruptures, absorbing energy plastically, while another portion of the fixation members deforms and absorbs forces elastically. In combinational embodiments it is conceivable that only the plastically deforming portion needs to be replaced after impact.
The upper part of FIG. 5 shows the outside of an attachment device 3 according to an embodiment in which the attachment device 3 comprises a head band 3 a , adapted to encircling the wearer's head, a dorso-ventral band 3 b reaching from the wearer's forehead to the back of the wearer's head, and being attached to the head band 3 a , and a latro-lateral 3 c band reaching from the lateral left side of the wearers head to the lateral right side of the wearer's head and being attached to the head band 3 a . Parts or portions of the attachment device 3 may be provided with sliding facilitators. In the shown embodiment, the material of the attachment device may function as a sliding facilitator in itself. It is also conceivable to provide the attachment device 3 with an added low friction material.
FIG. 5 further shows four fixation members 4 a , 4 b , 4 c , 4 d , fixated to the attachment device 3 . In other embodiments the attachment device 3 could be only a head band 3 a , or en entire cap adapted to entirely cover the upper portion of the wearer's head or any other design functioning as an attachment device for mounting on a wearer's head.
The lower part of FIG. 5 shows the inside of the attachment device 3 disclosing an adjustment device 6 for adjusting the diameter of the head band 3 a for the particular wearer. In other embodiments the head band 3 a could be an elastic head band in which case the adjustment device 6 could be excluded.
FIG. 6 shows an alternative embodiment of a fixation member 4 in which the first portion 8 of the fixation member 4 is fixated to the attachment device 3 , and the second portion 9 of the fixation device 4 is fixated to the energy absorbing layer 2 by means of an adhesive. The fixation member 4 is adapted to absorb impact energy and forces by deforming in an elastic, semi-elastic or plastic way.
FIG. 7 shows an alternative embodiment of a fixation member 4 in which the first portion 8 of the fixation member 4 is fixated to the attachment device 3 , and the second portion 9 of the fixation device 4 is fixated to the energy absorbing layer 2 by means of mechanical fixation elements 10 entering the material of the energy absorbing layer 2 .
FIG. 8 shows an alternative embodiment of a fixation member 4 in which the first portion 8 of the fixation member 4 is fixated to the attachment device 3 , and the second portion 9 of the fixation device 4 is fixated to inside of the energy absorbing layer 2 , for example by molding the fixation device inside of the energy absorbing layer material 2 .
FIG. 9 shows a fixation member 4 in a sectional view and an A-A view. The attachment device 3 is according to this embodiment attached to the energy absorbing layer 2 by means of the fixation member 4 having a second portion 9 placed in a female part 12 adapted for elastic, semi-elastic or plastic deformation, and a first part 8 connected to the attachment device 3 . The female part 12 comprises flanges 13 adapted to flex or deform elastically, semi-elastically or plastically when placed under a large enough strain by the fixation member 4 so that the second portion 9 may leave the female part 12 .
FIG. 10 shows an alternative embodiment of a fixation member 4 in which the first portion 8 of the fixation member 4 is fixated to the attachment device 3 , and the second portion 9 of the fixation device 4 is fixated to inside of the shell 1 , all the way through the energy absorbing layer 2 . This could be done for example by molding the fixation device 4 inside of the energy absorbing layer material 2 . It is also conceivable to place the fixation device 4 through a hole in the shell 1 from the outside of the helmet (not shown).
FIG. 11 shows an embodiment in which the attachment device 3 is fixated to the energy absorbing layer 2 at the periphery thereof by means of a membrane or sealing foam 24 , which could be elastic or adapted for plastic deformation.
FIG. 12 shows an embodiment where the attachment device 3 is attached to the energy absorbing layer 2 by means of a mechanical fixation element comprising mechanical engagement members 29 , with a self locking function, similar to that of a self locking tie strap 4 .
FIG. 13 shows an embodiment in which the fixating member is an interconnecting sandwich layer 27 , such as a sandwich cloth, which could comprise elastically, semi-elastically or plastically deformable fibers connecting the attachment device 3 to the energy absorbing layer 2 and being adapted to shear when shearing forces are applied and thus absorb rotational energy or forces.
FIG. 14 shows an embodiment in which the fixating member comprises a magnetic fixating member 30 , which could comprise two magnets with attracting forces, such as hyper magnets, or one part comprising a magnet and one part comprising a magnetically attractive material, such as iron.
FIG. 15 shows an embodiment in which the fixating member is re-attachable by means of an elastic male part 28 and/or an elastic female part 12 being detachably connected (so called snap fixation) such that the male part 28 is detached from the female 12 part when a large enough strain is placed on the helmet, in the occurrence of an impact, and the male part 28 can be reinserted into the female 12 part to regain the functionality. It is also conceivable to snap fixate the fixating member without it being detachable at large enough strain and without being re-attachable.
In the embodiments disclosed herein the distance between the energy absorbing layer and the attachment device could vary from being practically nothing to being a substantial distance without parting from the concept of the invention.
In the embodiments disclosed herein it is further more conceivable that the fixation members are hyperelastic, such that the material absorbs energy elastically but at the same time partially deforms plastically, without failing completely.
In embodiments comprising several fixation members it is further more conceivable that one of the fixation members is a master fixation member adapted to deform plastically when placed under a large enough strain, whereas the additional fixation members are adapted for purely elastic deformation.
FIG. 16 is a table derived from a test performed with a helmet according having a sliding facilitator (MIPS), in relation to an ordinary helmet (Orginal) without a sliding layer between the attachment device and the energy absorbing layer. The test is performed with a free falling instrumented dummy head which impacts a horizontally moving steel plate. The oblique impact results in a combination of translational and rotational acceleration that is more realistic than common test methods, where helmets are dropped in pure vertical impact to the horizontal impact surface. Speeds of up to 10 m/s (36 km/h) can be achieved both in horizontal and vertical direction. In the dummy head there is a system of nine accelerometers mounted to measure the translational accelerations and rotational accelerations around all axes. In the current test the helmets are dropped from 0.7 meter. This results in a vertical speed of 3.7 m/s. The horizontal speed was chosen to 6.7 m/s, resulting in an impact speed of 7.7 m/s (27.7 km/h) and an impact angle of 29 degrees.
The test discloses a reduction in translational acceleration transmitted to the head, and a large reduction in rotational acceleration transmitted to the head, and in the rotational velocity of the head.
FIG. 17 shows a graph of the rotational acceleration overtime with helmets having sliding facilitators (MIPS — 350; MIPS — 352), in relation to ordinary helmets (Org — 349; Or — 351) without sliding layers between the attachment device and the dummy head.
FIG. 18 shows a graph of the translational acceleration over time with helmets having sliding facilitators (MIPS — 350; MIPS — 352), in relation to ordinary helmets (Org — 349; Org — 351) without sliding layers between the attachment device and the dummy head.
Please note that any embodiment or part of embodiment as well as any method or part of method could be combined in any way. All examples herein should be seen as part of the general description and therefore possible to combine in any way in general terms.
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The present application provides a helmet. The helmet includes an energy absorbing layer ( 2 ) and a sliding facilitator ( 5 ). The sliding facilitator is provided on an inside surface of the energy absorbing layer ( 2 ). A method of manufacturing the helmet is further provided. The method includes the steps of: providing an energy absorbing layer in the mold, and providing a sliding facilitator contacting an inside surface of the energy absorbing layer.
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FIELD OF THE INVENTION
The present invention relates generally to a packing assembly used to seal an annular area in fluid flow devices. Specifically, the present invention relates to a pressure actuated packing assembly for use as valve seal, a stem seal, or a rod seal, and may be used in sealing the annular area of a seal gland, positioned between corresponding orifice mating surfaces in fluid flow devices such as, valves, pumps, stuffing boxes, hydraulic devices, flow-line meters, and the like, to provide an effective and long-term seal therein. The present invention has particular application for reducing the leakage and fugitive emission escape of gas and/or liquid, flowing through fluid flow devices, wherein the devices may be exposed to temperature differentials, pressure differentials, variable surface characteristics and variable seal performance characteristics.
BACKGROUND OF THE INVENTION
Providing an effective and long-term annular seal for fluid flow devices is a continuing problem in the fluid flow industry. In order to effectively seal an annular area adjacent to a valve, stem, rod or similar sealing application, in a fluid flow device, the force or load, F applied to the seal component, must equal the pressure, P under which the seal element is exposed, multiplied by the annular area, A to be sealed (F=PA). If the force or load, F applied to the seal component does not equal the pressure, P multiplied by the annular area, A to be sealed, the seal element can not effectively seal the annular area. The known annular seals for these types of above-identified fluid flow devices have been designed on the principal of either compression type or self-energizing lip type seals, or some combination thereof. Compression type seals, also known as squeeze type seals, typically incorporate a resilient material which is exposed to a compressive stress, wherein the compressive stress supplies the energy needed to create the initial seal. This type of seal may, for example, be inserted into a gland formed by two rigid sealing surfaces, wherein the gland has a seal receiving portion which has a slightly smaller outside diameter as compared to the outside diameter of the seal. This type of seal/gland arrangement applies compressive stresses to the seal, when the two mating surfaces contact the seal. As pressure is applied to the system, the initial compressive forces are augmented by the fluid flow pressure, or system pressure.
Self-energizing lip type seals generally achieve initial sealing by placing the seal lips under bending stress and exposure to the system pressure, wherein the lips are forced tightly against the gland surfaces.
In view of current Environmental Protection Agency guidelines for allowable leakage and fugitive emissions requirements for fluid flow devices, conventional lip and compression type seals often do not comport with acceptable standards. Additionally, depending upon the particular design, lip and compression type seals are prone to premature wear and failure, requiring frequent and costly maintenance. In dynamic applications, where at least one of the orifice or gland surfaces is in motion, wear rates typically increase in response to the increase in load or force applied to the seal element. Energized seals may be especially prone to premature wear and failure in this type of application. Additionally in dynamic applications involving high system pressures, once the system pressure is removed, the high pressure forces which were exerted on the seal often damage or destroy the initial interference of the seal, which is responsible for providing the initial stresses required to seal the annular area. When the initial interference of the seal becomes damaged or destroyed, the seal may cease to properly function.
In static applications, where neither gland surface is in motion, typically, tight, compressive seals have been employed. This type of static seal, includes squeeze type seals which rely upon the compressive stress created when the gland surfaces contact the seal, to provide the initial sealing forces. These types of seals include, for example, washers, gaskets, packings, o-rings and the like. Squeeze type seals due to their construction and composition, have a limited usefulness. Further, over time, static seals may experience stress relaxation which adversely affects the resilience of the seal.
Moreover, known seal materials which are solely constructed of rubber and other elastomeric materials are generally not conducive to long-term exposure to caustic, corrosive and harsh chemicals and oils, and may break-down and/or fail in a relatively short period of time. Encapsulation and partial encapsulation of rubber and elastomeric seal devices to create a protective coating to reduce the amount of exposure of the seal to harmful substances, is expensive and greatly restricts the type of seal available, due to molding process capabilities and other restrictions. Partial encapsulation of the rubber or elastomeric seal device is less expensive, but may not avoid exposure to and break-down of the seal device. Additionally, both the full and partially encapsulated rubber or elastomeric seal devices require the use of separate back up or anti-extrusion components at higher pressures, causing additional expense and assembly. An additional problem exists with the above discussed types of seals, in that these seals do not automatically adjust to wear, misalignment, temperature and pressure differentials and the changing characteristics of the mating surfaces for which they are used.
Fluid flow devices, such as valves, pumps, stuffing boxes, hydraulic devices, flow meter orifices and the like, are typically constructed of metal, and therefore typically have orifice or gland mating surfaces which expand and contract in response to temperature and pressure differentials. Often, seal components which fit snugly within the seal receiving portion of the gland may contract with the change in temperature such that the outer diameter surface of the seal breaks contact with the inner surface of the seal receiving portion of the gland, resulting in a leak path between the seal and the gland. It would be highly advantageous to create an annular seal, which included the benefits of elastomeric materials, and which also maintained its original dimensions during temperature and pressure differentials. Seal materials such as polytetrafluoroethylene, polyvinylchloride, polyethylene and other polymer materials are highly resistant to caustic, corrosive and harsh chemicals and oils, but have little or no elastomeric properties and therefore do not adapt well to the changing temperature and pressure characteristics of the mating surfaces. Additionally, it would be advantageous to achieve an annular seal adaptable to variable surface characteristics and variable seal performance characteristics.
In view of the lack of an effective annular seal for fluid flow devices such as valves, pumps, stuffing boxes, hydraulic devices, in-line flow meters and the like, which are thermally stable, resistant to pressure and stress relaxation, and which can withstand exposure to caustic, corrosive and harsh chemicals and oils over long periods of time and can expand and contract with the changing characteristics of the mating surfaces, a need for the present invention exists.
SUMMARY OF THE INVENTION
To achieve the foregoing features and advantages and in accordance with the purpose of the invention as embodied and broadly described herein, a preferred embodiment pressure actuated seal assembly is provided for generally reducing the amount of fugitive emissions and leakage of liquid and gas, retained within a fluid flow device. The preferred embodiment pressure actuated packing assembly may preferably include at least one elastomeric energizer; a thermoplastic jacket member having an internal groove, wherein the elastomeric energizer is retained within the internal groove; and a rigid sealing insert member also disposed within the internal groove to apply force to the eleastomeric energizer and generally seal the thermoplastic jacket member. Elastomeric energizers, for example, an o-ring, are normally very vulnerable to chemical exposure. The use of an elastomeric energizer may, however, have application in chemically hostile environments when used with a chemically resistant thermoplastic jacket member. The thermoplastic jacket member of the present invention preferably has an inner peripheral side portion, an outer peripheral side portion and at least one internal U-shaped channel for retaining the elastomeric energizer, defined by the inner and outer peripheral side portions. The outer peripheral side portion of the thermoplastic jacket member may also have a first circumferential lip, and the inner peripheral side portion may preferably have a second circumferential lip. The thermoplastic jacket member also includes a continuous opening in the channel for selective insertion and removal of the elastomeric energizer. The thermoplastic jacket member may further include at least one external, axial mating surface. The rigid sealing insert member, may preferably include a first axial mating surface, a second axial mating surface, and a chemically resistant plunger portion disposed between the first and second axial mating surfaces. The rigid sealing insert member may include at least one internal circumferential groove for engagement with the first circumferential lip of the jacket member and at least one external circumferential groove for engagement with the second circumferential lip of the jacket member. The first mating surface of the rigid sealing insert member is generally retained within the U-shaped channel of said thermoplastic jacket member. The elastomeric energizer may become compressionally disposed between and in contact with a trough portion of the U-shaped channel of the thermoplastic jacket member and the first mating surface of the sealing insert member. There may also, preferably, be a gap or space between the first axial mating surface of the rigid sealing insert member and a top surface of the thermoplastic jacket member, so as to provide for limited axial movement of the rigid sealing insert member within the continuous opening, in response to the selective expansion and contraction of the elastomeric energizer to compensate for wear, temperature differentials, pressure differentials and to adjust for movement between the gland surfaces. The gap allows the plunger portion of the rigid sealing insert member to move selectively into and out of the internal U-shaped channel to maintain a continuous, effective seal of the annular area. Additionally, the thermoplastic jacket member preferably includes at least one rib member formed integrally with and extending inwardly away from the inner peripheral side portion of the jacket member and at least one rib member formed integrally with and extending outwardly away from the outer peripheral side portion of the thermoplastic jacket member. The rib members may generally be laterally positioned on the jacket wall surfaces, adjacent to the trough portion of the U-shaped channel. When pressure, P is applied to the system, the pressure, P of the system multiplied by the annular area, A to be sealed, must be equal to the force, F applied to the pressure actuated seal assembly. In the present invention, the force, F applied to the external surface of the rigid sealing insert member is equal to the pressure, P on the elastomeric energizer multiplied by the annular area, A of the axial surface of the rigid sealing insert member engaged to the elastomeric energizer. The pressure exerted on the elastomeric energizer causes the inner and outer peripheral wall portions of the jacket member to radially expand, compressing the respective rib members against the sealing surface of the gland wall and against the stem, rod, valve, etc. disposed within the pressure actuated packing assembly. The seal formed between the gland wall, the thermoplastic jacket member and the rod, piston, valve, stem, etc., forms a primary seal to generally retain the fluid flowing with the system. The seal formed by the engagement of the plunger portion of the rigid insert sealing member with the inner and outer peripheral lip portions of the thermoplastic jacket member, forms a secondary seal, which generally prevents chemical invasion into the channel and protects the elastomeric energizer.
One objective of the present invention is to provide a pressure actuated packing assembly having an elastomeric energizer, capable of expansion and contraction in response to system pressure differentials and in response to the movement of the gland or orifice mating surfaces of the fluid flow devices, wherein the elastomeric energizer is enveloped within the thermoplastic jacket, in combination with a rigid sealing insert, to protect the elastomeric energizer from harmful exposure to caustic, corrosive and harsh chemicals and oils, by creating a low pressure seal between the thermoplastic jacket and the rigid sealing insert.
Another objective of the present invention is to provide a pressure actuated packing assembly which is responsive to radial expansion for use in applications where premature wear or stress relaxation may deteriorate the seal.
Further, an objective of the present invention is to provide a pressure actuated packing assembly for use in applications where gland surfaces are not suitable for use with conventional seal devices.
Yet another objective of the present invention is to provide a pressure actuated packing assembly for use in applications where thermal cycles may otherwise reduce the efficiency of conventional seals.
Still another objective of the present invention is to provide a pressure actuated packing assembly for use in low pressure applications, wherein a minimal sealing force is required to create the seal, and thereby lowering the amount of friction and wear experienced by the pressure actuated seal assembly.
An additional objective of the present invention is to provide a pressure actuated packing assembly having a dual plunger design for excessive loading on a first axial surface and a normal or lighter load on a second axial surface, i.e. to provide for a heavy load on the static gland surface and a lighter load on the dynamic gland surface.
Moreover, another objective of the present invention is to provide a pressure actuated packing assembly, wherein the plunger portion of the rigid insert sealing member may be used in conjunction with other seals and/or packings to seal against secondary leakage that may otherwise contact the elastomeric energizer.
Still another objective of the present invention is to provide a pressure actuated packing assembly which can withstand higher loading pressure on the rib member integrally formed within and extending inwardly away from the inner peripheral side portion and on the rib member integrally formed within and extending outwardly away from the outer peripheral side portion of the thermoplastic jacket member, wherein the radial compression of the rib members compensate for the contraction of the elastomeric energizer at temperatures generally below 50° Fahrenheit.
The rigid sealing insert, in combination with the thermoplastic jacket provides the added benefit of having a variety of rigid sealing insert geometry's, such that the rigid sealing insert functions as an integral backup to generally prevent extrusion of the thermoplastic jacket member. Additionally, the combination of a soft thermoplastic jacket member with a rigid sealing insert member, provides a seal having enhanced thermal stability. Typically, soft thermoplastic materials contract significantly at low temperatures, altering the dimensions and geometry of the seal structure and often create a leak path between the seal device and the gland portion of the fluid flow device. The gap between the first axial mating surface of the rigid sealing insert member and the elastomeric energizer provides for the selective expansion and contraction of the elastomeric energizer to maintain the seal of the annular area between the orifice surfaces of the gland in the fluid flow device, during temperature and pressure differentials and to compensate for uneven wear, motion and misalignment between the orifice surfaces. By combining the rigid sealing insert member, having thermal characteristics near those of metal, with the thermoplastic jacket member and elastomeric energizer, the thermal stability of the pressure actuated packing assembly is greatly enhanced, generally providing for use of the present invention in high and low temperature applications.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated into and constitute a part of this specification, illustrate a preferred embodiment of the invention and together with the general description of the invention given above and the detailed description of the preferred embodiment given below, serve to explain the principals of the invention.
FIG. 1 is a front view of a preferred embodiment pressure actuated packing assembly, made the subject of the present invention.
FIG. 1A is a cross-sectional view of the preferred embodiment pressure actuated packing assembly, depicted in FIG. 1, as it is used in a gland of a fluid flow device in association with a rod, piston, stem or other cylindrical member disposed with the pressure actuated packing assembly.
FIG. 2 is a cross-sectional view of the preferred embodiment pressure actuated, packing assembly, depicted in FIG. 1.
FIG. 3A is a cross-sectional, perspective view of the thermoplastic jacket member of the present invention, depicted in FIG. 2.
FIG. 3B is a cross-sectional, perspective view of the elastomeric energizer of the present invention, depicted in FIG. 2.
FIG. 3C is a cross-sectional, perspective view of the rigid sealing insert member of the present invention, depicted in FIG. 2.
FIG. 4 is a cross-sectional, partial-perspective view of a first alternate embodiment pressure actuated packing assembly.
FIG. 5 is a cross-sectional, partial-perspective view of a second alternate embodiment pressure actuated packing assembly.
FIG. 6 is a cross-sectional, partial-perspective view of a third alternate embodiment pressure actuated packing assembly.
FIG. 7 is a cross-sectional, partial-perspective view of a fourth alternate embodiment pressure actuated packing assembly.
FIG. 8 is a cross-sectional, partial-perspective view of a fifth alternate embodiment pressure actuated packing assembly.
FIG. 9 is a cross-sectional, partial-perspective view of a sixth alternate embodiment pressure actuated packing assembly.
FIG. 10 is a cross-sectional, partial-perspective view of a seventh alternate embodiment pressure actuated packing assembly.
FIG. 11 is a cross-sectional, partial-perspective view of a eighth alternate embodiment pressure actuated packing assembly.
FIG. 12 is a cross-sectional, partial-perspective view of a ninth alternate embodiment pressure actuated packing assembly.
FIG. 13 is a cross-sectional, partial-perspective view of a tenth alternate embodiment pressure actuated packing assembly.
FIG. 14 is a cross-sectional, partial-perspective view of a eleventh alternate embodiment pressure actuated packing assembly.
FIG. 15 is a cross-sectional, partial-perspective view of a twelfth alternate embodiment pressure actuated packing assembly.
FIG. 16 is a cross-sectional, partial-perspective view of a thirteenth alternate pressure actuated packing assembly, illustrating a stacked arrangement.
FIG. 17 is a cross-sectional, partial-perspective view of a fourteenth alternated embodiment pressure actuated packing assembly, illustrating an energizer comprised of a metal spring.
The above general description and the following detailed description are merely illustrative of the generic invention and additional modes, advantages and particulars will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings wherein like parts are designated by like numerals, FIGS. 1 and 1A illustrate the present invention, a preferred embodiment pressure actuated packing assembly 10 for use in sealing an annular area 9 of a gland 11, of a fluid flow device 13. The fluid flow device 13 may, for example, be a valve, pump, stuffing box, hydraulic device, in-line flow meter and similar or related devices. The external portions of the pressure actuated packing assembly 10 are comprised of a jacket member 12 and a rigid sealing insert member 14. The rigid sealing insert member 14 includes a first axial mating surface 16 for engagement to a first orifice mating surface 17 of the gland 11 of the fluid flow device 13. The pressure actuated packing assembly 10 also includes a gap or expansion/contraction space 21 between the first axial mating surface 16 of the rigid sealing insert member 14 and the jacket member 12. The rigid sealing insert member 14 also includes a plunger portion 18 which is received within the jacket member 12.
With reference now to FIGS. 1, 1A, 2, 3A, 3B and 3C, the preferred embodiment pressure actuated packing assembly 10 is shown in greater detail. The jacket member 12 includes an inner peripheral side portion 20, an outer peripheral side portion 22 and an internal U-shaped channel 24, defined by the inner peripheral side portion 20 and the outer peripheral side portion 22 and a trough portion 23. An elastomeric energizer 26 is preferably retained within the U-shaped channel 24, to provide resiliency and radial expansion capability to the pressure actuated packing assembly 10. The jacket member 12 has a first axial mating surface 28 for compressional engagement to the system pressure, and alternatively, for possible engagement to a second orifice mating surface 19 of the gland 11 of the fluid flow device 13. The outer peripheral side portion 22 of the jacket member 12 also preferably includes a first circumferential lip 32 and the inner peripheral side portion 20 includes a second circumferential lip 34. The jacket member 12 also preferably includes a continuous longitudinal opening 36 for insertion of the elastomeric energizer 26 and to accommodate the reciprocating motion of the plunger portion 18 of the rigid sealing insert member 14 into and out of the U-shaped channel 24. The jacket member 12 also preferably includes one or more rib members 38 which are formed integrally with and extend inwardly away from the inner peripheral side portion 20 of the jacket member 12 and are formed integrally with and extend outwardly away from the outer peripheral side portion 22 of the jacket member 12.
With reference now to FIGS. 1-3C and 9, radial expansion of the jacket member 12 in combination with compression of the elastomeric energizer 26 as a result of the force F applied by the pressure P of the system, multiplied by an annular area 9 to be sealed, preferably forms a primary seal 30 in the fluid flow device 13. The jacket member 12 is preferably comprised of one or a combination of the materials, including polytetrafluoroethylene, filled polytetrafluoroethylene, ultra high molecular weight polyethylene, urethane materials and soft polyamids. The elastomeric energizer 26 is preferably comprised of one or a combination of the materials, including: chloroprene, ethylene propylene, silicone, fluorosilicone, nitrile-butadiene and various fluorocarbon elastomers. Alternatively, the energizer 26 can be an energized flat band coil spring, as depicted in FIG. 17, below. As discussed below, the elastomeric energizer 26 may, for example, be pre-molded as a separate member or may be molded directly into the jacket member 12, as depicted in FIGS. 4 and 5.
As shown in FIG. 3, the rigid sealing insert member 14 has a second axial mating surface 40 which is preferably retained within the U-shaped channel 24 for selective compressive engagement with the elastomeric energizer 26. As the primary seal 30 expands and contracts in response to temperature and pressure fluctuations, the second axial mating surface 40 moves axially in compressive engagement to and from the elastomeric energizer 26. As the radial expansion of the jacket member 12 and elastomeric energizer 26 increase to form the primary seal 30, pressure increases on the elastomeric energizer 26 and the shape of the elastomeric energizer 26 is transformed from a generally cylindrical configuration, i.e. the at rest position shown in FIG. 3B, to a flattened and compressed position, which urges the rib members 38 to seal against the gland 11 surface and a cylindrical member 39. The elastomeric properties of the elastomeric energizer 26 provide for a consistent and continuous primary seal 30, even in situations where the characteristics of the mating surfaces 17, 19 of the fluid flow device 13 have changed, as well as any changes in temperature and/or pressure within the fluid flow device 13, and changes in the surface characteristics of the primary seal 30, without generally exposing the elastomeric energizer 26 to harsh chemicals or otherwise damaging the elastomeric energizer 26. The rigid sealing insert member 14 also includes an inner circumferential groove 42 and an outer circumferential groove 44, adjacent to the plunger portion 18. The rigid sealing insert member 14 may preferably be composed of a rigid material such as, for example, poly phenaline sulfide (PPS) or poly ether ether keyton (PEEK) metal, having thermal characteristics similar to those of metallic materials. The rigid sealing insert member 14 may also be constructed of FYFE with high levels of fillers such as carbon, glass or PPS.
Engagement of the plunger portion 18 of the rigid sealing insert member 14 within the first circumferential lip 32 and the second circumferential lip 34 of the jacket member 12, provides a secondary seal 46 to generally reduce the liquid and/or gas exposure to the elastomeric energizer 26. Further, one or more secondary rib members 37 may be formed to an outer peripheral end 48 of the first and second circumferential lips 32, 34, away from a opening 36 between the first and second circumferential lips 32, 34 which preferably engage the plunger portion 18. The one or more secondary rib members 37 formed to the first circumferential lip 32 and the second circumferential lip 34 of the jacket member 12, when in contact with a gland 11 surface of the fluid flow device 13 produces radial compression of the relatively softer jacket member 12 against the plunger portion 18 of the rigid sealing insert member 14 to form the low pressure secondary seal 46.
OPERATION
With reference now to FIGS. 1, 1A, 2, 3A, 3B, 3C and 9 the function of the sealed packing ring 10 will be described. The present invention is preferably deployed within the seal gland 11 and is secured between corresponding orifice mating surfaces 17, 19 of the fluid flow device 13. A rod, piston, stem, or some other type of cylindrical member 39 is preferably disposed concentrically within the jacket member 12 and is preferably in radial contact and compression with the one or more rib members 38 on the inner peripheral side wall 20. When the system pressure P is introduced to the pressure actuated packing assembly 10, a force F is applied to the first axial mating surface 28 of the jacket member 12, which in turn causes the first axial mating surface 16 of the rigid sealing insert member 14 to engage the first orifice mating surface 17. The rigid sealing insert 14 then applies a force F against the energizer 26, which radially expands the jacket member 12 and urges the rib members 38 to seal against the gland 11 surface and also to seal against the cylindrical member 39, thereby forming the primary seal 30, between the cylindrical member 39, the jacket member 12 and the surface of the gland 11. Additionally, radial compression is applied to the plunger portion 18 of the rigid sealing insert 14 by the one or more distal ends 48 of the first and second circumferential lips 32, 34 to form the secondary seal 46 between the plunger portion 18 and the inner circumferential lip 34 and outer circumferential lip 32, to generally restrict the amount of fluid invasion into the U-shaped channel 24 and to generally reduce the exposure and damage to the elastomeric energizer 26. Further, the one or more rib members 38, integrally formed on the inner peripheral side portion 20 of the jacket member 12, are designed to sealingly engage the cylindrical member 39 to generally restrict the escape of fluid through the inner peripheral side portion 20 of the jacket member 12.
While the rib members 38 are important for imparting radial compression on the gland wall 11 and cylindrical member 39 to form the primary seal 30, the gap 21 between the rigid sealing insert member 14 and the jacket member 12 provides for selective movement of the plunger portion 18 within the opening 36 in the U-shaped channel 24 to maintain adequate force F on the elastomeric energizer 26, wherein the pressure P experienced by the elastomeric energizer multiplied by the annular area 9 of the second axial mating surface 40 is equal to the force F exerted by the plunger portion 18. Additionally, the gap 21 allows for the uneven positioning of the rigid sealing insert member 14 within the jacket member 12 for creating an effective primary seal 30 in spite of uneven, misaligned, rough-surfaced or dynamic orifice surfaces, while maintaining contact between the orifice surface 17 of the gland 11 and the first axial mating surface 16 of the rigid sealing insert member 14.
Additionally, there may be numerous alternate embodiments of the present invention, as depicted in FIGS. 4-17, depending upon specific application and the desired qualities and characteristics necessary for that application. Structure similar to that illustrated in FIGS. 1-3C, is similarly numbered in FIGS. 4-17. FIG. 4 illustrates a first alternate embodiment pressure actuated packing assembly 100, wherein the elastomeric energizer 26 has an oval-shaped cross-section, which has been "molded" into the jacket member 12. The plunger portion 18 of the rigid sealing insert includes a plurality of protrusions 102 which may serve as a back up device for a jacket member 12 constructed of soft materials. The first alternate embodiment pressure actuated packing assembly 100 includes a single rib member 38 on the outer peripheral wall portion 22 laterally adjacent to the protrusions 102.
In FIG. 5, a second alternate embodiment pressure actuated packing assembly 200 is depicted. The second alternate embodiment pressure actuated packing assembly 200 also includes a pre-molded and inserted elastomeric energizer 26. The elastomeric energizer 26 could, for example, be molded in a square or rectangular shape. Additionally, the jacket member 12 of the second alternate embodiment pressure actuated packing assembly 200 does not include circumferential lips 32, 34 as depicted in FIG. 4.
In FIG. 6, a third alternate embodiment pressure actuated packing assembly 300 is depicted. The third alternate embodiment pressure actuated packing assembly 300 includes a first inset shoulder portion 302 in the outer peripheral wall portion 22 of the jacket member 12 and a second inset shoulder portion 304 in inner peripheral wall portion 20 of the jacket member 12, wherein the first axial surface 16 of the sealing insert member 14 is substantially retained within the jacket member 12. The third alternate embodiment pressure actuated packing assembly 300 does not include a back up configuration 102 as does the first alternate embodiment pressure actuated packing assembly 100 shown in FIG. 4.
In FIG. 7, a fourth alternate embodiment pressure actuated packing assembly 400 is depicted. The fourth alternate embodiment pressure actuated packing assembly 400 is similar in design to the third alternate embodiment pressure actuated packing assembly 300, with the exception that there are no rib members 38 integrally formed in the inner and outer peripheral wall portions 22, 21 of the jacket member 12, laterally adjacent to the elastomeric energizer 26, as shown in the third alternate embodiment pressure actuated packing assembly 300, in FIG. 6.
In FIG. 8, a fifth alternate embodiment pressure actuated packing assembly 500 is depicted. The fifth alternate embodiment pressure actuated packing assembly 500 includes an alternate embodiment jacket member 501, designed for an upper rigid sealing insert 502 and a lower rigid sealing insert 504. The fifth alternate embodiment pressure actuated packing assembly 500 provides the advantage of improved thermal stability.
In FIG. 9, a sixth alternate embodiment pressure actuated packing assembly 600 is depicted. The sixth alternate embodiment pressure actuated packing assembly 600 includes the gap 21 as shown in the preferred embodiment pressure actuated packing assembly 10, and functions in the same manner. Additionally, the rib members 38 may be "v" or wedge-shaped. As pressure P 1 from the system is applied to the annular area 9 to be sealed, a force F 1 is created against the first axial mating surface 28 of the jacket member 12. The force F 1 causes the first axial mating surface 16 of the rigid sealing insert member 14 to contact an orifice mating surface (not shown) which creates a second force F 2 , which in turn creates pressure P 2 on the elastomeric energizer 26 by engaging the annular area 40 or A 2 against the elastomeric energizer 26. An effective seal 30 is formed, as depicted in FIG. 1A, wherein P 1 multiplied by the annular area 9 is equal to F 1 and P 2 multiplied by the annular area A 2 is equal to F 2 .
In FIG. 10 a seventh alternate embodiment pressure actuated packing assembly 700 is illustrated. The seventh alternate embodiment pressure actuated packing assembly 700 includes an alternate embodiment jacket member 702 having a generally V-shaped channel 704. The seventh alternate embodiment pressure actuated packing assembly 700 also preferably includes a sealing insert member 14 having a first tapered axial mating surface 706 for engaging the V-shaped channel 704. The seventh alternate embodiment pressure actuated packing assembly 700, unlike the preferred embodiment 10, shown in FIG. 1, and alternate embodiment 100, 200, 300, 400, 500, and 600 pressure actuated packing assemblies, does not include a separate elastomeric energizer 26 member. The V-shaped channel 704 includes a trough portion 708 which is slightly narrower in width as compared to a nose portion 710 of the sealing insert member 14. The slightly narrower trough portion 708 applies a bias or spring-like pressure against the first tapered axial mating surface 712 during the free state or at rest position. The force F 2 creates radial expansion of the jacket member 702 to urge the rib members 38 to seal against the gland surface (not shown) and cylindrical member (not shown) which is preferably disposed concentrically within the seventh alternate embodiment pressure actuated packing assembly 700.
An eighth alternate embodiment pressure actuated packing assembly 800 is illustrated in FIG. 11. The general structure of the eighth alternate embodiment pressure actuated packing assembly 800 is similar to the preferred embodiment pressure actuated packing assembly 10, shown in FIGS. 1, 1A, 2, 3A, 3B, and 3C, however the jacket member 802 of the eighth alternate embodiment pressure actuated packing assembly 800 does not include any circumferential lip members 32, 34 as provided for in the preferred embodiment 10.
A ninth alternate embodiment pressure actuated packing assembly 900 is disclosed in FIG. 12. The ninth alternate embodiment sealed packing ring apparatus 900 is structurally similar to the eighth alternate embodiment pressure actuated packing assembly 800, with the exception that the ninth alternate embodiment pressure actuated packing assembly 900 includes a first plunger portion 902 and a second plunger portion 904 integrally formed with a common and singular first axial mating surface 906 and an alternate embodiment jacket member 908 includes a first channel 910 for reception of the first plunger portion 902 and a second channel 912 for reception of the second plunger portion 904, wherein the channels 910, 912 are conjoined at a common interior or intermediate wall 911. The plunger portions 902, 904 may, for example, be of unequal lengths to provide for a "tilting" of the first axial mating surface 906 to achieve a desired effect. The ninth alternate embodiment pressure actuated packing assembly 900 also includes a gap 21 between the first axial mating surface 906 and the jacket member 908 to provide for axial movement of the plunger portions 902, 904. The ninth alternate embodiment sealed packing ring 900 also preferably includes a first elastomeric energizer 914 retained within the first channel 910 and a second elastomeric energizer 916 retained the second channel 912.
In FIG. 13, a tenth alternate embodiment pressure actuated packing assembly 1000 is depicted. The tenth alternate embodiment pressure actuated packing assembly 1000 is similar to the sixth alternate embodiment pressure actuated packing assembly 600, as depicted in FIG. 9, but is used in combination with a conventional seal or packing 1002. As illustrated, the conventional seal or packing 1002 may be, for example, cylindrical and ring-like, having at least one or more generally flat mating surfaces 1004 to engage the sixth alternate embodiment pressure actuated packing assembly 600. Additionally, the conventional seal or packing 1000, may preferably have a generally vertical inner wall portion 1008 and a generally vertical outer wall portion 1006, wherein the generally vertical outer wall portion 1006 preferably engages an inner gland surface (not shown). Normally, conventional seals or packings 1002 are constructed of an elastomeric material which expands and contracts in response to differentials in temperature and pressure. In the past, conventional seals or packings 1002 have had a tendency to pull away or separate from the gland wall (not shown) when the conventional seal or packing 1002 experiences contraction due to temperature or pressure differentials. Should the conventional seal or packing 1002 contract and pull away from the gland wall (not shown) while the system is under pressure, a leak path (not shown) may form between the generally vertical outer wall portion 1006 of the conventional seal or packing 1002 and the gland wall (not shown).
In FIG. 14, an eleventh alternate embodiment pressure actuated packing assembly 1100 is illustrated in operable engagement with a power bevel seal or packing 1102. The power bevel 1102 preferably has an inclined mating surface 1104 which engages an inclined mating surface 1106 of the eleventh alternate embodiment pressure actuated packing assembly 1100. The power bevel 1102 preferably provides the inclined mating surface 1104 such that an apex 1108 of the inclined mating surface 1104 is adjacent to an inner vertical wall 1110 of the power bevel 1102 and a base 1109 of the inclined mating surface 1104 is adjacent to an outer vertical wall 1112 of the power bevel 1102. The outer vertical wall 1112 of the power bevel 1102 is shorter in length as compared to the inner vertical wall 1110 of the power bevel 1102. The pitch angle W of the power bevel 1102 may, for example, be in the range of 30° to 45. The inclined mating surface 1104 of the power bevel 1102 preferably pitches downward toward the outer periphery 1114 of the power bevel 1102, such that the inclined mating surface 1104 of the power bevel 1102 in compressed engagement with the inclined surface 1106 of the eleventh alternate embodiment pressure actuated packing assembly 1100, applies force to maintain continuous contact between an outer vertical wall portion 1116 of the eleventh alternate embodiment pressure actuated packing assembly 1100 and the surface of the gland (not shown). The outer vertical wall portion 1116 of the eleventh alternate embodiment sealed packing ring 1100 may, for example, be longer in length as compared to an inner vertical wall portion 1118. In all other respects however, the eleventh alternate embodiment pressure actuated packing assembly 1100 is structurally and functionally similar to the preferred embodiment pressure actuated packing assembly 10, illustrated in FIGS. 1, 1A, 2, 3A, 3B and 3C.
A twelfth alternate embodiment pressure actuated packing assembly 1200 is illustrated in FIG. 15. The twelfth alternate embodiment pressure actuated packing assembly 1200 includes a jacket member 12, a plunger portion 18 and an elastomeric energizer 26. The twelfth alternate embodiment pressure actuated packing assembly 1200 differs from the sixth alternate embodiment pressure actuated packing assembly 600, in that the plunger portion 18 of the twelfth alternate embodiment pressure actuated packing assembly 1200 includes a beveled edge portion 1202 in a first axial mating surface 1204 of the plunger portion 18 to urge the elastomeric energizer 26 toward the gland wall surface (not shown). In all other respects, the eleventh alternate embodiment pressure actuated packing assembly 1200 functions compatibly with the sixth alternate embodiment pressure actuated packing assembly 600, including the at least one rib member 38 formed integrally with the jacket member 12. The beveled edge portion 1202 in the first axial mating surface 1204 of the plunger portion 18 is designed to engage the elastomeric energizer 26, in such a manner so as to produce additional loading pressure on the energizer 26.
A thirteenth alternate embodiment pressure actuated packing assembly 1300 is illustrated in FIG. 16. The thirteenth alternate embodiment pressure actuated packing assembly 1300 is functionally equivalent to the preferred embodiment pressure actuated packing assembly 10 illustrated in FIGS. 1, 1A, 2, 3A, 3B, and 3C. The thirteenth alternate embodiment pressure actuated packing assembly 1300 teaches the vertical stacking of the preferred embodiment pressure actuated packing assembly 10, wherein a thirteenth alternate embodiment jacket member 1302 includes the formation of a thirteenth alternate embodiment seal insert member 1304 integrally formed in the first axial mating surface or base 1306 of the jacket member 1302. The thirteenth alternate embodiment seal insert member 1304 is received within a continuous opening 1308 in the thirteenth alternate embodiment jacket member 1302, just as taught in the preferred embodiment pressure actuated packing assembly 10 and engages an elastomeric energizer 1309. The thirteenth alternate embodiment jacket member 1302 also includes at least one rib member 1310 integrally formed in the inner peripheral side portion 1312 and the outer peripheral side portion 1314 of the thirteenth alternate embodiment jacket member 1302. The thirteenth alternate embodiment pressure actuated packing assembly 1300 may, for example, comprise one or more thirteenth alternate embodiment jacket member 1302, two or more elastomeric energizers 1309 and a seal insert member 1316 as taught in the preferred embodiment pressure actuated packing assembly 10, arranged in an operable configuration as shown in FIG. 16.
A fourteenth alternate embodiment pressure actuated packing assembly 1400 is illustrated in FIG. 17. The fourteenth alternate embodiment pressure actuated packing assembly 1400 is functionally equivalent to the preferred embodiment pressure actuated packing assembly 10 illustrated in FIGS. 1, 1A, 2, 3A, 3B, and 3C. The fourteenth alternate embodiment pressure actuated packing assembly 1400 teaches the use of a flat band coil spring and similar type spring devices for use as the energizer 26.
The foregoing description of the invention is illustrative and explanatory thereof. Various changes in the materials, apparatus, and particular parts employed will be apparent to those skilled in the art. It is intended that all such variations within the scope and spirit of the appended claims be embraced thereby.
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A pressure actuated packing assembly for use in sealing the annular area of fluid flow devices to provide and maintain an effective, long-term seal therein. The pressure actuated packing assembly is designed for use in chemically hostile environments, and for applications involving temperature and pressure differentials. The pressure actuated packing assembly automatically adjusts for wear, misalignment and service irregularities, while generally reducing the leakage and fugitive emission escape of fluid, flowing therethrough. The pressure actuated packing assembly is preferably constructed of an elastomeric energizer, a circular jacket member having an internal channel to substantially retain the elastomeric energizer and a rigid sealing insert member preferably disposed within the channel of the jacket member. The rigid sealing insert member, as a result of the system pressure within the fluid flow device, applies force to the energizer to radially expand the pressure actuated seal assembly to seal the annular area of the fluid flow device.
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BACKGROUND OF THE INVENTION
The present invention relates to a variable speed pumping-up system, and more particularly to a variable speed pumping-up system provided with a pump or a pump turbine which exhibits a stall characteristic with a reverse flow called a hump characteristic in an operating region of high total dynamic head.
The present invention relates to a variable speed pumping-up system, and more particularly to a method of controlling a variable speed pumping-up system sharing an upstream side pipe line or a downstream side pipe line with another hydraulic machine and having a pump or a pump turbine which exhibits a hump characteristic (a reverse flow characteristic) in a pump operation region.
It is considered that, in a pump turbine of a variable speed pumping-up system, the occurrence of the hump characteristic (wherein an operation of the pump turbine becomes dH/dQ>0, wherein H is a total dynamic head including head loss in the upstream and downstream pipelines; and Q is a flow rate), which is shown by a region indicated by z in FIG. 7, in a higher total dynamic head operating region of the pump cannot generally be avoided.
The operation of the pump turbine in the hump characteristic region is unstable and causes vibrations and noises. Moreover, since a flow rate Q of water can never be stabilized in the range of z on the H versus Q curve of FIG. 7, an operating point of the pump turbine which has been approaching the point (Q X , H X ) from the larger Q side changes suddenly to the point (Q Y , H X ) as soon as the total dynamic head H reaches H X . Thus abnormal water hammering phenomena occur in the upstream and downstream pipe lines.
The degree of depression of the hump characteristic differs depending upon the degree of opening of a guide vane as shown in FIG. 8. Each degree of opening of the guide vane in FIG. 8 is pointed out as Y 4 <Y 3 <Y 2 <Y 1 . Even when a clear depression portion does not appear in the hump characteristic region, a similar problem occurs, more or less, since the flow of water in a runner of the pump turbine becomes unstable.
It is said that the cause of such a problem resides in that, when the total dynamic head of the pump turbine is too high under a given guide vane opening, the flow of water is remarkably reduced and distorted allowing partial reverse flows as shown in FIGS. 5 and 6. In this condition, the flow of water separates from the surface of the runner, and is put in a so-called stalling state.
Japanese Patent Laid-Open No. 186069/1987 includes a description about the effect that, when a load on a variable speed pumping-up apparatus is to be increased, the steps of initially increasing an output level of an electric drive unit so as to set a rotating speed of a pump turbine higher, and thereafter increasing a degree of opening of a guide vane should be taken for the purpose of preventing an operation point of the pump turbine from falling transitionally into the above mentioned hump characteristic region.
This publication also discloses a proposal that, when the load on the variable speed pumping-up apparatus is to be reduced, the closing of the guide vane and the decreasing of the rotating speed of the pump turbine are performed simultaneously so that the closing operation of the guide vane terminates earlier than the rotating speed decreasing operation of the pump turbine.
A case where the pump turbine shares its upstream side pipe line or downstream side pipe line with some other hydraulic machines, namely a case where a plurality of hydraulic machines are provided so that the hydraulic machines are connected to the pipe lines branching from a single pipe line, will now be considered.
When the operation condition of any of the additional hydraulic machines including the flow rate of water therein is changed, water hammering phenomena occur in this hydraulic machine and is transmitted to the pump turbine under consideration as well via the common pipe line, so that the pump turbine is necessarily influenced by the water hammering phenomena.
Especially, when the total dynamic head in an independent variable speed pumping-up system is swung higher, it is possible that the operation point of the pump turbine therein falls into the hump characteristic region even if the variable speed pumping-up system itself is set in a perfectly controllable region.
Japanese Patent Laid-Open No. 149583/1986 discloses a pump turbine starting method for a variable speed pumping-up system, in which, when a pump turbine is started, namely, when the pump turbine operation is shifted from a priming pressure established state with guide vanes fully closed to a regular variable speed pumping-up operation with a desired load, the rotating speed of the pump turbine is increased in proportion to the opening of the guide vanes, whereby a proper rotating speed of the pump turbine and a proper degree of opening of the guide vane with respect to the desired load are finally attained.
However, this known patent publication does not refer at all to a control method for a variable speed pumping-up system to be used after a regular variable speed pumping-up operation has been commenced.
As may be understood from the above stated description, the conventional controlling method for the variable speed pumping-up system for preventing the operation point of the pump turbine from falling into the hump characteristic region discloses only a part of the control needed for an independent variable speed pumping-up system.
Further, Japanese Patent Laid-Open No. 175271/1986 discloses a controlling method for a variable speed pumping-up system, in which, when the static head, i.e., difference between water level; of an upper reservoir and water level of a lower reservoir has a predetermined value, the rotating speed of the pump turbine is raised and corrected in accordance with an overshoot thereof.
However, nothing is referred to with respect to the operation point of the pump turbine falling into the hump characteristic (the reverse flow characteristic) region by a temporary and much faster increase of the total dynamic head of this pump turbine due to the water hammering phenomena in the shared pipe line to which the present invention is directed.
As may be understood from the above stated description, the conventional controlling method for the variable speed pumping-up system for preventing the operation point of the pump turbine from falling into the hump characteristic region discloses only a part of the control that needs to be applied to an independent variable speed pumping-up system.
Namely, a countermeasure of the operation point of the pump turbine falling into the hump characteristic region due to the water hammering phenomena in the shared pipe line has not yet been proposed at all.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a variable speed pumping-up system wherein a stable and reliable control of a pump or a pump turbine can be obtained.
Another object of the present invention is to provide a variable speed pumping-up system wherein a countermeasure can be taken to prevent an operation point from falling into a hump characteristic region.
A further object of the present invention is to provide a variable speed pumping-up system wherein a countermeasure can be taken to prevent an operation point from falling into a hump characteristic region, in spite of an interference caused by water hammering phenomena from another hydraulic machine sharing the same pipe line.
In accordance with the present invention, a variable speed pumping-up system is provided with self-correcting functions, i.e. the functions of, especially, monitoring the operation point of the pump or pump turbine continuously, and taking a timely and proper action at a suitable time to prevent the operation point from falling into the hump characteristic region in accordance with an approaching degree of the operation point to the hump characteristic region.
Even when a water hammering phenomena from another hydraulic machine sharing the same pipe lines is experienced, the operation point is maintained without allowing any abnormal approach into the hump characteristic region.
In accordance with the present invention, a variable speed pumping-up system will function properly as detailed below. First, (1) the degree Y of the opening of the guide vanes and the rotating speed N of the pump turbine are measured continuously. (2) Model test data, which has been stored in a memory, are referred to so that dynamic head H X corresponding to a starting point of a hump characteristic region is calculated as a function of the measured rotating speed N of the pump turbine and the measured opening degree Y of the guide vanes.
(3) A total dynamic (head H pressure head alone or pressure head plus velocity head at the outlet of the pump turbine) is measured. (4) A difference between the dynamic head H X and the total dynamic head H is calculated. (5) When this difference in dynamic heads has become not higher than a predetermined level, an overriding control is put into service so as to forcibly increase the output level of the pump drive unit and to correspondingly raise the rotating speed N of the pump turbine. This prevents the operation point of the pump turbine from falling into the hump characteristic region.
With note taken of the fact that, at the change of the operation state of another hydraulic machinery sharing the pipe line, especially at the start of another hydraulic machine in the pump mode or in an output rapid-increase operation thereof, the total dynamic head H of the particular variable speed pumping-up system is temporarily raised by the water hammering phenomena in the shared pipe line. Thus the rotating speed N of the pump turbine of the particular variable speed pumping-up system is temporarily raised and corrected before, or concurrently with, the start of the output rapid-increase operation of the other hydraulic machine.
Then, after the peril of the interference of the water hammering phenomena in the shared pipe line attributed to the hydraulic machinery disappears, the overriding control, i.e., the rotating speed correction control for the pump turbine is removed, and the control of the variable speed pumping-up system is restored to normal.
Even when the operation point of the variable speed pumping-up system nearly falls into the hump characteristic region for some internal reasons or from external influences from the water hammering phenomena occurring in another hydraulic machine by which the upstream side pipe line or the downstream side pipe line of the variable speed pumping-up system are shared therewith, the possibility that the operation point will fall into the hump characteristic region is detected in advance and a self-correcting control operation of the variable speed pumping-up system is carried out.
Namely, the rotating speed of the pump turbine is increased to immediately carry out an operation for preventing the operation point from falling into the hump characteristic region.
FIG. 8 is a graph showing the relationship between a rate Q and a total dynamic head H with respect to various degrees of guide vane openings for a given rotating speed N of the pump turbine.
In this case, the given rotating speed N is assumed to be an optimum speed for a desired power at that instant and it is further assumed that a highest efficiency operation of the variable speed pumping-up system is being carried out so as to obtain the relationship expressed by an envelope of the broken line shown in FIG. 8.
The two curves, C 1 and C 2 shown in FIG. 9 are also optimum setting curves for the respective power level operations, C 1 for higher power, C 2 for lower power which are determined in the same manner as the envelope curve of FIG. 8, with respect to the pump turbine rotating speeds N 1 and N 2 respectively. Referring to FIG. 9, the rotating speed N 1 of the curve C 1 is set to be larger than the rotating speed N 2 of the curve C 2 .
It may be considered that, if the rotating speed N of the pump turbine is increased, these optimum setting curves C 1 , C 2 move up to the right side as shown in FIG. 9.
When the difference H 0 in the static heads of water at the upper reservoir and the lower reservoir is constant, the total dynamic head H increases as the flow rate Q increases since friction losses in the pipe lines increase. A curve expressing this phenomena is called a service curve L under the given static head difference H 0 (refer to FIG. 9).
H 1 and H 2 are the respective dynamic heads at the rotating speeds N 1 and N 2 under the same static head difference H 0 . It is assumed here that the optimizing controls of the rotating speed and the opening of the guide vanes in response to the desired power level is available in both the cases.
Even when the total dynamic head H increases temporarily as a result of the water hammering phenomena occurring in the shared pipe line, and, even when the operation point of the variable speed pumping-up system approaches the hump characteristic region, the rotating speed raising correction for the pump turbine is performed in advance, or concurrently therewith, and the operation point of the pump turbine within the hump characteristic region itself is avoided thereby making it possible to prevent the operation point from falling into the hump characteristic region as shown in FIG. 9.
This fact will be explained in detail in the following description.
As is clear from FIG. 9, as the rotating speed N of the pump turbine is increased, a difference between the service point of the total dynamic head H, i.e., H 1 or H 2 and a starting point H X (see FIG. 7) of the hump characteristic region on the same Q-H curve, i.e., H 1X or H 2X increases, and the operation point of the variable speed pumping-up system departs from the hump characteristic region.
When the rotating speed N of the pump turbine is increased, the starting point H X of the hump characteristic region goes up further, even under the same degree of opening of the guide vanes, and even when the total dynamic head H is temporarily increased by the affect of the water hammering phenomena in the shared pipe line. Thus it is possible to avoid the operating point of the variable speed pumping-up system from falling into the hump characteristic region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a control circuit schematic block diagram showing a variable speed pumping-up system according to one embodiment of the present invention;
FIG. 2 shows one example of a variable speed pumping-up system using a winding type induction machine to which one embodiment of the present invention is applied;
FIG. 3(a) to 3(g) show signal wave forms of the various parts of the control units in FIG. 1;
FIG. 4 shows an example of another type of flow pattern in a variable speed pumping-up system to which another embodiment of the present invention is applied;
FIGS. 5 and 6 are explanatory views of typical flow patterns occurring in the hump characteristic region;
FIG. 7 is an H-Q characteristic curve showing the hump characteristic region;
FIG. 8 is an H-Q characteristic curve graph showing the relationship of the degrees of opening of the guide vanes and the hump characteristic region;
FIG. 9 is an H-Q characteristic curve graph showing the relationship between the rotating speed of the pump turbine and the hump characteristic region;
FIG. 10 is a control circuit showing in schematic block diagram form a variable speed pumping-up system according to another embodiment of the present invention;
FIG. 11 shows another example of a variable speed pumping-up system using a winding type induction machine to which one embodiment of the present invention is applied;
FIG. 12(a)-12(g) show signal wave forms of various parts of the control units in FIG. 10; and
FIG. 13 shows an example of another type of variable speed pumping-up system to which another embodiment of the present invention is applied.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of a variable speed pumping-up system according to the present invention will now be explained with reference to FIG. 1.
FIG. 1 is a schematic block diagram of a control circuit of the variable speed pumping-up system according to the present invention. Since the details of an AC excitation circuit for controlling the cyclo converter do not have a direct relation with the present invention, they are not shown in FIG. 1.
A generator motor control loop consists of an adder or comparator 18, a power control correction signal generator 16, a power controller 7, a cyclo converter 3, a generator motor 2 with an inertia moment GD 2 and a power feedback circuit.
The speed function generator 12 receives as inputs a 1 motor drive power command P 0 from the outside and an actual total dynamic head H (that is defined as a simple difference between the static heads of the upper reservoir and the lower reservoir minus head losses in the upstream and downstream pipe lines) and provides as an output an optimum speed signal Na for the pump turbine 4.
The comparator 18 compares the sum of the optimum speed signal Na and the speed correction signal ΔNa with an actual rotating speed N and the calculates difference between the two.
The GD 2 schematic block indicates the effects of the inertia moments of the generator motor 2 and the pump turbine 4, and does not represent any separated special device.
The power control correction signal generator 16 includes an integrating element for use in eliminating a deviation signal [(Na+ΔNa)-N] in any steady state condition. A power correction signal ε, an output from the power control correction signal generator 16, is added to the drive power command P 0 in an adder 19, and a v combined power command signal (P 0 +ε) is compared with an actual generator motor output P M are in a comparator 20.
The power control circuit loop consists of the power controller 7, the cyclo converter 3, the generator motor 2, and a feedback circuit for the actual generator motor output P M and the power control circuit loop forms a negative feedback circuit. The power controller 7 includes an integrating element for use in eliminating a deviation [(P 0 +ε)-P M ] in any steady state condition.
A guide vane control loop consists of a guide vane opening degree function generator 13, guide vanes 25 (see FIG. 2), a comparator 21, a guide vane controller 9, and a feedback of an actual opening degree Y of the guide vanes 25 and thus the guide vane control loop forms a negative feedback circuit.
The guide vane opening degree function generator 13 receives as input the motor drive power command P 0 and the actual total dynamic head H and gives as output an optimum guide vane opening signal Ya. The comparator 21 is adapted to compare the optimum guide vane opening signal Ya from the guide vane opening degree function generator 13 with an actual opening degree Y of the guide vanes 25.
The guide vanes 25 are controlled by the guide vane controller 9 so that a deviation (Ya-Y) from the comparator 21 becomes zero in any steady state by an error eliminating function or an integrating function device in the guide vane controller 9.
Thus, in a steady state condition N=Na+ΔNa (if ΔNa=0, N=Na), P M =P 0 +ε and Y=Ya can be attained by the error eliminating functions of the power control correction signal generator 16, the power controller 7 and the guide vane controller 9, each associated with their negative feedbacks, respectively as detailed above.
Any difference (P M -P P ), i.e., actual generator motor output power P M minus pump input power P P , results in an acceleration/deceleration of the rotating parts of the generator motor 2 and the pump turbine 4, i.e., a change in the rotating speed N. The larger the inertia moment GD 2 is, the slower rate of speed change results in.
Since the rotating speed control loop consisting of the adder 18, the power control correction signal generator 16, the adder 19, the comparator 20, the power controller 7, the cyclo converter 3, the generating motor 2 and the inertia moment GD 2 and the feedback circuit of the actual rotating speed N to the adder 18 forms a negative feedback circuit as mentioned above, a control operation is carried out so that the difference (P M -P P ) becomes zero, that is, P M =P P , in any steady state condition.
If an error of the rotating speed function generator 12 is negligible, the pump input PP must be controlled naturally to be equal to the motor drive power command P 0 , i.e. P P =P 0 since the optimum guide vane opening signal Ya of the guide vanes 25 is the theoretically just corresponding to the motor drive power command P 0 .
To sum up, P 0 =P P =P M =P 0 +ε is obtained, therefore, the level of the power correction signal ε is finally set to zero. Owing to the above operations, the actual generator motor output P M can be controlled to meet the motor drive power command P 0 from the outside without having deviation due to ε.
The above description of the embodiment of FIG. 1 is graphically shown in FIG. 3.
Responses made when the motor drive power command P 0 is increased in step as the graph of FIG. 3(a) at the point of time t 0 are shown.
First, the actual generator motor output P M rises with a very short time constant as shown in the graph of FIG. 3(g).
The optimum guide vane opening signal Ya from the guide vane opening degree function generator 13 and the optimum rotating speed signal Na from the rotating speed function generator 12 respond as shown in the graphs of FIGS. 3(b) and 3(c), with their respective time constants.
An actual response Y of the guide vanes 25 to the optimum guide vane opening signal Ya in the graph of FIG. 3(d) is made as shown in the graph of FIG. 3(d). A straight line portion included in the response of Y of opening indicates that the opening speed of the guide vanes 25 is restricted by a traveling speed limiter for their guide vane servo-motor which is usually applied to a distributing valve for the guide vane servo-motor.
The actual rotating speed N of the pump turbine 4 is increased by a difference between the actual generator motor output P M in the graph 3(g) and the pump input P p in the graph 3(e), rises as shown in the graph 3(f) and stops rising when it finally reaches N=Na.
An increase based on both an increase in the opening degree Y of opening of the guide vanes 25 and an increase in the rotating speed N of the pump turbine 4 is added to the pump input P p , so that the pump input P p increases as shown in the graph 3(e).
In the graph 3(f), the actual rotating speed N of the pump turbine 4 varies slowly and stably, since the power correction signal generator 16 is designed to have a satisfactory damping.
This damping effect can be attained, for example, by forming the power control correction signal generator 16 by a shunt circuit of a proportional element and an integrating element, and suitably selecting the gains thereof.
The above is directed to a description of one embodiment of the variable speed pumping-up system according to the present invention in which the operation point of the pump turbine 4 remains in a normal operation region and does not approach the hump characteristic region very frequently.
The embodiment of the present invention is further provided with an operation point self-correcting function, which constitute the essential feature of the present invention, in the following manner.
First, a limit head calculator 22 determines the dynamic head H X (refer to FIG. 7) at the starting point of the hump characteristic region as it continuously detects the actual rotating speed N of the pump turbine 4 and the opening degree Y of the guide vanes 25 and as refers to the stored H-Q characteristic of the pump turbine with the detected parameters.
A comparator 23 is adapted to compare the dynamic head H X thus obtained with an actual measurement value of the total dynamic head H, and send a differential head signal εH to a hump characteristic avoiding correction signal generator 24.
This hump characteristic avoiding correction signal generator 24 is adapted to output a rotating speed correction signal ΔNa for the pump turbine 4 in accordance with the degree of nearness of the operation point to the hump characteristic region, when the level of the differential head signal εH has become abnormally low, i.e., when the operation point of the pump turbine 4 has approached abnormally close to the hump characteristic region.
This rotating speed correction signal ΔNa of the pump turbine 4 is inputted into the adder 18, in which the correction of the optimum rotating speed signal Na to (Na+ΔNa) is done.
FIG. 2 shows one example of the construction of a variable speed pumping-up system using the control circuit of FIG. 1 and a secondary winding type induction generator motor 2 is used as a variable speed generator motor. The reference numerals in FIG. 2 which are the same as those in FIG. 1 designate the same parts.
The primary side of the winding type induction machine 2 is connected to an electric power system 1, and the secondary side thereof to the cyclo converter 3, output power of the induction generator motor 2 being controlled by controlling the phase and the voltage of the AC excitation current from the cyclo converter 3.
An actual generator motor output P M is detected by a power detector 6 and inputted into a comparator 20, and an actual rotating speed N of the pump turbine 4 is detected by a rotating speed detector 5 and inputted into the adder 18.
FIG. 4 is a constructional diagram of another embodiment using the control circuit of FIG. 1, in which a synchronous machine 10 is used with a frequency converter 17 provided between the electric power system 1 and the synchronous machine 10. In order to produce a phase command to be directed to the frequency converter 17, a phase detector 11 is provided therein.
As is clear from the above stated description, the effect of this embodiment of the present invention resides in its capability of continuously monitoring the operation point of the variable speed pumping-up system constantly as to determine whether it is abnormally close to the hump characteristic region, taking a timely and proper countermeasure as necessary to prevent the operation point of the pump turbine 4 from falling into the hump characteristic region, and assuring a stable and reliable operation of the variable speed pumping-up system.
Designing a pump turbine apparatus so that the upstream side pipe line or the downstream side pipe line is shared with a plurality of pump turbines is done rather commonly for economical reasons, and the effect of this embodiment of the present invention in providing a variable speed pumping-up system which can be readily applied to this kind of system as well is very great.
Another embodiment of a variable speed pumping-up system according to the present invention will be explained with reference to FIGS. 10-13.
FIG. 10 shows another schematic block diagram of a control circuit of the variable speed pumping-up system having another hydraulic machine sharing the pipe line according to the present invention. The reference numerals in FIG. 10 which are the same as those in FIG. 1 designate the same parts.
FIG. 11 shows one example of the construction of a variable speed pumping-up system using the control circuit of FIG. 10. A secondary winding type induction generator motor 2 is used as a variable speed generator motor. The reference numerals in FIG. 11 which are the same as those in FIG. 10 and FIG. 2 designate the same parts.
When the variable speed pumping-up system having another hydraulic machine sharing the upstream side pipe line or the downstream side pipe line starts at the pumping-up mode or is operated in the output rapid-increase operation, the rotating speed N of the particular variable speed pumping-up power system is raised and corrected in advance by a predetermined rotating speed correction value ΔNa which is applied to the adder 18.
The predetermined rotating speed correction value ΔNa of the pump turbine 4 can be varied, needless to say, in accordance with the operation amount of another hydraulic machine.
Further, the predetermined rotating speed correction of ΔNa can be performed concurrently with the rapid change operation of the operation condition of the other hydraulic machine.
When the rapid operation of the other hydraulic machine finishes and the water hammering phenomena in the shared pipe line is set down, the predetermined rotating speed correction value ΔNa is brought to zero.
The response conditions of the particular variable speed pumping-up system are indicated together in FIG. 10 for the case when the above stated predetermined rotating speed value (ΔNa) correction is performed.
This embodiment shown in FIGS. 10, 11 and 12 differs from FIG. 3, in that the motor drive power command P 0 is not in motion, therefore the optimum guide vane opening signal Ya of the guide vanes 25 are not changed and accordingly the actual guide vane opening degree Y remains constant.
FIG. 13 is a constructional diagram of another embodiment using the control circuit of FIG. 10, in which a synchronous machine 10 is used with a frequency converter 17. The reference numerals in FIG. 13 which are the same as those in FIG. 11 and FIG. 4 designate the same parts.
As is clear from the above stated description, the effect of this embodiment of the present invention resides in its capability of avoiding the operation point of the pump turbine 4 from falling into the hump characteristic region even when the variable speed pumping-up system is subjected to the water hammering phenomena of another hydraulic machine sharing the same pipe line, and assuring a stable and reliable operation of the variable speed pumping-up system.
Designing a pump turbine apparatus so that the upstream side pipe line or the downstream side pipe line is shared with a plurality of pump turbines is made rather commonly for economical reasons, and the effect of this embodiment of the present invention in providing a variable speed pumping-up system which can be applied with a sense to security of this kind of system as well is significant.
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The operation of a variable speed electric driven pump turbine is monitored continuously during pumping to detect the operation point of the pump turbine, and to prevent it from falling into a hump characteristic region, which is recognizable on a graph of total dynamic head versus flow rate. Stalling occurs in the hump characteristic region as a result of a partial reverse flow of the water with respect to the runner. When the operation point of the pump turbine approaches the hump characteristic region, a corrective action is taken that includes increasing the output level of the electric driven pump turbine to increase its rotating speed, temporarily.
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BACKGROUND
[0001] The invention relates to a device for variably adjusting the timing of gas exchange valves of an internal combustion engine having a hydraulic phase adjustment unit and at least one volume accumulator, wherein the phase adjustment unit can be brought into drive connection with a crankshaft and a camshaft and at least one advance chamber and at least one retardation chamber, which can be supplied with pressure medium or from which pressure medium can be discharged via pressure medium lines, wherein a phase position of the camshaft relative to the crankshaft can be adjusted in the direction of early timing by supplying pressure medium to the advance chamber while simultaneously allowing pressure medium to flow out of the retardation chamber, wherein a phase position of the camshaft relative to the crankshaft can be adjusted in the direction of late timing by supplying pressure medium to the retardation chamber while simultaneously allowing pressure medium to flow out of the advance chamber, wherein pressure medium can be supplied to the volume accumulator or accumulators during the operation of the internal combustion engine.
[0002] In modern internal combustion engines, devices for variably adjusting the timing of gas exchange valves are used to enable variable configuration of the phase position of a camshaft relative to a crankshaft within a defined angular range between a maximum advance position and a maximum retardation position. For this purpose, a hydraulic phase adjustment unit of the device is integrated into a drive train via which torque is transmitted from the crankshaft to the camshaft. This drive train can be implemented as a belt, chain or gear drive, for example. The phase adjustment speed and the pressure medium requirement are significant parameters of such devices. To enable the phase position to be adapted in an optimum manner to the various driving situations, high phase adjustment speeds are desirable. In the context of measures for reducing consumption, there is furthermore a demand for an ever smaller pressure medium requirement so as to enable the pressure medium pump of the internal combustion engine to be of smaller design or to enable the delivery rate to be reduced when using controlled pressure medium pumps.
[0003] A device of this kind is known from EP 0 806 550 A1, for example. The device comprises a phase adjustment unit of the vane cell type with a drive input element, which is in drive connection with the crankshaft, and a drive output element, which is connected to the camshaft for conjoint rotation therewith. A plurality of pressure spaces is formed within the phase adjustment unit, wherein each of the pressure spaces is divided into two pressure chambers with an opposed action by means of a vane. The vanes are moved within the pressure spaces by supplying pressure medium to or discharging pressure medium from the pressure chambers, thereby bringing about a change in the phase position between the drive output element and the drive input element. In this case, the pressure medium required for phase adjustment is made available by a pressure medium pump of the internal combustion engine and is directed selectively to the advance or retardation chambers by means of a control valve. The pressure medium flowing out of the phase adjustment unit is directed into a pressure medium reservoir, the oil sump of the internal combustion engine. Phase adjustment is thus accomplished by means of the system pressure made available by the pressure medium pump of the internal combustion engine.
[0004] Another device is known from U.S. Pat. No. 5,107,804 A, for example. In this embodiment, the phase adjustment unit is likewise of the vane cell type, and a plurality of advance and retardation chambers is provided. In contrast to EP 0 806 550 A1, phase adjustment is not accomplished by supplying pressure medium to the pressure chambers by means of a pressure medium pump; instead, alternating moments acting on the camshaft are used. The alternating moments are caused by the rolling movements of the cams on the gas exchange valves, each of which is preloaded by a valve spring. In this case, the rotary motion of the camshaft is braked during the opening of the gas exchange valves and accelerated during closure. These alternating moments are transmitted to the phase adjustment unit, with the result that the vanes are periodically subjected to a force in the direction of the retardation stop and of the advance stop. As a result, pressure peaks are produced alternately in the advance chambers and the retardation chambers. If the phase position is supposed to be held constant, pressure medium is prevented from flowing out of the pressure chambers. In the case of a phase adjustment in the direction of earlier timing, pressure medium is prevented from flowing out of the advance chambers, even at times at which pressure peaks are being produced in the advance chambers. If the pressure in the advance chambers rises owing to the alternating moments, this pressure is used to direct pressure medium out of the retardation chambers into the advance chambers, using the pressure of the pressure peak generated. Phase adjustment in the direction of later timing is accomplished in a similar way. In addition, the pressure chambers are connected to a pressure medium pump, although only to compensate for leaks from the phase adjustment unit. Phase adjustment is thus accomplished by diverting pressure medium out of the pressure chambers to be emptied into the pressure chambers to be filled, using the pressure of the pressure peak generated.
[0005] Another device is known from US 2009/0133652 A1. In this embodiment, phase adjustment at small alternating moments is accomplished, in a manner similar to the device in EP 0 806 550 A1, by supplying pressure to the advance chambers or the retardation chambers by means of a pressure medium pump while simultaneously allowing pressure medium to flow out of the other pressure chambers to the oil sump of the internal combustion engine. In the case of high alternating moments, as in the device in U.S. Pat. No. 5,107,804 A, these are used to direct the pressure medium under high pressure out of the advance chambers (retardation chambers) into the retardation chambers (advance chambers). During this process, the pressure medium expelled from the pressure chambers is fed back to a control valve, which controls the supply of pressure medium to or discharge of pressure medium from the pressure chambers. This pressure medium passes via check valves within the control valve to the inlet port, which is connected to the pressure medium pump, wherein some of the pressure medium is expelled into the pressure medium reservoir of the internal combustion engine.
SUMMARY
[0006] It is the underlying object of the invention to provide a device for variably adjusting the timing of gas exchange valves of an internal combustion engine while increasing the phase adjustment speed thereof.
[0007] According to the invention, the object is achieved by virtue of the fact that at least two pressure medium channels are provided in addition, wherein the first pressure medium channel opens into one of the volume accumulators, on the one hand, and communicates with the advance chamber, on the other hand, wherein the second pressure medium channel opens into one of the volume accumulators, on the one hand, and communicates with the retardation chamber, on the other hand, and wherein each of the pressure medium channels is assigned a check valve, which prevents a pressure medium flow from the respective pressure chamber to the volume accumulator and can permit a pressure medium flow in the opposite direction.
[0008] The device has a hydraulic phase adjustment unit which has at least two pressure chambers with an opposed action, at least one advance chamber and at least one retardation chamber. The invention can be applied to any type of hydraulic phase adjustment unit, e.g. devices of the vane cell type, as disclosed in EP 0 806 550 A1, in the form of axial piston adjusters, as disclosed in DE 42 18 078 C1, for example, or in the form of pivoted lever adjusters, as disclosed in U.S. Pat. No. 4,903,650 A, for example.
[0009] The phase adjustment unit has at least one drive input element and one drive output element, wherein the drive input element is in drive connection with a crankshaft of the internal combustion engine, e.g. via a chain, belt or gear drive. The drive output element is in drive connection with the camshaft. This can likewise be effected by means of a chain, belt or gear drive or by means of a connection between the camshaft and the drive output element for conjoint rotation, for example.
[0010] By means of a pressure medium line, pressure medium is fed to and discharged from the pressure chambers. The pressure medium can be made available by a pressure medium pump of the internal combustion engine, for example, and the pressure medium to be discharged from the pressure chambers can be directed into a pressure medium reservoir, e.g. the oil sump of the internal combustion engine. It is thus possible to variably adjust the phase position of the device, even in the case of small alternating moments.
[0011] The device furthermore has one or more volume accumulators for holding pressure medium. The pressure medium can be stored in the unpressurized condition or under pressure in the volume accumulator or accumulators. During the operation of the internal combustion engine, the pressure medium is fed to the volume accumulator or accumulators.
[0012] In addition to the pressure medium lines which connect the pressure chambers to the pressure medium pump and the pressure medium reservoir, at least two pressure medium channels are provided, which connect the volume accumulator or accumulators to the pressure chambers. In this case, one end of each pressure medium channel opens into one of the volume accumulators, while the other end of the first pressure medium channel communicates with the advance chamber or chambers and the other end of the second pressure medium channel communicates with the retardation chamber or chambers. In this case, the first pressure medium channel communicates exclusively with the advance chamber or chambers and not with the retardation chambers. Similarly, the second pressure medium channel communicates exclusively with the retardation chamber or chambers and not with the advance chambers.
[0013] Embodiments with just one volume accumulator, which communicates with all the pressure chambers via the pressure medium channels, are conceivable, for example. Likewise conceivable are embodiments in which a plurality of volume accumulators is provided. In this case, some of the volume accumulators can communicate exclusively with the advance chambers while some of the volume accumulators communicate exclusively with the retardation chambers, for example. It is likewise conceivable for each volume accumulator to be assigned two pressure chambers, e.g. an advance chamber and a retardation chamber, with which the respective volume accumulator communicates via the pressure medium channels.
[0014] In addition to the embodiments in which two pressure medium channels are provided, in which the first/second pressure medium channel communicates with all the advance/retardation chambers, a plurality of pressure medium channels can be provided, e.g. one pressure medium channel per pressure chamber. As an alternative, it is possible to provide for one first (advance) retardation chamber to communicate with a volume accumulator via a pressure medium channel and for pressure medium to be fed to the other (advance) retardation chambers from the volume accumulator via the first (advance) retardation chamber.
[0015] Each of the pressure medium channels is assigned a check valve, wherein each of the check valves prevents a pressure medium flow from the associated pressure chamber to the volume accumulator and permits a pressure medium flow in the opposite direction when there is a suitable pressure difference upstream and downstream of the check valve. The check valves can be arranged within the pressure medium channel, for example, and can be designed as ball or plate check valves, for example. Likewise conceivable are embodiments in which a spring plate interacts with an outlet area of the associated pressure medium channel in the manner of a check valve.
[0016] The volume reservoir can communicate or be connectable to a pressure medium reservoir of the internal combustion engine by one or more pressure medium lines.
[0017] With this device, the phase position of the camshaft relative to the crankshaft can, on the one hand, be varied or maintained by means of the system pressure made available by the pressure medium pump of the internal combustion engine. On the other hand, the alternating moments acting on the camshaft can be exploited in order to bring about a phase adjustment. In this case, the proportion of the alternating moment acting counter to the direction of adjustment is absorbed, and the proportion acting in the direction of adjustment is exploited in order to increase the phase adjustment speed. The absolute value of the proportion of the alternating moment which is to be used for phase adjustment increases continuously from 0 to a maximum value and falls back to 0 in accordance with the angular position of the camshaft. During this process, the output drive element is turned relative to the input drive element in the direction of the desired phase position. On the one hand, this results in a rapid rise in the pressure in the pressure chambers to be emptied, thereby accelerating the emptying of the pressure chambers. On the other hand, the pressure medium requirement of the pressure chambers to be filled rises by the same amount. When the acting moment is small, the pressure medium requirement of the pressure chambers to be filled can be supplied by the pressure medium pump. In this case, provision can be made for the pressure medium flowing out of the pressure chambers to be emptied to fill the volume accumulator or accumulators. As the moment rises, the pressure medium requirement of the pressure chambers to be filled increases, and this can have the effect that the volume flow supplied by the pressure medium pump is not sufficient to completely fill the pressure chambers to be filled. A vacuum, which has a slowing effect on the speed of adjustment in conventional devices, thus arises in the pressure chambers to be filled. In the device according to the invention, the pressure accumulator or accumulators provided and the pressure medium channels enable the pressure medium stored in the volume accumulator or accumulators to be used to fill the pressure chambers in these phases. Owing to the pressure difference between the pressure chambers and the volume accumulator or accumulators, the check valves in the pressure medium channels open toward the pressure chambers to be filled, thus allowing pressure medium to enter the latter. Owing to the additional volume of pressure medium which is made available in the volume accumulator or accumulators and is fed during these phases to the pressure chambers to be filled, the phase adjustment speed can be increased considerably in comparison with devices which are operated exclusively by means of the system pressure made available by the pressure medium pump.
[0018] In devices in which the alternating moments are exploited in order to adjust the phase position of the camshaft relative to the crankshaft, the pressure medium which is expelled from the pressure chambers to be emptied is directed directly and under high pressure to the pressure chambers to be filled. However, only part of the pressure medium volume expelled from the pressure chambers reaches the pressure chambers to be filled. Another part is lost due to leakage. In some embodiments, losses also arise from the fact that the pressure medium is directed back into a control valve, wherein part of the pressure medium is expelled into a pressure medium reservoir of the internal combustion engine and can thus no longer reach the pressure chambers to be filled.
[0019] In these embodiments, therefore, there is insufficient pressure medium available to fill the expanding pressure chambers and hence, in turn, a vacuum arises in said pressure chambers, having a negative effect on the phase adjustment speed. Given suitable design of the volume accumulators of the device proposed, this loss is compensated by the pressure medium volume made available in the volume accumulator or accumulators, thus increasing the phase adjustment speed. At high alternating moments, the pressure medium is furthermore not directed into the pressure chambers under the high pressure generated by said moments. On the contrary, the vacuum arising in the pressure chambers to be filled is exploited in order to direct the pressure medium from the volume accumulator or accumulators into the pressure chambers. Thus, no abrupt phase changes occur and, as a result, the ability to control the device is maintained.
[0020] In an advantageous development of the invention, provision is made for the volume accumulator to be arranged within the phase adjustment unit. The stored pressure medium is thus in spatial proximity to the pressure chambers. As a result, pressure medium losses between the volume accumulator and the pressure chambers are reduced, and the response characteristics of the device are improved.
[0021] In this case, provision can be made for the volume accumulator to communicate or to be able to be connected to a pressure medium reservoir via one or more pressure medium lines, wherein the outlet area of the pressure medium channels into the volume accumulator is arranged at a greater distance from the axis of rotation of the phase adjustment unit than the outlet area of the pressure medium lines into the volume accumulator. This ensures that excess pressure medium can be carried away from the volume accumulator to the pressure medium reservoir of the internal combustion engine. Since the phase adjustment unit rotates about the axis of rotation thereof, the centrifugal force ensures that there is nevertheless pressure medium for onward transfer to the pressure chambers at the outlet areas of the pressure medium channels into the volume accumulator or accumulators.
[0022] In the case where the volume accumulator or accumulators communicate with or are connected to a pressure medium reservoir, provision can be made for the pressure medium line or lines which connect the volume accumulator to the pressure medium reservoir to be assigned a check valve, which prevents a pressure medium flow from the pressure medium reservoir to the volume accumulator and can permit a pressure medium flow in the opposite direction. If this check valve is dispensed with, the pressure prevailing in the volume accumulators is the pressure of the pressure medium reservoir, generally atmospheric pressure. By means of the check valve, the pressure level of the stored pressure medium can be raised, thereby ensuring that assistance to phase adjustment by the volume accumulator or accumulators starts even at relatively small alternating moments.
[0023] The volume accumulator or accumulators can be fed with pressure medium directly by a pressure medium pump. In this case, a pressure medium line can branch off directly from the engine oil gallery, for example, and open into the volume accumulator while bypassing the pressure chambers. For example, the pressure medium can reach the volume accumulator or accumulators via a control valve which controls the pressure medium flow to and from the pressure chambers. This ensures that the volume accumulator has an adequate supply of pressure medium at all times. As an alternative, pressure medium can be fed to the volume accumulator from the pressure chambers. During each phase adjustment, one group of pressure chambers expands at the expense of the other pressure chambers. The pressure medium flowing out of the other pressure chambers can be fed to the volume accumulator or accumulators and reused, thereby making it possible to reduce the delivery flow of the pressure medium pump. The pressure medium expelled from the pressure chambers can be directed to the volume accumulator or accumulators via a control valve which controls the pressure medium flows from and to the pressure chambers, for example.
[0024] In a development of the invention, provision is made for the device to have a control valve, by means of which the pressure medium supply from a pressure medium pump to the pressure chambers and the pressure medium discharge from the pressure chambers can be controlled.
[0025] In one specific embodiment of the invention, provision is made for the control valve to have an inlet port, a first and a second working port and at least one first volume accumulator port, wherein a first pressure medium line is provided, which communicates with the first working port, on the one hand, and opens into the advance chamber, on the other hand, wherein a second pressure medium line is provided, which communicates with the second working port, on the one hand, and opens into the retardation chamber, on the other hand, wherein a third pressure medium line is provided, which communicates with the inlet port, on the one hand, and communicates with a pressure medium pump, on the other hand, wherein at least one fourth pressure medium line is provided, which communicates with the volume accumulator port, on the one hand, and opens into the volume accumulator, on the other hand, and wherein a connection between the inlet port and the first or second working port and a connection between the volume accumulator port and the other working port can be established by means of the control valve.
[0026] In an alternative embodiment, provision is made for the control valve to have an inlet port, a first and a second working port, two volume accumulator ports and a drain port, wherein a first pressure medium line is provided, which communicates with the first working port, on the one hand, and opens into the advance chamber, on the other hand, wherein a second pressure medium line is provided, which communicates with the second working port, on the one hand, and opens into the retardation chamber, on the other hand, wherein a third pressure medium line is provided, which communicates with the inlet port, on the one hand, and with a pressure medium pump, on the other hand, wherein two fourth pressure medium lines are provided, which open into the volume accumulator, on the one hand, and each communicate with one of the volume accumulator ports, on the other hand, wherein a fifth pressure medium line is provided, which communicates with the drain port, on the one hand, and with a pressure medium reservoir, on the other hand, wherein a connection between the inlet port and the first or second working port, a connection between one of the volume accumulator ports and the other working port and a connection between the other volume accumulator port and the drain port can be established by means of the control valve.
[0027] The pressure medium flows to the pressure chambers to be filled and the pressure medium outflows from the pressure chambers to be emptied are controlled by means of a control valve which simultaneously controls the filling of the volume accumulator or accumulators from the pressure chambers to be emptied. The pressure medium flows are passed via control edges within the control valve and can be influenced through the design of the flow areas present between the control edges. The device can thus operate both in a mode in which phase adjustment is accomplished by means of the system pressure generated by the pressure medium pump and in a mode in which the alternating moment is used for phase adjustment. The changeover from one mode to the other is accomplished automatically by virtue of the fact that the delivery volume of the pressure medium pump either no longer covers or once again covers the pressure medium requirement of the pressure chambers to be filled. Phase adjustment can furthermore be controlled by means of outflow control, i.e. the adjustment speed is determined by the quantity of pressure medium flowing out of the pressure chambers and not by the quantity of pressure medium flowing to the pressure chambers to be filled. This can be achieved in a simple manner by making a flow area from the pressure chambers to the volume accumulator or accumulators or to the pressure medium reservoir smaller in all cases than a flow area from the pressure medium pump to the pressure chambers. This avoids a situation where air is sucked into the pressure chambers. Moreover, the pressure medium flow to and from the pressure chambers does not increase abruptly in accordance with a control parameter of the control valve, thus ensuring simple and stable control of the device.
[0028] The pressure medium channels, which can connect the volume accumulator or accumulators to the pressure chambers, can open directly into the corresponding pressure chambers, for example, or into the pressure medium lines which connect the working ports of the control valve to the pressure chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Further features of the invention will emerge from the following description and from the drawings, in which embodiments of the invention are illustrated in simplified form, and in which:
[0030] FIG. 1 shows an internal combustion engine, although only in a very schematic form,
[0031] FIG. 2 shows a first embodiment of a device according to the invention in longitudinal section,
[0032] FIG. 3 shows a plan view of the phase adjustment unit from FIG. 2 in the direction of arrow III,
[0033] FIG. 4 shows a schematic illustration of the device from FIG. 2 ,
[0034] FIGS. 5 and 6 each show an enlarged illustration of the detail Z from FIG. 2 ,
[0035] FIGS. 7 and 8 show a second embodiment of a device according to the invention similar to the illustration in FIGS. 5 and 6 ,
[0036] FIG. 9 shows a schematic illustration of a third device according to the invention similar to the illustration in FIG. 4 , and
[0037] FIGS. 10 and 11 show an illustration of the third embodiment of a device similar to the illustration in FIGS. 5 and 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIG. 1 shows a sketch of an internal combustion engine 1 , in which a piston 3 seated on a crankshaft 2 in a cylinder 4 is indicated. In the embodiment illustrated, the crankshaft 2 is connected to an intake camshaft 6 and an exhaust camshaft 7 by respective flexible drives 5 , wherein a first and a second device 11 for variable adjustment of the timing of gas exchange valves 9 , 10 of an internal combustion engine 1 can provide a relative rotation between the crankshaft 2 and the camshafts 6 , 7 . Cams 8 of the camshafts 6 , 7 actuate one or more intake gas exchange valves 9 and one or more exhaust gas exchange valves 10 , respectively. Provision can likewise be made for just one of the camshafts 6 , 7 to be fitted with a device 11 or to provide just one camshaft 6 , 7 , which is fitted with a device 11 .
[0039] FIG. 2 shows a first embodiment of a device 11 according to the invention in longitudinal section. FIG. 3 shows a plan view of a phase adjustment unit 12 of the device 11 , in which the side cover 17 arranged in the line of sight has been omitted.
[0040] The device 11 has a phase adjustment unit 12 and a control valve 13 . The phase adjustment unit 12 has a drive input element 15 and a drive output element 16 . Arranged on an outer circumferential surface of the drive input element 15 is a chain wheel 14 , by means of which torque can be transmitted from the crankshaft 2 to the drive input element 15 by means of a chain drive (not shown). A side cover 17 is secured for conjoint rotation on each of the axial faces of the drive input element 15 .
[0041] The drive output element 16 is in the form of a vane wheel and has a hub element 18 of substantially cylindrical construction, from the outer cylindrical circumferential surface of which, in the embodiment illustrated, two vanes 19 extend outward in the radial direction and are of integral construction with the hub element 18 . A camshaft 6 , 7 of hollow construction passes through a central through opening in the drive output element 16 , wherein the drive output element 16 is connected to the camshaft 6 , 7 by means of a press fit for conjoint rotation therewith.
[0042] Four projections 21 extend radially inward, starting from a circumferential wall 20 of the drive input element 15 . In the embodiment illustrated, the projections 21 are of integral construction with the circumferential wall 20 . The drive input element 15 is mounted on the drive output element 16 in such a way as to be rotatable relative to the latter by means of radially inner circumferential walls of the projections 21 .
[0043] Respective pressure medium spaces 22 are formed within the phase adjustment unit 12 between in each case two projections 21 that are adjacent in the circumferential direction. Each of the pressure medium spaces 22 is delimited in the circumferential direction by opposite, substantially radially extending boundary walls 23 of adjacent projections 21 , in the axial direction by the side covers 17 , in the radially inward direction by the hub element 18 and in the radially outward direction by the circumferential wall 20 . Respective vanes 19 project into two of the four pressure medium spaces 22 , wherein the vanes 19 are designed in such a way that they rest both against the side covers 17 and also against the circumferential wall 20 . Each vane 19 thus divides the respective pressure medium space 22 into two oppositely acting pressure chambers 24 , 25 , an advance chamber 24 and a retardation chamber 25 . The other two pressure medium spaces 22 , which are not divided into pressure chambers 24 , 25 by a vane 19 , are used as volume accumulators 31 . Each of the pressure chambers 24 , 25 communicates with one of the volume accumulators 31 via a pressure medium channel 32 a, b formed in the projections 21 . In this arrangement, a respective first pressure medium channel 32 a connects a volume accumulator 31 to an advance chamber 24 and a respective second pressure medium channel 32 b connects a volume accumulator 31 to a retardation chamber 25 . Each pressure medium channel 32 a, b is assigned a first check valve 33 , which prevents a pressure medium flow from the respective pressure chamber 24 , 25 to the respective volume accumulator 31 and permits a pressure medium flow from the volume accumulator 31 to the respective pressure chamber 24 , 25 as soon as a defined pressure difference prevails between the pressure chamber 24 , 25 and the volume accumulator 31 . The first check valves 33 can be arranged within the pressure medium channels 32 a, b , for example, and can be designed as ball check valves.
[0044] The drive output element 16 is accommodated in the drive input element 15 and is mounted in such a way as to be rotatable relative to the latter within a defined angular range. In one direction of rotation of the drive output element 16 , the angular range is limited by the fact that the vanes 19 come to rest against a respective corresponding boundary wall 23 (advance stop 23 a ) of the associated pressure medium spaces 22 . Similarly, the angular range in the other direction of rotation is limited by the fact that the vanes 19 come to rest against the other boundary walls 23 of the associated pressure medium spaces 22 , which serve as a retardation stop 23 b.
[0045] By supplying pressure to the advance chambers 24 while simultaneously allowing pressure medium to flow out of the retardation chambers 25 , the phase position of the drive output element 16 relative to the drive input element 15 can be adjusted in the direction of earlier timing. In this case, the drive output element 16 is turned relative to the drive input element 15 in the direction of rotation of the device 11 , indicated by the arrow 29 .
[0046] By supplying pressure to the retardation chambers 25 while simultaneously allowing pressure medium to flow out of the advance chambers 24 , the phase position of the drive output element 16 relative to the drive input element 15 can be adjusted in the direction of later timing. In this case, the drive output element 16 is turned relative to the drive input element 15 counter to the direction of rotation 29 of the device 11 .
[0047] By supplying pressure to both groups of pressure chambers 24 , 25 , the phase position can be held constant. As an alternative, provision can be made to supply none of the pressure chambers 24 , 25 with pressure medium during phases in which the phase position is constant. The lubricating oil of the internal combustion engine 1 is generally used as the hydraulic pressure medium.
[0048] Pressure medium is supplied to and discharged from the pressure chambers 24 , 25 by means of a hydraulic circuit, which is illustrated in FIG. 4 and is controlled by means of the control valve 13 . The control valve 13 has an inlet port P, a volume accumulator port V 1 and two working ports A, B. The hydraulic circuit has five pressure medium lines 26 a, b, p, v, t . The first pressure medium line 26 a communicates with the first working port A, on the one hand, and opens into the advance chambers 24 , on the other hand. The second pressure medium line 26 b communicates with the second working port B, on the one hand, and opens into the retardation chambers 25 , on the other hand. The third pressure medium line 26 p connects a pressure medium pump 27 to the inlet port P, wherein a second check valve 34 prevents a pressure medium flow from the control valve 13 to the pressure medium pump 27 and can permit a pressure medium flow in the opposite direction. The fourth pressure medium line 26 v communicates with the volume accumulator port V 1 , on the one hand, and opens into the volume accumulators 31 , on the other hand. The fifth pressure medium line 26 t opens into the volume accumulators 31 , on the one hand, and into a pressure medium reservoir 28 , e.g. an oil sump of the internal combustion engine 1 , on the other hand. In this case, the fifth pressure medium line can open directly the pressure medium reservoir 28 (solid line in FIG. 4 ) or via a third check valve 50 (dashed line in FIG. 4 ).
[0049] The control valve 13 can assume three control positions S 1 -S 3 . In the first control position S 1 , the inlet port P is connected to the first working port A, and the second working port B is connected to the volume accumulator port V 1 . In the second control position S 2 , there is no connection between the working ports A, B, on the one hand, and the inlet port P and the volume accumulator port V 1 , on the other hand. In the third control position S 3 , the inlet port P is connected to the second working port B, and the first working port A is connected to the volume accumulator port V 1 .
[0050] During the operation of the internal combustion engine 1 , the camshaft 6 , 7 rotates about the longitudinal axis thereof. During this process, each gas exchange valve 9 , 10 is opened periodically by means of a cam 8 , counter to the force of a valve spring 30 ( FIG. 1 ), and closed again. During the opening phase of the gas exchange valve 9 , 10 (rising cam 8 ), the camshaft 6 , 7 is acted upon by a braking torque, which corresponds to the vector product of the force of the valve spring 30 and the lever arm of the cam 8 . During the closing of the gas exchange valve 9 , 10 (falling cam), the camshaft 6 , 7 is acted upon by an accelerating torque, which corresponds to the vector product of the force of the valve spring 30 and the lever arm of the cam 8 . The camshaft 6 , 7 is thus acted upon by a periodic alternating moment. The alternating moment has the effect that, in the case of the rising cam 8 , the vanes 19 are urged counter to the direction of rotation 29 of the phase adjustment unit 12 . As a result, the pressure in the advance chambers 24 is increased, and the pressure in the retardation chambers 25 is lowered. In the case of the falling cam 8 , the vanes 19 are urged in the direction of rotation 29 of the phase adjustment unit 12 , as a result of which the pressure in the advance chambers 24 falls and the pressure in the retardation chambers 25 rises.
[0051] During the operation of the internal combustion engine 1 , two states can thus occur. In a first operating state, the system pressure produced within the hydraulic circuit by the pressure medium pump 27 exceeds the pressure produced in the pressure chambers 24 , 25 by the alternating moments acting on the camshaft 6 , 7 . In a second operating state, the pressure peaks produced in the pressure chambers 24 , 25 by the alternating moments exceed the system pressure made available by the pressure medium pump 27 .
[0052] If a phase adjustment in the direction of earlier timing is demanded, the control valve 13 assumes the first control position S 1 . In operating phases in which the operating pressure delivered by the pressure medium pump 27 exceeds the pressure level generated by the alternating moment in the pressure chambers 24 , 25 , the pressure medium delivered by the pressure medium pump 27 passes via the third pressure medium line 26 p , the inlet port P, the first working port A and the first pressure medium line 26 a to the advance chambers 24 . As a result, the vanes 19 within the respective pressure medium spaces 22 are moved in the direction of rotation 29 of the phase adjustment unit 12 . At the same time, pressure medium is displaced from the retardation chambers 25 , via the second pressure medium line 26 b , the second working port B, the volume accumulator port V 1 and the fourth pressure medium line 26 v , into the volume accumulators 31 . The volume of thus urged 31 . The volume of the advance chambers 24 thus increases at the expense of the retardation chambers 25 , and the vanes 19 are moved in the direction of rotation 29 of the phase adjustment unit 12 . As a result, the camshaft 6 , 7 is turned relative to the crankshaft 2 in the direction of earlier timing. The volume accumulators 31 are filled by the pressure medium flowing out of the retardation chambers 25 and excess pressure medium is expelled into the pressure medium reservoir 28 via the fifth pressure medium line 26 t against atmospheric pressure or the third check valve 50 . The pressure level prevailing both in the advance chambers 24 and in the retardation chambers 25 is thus higher than in the volume accumulators 31 , as a result of which the first check valves 33 prevent a pressure medium flow from the volume accumulators 31 into the pressure chambers 24 , 25 .
[0053] In operating phases in which the pressure level generated by the alternating moment in the pressure chambers 24 , 25 exceeds the operating pressure delivered by the pressure medium pump 27 , a distinction must be drawn between two cases: an assisting moment acting in the direction of adjustment and a moment acting counter to the direction of adjustment.
[0054] In the case of an assisting moment, the camshaft 6 , 7 is accelerated, and the vanes 19 are thus moved in the direction of the advance stop 23 a . This results in a pressure drop in the advance chambers 24 and an increase in the pressure in the retardation chambers 25 . The pressure prevailing in the retardation chambers 25 is thus higher than in the advance chambers 24 , and indeed the pressure in the advance chambers 24 can fall below atmospheric pressure. Pressure medium is thus fed from the retardation chambers 25 , via the second pressure medium line 26 b , the second working port B, the volume accumulator port V 1 and the fourth pressure medium line 26 v , to the volume accumulators 31 . Owing to the fifth pressure medium line 26 t opening into the pressure medium reservoir 28 , atmospheric pressure prevails in the volume accumulators 31 or, in embodiments in which a third check valve 50 is provided in the fifth pressure medium line 26 t , a higher pressure level defined by the third check valve 50 prevails, although this is lower than the pressure level within the retardation chambers 25 . Owing to the higher pressure level in the retardation chambers 25 , the first check valves 33 , which connect the volume accumulators 31 to the retardation chambers 25 , block a pressure medium flow from the volume accumulators 31 into the retardation chambers 25 . At the same time, pressure medium passes from the pressure medium pump 27 , via the inlet port P, the first working port A and the first pressure medium line 26 a , to the advance chambers 24 . If the pressure medium requirement of the pressure chambers 24 to be filled exceeds the volume flow supplied by the pressure medium pump 27 , the pressure in the advance chambers 24 falls below the pressure prevailing in the volume accumulators 31 . The first check valves 33 thus allow a pressure medium flow from the volume accumulators 31 to the advance chambers 24 through the first pressure medium channels 32 a . Since the outlet points of the pressure medium channels 32 a, b into the volume accumulators 31 are at a greater distance from the axis of rotation of the phase adjustment unit 12 in the radial direction than the outlet points of the fifth pressure medium line 26 t , the centrifugal forces prevailing in the rotating device 11 ensure that no air is sucked into the advance chambers 24 . At the same time, the volume accumulators 31 are continuously replenished during this process by the pressure medium flowing out of the retardation chambers 25 . In comparison with conventional devices 11 , the advance in the case of a moment with an assisting action is thus assisted by a pressure medium volume stored in the volume accumulators 31 . Compared with devices 11 in which the pressure medium emerging from the retardation chambers 25 is directed to the inlet port P of the control valve 13 and passes from there to the advance chambers 24 , there is the advantage that leakage losses are compensated or even overcompensated by the pressure medium volume already present in the volume accumulators 31 . The phase adjustment speed is thus increased in a reliable manner.
[0055] In the case of a moment acting counter to the direction of adjustment, the camshaft 6 , 7 is acted upon by a braking moment, as a result of which the vanes 19 are urged in the direction of the retardation stop 23 b . The pressure in the advance chambers 24 thus rises, and the pressure medium is hindered from leaving the advance chambers 24 by the second check valve 34 and the first check valves 33 . As a result, the vanes 19 are held in position, with the result that the pressure in the retardation chambers 25 does not drop and thus does not fall below the pressure prevailing in the volume accumulators 31 . The first check valves 33 thus prevent a pressure medium flow from the volume accumulators 31 to the retardation chambers 25 . As a consequence, there is no reverse rotation of the device 11 in the case of a moment directed counter to the phase adjustment direction; on the contrary, the current phase position is maintained.
[0056] If a phase adjustment in the direction of later timing is demanded, the control valve 13 assumes the third control position S 3 . In operating phases in which the operating pressure delivered by the pressure medium pump 27 exceeds the pressure level generated by the alternating moment in the pressure chambers 24 , 25 , the pressure medium delivered by the pressure medium pump 27 passes via the third pressure medium line 26 p , the inlet port P, the second working port B and the second pressure medium line 26 b to the retardation chambers 25 . As a result, the vanes 19 are moved within the respective pressure medium spaces 22 counter to the direction of rotation 29 of the phase adjustment unit 12 . At the same time, pressure medium is forced out of the advance chambers 24 , via the first pressure medium line 26 a , the first working port A, the volume accumulator port V 1 and the fourth pressure medium line 26 v , into the volume accumulators 31 . The volume of the retardation chambers 25 thus increases at the expense of the advance chambers 24 , and the vanes 19 are moved counter to the direction of rotation 29 of the phase adjustment unit 12 . As a result, the camshaft 6 , 7 is turned relative to the crankshaft 2 in the direction of later timing. The volume accumulators 31 are filled by the pressure medium flowing out of the advance chambers 24 , and excess pressure medium is expelled via the fifth pressure medium line 26 t into the pressure medium reservoir 28 against atmospheric pressure or the third check valve 50 . The pressure level prevailing both in the advance chambers 24 and in the retardation chambers 25 is thus higher than in the volume accumulators 31 , as a result of which the first check valves 33 prevent a pressure medium flow from the volume accumulators 31 into the pressure chambers 24 , 25 .
[0057] In operating phases in which the pressure level generated by the alternating moment in the pressure chambers 24 , 25 exceeds the operating pressure delivered by the pressure medium pump 27 , a distinction must once again be drawn between an assisting moment acting in the direction of adjustment and a moment acting counter to the direction of adjustment.
[0058] In the case of an assisting moment, the camshaft 6 , 7 is braked, and the vanes 19 are thus moved in the direction of the retardation stop 23 a . This results in a pressure drop in the retardation chambers 25 and an increase in the pressure in the advance chambers 24 . The pressure prevailing in the advance chambers 24 is thus higher than in the retardation chambers 25 , and indeed the pressure in the retardation chambers 25 can fall below atmospheric pressure. Pressure medium is thus fed from the advance chambers 24 , via the first pressure medium line 26 a , the first working port A, the volume accumulator port V 1 and the fourth pressure medium line 26 v , to the volume accumulators 31 . Owing to the fifth pressure medium line 26 t opening into the pressure medium reservoir 28 , atmospheric pressure prevails in the volume accumulators 31 or, in embodiments in which a third check valve 50 is provided in the fifth pressure medium line 26 t , a higher pressure level defined by the third check valve 50 prevails, although this is lower than the pressure level within the retardation chambers 25 . Owing to the higher pressure level in the advance chambers 24 , the first check valves 33 , which connect the volume accumulators 31 to the advance chambers 24 , block a pressure medium flow from the volume accumulators 31 into the advance chambers 24 .
[0059] At the same time, pressure medium passes from the pressure medium pump 27 , via the inlet port P, the second working port B and the second pressure medium line 26 b , to the retardation chambers 25 . If the pressure medium requirement of the pressure chambers 25 to be filled exceeds the volume flow supplied by the pressure medium pump 27 , the pressure in the retardation chambers 25 falls below the pressure prevailing in the volume accumulators 31 . The first check valves 33 thus allow a pressure medium flow from the volume accumulators 31 to the retardation chambers 25 through the second pressure medium channels 32 b . Since the outlet points of the pressure medium channels 32 a, b into the volume accumulators 31 are at a greater distance from the axis of rotation of the phase adjustment unit 12 in the radial direction than the outlet points of the fifth pressure medium line 26 t , the centrifugal forces prevailing in the rotating device 11 ensure that no air is sucked into the retardation chambers 25 . At the same time, the volume accumulators 31 are continuously replenished during this process by the pressure medium flowing out of the retardation chambers 25 .
[0060] In comparison with conventional devices 11 , the retardation in the case of a moment with an assisting action is thus assisted by a pressure medium volume stored in the volume accumulators 31 . Compared with devices 11 in which the pressure medium emerging from the advance chambers 24 is directed to the inlet port P of the control valve 13 and passes from there to the retardation chambers 25 , there is the advantage that leakage losses are compensated or even overcompensated by the pressure medium volume already present in the volume accumulators 31 . The phase adjustment speed is thus increased in a reliable manner.
[0061] In the case of a moment acting counter to the direction of adjustment, the camshaft 6 , 7 is accelerated, and the vanes 19 are thus urged in the direction of the advance stop 23 a . The pressure in the retardation chambers 25 thus rises, and the pressure medium is hindered from leaving the retardation chambers 25 by the second check valve 34 and the first check valves 33 . As a result, the vane 19 is held in position, with the result that the pressure in the advance chambers 24 does not drop and thus does not fall below the pressure prevailing in the volume accumulators 31 . The first check valves 33 thus prevent a pressure medium flow from the volume accumulators 31 to the advance chambers 24 . As a consequence, there is no reverse rotation of the device 11 in the case of a moment directed counter to the phase adjustment direction; on the contrary, the current phase position is maintained.
[0062] If the current phase position is to be maintained, the control valve 13 assumes the second control position S 2 . In this control position, the working ports A, B are closed. Thus the pressure medium delivered to the inlet port P by the pressure medium pump 27 does not reach either of the working ports A, B. Similarly, no pressure medium flows out of the pressure chambers 24 , 25 to the volume accumulator port V 1 . When pressure peaks caused by the alternating moment acting on the camshaft 6 , 7 occur in the pressure chambers 24 , 25 , pressure medium is prevented from leaving the pressure chambers 24 , 25 by the closed working ports A, B. The vanes 19 are thus clamped hydraulically between the pressure chambers 24 , 25 and, as a result, the current phase position is maintained. At the same time, it is ensured that the pressure prevailing in the pressure chambers 24 , 25 exceeds the pressure prevailing in the volume accumulators 31 , and, as a result, a pressure medium flow from the volume accumulators 31 into the pressure chambers 24 , 25 via the pressure medium channels 32 a, b is prevented.
[0063] FIGS. 5 and 6 show the detail Z from FIG. 2 in an enlarged view, wherein the control valve 13 is illustrated in the first ( FIG. 5 ) and the third control position S 3 ( FIG. 6 ) respectively. The first and the second pressure medium line 26 a, b are designed as radial holes within the drive output element 16 that are offset axially relative to one another. In this embodiment, two fourth pressure medium lines 26 v are provided, which are likewise designed as radial holes within the drive output element 16 that are offset axially relative to one another. The first, the second and the fourth pressure medium lines 26 a, b, v are arranged offset relative to one another in the circumferential direction of the drive output element 16 (see FIG. 3 ), but are shown in one plane in FIGS. 5 and 6 for the sake of clarity. At one end, the first, the second and the fourth pressure medium lines 26 a, b, v open into the advance chambers 24 , the retardation chambers 25 and the volume accumulators 31 , respectively. The other ends of the pressure medium lines 26 a, b, v open into radial holes in the camshaft 6 , 7 , which in turn communicate respectively with the first working port A, the second working port B and two volume accumulator ports V 1 of the control valve 13 , which are designed as radial openings 37 in a valve housing 36 of the control valve 13 . Arranged within the valve housing 36 is a control plunger 38 , which can be moved in the axial direction within the valve housing 36 in the axial direction within the valve housing 36 by means of an actuating unit (not shown), against the force of a spring 39 a spring 39 . The control plunger 38 can be moved into and held in any position between the position illustrated in FIG. 5 and that illustrated in FIG. 6 .
[0064] When the control valve 13 is in the first control position S 1 ( FIG. 5 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via a plunger opening 40 to the first working port A. During this process, the pressure medium passes a first control area 41 , which is defined by the overlap between the plunger opening 40 and the radial opening 37 of the first working port A. From the first working port A, the pressure medium passes via the first pressure medium line 26 a to the advance chambers 24 . At the same time, pressure medium passes out of the retardation chambers 25 , via the second pressure medium line 26 b , to the second working port B. This port is connected by a first annular groove 42 formed on the outer circumferential surface of the control plunger 38 to the volume accumulator port V 1 . On the way from the second working port B to the volume accumulator port V 1 , the pressure medium passes a second control area 43 , which is defined by the overlap between the radial opening 37 of the second working port B and the first annular groove 42 . In the embodiment illustrated, the second control area 43 is made smaller than the first control area 41 (outflow control). The flow out of the retardation chambers 25 is thus restricted relative to the flow to the advance chambers 24 , thereby ensuring that the pressure chambers 24 , 25 are always completely filled during the operation of the internal combustion engine 1 .
[0065] The first control position S 1 can be achieved by a large number of positions of the control plunger 38 relative to the valve housing 36 . At the same time, the control plunger 38 must be in a position in which pressure medium can pass from the inlet port P to the first working port A and pressure medium can pass from the second working port B to the volume accumulator port V 1 . In this case, the first and the second control area 41 , 43 and, in corresponding fashion, the pressure medium flow to and from the pressure chambers 24 , 25 become larger, the further the control plunger 38 moves toward the position illustrated in FIG. 5 .
[0066] When the control valve 13 is in the third control position S 3 ( FIG. 6 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via the plunger opening 40 to the second working port B. During this process, the pressure medium passes a third control area 44 , which is defined by the overlap between the plunger opening 40 and the radial opening 37 of the second working port B. From the second working port B, the pressure medium passes via the second pressure medium line 26 b to the retardation chambers 25 . At the same time, pressure medium passes out of the advance chambers 24 , via the first pressure medium line 26 a , to the first working port A. This port is connected by a second annular groove 45 formed on the outer circumferential surface of the control plunger 38 to the volume accumulator port V 1 . On the way from the first working port A to the volume accumulator port V 1 , the pressure medium passes a fourth control area 46 , which is defined by the overlap between the radial opening 37 of the first working port A and the second annular groove 45 . In the embodiment illustrated, the fourth control area 46 is made smaller than the third control area 44 (outflow control). The flow out of the advance chambers 24 is thus restricted relative to the flow to the retardation chambers 25 , thereby ensuring that the pressure chambers 24 , 25 are always completely filled during the operation of the internal combustion engine 1 .
[0067] The third control position S 3 can be achieved by a large number of positions of the control plunger 38 relative to the valve housing 36 . At the same time, the control plunger 38 must be in a position in which pressure medium can pass from the inlet port P to the second working port B and pressure medium can pass from the first working port A to the volume accumulator port V 1 . The third and the fourth control area 44 , 46 and, in corresponding fashion, the pressure medium flow to and from the pressure chambers 24 , 25 become larger and larger the further the control plunger 38 moves toward the position illustrated in FIG. 6 .
[0068] FIGS. 7 and 8 show a second embodiment similar to the illustrations in FIGS. 5 and 6 . This embodiment is very largely identical with the first embodiment and therefore only the differences are explained below. In the second embodiment, just one fourth pressure medium line 26 v is provided, which communicates with the volume accumulators 31 , on the one hand, and with the single volume accumulator port V 1 , on the other hand. The fourth pressure medium line 26 v is arranged between the first and the second pressure medium line 26 a, b in the axial direction.
[0069] The control plunger 38 has two plunger openings 40 , 47 and an annular groove 42 on the outer circumferential surface thereof, wherein the plunger openings 40 , 47 and the annular groove 42 are spaced apart in the axial direction. The annular groove 42 is arranged between the plunger openings 40 , 47 .
[0070] When the control valve 13 is in the first control position S 1 ( FIG. 7 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via the first plunger opening 40 to the first working port A. During this process, the pressure medium passes a first control area 41 , which is defined by the overlap between the first plunger opening 40 and the radial opening 37 of the first working port A. From the first working port A, the pressure medium passes via the first pressure medium line 26 a to the advance chambers 24 . At the same time, pressure medium passes out of the retardation chambers 25 , via the second pressure medium line 26 b , to the second working port B. This port is connected by the annular groove 42 to the volume accumulator port V 1 . On the way from the second working port B to the volume accumulator port V 1 , the pressure medium passes a second control area 43 , which is defined by the overlap between the radial opening 37 of the second working port B and the annular groove 42 . In the embodiment illustrated, the second control area 43 is made smaller than the first control area 41 (outflow control). The flow out of the retardation chambers 25 is thus restricted relative to the flow to the advance chambers 24 , thereby ensuring that the pressure chambers 24 , 25 are always completely filled during the operation of the internal combustion engine 1 .
[0071] When the control valve 13 is in the third control position S 3 ( FIG. 8 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via the second plunger opening 47 to the second working port B. During this process, the pressure medium passes a third control area 44 , which is defined by the overlap between the second plunger opening 47 and the radial opening 37 of the second working port B. From the second working port B, the pressure medium passes via the second pressure medium line 26 b to the retardation chambers 25 . At the same time, pressure medium passes out of the advance chambers 24 , via the first pressure medium line 26 a , to the first working port A. This port is connected by the annular groove 42 to the volume accumulator port V 1 . On the way from the first working port A to the volume accumulator port V 1 , the pressure medium passes a fourth control area 46 , which is defined by the overlap between the radial opening 37 of the first working port A and the annular groove 42 . In the embodiment illustrated, the fourth control area 46 is made smaller than the third control area 44 (outflow control). The flow out of the advance chambers 24 is thus restricted relative to the flow to the retardation chambers 25 , thereby ensuring that the pressure chambers 24 , 25 are always completely filled during the operation of the internal combustion engine 1 .
[0072] FIG. 9 shows another embodiment of a device 11 according to the invention. The third embodiment is largely identical with the first two embodiments and therefore only the differences are explained below. In contrast to the first two embodiments, the control valve 13 has two volume accumulator ports V 1 , V 2 and an additional drain port T. Each volume accumulator port V 1 , V 2 is connected to the volume accumulators 31 by a respective fourth pressure medium line 26 v . The drain port T is connected to the pressure medium reservoir 28 by means of the fifth pressure medium line 26 t.
[0073] Once again, the control valve 13 can assume three control positions S 1 -S 3 . In the first control position S 1 , the inlet port P is connected to the first working port A, the second working port B is connected to the second volume accumulator port V 2 , and the first volume accumulator port V 1 is connected to the drain port T. In the second control position S 2 , there is no connection between the working ports A, B, on the one hand, and the inlet port P and the volume accumulator ports V 1 , V 2 , on the other hand. In the third control position S 3 , the inlet port P is connected to the second working port B, the first working port A is connected to the first volume accumulator port V 1 , and the second volume accumulator port V 2 is connected to the drain port T.
[0074] FIGS. 10 and 11 show the control valve 13 of the third embodiment and the associated pressure medium lines 26 a, b, v, t.
[0075] The first, the second and the two fourth pressure medium lines 26 a, b, v are once again designed as radial holes within the drive output element 16 that are offset axially relative to one another. The first and second pressure medium lines 26 a, b once again open into the corresponding pressure chambers 24 , 25 and are connected to the working ports A, B. The fourth pressure medium lines 26 v open into the volume accumulators 31 and are each connected to one of the volume accumulator ports V 1 , V 2 . The fifth pressure medium line 26 t is embodied as a radial opening 37 in the camshaft 6 , 7 and communicates with the drain port T and the pressure medium reservoir 28 . Arranged within the valve housing 36 there is once again a control plunger 38 that can be positioned in the axial direction relative to the valve housing 36 . The control plunger 38 is provided with a radial plunger opening 40 , which is arranged between two annular grooves 42 , 45 formed on the outer circumferential surface of the control plunger 38 .
[0076] When the control valve 13 is in the first control position S 1 ( FIG. 10 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via the plunger opening 40 to the first working port A. During this process, the pressure medium passes a first control area 41 , which is defined by the overlap between the plunger opening 40 and the radial opening 37 of the first working port A. From the first working port A, the pressure medium passes via the first pressure medium line 26 a to the advance chambers 24 . At the same time, pressure medium passes out of the retardation chambers 25 , via the second pressure medium line 26 b , to the second working port B. This port is connected by a second annular groove 45 to the second volume accumulator port V 2 . On the way from the second working port B to the second volume accumulator port V 2 , the pressure medium passes a second control area 43 , which is defined by the overlap between the radial opening 37 of the second working port B and the second annular groove 45 . Once the volume accumulators 31 are completely filled, pressure medium passes out of the volume accumulators 31 , via the fourth pressure medium line 26 v , to the first volume accumulator port V 1 , which is connected by the first annular groove 42 to the drain port T. During this process, the pressure medium passes a third control area 44 , which is defined by the overlap between the radial opening 37 of the first volume accumulator port V 1 and the first annular groove 42 . In the embodiment illustrated, the third control area 44 is made smaller than the second control area 43 and smaller than the first control area 41 . The flow out of the retardation chambers 25 is thus restricted relative to the flow to the advance chambers 24 , and hence outflow control is achieved in this embodiment too. At the same time, the inlet flow to the volume accumulators 31 is unrestricted in comparison with the first two embodiments, thereby ensuring that the pressure medium enters said accumulators at a higher pressure.
[0077] When the control valve 13 is in the third control position S 3 ( FIG. 11 ), pressure medium enters the interior of the valve housing 36 via the inlet port P and progresses into the interior of the control plunger 38 . From there, the pressure medium passes via the plunger opening 40 to the second working port B. During this process, the pressure medium passes a fourth control area 46 , which is defined by the overlap between the plunger opening 40 and the radial opening 37 of the second working port B. From the second working port B, the pressure medium passes via the second pressure medium line 26 b to the retardation chambers 25 . At the same time, pressure medium passes out of the advance chambers 24 , via the first pressure medium line 26 a , to the first working port A. This port is connected by the first annular groove 42 to the first volume accumulator port V 1 . During this process, the pressure medium passes a fifth control area 48 , which is defined by the overlap between the radial opening 37 of the first working port A and the first annular groove 42 . Once the volume accumulators 31 are completely filled, pressure medium passes out of the volume accumulators 31 , via the fourth pressure medium line 26 v , to the second volume accumulator port V 2 , which is connected by the second annular groove 42 to the drain port T. During this process, the pressure medium passes a sixth control area 49 , which is defined by the overlap between the radial opening 37 of the second volume accumulator port V 2 and the second annular groove 45 . In the embodiment illustrated, the sixth control area 49 is made smaller than the fourth control area 46 and smaller than the fifth control area 48 . The flow out of the advance chambers 24 is thus restricted relative to the flow to the retardation chambers 25 , and hence outflow control is achieved in this embodiment too. At the same time, the inlet flow to the volume accumulators 31 is unrestricted in comparison with the first two embodiments, thereby ensuring that the pressure medium enters said accumulators at a higher pressure.
[0078] The third embodiment operates in a manner similar to the first two embodiments.
[0079] The devices 11 presented are distinguished by significantly increased phase adjustment speeds. Moreover, the outflow control achieved ensures that there are no major changes in the flow of pressure medium to the pressure chambers 24 , 25 to be filled in the case of small movements of the control plunger 38 , thereby considerably facilitating control of the phase position. Another advantage is that the positions of the control plunger 38 relative to the valve housing 36 which are to be set is independent of whether the volume flow delivered by the pressure medium pump 27 covers the pressure medium requirement of the pressure chambers 24 , 25 to be filled or not. Thus, all that is needed is a single control strategy that can be applied to both operating states of the internal combustion engine 1 , thereby further simplifying control of the device 11 .
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A device ( 11 ) for variably adjusting the control times of gas exchange vales ( 9, 10 ) of an internal combustion engine ( 1 ) having a hydraulic phase adjustment device ( 12 ) and at least one volume accumulator ( 31 ), wherein the phase adjustment device ( 12 ) can be brought into driving connection with a crankshaft ( 2 ) and a camshaft ( 6, 7 ) and at least one early adjustment chamber ( 24 ) and at least one late adjustment chamber ( 25 ) which can be supplied with pressure medium via pressure medium lines ( 26 a, b, p. v ), or from which pressure medium can be drained. A phase position of the camshaft ( 6, 7 ) can be adjusted relative to the crankshaft ( 2 ) in the direction of early control times by supplying pressure medium to the early adjustment chamber ( 24 ) while simultaneously draining pressure medium from the late adjustment chamber ( 25 ), wherein a phase position of the camshaft ( 6, 7 ) can be adjusted relative to the crankshaft ( 2 ) in the direction of late control times by supplying pressure medium to the late adjustment chamber ( 25 ) while simultaneously draining pressure medium from the early adjustment chamber ( 24 ), wherein pressure medium can be supplied to the volume accumulator(s) ( 31 ) during operation of the internal combustion engine ( 1 ).
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an image reading apparatus, an image reading method, and an image reading program for reading image data and performing character recognition on a portion of the image data.
[0003] 2. Description of the Related Art
[0004] An image reading apparatus that reads image data and generates document data therefrom is conventionally used. Also, an image reading apparatus that reads image data and performs character recognition thereon is becoming increasingly popular. However, image reading may not necessarily be performed in the proper order and direction. Japanese Laid-Open Patent Publication No. 9-83691 discloses an image processing technique implemented in the case of alternatingly inputting odd numbered pages and even numbered pages of a book, the technique enabling images to be read in the proper direction and output in proper order based on the alignment direction of characters and preventing the pages from being read in reverse order.
[0005] However, the above-disclosed technique is implemented under the premise that the pages are arranged in proper order when they are read. Specifically, the above-disclosed technique merely relates to switching the direction in which pairs of successive pages are read according to whether characters are aligned vertically or horizontally. In other words, the disclosed technique does not relate to rearranging the direction of images that are read in different directions or rearranging the order of images that are not read in order. Thus, pages have to be arranged in proper order before image data of the pages are read according to the disclosed technique. However, in the case of processing image data of dual-side printed document pages, for example, it may be more convenient to read odd numbered pages first before reading the even-numbered pages. In the case of arranging image data of such document pages in order, the front and back side of each page may have to be read which may be quite burdensome. Accordingly, a technique is in demand for rearranging read image data in proper order and recombining the image data.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention are directed to an image reading apparatus, an image reading method, and an image reading program that are configured to assign order to image data of a document that are input and read in random order, rearrange the image data in proper order, and generate a new document that is arranged in proper order.
[0007] According to one embodiment of the present invention, an image reading apparatus is provided that includes:
[0008] an image data acquiring unit configured to acquire document image data including more than one set of page image data;
[0009] an image reading unit configured to read an image located at a predetermined page position from the acquired set of page image data;
[0010] a conversion unit configured to recognize the read image of the predetermined page position and convert the recognized image into text data; and
[0011] an order assigning unit configured to assign page number order to the set of page image data according to value information represented by the converted text data.
[0012] According to another embodiment of the present invention, an image reading method is provided that includes the steps of:
[0013] acquiring document image data including more than one set of page image data;
[0014] reading an image located at a predetermined page position from the acquired set of page image data;
[0015] recognizing the read image of the predetermined page position and converting the recognized image into text data; and
[0016] assigning page number order to the set of page image data according to value information represented by the converted text data.
[0017] According to another embodiment of the present invention, a computer-readable program is provided that is run on a computer to execute the image reading method according to an embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a diagram showing an overall configuration of an image reading apparatus according to an embodiment of the present invention;
[0019] FIG. 2 is a block diagram showing an exemplary hardware configuration of an image reading apparatus according to an embodiment of the present invention;
[0020] FIG. 3 is a diagram illustrating a process of reading image data of pages of a document;
[0021] FIG. 4 is a diagram illustrating how the image data are arranged after reading the document;
[0022] FIG. 5 is a diagram illustrating a process of rearranging the image data in proper order after reading the page numbers of the pages;
[0023] FIG. 6 is a diagram illustrating a process of recombining the rearranged image data;
[0024] FIG. 7 is a diagram illustrating a process of recognizing image data of an odd page number;
[0025] FIG. 8 is a diagram illustrating a process of recognizing image data of an even page number;
[0026] FIG. 9 is a flowchart illustrating a process sequence of reading, recognizing, and rearranging image data;
[0027] FIG. 10 is a diagram illustrating a process of reading a page number area from image data of an odd-numbered page as is read;
[0028] FIG. 11 is a diagram illustrating a process of reading a page number area from image data of the odd-numbered page turned upside down;
[0029] FIG. 12 is a diagram illustrating a process of reading a page number area from image data of an even-numbered page as is read;
[0030] FIG. 13 is a diagram illustrating a process of reading a page number are from image data of the even-numbered page turned upside down;
[0031] FIG. 14 is a diagram illustrating a process of reading an upper section of image data of a page;
[0032] FIG. 15 is a diagram illustrating a page number recognition process involving image data rotation;
[0033] FIG. 16 is a diagram showing a designation screen for specifying a page number area;
[0034] FIG. 17 is a diagram illustrating a process of reading a page number area from image data of two facing pages oriented in a proper direction;
[0035] FIG. 18 is a diagram illustrating a process of reading a page number area from image data of two facing pages turned upside down;
[0036] FIG. 19 is a diagram illustrating a process of recognizing a page number from image data of two facing pages;
[0037] FIG. 20 is a diagram illustrating a process of reading a page number area from image data of two facing pages turned sideways;
[0038] FIG. 21 is a diagram illustrating a process of recognizing an even page number from image data of two facing pages turned sideways;
[0039] FIG. 22 is a diagram illustrating a process of recognizing an odd page number from image data of two facing pates turned sideways;
[0040] FIG. 23 is a diagram illustrating a process of identifying the direction of a page number based on the direction of a title of a page;
[0041] FIG. 24 is a flowchart illustrating a page number reading pre-process;
[0042] FIG. 25 is a diagram illustrating a process of determining an original page size based on histograms of image data;
[0043] FIG. 26 is a diagram illustrating a process of moving a page number area;
[0044] FIG. 27 is a diagram illustrating a document including image data having unnecessary margin portions;
[0045] FIG. 28 is a diagram illustrating a document including image data having margin portions removed therefrom; and
[0046] FIG. 29 is a flowchart illustrating another process of recognizing and rearranging image data.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] In the following, preferred embodiments of the present invention are described with reference to the accompanying drawings.
[0048] FIG. 1 is a diagram showing a configuration of an image reading apparatus according to an embodiment of the present invention. The illustrated image reading apparatus may be used to scan a document 110 , for example. Image data of the pages of the document 110 may be read to obtain image data of the document. However, it is noted that the pages may not necessarily be read in proper order. Accordingly, the image data of the pages may desirably be rearranged in proper order upon generating image data of the document 110 .
[0049] FIG. 2 is a block diagram showing an exemplary hardware configuration of the image reading apparatus according to an embodiment of the present invention. In the illustrated example of FIG. 2 , the image reading apparatus 100 includes a CPU (central processing unit) 201 , a ROM (read only memory) 202 , a RAM (random access memory) 203 , a HDD (hard disk drive) 204 , a HD (hard disk) 205 , a CD/DVD drive 206 , a CD/DVD 207 , a display 208 , an I/F (interface) 209 , a keyboard 210 , a mouse 211 , a scanner 212 , and a printer 213 . Also, the above component elements 201 - 213 are interconnected by a bus 220 .
[0050] The CPU 201 controls overall operations of the image reading apparatus 100 . The ROM 202 stores various programs. The RAM 203 is used as a working area for the CPU 201 . The HDD 204 controls reading/writing of data on the HD 205 in accordance with control command signals from the CPU 201 . The HD 205 stores data that are written thereon by the HDD 204 . The CD/DVD drive 206 controls reading/writing of data on the CD/DVD 207 in accordance with control command signals from the CPU 201 .
[0051] The CD/DVD 207 stores data written thereon by the CD/DVD drive 206 and may be detached from the image reading apparatus 100 . The CD/DVD 207 as an attachable storage medium may correspond to a CD-ROM (CD-R, CD-RW) or a DVD (digital versatile disk), for example. In other embodiments, a FD (flexible disk), a MO (magneto-optic disk), or a memory card may be used as the detachable medium, for example. The display 208 may be a TFT (thin film transistor) liquid display, a CRT (cathode ray tube), or a plasma display, for example.
[0052] The I/F 209 functions as an interface of the image reading apparatus 100 and may be connected to a network 203 such as a phone line, the Internet, or a local area network via a communication line. The I/F 209 controls input/output of data to/from a terminal.
[0053] The keyboard 210 and mouse 211 are used for inputting/setting data to the image reading apparatus 100 . The scanner 21 optically reads image information. The printer 213 may be a laser printer or an inkjet printer that prints image information, for example.
[0054] FIG. 3 is a diagram illustrating an exemplary process for reading image data of a document. In the illustrated example, image data of six pages that are in random order are read, namely, pages 5, 7, 9, 10, 8, and 4 are read in this order. The image data of the pages include corresponding page numbers. That is, a page number 302 is written in each set of image data 301 so that the page number 302 may be read when the image data 301 are read. In the illustrated example, image data of the pages are successively read along the direction of arrow 303 .
[0055] FIG. 4 is a diagram illustrating how the image data are arranged after reading the pages. At this stage, the image data 301 and page number 302 of each page are read, and character recognition is performed on the read page number 302 . The number identified by the character recognition is assigned to the corresponding image data 301 as page number information. Specifically, the page numbers 302 of the image data 301 of the read pages may be identified as pages numbers 5, 7, 9, 10, 8, and 4 (from the left side) in the illustrated example, and in turn, page number order information 400 is assigned to the read pages.
[0056] FIG. 5 is a diagram illustrating a process of rearranging the image data after the page numbers are read. As is described above in relation to FIG. 4 , the page numbers 302 of image data 301 are read, but at this point, the image data 301 are not yet arranged in proper order according to their corresponding page numbers as is illustrated by arrangement 501 where the image data 301 of pages 5, 7, 9, 10, 8, 4 are arranged in this order. Since the page numbers 302 of the image data 301 are recognized, the image data 301 may be rearranged in proper order based on the recognized page number information assigned to the image data 301 as is illustrated by arrangement 502 . Specifically, in arrangement 502 , the image data 301 of pages 4, 5, 7, 8, 9, and 10 are arranged in this order.
[0057] FIG. 6 is a diagram illustrating how the rearranged image data are recombined. As is described above in relation to FIG. 5 , the image data 301 are rearranged in proper order as is illustrated by arrangement 502 , but at this point, the image data 301 are not yet compiled into one document file. Thus, the image data 301 of pages 4, 5, 7, 8, 9, and 10 arranged in this order have to be combined and stored as a new set of image data.
[0058] In the above-described example, it is assumed that the page number of each page is located at the same position. However, in certain types of documents such as a book, the position of page numbers may be different depending on whether the page is an odd-numbered page or an even-numbered page, for example. Specifically, in a case where the page number of a book is arranged to be positioned at the outer edge of a page, odd page numbers and even page numbers may be located at opposite sides. When character recognition of page numbers is performed without taking such a factor into consideration, only page numbers located on one side may be recognized while page numbers located on the other side may not be recognized. Or in another example, character recognition may be completely off target so that page numbers may not be recognized at all from any of the pages. However, performing character recognition on the entire image data of each page to recognize the page number may be inefficient and impractical. Thus, in a preferred embodiment, differing character recognition positions are designated for an odd-numbered page and an even-numbered page.
[0059] FIG. 7 is a diagram illustrating a process of recognizing image data of an odd page number. In the illustrated example, a page number 701 is written in image data 700 subject to image reading. Since page numbers are located at different positions depending on whether the page is an odd-numbered page or an even-numbered page, it is first assumed that the page number 701 is an odd number. Accordingly, character recognition position 702 for an odd page number is read and character recognition is performed thereon to recognize page number 701 . In this way, the page number 701 of the image data 700 may be identified as page 5.
[0060] FIG. 8 is a diagram illustrating a process of recognizing image data of an even page number. In this illustrated example, a page number 801 is written in image data 800 subject to image reading. As in the example of FIG. 7 , the page number 801 is first assumed to be an odd number. Accordingly, character recognition position 802 for an odd page number is read and character recognition is performed thereon. However, since the page number 801 is not located at this position 802 , no page number is recognized. In such a case, it is assumed that the page number 801 is an even number, and the character recognition position 802 is moved along arrow 803 to character recognition position 804 for an even page number so that character recognition may be performed thereon. Thus, the page number 801 is recognized from character recognition position 804 . In this way, the page number 801 of the image data 800 may be identified as page 4.
[0061] FIG. 9 is a flowchart illustrating an image reading process sequence that involves reading, recognizing, and rearranging image data. In this process, first, information on a page number area is specified (step S 901 ). For example, information on the page number area may be specified by designating whether the image data represent a single page or two facing pages, whether a page number is located at the center, whether an odd page number is located at the right side or the left side, and whether the odd page number is positioned at an upper side or a lower side.
[0062] Then, image data of a page are read (step S 902 ). Specifically, an image is read from the specified page number area. Then, the read image data are stored (step S 903 ). After storing the read image data, a determination is made as to whether image data have been read for all the relevant pages (step S 904 ). If image reading for all the pages is not yet complete (step S 904 , NO), the process goes back to step S 902 in order to complete reading of the image data of all pages.
[0063] If it is determined that the image data of all pages have been read (step S 904 , YES), a determination is made as to whether an image exits within an odd page number area (step S 905 ). If an image exits within the odd page number area (step S 905 , YES), namely, if a page number is found in this area, page number character recognition is performed on this odd page number area (step S 906 ) and the process moves on to step S 913 .
[0064] If an image does not exist within the odd page number area (step S 905 , NO), a determination is made as to whether an image exists in an even page number area (step S 907 ). If an image exists within the even page number area (step S 907 , YES), namely, if a page number is found in this area, page number recognition is performed on this even page number area (step S 908 ) and the process moves on to step S 913 .
[0065] If an image does not exist within the even page number area (step S 907 , NO), a determination is made as to whether an image exists within a reversed odd page number area (step S 909 ). If an image exists within the reversed odd page number area (step S 909 , YES), namely, if a page number is found in this area, page number character recognition is performed on this reversed odd page number area (step S 910 ) and the process moves on to step S 913 .
[0066] If an image does not exist within the reversed odd page number area (step S 909 , NO), a determination is made as to whether an image exists within a reversed even page number area (step S 911 ). If an image exists within this area (step S 911 , YES), namely, if a page number is found in this area, page number character recognition is performed on this reversed even page number area (step S 912 ) and the process moves on to step S 913 .
[0067] If an image does not exist within the reversed even page number area (step S 911 , NO), a determination is made as to whether character recognition has been performed on all pages (step S 913 ). If character recognition has not been performed on all pages (step S 913 , NO), the process goes back to step S 905 . If character recognition has been performed on all pages (step S 913 , YES), image data of the pages are sorted and rearranged in proper order based on the page number information to be stored (step S 914 ) after which the process sequence is ended.
[0068] FIG. 10 is a diagram illustrating a process of reading image data of an odd-numbered page. In the illustrated example, a page number 1001 is written in image data 1000 subject to image reading. As in FIG. 7 , first it is assumed that the page number 1001 is an odd page number upon performing character recognition. Thus, character recognition position 1002 is read and character recognition is performed thereon. However, since a page number cannot be found in this position 1002 , it is then assumed that the page number 1001 is an odd page number. Thus, character recognition position 1003 is read and character recognition is performed thereon. However, a page number cannot be found in this position 1003 either.
[0069] FIG. 11 is a diagram illustrating a process of reading image data of the odd-numbered page turned upside down. Specifically, after performing character recognition on the character recognition positions 1002 and 1003 in FIG. 10 , the image data 1000 are turned upside down (reversed) to obtain image data 1100 having a page number 1101 written therein. Then, as in FIG. 10 , it is assumed that the page number 1101 is an odd page number, and character recognition position 1102 is read to perform character recognition thereon. In this case, the page number 1101 is recognized at position 1102 . In this way, the page number 1101 of the image data 1100 may be identified as page 5.
[0070] FIG. 12 is a diagram illustrating a process of reading image data of an even-numbered page. In the illustrated example, a page number 1201 is written in image data 1200 subject to image reading. As in the example of FIG. 7 , first it is assumed that the page number 1201 is an odd page number. Thus, character recognition position 1202 for an odd page number is read and character recognition is performed thereon. However, since the page number 1201 is not recognized from this position 1202 , it is then assumed that the page number 1201 is an even page number. Thus, character recognition position 1203 for an even page number is read and character recognition is performed thereon. However, the page number 1201 is not recognized from this position 1203 either.
[0071] FIG. 13 is a diagram illustrating a process of reading image data of the even-numbered page turned upside down. After character recognition is performed on positions 1202 and 1203 in FIG. 12 , the image data 1200 are turned upside down (reversed) to obtain image data 1300 having a page number 1301 written therein. Then, as in FIG. 12 , it is first assumed that the page number 1301 is an odd page number. Accordingly, character recognition position 1302 for an odd page number is read and character recognition is performed thereon. However, the page number 1301 is not recognized from this position 1302 so that the page number 1301 is then assumed to be an even page number. Accordingly, the character recognition position is moved in the direction indicated by arrow 1303 to position 1304 , and the page number 1301 is recognized from this position 1304 . In this way, the page number 1301 of the image data 1300 may be identified as page 4.
[0072] As can be appreciated from the above descriptions, when image data read from a page are turned upside down (reversed), the image data are reversed after confirming that an image (page number) cannot be recognized from the image data in its original orientation and page number character recognition is performed on the reversed image data. In this example, image data may be rearranged in proper order based on their page number information regardless of the orientation in which the image data are read.
[0073] It is noted that the above-described example illustrates a case of reading image data that are reversed vertically (i.e., turned upside down); however, in other examples, image data may be turned sideways. In one embodiment, an image of a page number may be read from one of four corner positions of image data subject to image reading, and the image of the page number may be rotated according to its orientation so that the page number may be successfully recognized, for example.
[0074] In the following, a page number character recognition process that involves such image rotation is described. In this process, as in FIGS. 10 and 12 , first, an odd page number area (e.g., position 1002 and position 1202 ) and an even page number area (e.g., position 1003 and position 1203 ) are read. Then, when an image (page number) is not recognized from any of these areas, a next process as is illustrated in FIGS. 14 and 15 is performed instead of the process of reversing the image data as is illustrated in FIGS. 11 and 13 .
[0075] FIG. 14 is a diagram illustrating a process of reading an upper portion of image data. Specifically, after reading a lower portion of image data as is described above, the process moves on to read an upper portion of image data 1000 . It is noted that the position of a page number varies depending on whether the page number is an odd page number or an even page number. Therefore, at first, it is assumed that the page number to be recognized is an odd page number. Accordingly, position 1401 for an odd page number is read. However, since a page number cannot be read from position 1401 , the page number to be recognized is then assumed to be an even page number. Accordingly, position 1402 for an even page number is read and a page number is read from this position 1402 .
[0076] It is noted that at this point, the page number is not yet identified. That is, although image data of the page number are read, the page number is not yet recognized as page number information for determining the page order. In the present example, recognition of the page number is performed by rotating image data of the page number.
[0077] FIG. 15 is a diagram illustrating a page number recognition process involving image rotation. In FIG. 14 , image data of a page number is read from position 1402 . If the page number is properly oriented within the image data, the page number may be recognized from the image data as is read. However, if the page number is turned upside down or sideways, the page number may not be properly recognized. Accordingly, in the present example, character recognition is successively performed on image data of position 1402 in its original orientation, in a reversed orientation, in a 90-degree-rotated orientation, and in a 270-degree-rotated orientation. A character properly recognized from one of these character recognition processes is identified as the page number of the image data.
[0078] Specifically, FIG. 15 illustrates a case in which page number 1500 (in the form of image data) is read from position 1402 . As is shown in this drawing, the character of page number 1500 is not properly oriented (i.e., turned to the right). First, character recognition is performed on page number 1500 in its original orientation. However, a character cannot be properly recognized from page number 1500 since the character is turned sideways. Then, character recognition is performed on image data of the page number 1500 in a reversed orientation. However, a character cannot be properly recognized from the reversed image data either.
[0079] Then, character recognition is performed on image data of the page number 1500 rotated clockwise by 90 degrees. However, a character cannot be properly recognized from the 90-degree-rotated image data since the character is turned upside down in this case. Then, character recognition is performed on image data of the page number 1500 rotated clockwise by 270 degrees, namely, rotated counterclockwise by 90 degrees. In this case the number ‘5’ may be recognized from the image data and the page number 1500 may be recognized as page 5. In turn, the image data 1000 is rotated clockwise by 270 degrees to obtain image data 1501 having a properly oriented page number 1502 written therein.
[0080] As can be appreciated from the above descriptions, according to an embodiment of the present invention, page numbers may be read, recognized, and used for rearranging image data in proper order regardless of whether the image data are properly oriented, turned upside down, or turned sideways.
[0081] It is noted that the above-described examples relate to reading a single page of a document and performing character recognition thereon. However, there may be cases in which two facing pages of a document are read at once and character recognition is performed thereon. In the following, a character recognition process that is performed in such a case is described.
[0082] FIG. 16 is a diagram showing an exemplary designation screen for specifying information on a page number area. In the illustrated example, first, a designation is made as to whether single-page reading or double-page reading is performed. In this case, double-page reading is designated. Then, the page number area of an odd page number is designated. It is noted that the illustrated screen portion for designating the page area number is displayed when double-page reading is designated; however, a similar screen portion may be displayed when single-leaf reading is designated as well. In the present example, a designation is made as to whether the page number area of the odd page number is located at the top, center, or bottom of a page (‘bottom’ is designated in FIG. 16 ). Then, a designation is made as to whether the page number area is located at the right side, center, or left side (‘left’ is designated in FIG. 16 ).
[0083] FIG. 17 is a diagram illustrating a process of recognizing the page numbers of two facing pages that are properly oriented. In the illustrated example, image data 1700 is subject to the present process. Image data 1700 includes page numbers 1701 and 1702 . Since the lower left hand side area of two facing pages is designated as the page number area in FIG. 16 , image data of position 1703 is read. In turn, the page number 1701 is recognized from position 1703 . In this way, the page number 1701 at the lower left hand side of the image data 1700 may be identified as page 5. It is noted that the page number 1702 at the lower right hand side may be identified as page 6 without performing character recognition on the relevant position since it is known that the page number 1702 is that coming right after page number 1701 .
[0084] FIG. 18 is a diagram illustrating a process of reading and recognizing an image from image data of two facing pages turned upside down. In this process, first a page number recognition process is performed on image data 1800 . The image data 1800 includes page numbers 1801 and 1802 . Since it is designated in FIG. 16 that the lower left hand side area of two facing pages corresponds to the page number area, image reading is performed on position 1803 at the lower left hand side of image data 1800 . However, since no image (page number) can be read from position 1803 , the process moves on to performing image reading on position 1804 at the upper right hand side of image data 1800 corresponding to the position 1803 turned upside down. In this case, the page number 1802 can be read from position 1804 so that the process moves on to character recognition of the page number 1802 .
[0085] In the present example, since the image data 1800 is turned upside down, the page number 1802 is also turned upside down so that the page number (character) may not be properly recognized from the image data of page number 1802 in its original orientation. Accordingly, character recognition is performed on image data of page number 1802 oriented in four different directions as in the example of FIG. 15 .
[0086] FIG. 19 is a diagram illustrating a process of recognizing a page number from image data of two facing pages. As is described in relation to FIG. 15 , when image data of a page number are turned upside down or sideways, the page number (character) may not be properly recognized from the image data as is read. Accordingly, character recognition is successively performed on image data of position 1804 in its original orientation, in an upside down orientation, in a 90-degree rotated orientation, and in a 270-degree rotated orientation so that a character may be properly recognized from the character recognition process, and such a character is identified as page number information of the image data.
[0087] Specifically, in FIG. 19 , page number 1900 (in the form of image data) is not oriented in a proper direction (i.e., is turned upside down). First, character recognition is performed on page number 1900 in its original orientation. However, a character is not properly recognized from page number 1900 since it is not oriented in the proper direction. Then, character recognition is performed on image data of page number 1900 turned upside down. As a result, the number ‘7’ is recognized from the upside down image data, and the page number 1900 is identified as page 7. Thus, it may be determined that image data 1800 represents an image of pages 7 and 8 of a document.
[0088] The image data 1800 is then turned upside down to obtain image data 1901 having page numbers 1902 and 1903 corresponding to page numbers 1802 and 1801 oriented in the proper direction. It is noted that in the above-described example, the page number 1900 is turned upside down; however, there may be cases in which image data of a page number is turned sideways as well. In such cases, a character may not be properly recognized from image data of the page number turned upside down. Accordingly, character recognition is performed on image data of the page number rotated clockwise by 90 degrees. When a character is not properly recognized from such image data, character recognition is performed on image data of the page number rotated clockwise by 270 degrees.
[0089] FIG. 20 is a diagram illustrating a process of reading and recognizing image data of two facing pages that are turned sideways. In this process, first, a recognition process is performed on image data 2000 . Since the page number area is designated to be at the lower left hand side of two facing pages, image reading is performed on position 2001 . In this case, an image can be read from position 2001 . However, since the read image data 2100 are turned sideways, a page number (character) may not be properly recognized from the image data 2100 as is read. Accordingly, character recognition is performed on image data of the page number oriented in different directions as is described in relation to FIGS. 15 and 19 .
[0090] FIG. 21 is a diagram illustrating a process of recognizing the page number of an even-numbered page of two facing pages that are oriented sideways. In this process, character recognition is successively performed on image data of position 2001 in its original orientation, in an upside down orientation, in a 90-degreee rotated orientation, and in a 270-degree rotated orientation, and a character that is properly recognized from the image data is identified as a page number. In FIG. 21 , the character of page number 2100 is not oriented in a proper direction (i.e., is turned to the right). First, character recognition is performed on the page number 2100 in its original orientation. However, a character cannot be properly recognized from page number 2100 since it is not oriented in the proper direction. Then, character recognition is performed on image data of the page number 2100 turned upside down. However, a character cannot be properly recognized from the upside down image either.
[0091] Then, character recognition is performed on image data of the page number 2100 rotated clockwise by 90 degrees in which case the number ‘6’ may be recognized from the image data. On the other hand, when character recognition is performed on image data of the page number 2100 rotated clockwise by 270 degrees, the number ‘9’ may be recognized from the image data. As can be appreciated, in the present case, two numbers ‘6’ and ‘9’ are recognized from the character recognition processes so that the page number cannot be identified. Thus, in such a case, character recognition is performed on position 2101 .
[0092] FIG. 22 is a diagram illustrating a process of recognizing the page number of an odd-numbered page of two facing pages that are turned sideways. In this process, character recognition is performed on image data of position 2101 in different orientations (i.e., original orientation, upside down, 90-degree rotation, 270-degree rotation) in a manner similar to that described above, and a character properly recognized in the character recognition processes is identified as a page number. First, character recognition is performed on page number 2200 as the image data of position 2101 in its original orientation. However, a character cannot be properly recognized since page number 2200 is not oriented in the proper direction. Then, character recognition is performed on image data of the page number 2200 turned upside down. However, a character is not properly recognized from the upside down image data either.
[0093] Then, character recognition is performed on image data of the page number 2200 rotated clockwise by 90 degrees. However, a character is not properly recognized in this case either. On the other hand, when character recognition is performed on image data of the page number 2200 rotated clockwise by 270 degrees, namely, rotated counterclockwise by 90 degrees, the number ‘5’ may be recognized from the image data. As can be appreciated, only one character is recognized from the character recognition processes performed with respect to page number 2200 . Specifically, the page number 2200 is identified as page number 5. Thus, the image data 2000 may be identified as an image of pages 5 and 6 as two facing pages of a document. In turn, the image data 2000 are rotated clockwise by 270 degrees to obtain image data 2201 having page numbers 2202 and 2203 oriented in the proper direction.
[0094] FIG. 23 is a diagram illustrating a process of identifying the direction of a page number based on the direction of a title. It is noted that the previously-described embodiments of the present invention involve performing character recognition on image data as is read, changing the orientation of image data of a page and performing character recognition thereon, or changing the orientation of image data of a page number character and performing character recognition thereon. In another embodiment, the direction of image data may be determined by determining the direction of a title and a page number may be identified based on the determined direction of the title.
[0095] Specifically, in the illustrated example of FIG. 23 , image data 2301 includes a title 2302 . By identifying this title 2302 upon reading the image data 2301 , the direction of the image data 2301 may be determined. In turn, position 2304 may be located along arrow 2303 . That is, by identifying the title 2302 , it may be determined that the page number area is at position 2304 . In turn, the page number ‘5’ may be read and identified from position 2304 .
[0096] It is noted that the above process relates to identifying the page number from the image data 2301 of an odd-numbered page. However, a similar process may be performed for identifying a page number from image data 2311 of an even-numbered page although the page number area of the even-numbered page may be located at a different position. Specifically, by reading the image data 2311 , a title 2312 that is included therein may be identified and the direction of the image data 2311 may be determined. Then, position 2314 may be located along arrow 2313 . That is, by identifying the title 2312 , it may be determined that the page number area is at position 2314 . Accordingly, page number ‘6’ may be read and identified from position 2314 .
[0097] FIG. 24 is a flowchart illustrating an image reading process including a page number reading pre-process. The present pre-process may be performed before actually performing page number character recognition in the image reading process illustrated in FIG. 9 to improve the accuracy of the recognition process. Specifically, the present pre-process may be performed between steps S 903 and S 905 of FIG. 9 .
[0098] In the process of FIG. 24 , steps S 901 through S 903 are identical to the process of FIG. 9 . Then, an original page size is determined based on vertical/horizontal histograms (step S 2401 ). It is noted that this process is described in detail below with reference to FIG. 25 . Then, a determination is made as to whether image data reading has been performed on all relevant pages (step S 904 ) as in FIG. 9 . If image data reading is not performed on all pages (step S 904 , NO), the process goes back to step S 902 to complete image reading of all pages.
[0099] When image reading of all pages is complete (step S 904 , YES), the original page sizes of the pages are statistically processed to calculate a root mean square value (step S 2402 ). It is noted that this process is described in detail below with reference to FIG. 27 . Then, page portions of all pages are extracted based on the histograms and calculated original page sizes of these pages (step S 2403 ). This process is described in detail below with reference to FIG. 28 . Then, the pre-process sequence may be completed and the process moves on to step S 905 of FIG. 9 .
[0100] FIG. 25 is a diagram illustrating the process of determining a original page size based on histograms. For example, in a case where the document subject to image reading is a copied document of an original document, the copied document may include black margins in when the original document is smaller than the copied document. In such a case, page numbers of the copied document may not be successfully read when the position of the page number area is uniformly set. Accordingly, in the present process, a relevant page portion is identified and the page number area is changed accordingly in order to improve the accuracy of the page number recognition process.
[0101] Specifically, image data 2500 includes black margins as described above so that a page number cannot be recognized from reading image data of position 2501 . Accordingly, histograms of the image data 2500 are obtained. That is, with respect to the horizontal direction, a horizontal histogram 2502 of the image data 2500 is obtained so that a horizontal margin (side margin) 2503 may be determined based on changes in the horizontal histogram 2502 . Similarly, with respect to the vertical direction, a vertical histogram 2504 of the image data 2500 is obtained so that a vertical margin (bottom margin) 2505 may be determined based on changes in the vertical histogram 2504 . In this way, a original page size of the image data 2500 excluding the margins 2503 and 2505 (relevant page portion) may be determined, and the page number area 2501 may be moved to an appropriate position based on the determined original page size.
[0102] FIG. 26 is a diagram illustrating a process of moving the page number area. It can be appreciated that a page number cannot be recognized from performing character recognition on the page number area 2501 when the existence of margins is determined based on the histograms as in FIG. 25 . Thus, the page number area 2501 is moved to a new page number area 2601 , and image reading and character recognition are performed on the new page number area 2601 so that a page number may be successfully read and recognized.
[0103] FIG. 27 is a diagram illustrating image data of a document including unnecessary margins. The document includes image data 2701 , image data 2702 , and image data 2703 . The image data 2701 includes a relevant page portion 2704 and a margin portion. The image data 2702 includes a relevant page portion 2705 and a margin portion. The image data 2703 includes a relevant page portion 2706 and a margin portion. As is described above, the respective margin-excluded original page sizes of the image data 2701 - 2703 may be obtained based on their histograms. Additionally, in the case of reading image data of plural pages, statistical information on the original page sizes of the image data may be obtained and a standard original page size may be calculated therefrom. This standard original page size may be used to determine the page number area and document range of the image data 2701 - 2703 , for example.
[0104] FIG. 28 is a diagram illustrating a document with pages having unnecessary margins removed therefrom. The image data 2701 - 2703 shown in FIG. 27 may have margins removed therefrom in the manner illustrated in FIG. 25 , for example, and the resulting image data may be rearranged in proper order according to their page number information and recomposed into a document including image data 2801 - 2803 that are properly arranged in numerical order.
[0105] FIG. 29 is a flowchart illustrating another process for recognizing and rearranging image data. In FIG. 9 , character recognition is performed on image data in its original orientation (as is read) and image data that are turned upside down. However, a document page may be read sideways in addition to being read in the proper direction or upside down. Also, the character recognition position may need to be adjusted, for example. FIG. 29 illustrates a process that takes such additional factors into consideration upon recognizing a page number and rearranging image data. It is noted that the process steps S 901 -S 904 of FIG. 9 or the process illustrated in FIG. 24 may be performed before moving on to the present process of recognizing and rearranging image data.
[0106] In this process, first, a determination is made as to whether an image exists in an odd page number area (step S 905 ). If an image is found in this area (step S 905 , YES), page number character recognition in four orientations mode is performed (step S 2901 ). Specifically, it is determined whether the character to be recognized is oriented in the proper direction, turned upside down, turned 90 degrees, or turned 270 degrees, and the orientation of the image is properly adjusted as is necessary to perform character recognition thereon. Then, a determination is made as to whether a correlation between page number and mode is correct (step S 2902 ). If the correlation is not correct (step S 2902 , NO), the process moves on to step S 907 . If the correlation is correct (step S 2902 , YES), the process moves on to step S 2909 .
[0107] If an image is not found in the odd page number area (step S 905 , NO), a determination is made as to whether an image exists in an even page number area (step S 907 ). If an image is found in this area (step S 907 , YES), page number character recognition in four orientations mode is performed (step S 2903 . Specifically, it is determined whether the character to be recognized is oriented in the proper direction, turned upside down, turned 90 degrees, or turned 270 degrees, and the image is properly adjusted as is necessary to perform character recognition thereon. Then, a determination is made as to whether a correlation between page number and mode is correct (step S 2904 ). If the correlation is not correct (step S 2904 , NO), the process moves on to step S 909 . If the correlation is correct (step S 2904 , YES), the process moves on to step S 2909 .
[0108] If an image is not found in the even page number area (step S 907 , NO), a determination is made as to whether an image exists in a reversed odd page number area (step S 909 ). If an image is found in this area (step S 909 , YES), page number character recognition is performed in four orientations mode (step S 2905 ). Then, a determination is made as to whether a correlation between page number and mode is correct (step S 2906 ). If the correlation is not correct (step S 2906 , NO), the process moves on to step S 911 . If the correlation is correct, (step S 2906 , YES), the process moves on to step S 2909 .
[0109] If an image is not found in the reversed odd page number area (step S 909 , NO), a determination is made as to whether an image exists in a reversed even page number area (step S 911 ). If an image is found in this area (step S 911 , YES), page number character recognition in four orientations mode is performed (step S 2907 ), and the process moves to step S 2902 .
[0110] If an image is not found in the even page number area (step S 911 , NO), corrections may be made to the page number character recognition (step S 2909 ). That is, a page number may not necessarily be recognized all the time, and at times a character recognition process may end in failure or an inaccurate character recognition result may be obtained, for example. In view of such circumstance, in one preferred embodiment, a page screen may be displayed on a display screen to accept correction inputs, for example. By accepting such corrections, errors in the arrangement order of image data due to image reading errors may be prevented. Then, page number information and image data of corresponding pages are stored (step S 2910 ). Then, the present process may move on to step S 913 of FIG. 9 .
[0111] As can be appreciated from the above descriptions, according to an embodiment of the present invention, a portion of image data of a document is read to recognize a page number included therein so that the order of the image data may be determined. In this way, image data of a document may be rearranged in proper order. That is, image data of pages of a document that are not read in proper order may be processed and rearranged in proper order so that a user may be relieved of the burden of rearranging the pages of a document himself/herself upon before reading the document. For example, embodiments of the present invention may be implemented in the case of reading a double-side printed document where all the odd numbered pages are read before the even numbered pages or reading randomly gathered pages of a document that needs to be rearranged in proper order.
[0112] It is noted that an image reading method according to an embodiment of the present invention may be embodied by a computer program that is executed on a computer such a personal computer or a work station. Such a program may be stored in a computer-readable medium such as a hard disk, a flexible disk, a CD-ROM, a MO, or a DVD and may be executed by being downloaded from the computer-readable medium to a computer. Also, the program may be embodied by a transfer medium that is configured to distribute the program via a network such as the Internet.
[0113] Also, an image data acquiring unit, an image reading unit, a conversion unit, an order assigning unit, a data generating unit, a rotating unit, a determining unit, and a correction unit of an image reading apparatus according to an embodiment of the present invention may be embodied by a computer performing an image reading method according to an embodiment of the present invention. In one specific example, the above units may be realized by the CPU 201 of FIG. 2 performing relevant control operations according to relevant instructions of an image reading program read from the ROM 202 .
[0114] Further, it is noted that an image reading apparatus, an image reading method, and an image reading program according to embodiments of the present invention may be advantageously implemented in a scanner, a multifunction machine, and other various types of image processing machines having image reading functions, for example.
[0115] Although the present invention is shown and described with respect to certain preferred embodiments, it is obvious that equivalents and modifications may occur to others skilled in the art upon reading and understanding the specification. The present invention includes all such equivalents and modifications, and is limited only by the scope of the claims.
[0116] The present application is based on and claims the benefit of the earlier filing date of Japanese Patent Application No. 2006-201109 filed on Jul. 24, 2006, the entire contents of which are hereby incorporated by reference.
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An image reading technique is disclosed that involves acquiring document image data including more than one set of page image data, reading an image located at a predetermined page position from the acquired set of page image data, recognizing the read image of the predetermined page position and converting the recognized image into text data, and assigning page number order to the set of page image data according to value information represented by the converted text data.
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FIELD OF THE INVENTION
The invention relates generally to chemical dispensing systems for laundry, ware-wash, and healthcare, and more particularly to systems and methods for automatic control of product dispensing in a chemical dispensing system.
BACKGROUND OF THE INVENTION
The dispensing of liquid chemical products from one or more chemical receptacles is a common requirement of many industries, such as the laundry, textile, ware wash, healthcare instruments, and food processing industries. For example, in an industrial laundry facility, one of several operating washing machines will require, from time to time, aqueous solutions containing quantities of alkaloid, detergent, bleach, starch, softener and/or sour. Increasingly, such industries have turned to automated methods and systems for dispensing chemical products. Such automated methods and systems provide increased control of product use and reduce human contact with potentially hazardous chemicals.
Contemporary automatic chemical dispensing systems used in the commercial washing industry typically rely on pumps to deliver liquid chemical products from bulk storage containers. Generally, these pumps deliver raw product to a washing machine via a flush manifold, where the product is mixed with a diluent, such as water, that delivers the chemical product to the machine. A typical chemical dispensing system used to supply a washing machine will include a controller that is coupled to one or more peristaltic pumps in a pump-stand by a plurality of dedicated signal lines. The controller will also typically be coupled to a washing machine interface by another plurality of dedicated signal lines, so that the controller is provided with signals indicating the operational state of the machine. In operation, the machine interface transforms high voltage trigger signals generated by the washing machine into lower voltage signals suitable for the controller, and transmits these low voltage trigger signals to the controller over the set of dedicated signal lines, which are typically in the form of a multi-conductor cable. In response to these individual trigger signals, the controller will individually activate one or more of the pump-stands over another set of dedicated lines so that the pumps dispense a desired amount of a chemical product into the flush line. The chemicals are then are mixed with a dilutant before being delivered to the machine.
In the chemical dispensing system described above, the controller is connected to each washing machine trigger signal output and pump by a dedicated line, and the controller directly activates and deactivates each of the pumps. This arrangement, while generally satisfactory for its intended purpose, places practical limits on how many trigger signals and pumps can be connected to a single controller and creates a need for large numbers of wires and controller input ports. Installation of these types of systems can be cumbersome since installers must keep track of each signal line and ensure that the each line couples the proper controller port to the proper trigger signal source or pump. An incorrect connection may result in the wrong chemical being dispensed at the wrong time by the system, and may not be immediately apparent, resulting in many incorrectly processed loads and resulting monetary losses. Moreover, because the controller is merely switching the pumps on and off for an amount of time expected to provide a desired amount of chemical to the flush manifold, the controller receives no feedback regarding whether the pump is actually dispensing the amount of product desired.
Chemical dispensing systems employed with commercial washing machines typically employ peristaltic pumps to minimize both operator and system component contact with the chemical products, which are often corrosive and toxic. Peristaltic pumps of this type include a flexible tube (or squeeze tube) and a rotor with one or more rollers located in a pump chamber. The one or more rollers compress a section of the squeeze tube against a wall of a pump chamber, pinching off the section of squeeze tube. When the rotor is rotated, the location of the pinched section of the squeeze tube moves along the length of the tube, thereby forcing, or pumping, fluid through the tube. The amount of fluid pumped per unit time tends to vary from pump to pump, depending on multiple variables such as the speed with which the rotor turns, the interior diameter of the squeeze tube, and the viscosity of the product being dispensed. Therefore, system installers must perform calibration measurements on each pump so that the system controller dispenses accurate amounts of product. This requirement for calibrating each pump during installation greatly increases installation time and expense.
Squeeze tubes are also subject to wear over time from the repeated compression and pulling of the rollers, which causes the volume of chemical pumped by the pump-stand to vary over time. Worn out squeeze tubes must also be periodically replaced to prevent tube failure. Squeeze tube replacement can be a cumbersome endeavor, as chemical product often leaks from the feed lines when the seal is broken between the squeeze tube and feeder tubes. In addition to causing a loss of product and undesirably exposing workers to potentially hazardous chemicals, the spilled product may also contaminate the surfaces of the squeeze tube and pump chamber. If the chemical product is not sufficiently cleaned from these surfaces, the resulting sticky residue can cause the roller to pull the squeeze tube through the pump chamber so that the tube becomes damaged or tangled, resulting in pump failure and further potential product spills. In addition, because the controller cannot determine that the pump is not dispensing the correct amount of product, any processed wash loads that rely on the failed pump will have to be re-processed. Further, because the timing of the pump failure may be difficult to determine, multiple wash loads may have to be reprocessed.
Therefore, there is a need in the art for improved chemical dispensing system components and methods that more accurately and reliably control the dispensing of chemical products into washing machines, and that reduce the maintenance burden and number of potential failure modes associated with peristaltic pumps.
SUMMARY OF THE INVENTION
In a first aspect of the invention, a chemical dispensing system controller includes a plurality of serial data bus interfaces that allow the system controller to communicate with other chemical dispensing system components over one or more intelligent networks. To this end, the system controller may include serial data bus interfaces that provide communications between the system controller and a plurality of pump controllers, machine interfaces, network gateways, as well as other system controllers. The system controller may also include additional serial bus interfaces to accommodate future system expansion. By communicating over serial data buses instead of using dedicated signaling lines, the system controller may reduce the number of physical connections required between the dispensing system components, thereby increasing system reliability and reducing installation time. The flexibility provided by digital communications over the serial data buses also provides additional advantages to the chemical dispensing system, such as providing support for more intelligent system components as well as future system improvements, the addition of new features, and system expansion.
To support networking functions between the system controller and the pump-stand, each pump includes a pump controller with a user selectable serial data bus address. The system controller controls the timing and amounts of chemicals dispensed to the washing machine by communicating with individual pump controllers connected to the pump controller serial data bus interface using the user selectable addresses. The pump controller provides several advantages to the chemical dispensing control system in addition to supporting the system controller networking function, such as improved dispensing accuracy and pump status monitoring.
In a second aspect of the invention, the pump controller may be loaded with pump calibration data at the factory. The pump calibration data is accessible to the pump and system controllers and is used to calculate pump run times and/or the number of pump rotor rotations necessary to deliver a desired amount of chemical product. Advantageously, by loading pump calibration data into the pump controller at the factory, the need to perform pump-stand calibrations during installation is reduced or eliminated, thereby reducing installation time and expense.
In a third aspect of the invention, the chemical dispensing system tracks the operational time and/or number of operational cycles on each of the squeeze tubes installed in the pumps. Using test data regarding the expected service life of the squeeze tube, the chemical dispensing system estimates the remaining service life of the tube from aging and wear based on the operational conditions (e.g., age, type of chemicals pumped, amount of chemicals pumped, etc.) experienced by the squeeze tube. The chemical dispensing system may then report out the estimated remaining tube life, as well as provide an indication to system operators when a squeeze tube should be replaced because the squeeze tube is nearing the end of its useful service life. Tracking estimated remaining service life may also provide additional operational benefits and advantages to the dispensing system.
For example, to improve produce dispensing accuracy, the chemical dispensing system may adjust pump activation periods for a specific output based on expected changes in pump capacity due to estimated wear and aging of the squeeze tube. To this end, the pump controller may increase the amount of time the pump is activated for a given amount of product to be dispensed as the squeeze tube ages to compensate for an expected reduction in pump capacity. The pump controller may thereby improve pump dispensing accuracy over the life of the squeeze tube. When the squeeze tube is replaced, the time and usage tracking in the pump controller may be reset by a system operator through a user interface on the system controller. The system controller may also provide an interface that allows the system operator to update the pump calibration data based on a new pump calibration.
In a fourth aspect of the invention, the system controller controls the amount and type of chemical product dispensed by sending data addressed to the pump controller for the pump from which a desired amount of chemical is to be dispensed. The data includes data indicative of the amount of chemical product to be dispensed, which the pump controller uses to determine the amount of time and/or number of rotor rotations for which to activate the pump. The pump controller may also use stored calibration data and/or wear data for the squeeze tube to adjust the pump activation period. In an alternative embodiment, the system controller may retrieve the calibration data from the pump controller and use the calibration data to determine an activation period for the pump. In either case, once the required activation period is determined and communicated to the pump controller, the pump controller activates the pump for the determined period, thereby supplying the desired amount of chemical product to the washing machine.
Advantageously, by communicating the amount of product to be dispensed to the pump controller rather than directly activating and deactivating the pump, the pump may more accurately dispense the desired amount of chemical product. More advantageously, because the pump controller controls activation of the pump locally, if communication is lost between the system controller and pump controller after activation of the pump (for example, due to a loose or intermittent connection), the pump controller can still dispense the desired amount of product. This is in contrast to a pump activated directly by a system controller, which might stop dispensing chemical product prematurely upon loss of communications with the system controller, or worse yet, might continue running indefinitely if communications are lost between the time the pump is activated and the time the deactivation signal is sent.
To further improve the accuracy of the amount of product dispensed, the pump controller may be coupled to one or more temperature sensors that provide signals indicating the temperature of the chemical product that the pump is dispensing. Advantageously, this may improve the accuracy of the chemical dispensing over a range of temperatures. For example, if a container of chemical product that was recently delivered (or that is stored in an unheated area) is coupled to the pump, the temperature of the product could be substantially different from the temperature of the product used to calibrate the pump. To account for the effect of viscosity on the amount of product dispensed, the pump controller may use information regarding the temperature of the product to calculate the viscosity of the product, and adjusts pump activation periods accordingly.
In a fifth aspect of the invention, each pump controller may include a detection circuit that allows the pump controller to determine if the product container to which it is coupled is running low on product. To this end, the pump controller may include ports which may be coupled to product level probes that provide signals indicative of the amount of chemical product left in a product container coupled to the pump. In response to sensing that the product is running low, the pump controller may activate local alarms (such as a flashing LED or buzzer) and/or communicate the product level condition to the system controller over the serial data bus. In response to receiving a low level product condition message from the pump controller, the system controller may also activate a local alarm, and/or send an alarm message to the system operator through a network gateway.
To provide an out of product indication to the system, the pump controller may begin tracking the amount of chemical product dispensed beginning from the time at which a low level indication is received from a product level probe. If the low level indication is not cleared by refilling or replacing the container before a predetermined amount of additional product is dispensed, the pump controller may stop activating the pump and inform the system controller that the product has run out. Advantageously, this allows the chemical dispensing system to keep operating up until the point where a chemical product is about to run out, but prevents the system from operating without sufficient chemical product to properly process wash loads.
In an alternative embodiment, the pump may include an integrated out-of-product detection capability. This integrated out-of-product detection capability includes conductive plastic inserts in the flow path of the product so that the conductive plastic inserts are in contact with product passing through the pump. The conductive plastic inserts are electrically coupled to the detection circuit in the pump controller. The detection circuit is sensitive to the impedance between the inserts so that when product is present in the line between the inserts, the impedance presented causes the detection circuit to provide an indication to the pump controller that product is present. However, when product is not present in the line, such as if the pump begins drawing air from an empty chemical product container, the impedance between the conductive plastic inserts increases. This increase in impedance between the conductive plastic inserts, in turn, causes the detection circuit to provide an indication to the pump controller that the chemical product has run out. In response, the pump controller stops activating the pump and informs the system controller that the product has run out. Advantageously, this provides an additional mechanism that prevents the chemical dispensing system from operating when a chemical product has run out, thereby preventing the system from operating when there is insufficient chemical product to properly process wash loads. The pump controller may also activate local or remote alarms indicating an out product condition so that the condition is brought the attention of the system operator.
The system controller may include a selectable alarm notification feature that allows the system operator to select the types of alarms that are activated, as well as the time and duration of the alarms, based on the condition causing the alarm. Advantageously, this feature allows the system operator to customize the type of notification based on the perceived severity of the alarm. For example, alarms caused by conditions that do not immediately affect the performance of the system (such as low level alarms) may be logged in a productivity report maintained by the system controller, or could trigger a notification message sent through the network gateway to an e-mail address. Other more severe alarms (such as out of product alarms) may be configured to provide a more urgent indication, such as audible indicators (e.g., a buzzer) and/or visual indicators (e.g., a strobe light) at the system controller and/or pump-stand location.
In a sixth aspect of the invention, the pump controller provides a selectable flush manifold status monitoring feature. To this end, the pump controller includes an electrical input port that is operatively coupleable to one or more sensors in the flush manifold. The sensors (e.g., a flow switch) provide an indication of whether the flush manifold is ready to receive a dispensed chemical product. If the flush manifold is not ready to receive the dispensed chemical (e.g., the flow switch signal indicates that there is insufficient flow of diluent through the flush manifold), the pump controller refrains from activating the pump, and provides local and/or remote alarm notifications indicating the problem encountered.
In seventh aspect of the invention, the pump includes a pump chamber lid interlock system. The interlock system includes a sensor that provides a signal to the pump controller indicating the position of the pump chamber lid. For example, a magnet located in the pump chamber lid and a Hall Effect sensor located in the pump housing. In response to receiving a signal indicating that the pump chamber lid is open, the pump controller disables the pump. Advantageously, the pump chamber lid interlock system may thereby prevent injuries from pinched fingers and damage to the pump that may result if the pump is activated while a system operator is, for example, replacing a squeeze tube.
In an eighth aspect of the invention, the pump includes a housing that includes integral input and output channels and a motor having a horizontal orientation. The input end of the squeeze tube is coupled to a product supply line by the integral input channel, and the output end of the squeeze tube is coupled to a product delivery line by the integral output channel. The squeeze tube is thereby isolated by the pump housing from mechanical forces present on the supply lines. The squeeze tube is fluidically coupled to the input and output channels by 90 degree elbows so that the squeeze tube is oriented in a horizontal orientation. The 90 degree elbows are free to pivot inside the integral channels, and thereby allow axial motion at the ends of the squeeze tube. This axial motion is believed to further reduce mechanical stresses on the squeeze tube when the pump rotor is in motion, potentially extending squeeze tube service life. The 90 degree elbows also facilitate removal and replacement of the squeeze tube by allowing the squeeze tube to be in a horizontal position at a high point in the chemical product supply path. Gravity thus urges the chemical product to retreat back into the supply lines when the squeeze tube assembly is removed, reducing the likelihood of a spill.
The horizontal orientation of the motor facilitates positioning the rotor in a proper relationship with the horizontally oriented squeeze tube, and improves pump packaging. In an embodiment of the invention, the integral input and output channels are located in a back side of the pump housing so that the supply lines are positioned out of the way, and to facilitate use of European industry standard DIN rail system to secure the pumps comprising the pump stand to a vertical surface, such as a wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
FIG. 1 is an illustration of an exemplary chemical dispensing system including a system controller, pump-stand, and machine interface.
FIG. 2 is a schematic diagram of the chemical dispensing system in FIG. 1 illustrating the interconnectivity between the system controller, machine interface, pumps, washing machine, and chemical product containers in an embodiment of the invention where the system controller located with the washing machine.
FIG. 3 is a schematic diagram of the chemical dispensing system in FIG. 2 with the system controller relocated to the pump-stand.
FIG. 4 is a schematic illustrating details of the system controller.
FIG. 5 is a schematic illustrating details of the pump including a pump controller and motor, as well as sensors and indicators associated with operation of the pump controller.
FIG. 6A is a detailed schematic of a detection circuit shown in FIG. 5 including an oscillator with an input coupled to a probe assembly.
FIG. 6B is a schematic of the detection circuit in FIG. 6A with a high impedance being provided by the probe assembly showing the oscillator in an oscillating state.
FIG. 6C is a schematic of the detection circuit in FIG. 6A with an impedance being provided by the probe assembly that causes the oscillator to be in a different state to include a non-oscillating state.
FIG. 7 is a schematic illustrating additional details of the machine interface presented in FIGS. 1-3 .
FIG. 8 is an isometric view of the pump illustrating features of the pump housing and pump components.
FIG. 9 is a cross-sectional diagram of the pump in FIG. 8 illustrating the integral input and output channels.
FIG. 10 is a top view of the pump illustrating the squeeze tube, rotor, and pump chamber.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the sequence of operations as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes of various illustrated components, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and a clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention provide a networked control system for dispensing chemical products in commercial washing machine applications that assists in overcoming the difficulties with contemporary chemical dispensing systems. In an embodiment of the invention, a system controller serves as a master controller and is linked via a plurality of serial data buses the other system nodes. The serial data bus interfaces provide an increased communications capability between the system controller and the system nodes as compared to conventional systems. The serial data buses thereby support adding intelligence to system nodes so that control functions may be distributed among the system nodes rather than concentrated in the system controller. By way of example, each pump controlled by the system includes a pump controller, which enables chemical product dispensing to be controlled locally in each pump based on commands received from the system controller over the serial data bus.
The serial data bus network allows the system controller to query the operational status of each of the other system components (such as a machine interface or any of a plurality of pump-stands) to determine if the system is ready to dispense chemicals before issuing commands. The serial data bus also provides power to network components so that additional nodes may be added to the network by simply daisy-chaining a new node to an existing node. This allows, for example, an additional pump to be added to an existing group of pumps comprising a pump-stand by merely coupling the new pump to the end of the chain of pumps with a jumper.
The system controller provides a user interface, stores process formulas, and displays system alarms and status indicators, as well as serving as the master controller for the serial data busses. To dispense chemical products according to a stored formula (e.g., a product dispensing profile for a particular process), the system controller sends data to one or more the pumps indicting the amount of chemical product that the pump stand is required to dispense. The system controller also periodically interrogates the pumps to verify that the pumps are operating properly. To this end, the system controller will typically query the status of a network node before issuing a command. The system controller may thereby obtain positive verification that the node is operating properly before issuing a command. The system controller may also include a serial data port configured to communicate with an optional network gateway. When present, the network gateway provides a data link between the system controller and an outside network, such as the Internet, so that system operators may communicate with one or more system controllers from a remote location.
To support the serial data bus network, each pump-stand includes a pump controller that provides local control of the pump motor and enables a data link process with the system controller. To this end, the pump controller includes a user selectable address that allows the system controller to address each pump controller individually over the shared serial data bus. The pump controller provides intelligence to the pump that supports more accurate dispensing of chemical product based on stored calibration data, monitoring and reporting of pump status, chemical product level monitoring, control of flush manifold operation (if present), and transmission of alarms to the system controller.
Referring now to the drawings, FIGS. 1-3 illustrate an exemplary chemical dispensing system 10 shown in two typical deployment configurations with a washing machine 11 , which may be a laundry machine, a ware-wash machine, a healthcare wash, or any other type of machine that uses dispensed chemicals. One of ordinary skill in the art will recognize that this system 10 is only for illustration purposes and that embodiments of the invention may be used with other configurations of the chemical dispensing system 10 . The base configuration of the chemical dispensing system 10 includes a system controller 12 coupled to a plurality of pumps 14 a - 14 c comprising pump-stand 15 by a pump serial data bus 16 . For illustrative purposes, FIGS. 1-3 show a system with 3 pumps 14 a - 14 c . However, it is understood that other numbers of pumps may be used, and the invention is not limited to any specific number of pumps. The pumps 14 a - 14 c each include a pass-through serial data bus connector 18 ( FIG. 5 ) so that the pumps 14 a - 14 c may be connected in a daisy-chain configuration on the pump-stand 15 . Each pump 14 a - 14 c is thereby connected to an adjacent pump by a jumper 22 so that the pumps 14 a - 14 c are each electrically coupled to the pump serial data bus 16 . The pump serial data bus 16 thus includes multiple jumpers 22 and pass-through connectors 18 . In an embodiment of the invention, jumpers 22 may be comprised of a printed circuit board (PCB) encapsulated in plastic to facilitate quick connections between pumps 14 a - 14 c and power supply 20 .
System power is supplied by a power supply 20 mounted to the pump-stand 15 near one end of the chain of pumps 14 a - 14 c . The power supply 20 may be coupled to the pump serial data bus 16 by connecting the output of the power supply 20 to one end of the pass-though connector 18 in the end pump, shown here as the left most pump 14 a . The power supply 20 is thereby coupled to the pumps 14 a - 14 c and the system controller 12 by the serial data bus 16 . In a preferred embodiment, the pumps 14 a - 14 c , and power supply 20 may be mounted to a DIN rail 28 on the pump stand 15 , although the invention is not so limited, and other mounting locations and methods may be used.
To obtain data concerning the operational status of the washing machine 11 , the system controller 12 is coupled to a machine interface 24 by a machine interface serial data bus 26 . Typically, the system controller 12 will be located near (or mounted to) the washing machine 11 as shown in FIGS. 1 and 2 , but the system controller 12 may also be located remotely from the washing machine 11 as shown in FIG. 3 . For example, in the alternative embodiment illustrated in FIG. 3 , the system controller 12 is mounted to the DIN rail 24 so that the system controller 12 , pumps 14 a - 14 c and power supply 20 are all affixed to the pump-stand 15 by the DIN rail 28 .
The pump-stand 15 is configured to provide product to the washing machine 11 from various chemical storage containers 30 , 32 , 34 , each of which is fluidically coupled to one of pumps 14 a - 14 c by a product supply line 36 . Typically, the output of each pump 14 a - 14 c is fluidically coupled to a flush manifold 42 by flush manifold supply lines 44 as shown in FIGS. 1-3 . However, the pumps 14 a - 14 c may also be fluidically coupled directly to the washing machine 11 so that undiluted product is delivered to the machine 11 . In embodiments including the flush manifold 42 , an output of the flush manifold 42 is coupled to the washing machine 11 by a machine supply line 45 , and an input of the flush manifold 42 is coupled to a diluent source 46 by a diluent valve 48 . The diluent valve 48 may be electrically coupled to one or more of the pumps 14 a - 14 c , ( FIG. 5 ) so that the chemical dispensing system 10 can control delivery of product to the washing machine 11 by regulating the flow of diluent through the flush manifold 42 .
The power supply 20 is typically mounted on the DIN rail 28 next to a pump 14 a - 14 c , although other mounting locations may be used. The power supply 20 is connected to source of AC line voltage (not shown) and provides a DC voltage (such as to 24 VDC) suitable for powering system controller 12 , pumps 14 a - 14 c , and machine interface 24 . When mounted on the DIN rail 28 , the power supply 20 will typically be coupled to either the left side of pass-through connector 18 of rightmost pump 14 a , (as shown); or to the right side of pass-through connector 18 of the leftmost pump 14 c . Power is thereby distributed to the system controller 12 and pumps 14 a - 14 c via the serial data bus 16 . To this end, the serial data bus 16 may include power and ground conductors, as well as one or more data conductors. In an embodiment of the invention, the pump serial data bus 16 includes a power conductor, a ground conductor, a positive data conductor, and a negative data conductor. The data conductors thereby form a balanced, or differential, serial data transmission line. The system controller 12 , in turn provides power to the machine interface 24 over the machine interface serial data bus 26 , which is typically configured to have the same conductor layout as the pump serial data bus 16 . Advantageously, the pass-through connectors 18 and pump serial data bus configuration make adding additional pumps to the pump-stand 15 a simple process, thereby facilitating the addition of additional chemical products to the chemical dispensing system 10 .
Some embodiments of the invention may also include probe assemblies 50 operatively disposed in containers 30 , 32 , 34 . The probe assemblies 50 , in turn, may be electrically coupled to a detection circuit 52 ( FIG. 5 ) in the pump 14 a - 14 c that dispenses product from the container 30 , 32 , 34 in which the probe assembly 50 is located. Probe assemblies 50 may be configured to provide a signal to the detection circuit 52 indicative of the level of product in the container 30 , 32 , 34 so that the pumps 14 a - 14 c may monitor product levels in their associated containers 30 , 32 , 34 . Probe assemblies 50 are known in the art and typically include one or more conductive probes that present different impedances to the detection circuit 50 depending on whether the probe assembly 50 is in contact with product. Suitable probe assembles and detection circuits are described in U.S. patent application Ser. No. 13/164,878, entitled “System and Method for Product Level Monitoring in a Chemical Dispensing System”, the disclosure of which is incorporated herein by reference in its entirety.
Referring now to FIG. 4 and in accordance with an embodiment of the invention, the system controller 12 includes a processor 54 , memory 56 , an input/output (I/O) interface 58 , a user interface 60 , a system controller voltage supply circuit 62 , and a machine interface power supply output circuit 64 . The I/O interface 58 is communicatively coupled to the processor 54 and employs a suitable communication protocol for communicating over the serial data busses. The processor 54 may thereby communicate through the I/O interface 58 to the machine interface 24 via the machine interface serial data bus 26 , the pumps 14 a - 14 c (shown as a single pump for purposes of illustration) through pump serial data bus 16 , and a network gateway 68 via a network gateway serial data bus 70 . The system controller 12 may also include one or more additional serial data bus interfaces 72 to accommodate future system expansion. The serial buses may be connected to the I/O interface 58 (as well as the various network nodes) though serial bus interfaces, each of which includes a suitable multi-pin connector 74 .
Processor 54 may be a microprocessor, microcontroller, programmable logic or any other suitable device that manipulates signals based on operational instructions, which may be stored in memory 56 . The memory 56 may be a single memory device or a plurality of memory devices including but not limited to read-only memory (ROM), random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, and/or any other device capable of storing digital information. The memory 56 may also be integrated with the processor 54 .
The processor 54 executes or otherwise relies upon computer program code, instructions, or logic (collectively referred to as program code) to execute the functions of the system controller 12 . To this end, a system controller application 66 may reside in memory 56 and may be executed by the processor 54 . The system controller application 66 controls and manages the chemical dispensing system 10 by communicating with other system components via the I/O interface 58 and serial data buses 16 , 26 , 70 . The system controller application 66 may thereby obtain information regarding the operational status of the washing machine 11 from the machine interface 24 , and in response, causes the pumps 14 a - 14 c to dispense chemicals in a controlled way.
The user interface 60 may be operatively coupled to the processor 54 of the system controller 12 in a known manner. The user interface 60 includes output devices, such as alphanumeric displays, one or more touch screens, light emitting diodes (LEDs), acoustic transducers, and/or any other suitable visual and/or audio indicators; and input devices and controls, such as the aforementioned touch screen, an alphanumeric keyboard, a pointing device, keypads, pushbuttons, control knobs, etc., capable of accepting commands or input from the system operator and transmitting the entered input to the processor 54 . The user interface 60 thereby provides a mechanism by which the system operator may enter new washing process formulas, set and/or deactivate alarms, update calibration data, retrieve and view system data (such as amounts of product dispensed and number and type of wash loads run) and otherwise operate and manage the chemical dispensing system 10 .
The system controller voltage supply 62 receives power from the power supply 20 via the pump serial data bus 16 . The system controller voltage supply may contain circuits, such as voltage regulators, that condition and adjust the voltage received from the power supply 20 , thereby providing suitable voltages for running the processor 54 and other system controller components. The machine interface power supply output circuit 64 may receive power from the system controller voltage supply 62 , or directly from the power supply 20 via the pump serial data bus 16 . The machine interface power supply circuit 64 may condition the power before transmitting it to the machine interface 24 ; or the machine interface power supply circuit 64 may merely pass the power received from the power supply 20 on to the machine interface 24 over the machine interface serial data bus 26 without significant alteration.
The network gateway 68 may be a computer equipped to provide an interface between the system controller 12 and an external network 76 , such as the Internet. To this end, the network gateway 68 may include a network gateway application running on a processor that performs protocol translation, converts data rates, and/or provides any other functions necessary to provide interoperability between the chemical dispensing system and the external network. The network gateway 68 may thereby allow computers or other communication devices that are attached to the external network 76 to communicate with the system controller 12 so that system operators may remotely control and monitor the chemical dispensing system 10 . The network gateway 68 may also be configured to address multiple system controllers 12 over a single network gateway serial data bus 70 .
Referring now to FIGS. 5 and 6A-6C , each pump 14 a - 14 c includes a pump controller 78 in communication with a motor 80 . The pump controller 78 may also be in communication with the detection circuit 52 , internal and external temperature sensors 82 , 84 , a plurality of status indicator LEDs 86 , a local alarm buzzer 88 , a mute switch 90 , a flow sensor 96 , a pump chamber lid sensor 98 , address selector switch 99 , pump prime switch 101 , and a valve driver circuit 103 . The pump controller 78 may also include a pump controller voltage supply 105 that provides suitable voltage levels for running the controller components. The motor 80 may be a brushless direct current (BLDC) electric motor coupled to a rotor 100 by a transmission 102 . The rotor 100 includes one or more rollers 104 and is positioned in a pump chamber 106 with a squeeze tube 108 . The rotor 100 , pump chamber 106 , and squeeze tube 108 are further configured so that when torque is applied to the rotor 100 by the motor 80 , the rotor 100 rotates in such a way that the rollers 104 compress the squeeze tube 108 against a side wall of the pump chamber 106 in a progressive fashion that causes fluid to be urged through the squeeze tube 108 .
So that the pump 14 a - 14 c may dispense product, one end of the squeeze tube 108 is coupled to an integral input channel 110 , and the other end of the squeeze tube 108 is coupled to an integral output channel 112 . The integral input and output channels 110 , 112 are in turn fluidically coupled to the product supply and flush manifold supply lines 36 , 44 , respectively. Activating the motor 80 thereby causes fluid to be drawn into the squeeze tube 108 from the product supply line 36 via the integral input channel 110 and expelled into the flush manifold supply line 44 via the integral output channel 112 . Product may thereby be conveyed from the product container 30 , 32 , 34 to the flush manifold 42 by pumps 14 a - 14 c.
Similarly as described with respect to the system controller 12 , the pump controller 78 includes a processor 114 , memory 116 , and an I/O interface 118 that provides a communications link between the pump controller processor 114 and the pump serial data bus 16 via the pass-through connector 18 . The pump controller processor 114 may be further operatively coupled to detection circuit 52 , motor 80 , internal and external temperature sensors 82 , 84 , status indicator LEDs 86 , local alarm buzzer 88 , mute switch 90 , flush manifold flow sensor 96 , pump chamber lid sensor 98 , address selector switch 99 , pump prime switch 101 , and valve driver circuit 103 .
Memory 116 may contain a pump controller application 120 comprised of program code that, when executed by the processor 114 , causes the pump controller 78 to provide local motor control and support a data link process that allows the system controller 12 and pump controller 78 to communicate over the pump serial data bus 16 . The address selector switch 99 may be any suitable switch, such as a rotational selector switch or dip switch that is accessible from the outside of the pump 14 a - 14 c . Advantageously, the address selector switch 99 thereby provides a quick and easy means to visually identify the current address of each pump controller 78 in the network.
Each pump controller 78 that is sharing the pump serial data bus 16 has a unique address that is set on the address selector switch 99 prior to applying power to the pumps 14 a - 14 c . The pump controller application 120 reads the address selector switch at power up and loads the network address into memory 116 . Once the pump controller application 120 has loaded the network address into memory, the network address will remain fixed so long as the pump controller 78 is under power. Advantageously, this feature reduces the risk of the pump controller's network address being changed inadvertently while the system 10 is in operation, which could result in more than one pump controller 78 having the same network address. To change the network address of the pump controller 78 , the system operator must power down the pump stand 15 , change the configuration of the address selector switch 99 , and reapply power so that the new address is loaded by the pump controller application 120 .
The pump prime switch 101 , when enabled, provides an automated pump priming function. To prevent inadvertent activation of the priming function, the operation of the pump prime switch 101 may have to be enabled in the system controller 12 through a password protected menu accessed through the system controller user interface 60 . Enabling the pump prime function in the system controller 12 causes the system controller application 66 to set a priming feature enable flag in the pump controller 78 . In response to sensing that the pump prime switch 101 has been activated, the pump controller application 120 checks the priming feature enable flag. If the flag is set, the pump controller application 120 activates the motor 80 for a sufficient amount of time to ensure that the supply lines 36 , 44 and pump 14 a - 14 c are primed with product. In contrast, if the feature enable flag is not set, the pump controller application 120 may simply ignore the state of the pump prime switch 101 .
The pump chamber lid sensor 98 provides a signal indicative of the position of a pump chamber lid 178 ( FIG. 9 ) to the processor 114 . To this end, the lid sensor 98 may include a magnet 122 and a Hall Effect sensor 124 configured to provide a first signal to the processor 114 when the lid 178 is in an open position, and a second signal to the processor 114 when the lid 178 is in a closed position. To reduce the risk of damage to the pump 14 a - 14 c as well as injury to the system operator, the pump controller application 120 checks the pump chamber lid sensor signal before activating the motor 80 . If the signal indicates that the pump chamber lid 178 is in a closed position, the pump controller application 120 will activate the motor in the normal manner. However, in response to a signal indicating that the pump chamber lid 178 is in an open position, the pump controller application 120 may disable the motor 80 as well as provide an indication to the system controller 12 that the motor 80 is not in a condition to be activated.
The detection circuit 52 supports a low level detection feature, which may be enabled in the pump controller application 120 by activating the feature through the system controller user interface 60 . The detection circuit 52 includes in input port coupleable to the probe assembly 50 through a probe assembly connector 126 , which may be located on the bottom of the pump 14 a - 14 c . The detection circuit 52 includes a low frequency oscillator that includes an active element, or oscillator 128 ( FIGS. 6A-6C ) and a load element 130 . The oscillator 128 may include a CMOS inverter or any other suitable device capable of producing an oscillation when coupled to load element 130 . Load element 130 may be a resistor-capacitor (RC) circuit or some other suitable circuit that provides a suitable load or feedback to the oscillator 128 to cause the oscillator 128 to oscillate. The detection circuit 52 produces an oscillation when a high impedance electrical load is present on the input to the probe assembly connector 126 , such as an electrical load with an impedance greater than 5 megohms. The detection circuit 52 thereby provides a low frequency oscillation signal when the quality factor of the oscillator 128 is sufficiently unaltered by the electrical load from a probe assembly 50 that is not in contact with a monitored product. When an electrical load that has a high impedance is coupled to the input 126 , the oscillator 128 comprising detection circuit 52 is tuned to oscillate at a nominal operating frequency, such as about 10 Hz, for example. The pump controller application 120 may thereby determine if there is sufficient product remaining to contact the probe assembly 50 by monitoring the output of the detection circuit 52 for an oscillation.
A pair of conductive probes 132 , 134 comprising the probe assembly 50 may be connected to the detection circuit 52 . The probe assembly 50 is connected across the input 126 of the detection circuit 52 so that one probe 132 is connected to one side of load element 130 and the other probe 134 is connected to the other side of load element 132 , which may also be coupled to a reference ground 136 . When the probe assembly 50 is suspended in air, such as when the product in the monitored container 30 , 32 , 34 has dropped below the probe assembly 50 , the impedance of the probe assembly 50 as seen by the detection circuit 52 has a low loading effect on the oscillator 128 . The quality factor of the oscillator 128 is thus relatively unaffected by the presence of the probe assembly 50 so that the detection circuit 52 outputs a time varying voltage signal at the nominal frequency as illustrated in the schematic diagram of FIG. 6B .
However, when one or both of the probes 132 , 134 are in contact with a conductive solution, an impedance 138 from the probes 132 , 134 is seen by the detection circuit 52 . A typical impedance between the probes 132 , 134 when in contact with product will be between 10 kilohms and 1 megohms. The impedance 138 will lower the quality factor of the oscillator 128 , which changes the operating parameters of the oscillator 128 due to the parallel loading effect of the probe assembly 50 . These changed parameters will cause the oscillator 128 to oscillate at a frequency different from the nominal frequency or to cease oscillating depending on the load presented by the probe assembly 50 , as illustrated in the schematic diagram of FIG. 6C . Thus, in response to being coupled to a probe assembly 50 that is in contact with product, the detection circuit 52 will output a signal having a different frequency or that stops varying altogether, such a constant voltage at ground potential. This change in the output of the detection circuit 52 thereby provides an indication to the processor 114 of the presence or absence of product at the probe assembly 50 .
The status indicator LED's 86 may include a first LED that provides a visual indication that the pump 14 a - 14 c is powered, a second LED that provides an indication of the presence of data traffic on the pump serial data bus 16 , a third LED to indicate if a local error is active, and a fourth alarm LED that provides an indication of the level of product detected by the pump controller application 120 . The power and data traffic status indicator LEDs may be coupled to and activated by the processor 114 , or may be directly tied to a pump power supply and/or data lines as the case may be. The alarm LED may be used to indicate a variety of conditions. By way of example, the pump controller application 120 may cause the alarm LED to flash when a probe assembly 50 is coupled to the detection circuit and the product level feature is active to provide an indication of such to the system operator. In response to detecting a low product condition, the pump controller application 120 may cause the alarm LED to be illuminated continuously so that the system operator is provided with a visual indication of the low product level condition.
The pump controller application 120 may also be configured to activate the local alarm buzzer 88 in response to detecting a low product level condition. The system operator may cause the pump controller application 120 to silence the alarm buzzer 88 by pressing mute switch 90 . In some embodiments, the pump controller application 120 may send an alarm message to the system controller 12 in response to a status query so that the system controller 12 may activate an alarm or otherwise report to the system operator that an alarm condition exists at the pump-stand 15 . The pump controller application 120 may be configured to provide different mute responses depending on how long or how many times the mute switch 90 is activated. By way of example, in some embodiments of the invention, the first time the mute switch 90 is pressed, the alarm might be silenced for a short period, such as an hour. If the mute switch 90 is held down for a length of time, such as 3-4 seconds, the alarm might be silenced for a longer period, such as a weekend. To provide an indication that the local alarm buzzer 88 has been muted, the local alarm LED may be made to flash at a slower rate than normal. The rate of flashing may be further adjusted so that the local alarm LED flashes at a slower rate when a long duration alarm silencing period has been activated (such as a weekend) than when a short duration silencing period has been activated (such as an hour).
The pump-stand 15 may be configured to deliver product directly to the washing machine 11 , or the product may be dispensed into the flush manifold 42 and delivered to the machine 11 by a diluent, which is the configuration illustrated in FIGS. 1 - 3 . When the pump-stand 15 is deployed with flush manifold 42 , a flush-flow control feature may be activated in the pump controller application 120 of at least one of the pumps 14 a - 14 c associated with the system controller 12 . As with the previous optional features, the flush-flow feature is activated in the pump controller application 120 through the user interface 60 of the system controller 12 . Typically, the flush flow feature is only activated in one pump 14 a - 14 c per pump-stand 15 , with the system controller 12 controlling the flush manifold 42 by addressing flush manifold related commands to the pump controller 78 that is coupled to the diluent valve 48 . In order to provide sufficient drive current and voltages to the diluent valve 48 , the processor 114 may be coupled to the diluent valve 48 by a valve circuit driver 103 . In cases where the valve circuit driver 103 is not coupled to the diluent valve 48 , the valve circuit driver output port 140 may be used to provide a switched voltage output, such as a 24 VDC switched output, for activating external alarms or other uses.
The pump controller application 120 may also monitor the flow sensor 96 , which provides a signal indicative of the rate that diluent is flowing through the flush manifold 42 . The pump controller application 120 may thereby make determinations concerning the dispensing of product into the flush manifold 42 based on whether there is sufficient diluent flow to deliver the product to the washing machine 11 . The pump controller application 120 may also report alarm conditions to the system controller 12 if the detected diluent flow rate deviates from an acceptable level.
Referring now to FIG. 7 , the machine interface 24 includes a processor 142 that is operatively coupled to a memory 144 , an I/O interface 146 , a trigger signal interface 148 , and a display 150 . A machine interface voltage supply 152 is coupled to and receives power from the machine interface serial data bus 26 , and includes voltage regulation circuits that provide suitable voltages to the circuits comprising the machine interface 24 . The trigger signal interface 148 is coupled to trigger signals in the washing machine 11 by optical isolators 154 a - 154 n , which provide galvanic isolation between the high voltage triggers in the washing machine 11 and the other chemical dispensing system components. In an embodiment of the invention, there may be 10 trigger signals, with each signal being coupled to the trigger signal interface by an optical isolator 154 a - 154 n.
Memory 144 may contain a machine interface application 156 comprised of program code that, when executed by the processor 142 , causes the machine interface 24 to determine the operational state of the washing machine 11 based on machine trigger signals detected by the processor 142 via the trigger signal interface 148 . The machine interface application 152 may also handle the networking and messaging functions required to communicate with the system controller 12 over the machine interface serial data bus 26 . To this end, the I/O interface 146 may employ a suitable communication protocol for communicating over the machine interface serial data bus 26 . In an embodiment of the invention, the machine interface 24 is configured as a slave module, and will only respond back to the system controller 12 in response to being queried by the system controller 12 .
The trigger signal interface 148 works cooperatively with optical isolators 154 a - 154 n to convert the local high voltage trigger signals received from the washing machine 11 into signals suitable for coupling to the processor 144 . The machine interface application 156 determines the state of the washing machine 11 based on the detected trigger signals, and may store time stamped trigger signals in memory 144 for later use and reporting. In response to a query from the system controller 12 , the machine interface application 152 communicates the determined state of the machine 11 and/or detected triggers to the system controller application 66 . In response to the washing machine state (e.g., beginning wash cycle), the system controller application 66 may, in turn, cause the pump controller application 120 to dispense product to the washing machine 11 (e.g., dispense 100 milliliters of detergent). The machine interface display 150 may include an electronic membrane overlay having LEDs that are illuminated by the machine interface application 156 to indicate the particular triggers that have been detected and qualified. The display 150 may also include an additional LED that is illuminated to indicate the presence of data traffic on the machine interface serial data bus.
With reference to FIGS. 8-10 , in which like reference numerals refer to like features in FIGS. 1-7 and in accordance with an embodiment of the invention, the representative pump 14 a - 14 c includes a housing 158 having a pump chamber 106 , an integral input channel 110 , and an integral output channel 112 . The rotor 100 and squeeze tube 108 are positioned in the pump chamber 106 , and the rotor 100 includes rollers 104 configured to compress the squeeze tube 108 against a sidewall 160 of the pump chamber 106 . The squeeze tube 108 has a first end coupled to the integral input channel 110 by an inlet fitting 162 and a second end coupled to the integral output channel 112 by an outlet fitting 164 . The inlet and outlet fittings 162 , 164 include a 90 degree elbow so that the squeeze tube 108 is oriented in a plane perpendicular to the integral input and output channels 110 , 112 . Each fitting 162 , 164 includes upper and lower o-rings 166 , 168 that provide a fluid-tight seal between the fitting 162 , 164 and its respective integral channel 110 , 112 . Advantageously, the o-rings 162 , 164 allow the fittings 162 , 164 to pivot axially, which may reduce lateral bending forces on the squeeze tube 108 at the squeeze tube/fitting connection points.
The pump controller 78 and associated circuits are mounted in a lower cavity 170 near the bottom of the pump housing 158 to facilitate access to the various electrical connectors associated with the pump controller 78 . The pump motor 80 and transmission 102 are stacked vertically in a central cavity 172 , so that the motor 80 has a horizontal orientation. The transmission 102 may provide speed and torque conversion between the motor 80 and rotor 100 so that the rotor rotates at a desirable speed. In an alternative embodiment of the invention, the transmission 102 may be omitted and the motor 80 directly coupled to the rotor 100 . The motor 80 may be a brushless DC motor, and may include an integrated motor controller (not shown) that provides signals indicative of the motor speed in rotations per minute to the pump controller processor 114 . Advantageously, the integrated motor controller thereby allows the pump controller application 120 to determine and report motor status (such as a locked rotor condition) as well as precisely measure product volume dispensing by tracking the speed and/or number of rotations of the rotor 100 .
The product and flush manifold supply lines 36 , 44 are coupled to the integral input and output channels 110 , 112 by plastic inserts 174 , 176 , respectively. Plastic inserts 174 and 176 may include a threaded upper end configured to engage the lower ends of the integral input and output channels 110 , 112 . The plastic inserts 174 , 176 each include a barbed lower end that provides a fluid tight seal when coupled to the product and flush manifold supply lines 36 , 44 . In an embodiment of the invention, the plastic inserts 174 , 176 may be comprised of a conductive plastic, such as carbon impregnated polypropylene. In this alternative embodiment, the conductive plastic inserts 174 , 176 may be electrically coupled to the detection circuit 52 and thereby serve as integrated conductive probes 132 , 134 that provide an out-of-product indication to the detection circuit 52 .
The pump chamber lid 178 may be comprised of transparent plastic that allows system operators to view the operation of rotor 100 and squeeze tube 108 . The magnet 122 is positioned within the pump chamber lid 178 so that when the lid 178 is closed, the magnet 122 causes the Hall Effect sensor 124 to change its output, indicating to the pump controller application 120 that the pump chamber lid 178 is in a closed position. When the pump chamber lid 178 is opened, the change the magnetic field in the region of the Hall Effect sensor 124 causes the Hall Effect sensor to provide a signal to the pump controller application 120 that indicates the lid 178 is not closed. In response, the pump controller application 120 may disable the motor 80 to reduce the risk of injury to system operators and/or damage to the squeeze tube 108 from fingers or other objects becoming entangled with the rotor 100 .
In operation, the system controller 12 may be configured as a master, and the machine interface 24 and pump controllers 78 configured as slaves. Using this master/slave configuration, the machine interface 24 and pump controllers 78 only communicate with the system controller 12 in response to a query or other message from the system controller 12 . This master/slave arrangement thus ensures that only one system node transmits data over their associated serial data bus at a time. Process formulas are programmed into the system controller 12 over the user interface 60 , and the system operator selects which chemical dispensing process formula the system controller 12 will implement based on the type of load the washing machine 11 is processing. The system controller 12 is thus the master controller in the network and handles all of the process formulas and any required mathematical calculations, as well as providing a human-machine interface to the chemical dispensing system 10 .
Operations in the chemical dispensing system 10 are initiated by the system controller 12 querying the status of the machine interface 24 . To this end, the system controller application 66 sends a status query message to the machine interface 24 over the machine interface data bus 26 . The machine interface application 156 responds to the status query message with a status update that includes data regarding any qualified triggers that have been logged by the machine interface 24 since the last query message the system controller 12 . In response to the content of the machine controller response message, the system controller application 66 determines the state of the washing machine 11 . Based on the state of the washing machine 11 and the process formula selected by the system operator, the system controller application 66 further determines which product, if any, needs to be dispensed as well as how much of the product should be dispensed. All pump operations are thus ultimately dependent on the qualified triggers, which are processed locally by the machine interface 24 and sent to the system controller 12 by the machine interface 24 when prompted.
If the washing machine 11 is in a state requiring product to be dispensed (e.g., beginning a wash load), the system controller application 66 queries the status of the pump 14 a - 14 c associated with the container 30 , 32 , 34 holding the product to be dispensed. To this end, the system controller application 66 sends a query message addressed to the pump controller 78 associated with the product to be dispensed over the pump serial data bus 16 . The pump controller application 120 responds to the query message by reporting back pump status, including any out of product or other system alarms, which (if present) are displayed by the system controller 12 .
If the pump controller application 120 response indicates that the pump 14 a - 14 c is ready to dispense product, the system controller application 66 will determine the amount of product that is to be dispensed, and communicate this to the pump controller application 120 . Advantageously, by sending data to the pump 14 a - 14 c that allows the pump controller 78 to determine a required run time rather than merely a pump OFF/ON command (as is conventional), the system 10 ensures that the motor 80 will not run continuously if the system controller 12 loses communication with the pump controller 78 after the motor 80 has been activated.
In response to receiving the dispense product message from the system controller 12 , the pump controller application 120 checks the pump status to verify that the pump 14 a - 14 c is ready to dispense product (i.e., there are no active alarms that would preclude dispensing product), and activate the motor 80 for an amount of time or number of rotations calculated to dispense the required amount of product. The pump controller 78 may accumulate the total motor activation time and/or number of rotations (collectively referred to as an activation period) and store this value in memory 116 . The accumulated activation period value may be used in estimating remaining squeeze tube service life and/or a deterioration in pump flow rate due to wear on the squeeze tube 108 . The pump controller application 120 may also open the diluent valve 48 (when present) for an amount of time sufficient to flush the product into the washing machine 11 , and may monitor the flow sensor 96 to ensure that sufficient diluent flow is present. In response to the pump controller application 120 determining that the required amount of product has been delivered to the washing machine 11 , the application 120 notifies the system controller 12 that the dispensing operation is complete. If the pump controller application 120 determines that the required amount of product was not delivered to the washing machine 11 , the application 120 may send an alarm or other error message to the system controller 12 so that the system controller 12 can notify the system operator.
To increase the reliability of communications over the serial data bus network, the system controller 12 may make several attempts to deliver data packets to the system nodes if no response is received to earlier transmissions. The machine interface and pump serial data bus protocols may include both acknowledge (ACK) and negative-acknowledge (NACK) response messages to fully validate system node operation, and may also include cyclic redundancy checking (CRC) to further ensure data robustness.
The system controller 12 may periodically interrogate the pumps 14 a - 14 c to monitor the performance of the motor 80 , squeeze tube 108 , and any other system errors or alarms. By way of example, the pump controller 78 may track the amount of pump activation time and/or number of rotations to which the squeeze tube 108 has been subjected and use this data to estimate the remaining service life of the squeeze tube 78 . The system controller 12 may obtain operational data from the pump controller 78 regarding the estimated remaining squeeze tube service life and display this data in a squeeze tube life menu over the user interface 60 . The system controller 12 may also include a menu selection that allows the system operator to reset the percentage of life remaining statistic for an individual pump 14 a - 14 c when that pump's squeeze tube 108 is replaced. The system controller 12 may also generate system maintenance alerts or alarms based on this squeeze tube percentage of life remaining exceeding a lower threshold (e.g., below 5%), which may be settable by the system operator. Advantageously, by closely monitoring the percentage of life remaining, the system controller 12 and/or pump controller 78 may adjust the run time of the motor 80 to compensate for reductions in the volume of product dispensed due to tube wear. More advantageously, by actively monitoring squeeze tube life, the replacement schedules for squeeze tubes 108 may be extended while simultaneously reducing the risk of squeeze tube failure, thereby reducing overall system maintenance costs.
While the present invention has been illustrated by a description of one or more embodiments thereof and while these embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, as is understood by a person having ordinary skill in the art, the various functions and methods described herein may be distributed between the system, pump, and machine interface controllers in various ways and combinations, so that any controller in the system may perform functions currently ascribed to another controller. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
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System and method for dispensing product to a washing machine. A chemical dispensing system includes a system controller, machine interface, and pump controller that communicate through serial data buses. The system controller provides a user interface, retrieves washing machine status information from the machine interface, and issues product dispensing commands to the pump controller. The pump controller monitors pump status and dispenses product in response to commands from the system controller. The pump controller: (1) determines pump activation periods based on calibration data stored in a pump controller memory; (2) tracks pump usage and adjusts the activation period to compensate for pump wear as the pump ages; (3) disables the pump if conditions exists that preclude operating the pump; (4) monitors product levels, and (5) reports pump status to the system controller. Integral channels are included in the pump housing to provide stress relief to a squeeze tube.
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The present invention relates to the field of portable electric generators. More specifically, the present application relates to footwear having a hydroelectric generator assembly located therewithin.
BACKGROUND OF THE INVENTION
With the increase in the number of battery powered, portable devices used both commercially and for recreation, there is an increasing need to provide a long lasting, adaptable, efficient electrical source. Two-way radios, GPS equipment, portable computers, cell phones, CD and tape players and the like generally use conventional batteries as a power source. These batteries may be disposable or rechargeable. Regardless of the type of battery used, after a certain time, the batteries in the equipment must be replaced with new or recharged batteries. This is inconvenient and, in many situations, requires the user to carry spare batteries.
There have been a number of attempts to provide electrical generator units which derive their power from the walking movement of the user. For example, U.S. Pat. No. 4,674,199 to Lakic discloses a shoe with an internal warming mechanism. The warming mechanism comprises an electrical resistance coil in the sole or the covering of the shoe and a mechanical electricity generation mechanism in the heel of the shoe. The generator is driven by the up and down movement of a wearers' heel. The generator described by Lakic includes an armature mounted for rotational movement in a magnetic field and mechanically connected to a vertical post which depends from the under surface of the heel portion of the inner sole of the shoe.
U.S. Pat. No. 4,870,700 to Ormanns discloses a personal safety radio device which can be mounted in the heel of a work shoe. The radio includes a transmitter powered by a rechargeable accumulator, a receiver and an antenna arrangement. Ormanns teaches that the rechargeable accumulator may be charged by a generator arrangement which includes a piezo-electric converter. The piezo-electric converter is arranged in the shoe such that it is acted on by the weight of the person wearing the shoe and thus converts the pressure of the weight into electrical energy.
U.S. Pat. No. 5,167,082 to Chen discloses a dynamo-electric shoe which has a pressure-operated electric generator inside a water tight compartment adjacent to the heel portion of the shoe. An electrical socket is mounted on the sole of the shoe and a rechargeable battery cell is wired to the electrical socket. Chen teaches that the dynamo-electric shoe can be used to operate a portable wireless telephone, a portable radio, a light device, a heating device or the like. The generator disclosed by Chen is mechanical.
U.S. Pat. No. 5,495,682 also to Chen discloses a similar dynamo-electric shoe in which the mechanical electric generator is operated by pressure on a pivot plate mounted to the heel of the shoe.
Other mechanical-type electricity generators are disclosed in U.S. Pat. Nos. 4,782,608, 4,845,338 and 5,367,788.
Mechanical electricity generators of the type known in the art have a number of disadvantages in that they are generally heavy, expensive to construct, require specialist shoe design, and are prone to mechanical breakdown.
It is an object of the present invention to provide a footwear-based electrical generation system which overcomes at least one of the disadvantages of the prior art.
SUMMARY OF THE INVENTION
Accordingly, in one aspect, the present invention provides a hydroelectric generator assembly for use within footwear, comprising:
a first compressible, fluid-filled sac for placement in a heel section of the footwear, the first sac having a first fluid conduit with a proximal end, connected to the first sac, and a distal end;
a second compressible, fluid-filled sac for placement in a toe section of the footwear, the second sac having a second fluid conduit with a proximal end, connected to the second sac, and a distal end;
the distal ends of the conduits each having an inlet and an outlet wherein the outlet and inlet of the first conduit is in fluid connection with the inlet and outlet, respectively, of the second conduit; and
a hydroelectric generator module in fluid communication with the distal ends of the first and second conduits;
whereby, upon the wearer of the footwear walking, the first and second sacs are reciprocally compressed thereby causing fluid to flow from one of the sacs via the generator to the other of the sacs, resulting in generation of electricity by the generator.
BRIEF DESCRIPTION OF THE FIGURES
Embodiments of the present invention will now be described, by way of example only, with reference to the following figures, in which:
FIG. 1 is a partial cross-section through a shoe incorporating one embodiment of the present invention;
FIG. 2 is a schematic plan view of the shoe of FIG. 1; and
FIG. 3 is a schematic representation of the hydroelectric generator assembly of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A hydroelectric generator assembly in accordance with one embodiment of the present invention is shown in situ at 10 in FIGS. 1, 2 and 3 . In this particular embodiment the assembly is formed within the sole 12 of an item of footwear. The sole is of two-part construction; a resilient hardwearing ground engaging lower section 12 a and a flexible, comfortable foot support layer 12 b .
The assembly generally comprises a pair of fluid-filled, compressible sacs 14 and 16 which are preferably located in the heel section of the sole and in a front section of the sole, i.e., the section which supports the ball of the foot, respectively. The sacs are located between the two sections of the sole. It will be appreciated that in other embodiments, the sacs 14 and 16 may be placed in other locations of the sole wherein the required function, as described below, may be obtained.
Each fluid sac 14 and 16 is connected by a fluid conduit ( 18 and 19 , respectively) to a hydroelectric generator module 20 . The hydroelectric generator module is preferably located between the pair of fluid sacs, in the arch support section of the sole. In an alternative embodiment the hydroelectric generator module may be located, for example, in the heel of a boot.
As shown in FIGS. 2 and 3, the hydroelectric generator module 20 preferably comprises a vane rotor 22 located within a turbine housing. The vane rotor drives a shaft 24 which communicates rotation of the vane rotor to a microgenerator 26 . The microgenerator is designed to optimize electrical output over a variable rpm matched to the torque and rpm characteristics of the turbine. Shaft 24 may be provided with gearing to facilitate the efficiency optimization of the microgenerator. Suitable microgenerators are known in the art.
Depending on the nature of the fluid in the assembly, a shaft seal 28 is provided. The shaft seal allows for rotation of the shaft but prevents fluid leakage from the turbine housing. In an alternative embodiment, the microgenerator 26 may be immersed within a non-flammable hydraulic fluid, thereby negating the requirement for shaft seal 28 .
Conduits 18 and 19 are bifurcated, with each arm of the conduit being provided with a check valve ( 31 - 34 ) to prevent reverse flow of the fluid through the turbine. The check valves may be, for example, spring loaded. Other conventional check valves may be employed, as will be apparent.
Conduits 18 and 19 are secured within hydroelectric generator module 20 by fittings 40 and 42 , respectively.
Electricity generated by microgenerator 26 is conducted by wires 45 to a watertight socket 47 located on the exterior of the sole. The watertight socket may be provided with a protective cap 49 which protects the socket when not in use.
In an alternative embodiment, socket 47 and/or an additional socket (not shown) may be provided on the interior of the sole. Such an interior socket may be used to connect to, for example, electric foot warmers, electric coolers or a rechargeable battery pack located within the footwear itself.
When located on the exterior, socket 47 is used as a connector to supply electricity via external wires 51 , as shown in FIG. 1, to the desired portable device. In a preferred mode of operation, wires 51 are connected to a power control output unit (not shown) which can be mounted on a user's belt. Electronic devices can be attached to this power control output unit. The unit helps ensure an even supply of electricity, regardless of whether the user is in motion at the time. The power control output unit also allows for the regulation of the output voltage so the system is adaptable to a variety of equipment. When the electricity is not being used, the generated electricity can be stored in a rechargeable battery pack which, once again, can be carried on a user's belt.
In use, when the wearer of the footwear walks, the downward movement of the wearer's heel within the footwear will result in compression of the fluid filled sac 14 . Fluid will be forced through conduit 18 and into hydroelectric generator module 20 . The fluid will flow through one arm of the bifurcated conduit, through the forward-flow check valve 32 and into the turbine housing (Arrow A). Movement of the fluid will result in rotation of the vane rotor 22 and shaft 24 , thereby producing electricity by means of microgenerator 26 .
Fluid will then pass through the turbine housing under pressure and exit via check valve 34 , along conduit 19 and into sac 16 (Arrow B).
As the user continues the stride, the heel will be lifted and downward pressure will be exerted on sac 16 preferably located under the ball of the user's foot. In this manner, Sac 16 will be compressed, forcing fluid under pressure back through conduit 19 and into the turbine housing via check valve 33 (Arrow C). Once again, movement of the fluid will result in rotation of the vane rotor 22 and shaft 24 , thereby producing electricity in microgenerator 26 .
Fluid will then pass through the turbine housing under pressure and exit via check valve 31 , through conduit 18 and back into sac 14 (Arrow D).
In the embodiment shown in FIGS. 1 and 2, the hydroelectric generator assembly is located within the molded sole of a shoe or boot. The assembly may be formed integral with the sole or may be formed as a separate unit which can be inserted into cavities in a pre-formed sole. This latter arrangement would allow for access to the various components of the assembly via a removable insole.
Various hydraulic fluids may be used in the present application. These fluids include, for example, water, brine, glycerine solutions, alcohol solutions, silicon based oils, petroleum oils and vegetable, grain and fish oils. The selection of a suitable fluid would depend upon the parameters of the turbine assembly as well as the conditions in which the footwear is to be used. For example, if the footwear is to be used in extreme cold environments, it is preferable that the fluid have a low freezing point and a low viscosity.
In an alternative embodiment, the entire hydroelectric generator assembly may be formed within an insole which can be removably placed within existing footwear. As will be apparent, in this particular embodiment, the socket into which appliances may be plugged will be located adjacent the insole and will not be formed as an integral part of the shoe or boot. In order to be able to keep the insole as thin as possible, it is preferable if the fluid sacs are thin but cover a large surface area, thereby maximizing the volume of fluid which can be displaced without comprising on thickness. As the inside embodiment must be extremely durable, it is envisioned that the fluid sacs may be attached directly to the hydroelectric generator module, with the check valves being formed at the junction between the sac wall and the module. In this particular case the check valves themselves, would act as the fluid conduits, thereby negating the necessity for tubing-type conduits.
In yet another embodiment, fluid may only pass through the hydroelectric generator module as it flows in one direction, for example, from the heel sac to the front sac. In the reverse direction the fluid passes along a conduit which connects directly between the front sac and the heel sac, i.e., the hydroelectric generator module is bypassed.
The hydroelectric generator module has been described with reference to a turbine assembly. However, other hydroelectric generating systems such as magnetohydrodynamic systems may also be used. In the case of a magnetohydrodynamic system, a magnetic hydraulic fluid may be used, wherein the magnetic fluid passes along a conduit, through an electric coil. Movement of the magnetic fluid within the coil will result in the generation of electricity. In an alternative magnetohydrodynamic system, a conductive fluid may be passed through a coiled conduit located within a magnetic field. Electricity will be generated in conductive electrode strips located on opposite sides of the coil. Suitable magnetic hydraulic fluids would include, for example, mercury or hydraulic fluids which contain a suspension of fine magnetic materials therein. Ferromagnetic fluids of this type are known in the art.
The present application has been described with reference to various presently preferred embodiments. Modifications and variations of these embodiments will be apparent to a person of skill in the art. Such modifications and variations are believed to be within the scope of the present invention as defined in the claims appended hereto.
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A hydroelectirc generator assembly for use in footwear includes a pair of fluid filled sacs contained in the sole of the footwear. The sacs are connected by conduits whereby, when the footwear is used for walking, fluid is transferred between the sacs, via the conduits. A turbine positioned between the conduits is rotated by the moving fluid thereby resulting in the generation of electricity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to tubular or sleeve-shaped heating and measurement devices, especially glow plugs, heating plugs for preheating water, measurement and sensor elements.
2. Description of Related Art
It is desirable to produce glow plugs, heating plugs for preheating water, measurement and sensor elements to be as slender as possible for reasons of minimization of material consumption, the amount of space required, and weight. However, thermal stresses occur during the operation of the more slender and narrowly-dimensioned glow plugs known in the prior art lead to adverse effects on the function of these prior art glow plugs. In conventional glow plugs produced with an annular gap, vapor bubble formation and coking occurs in the annular gap thereby resulting in faulty measurements from a correspondingly built sensor.
Due to the reduction in the diameter of these devices though slenderizing together with the simultaneous demand for longer dimensioned rod glow plugs, major technical difficulties arise because of the required tolerances and the necessity of economical production of these devices. In particular, major technical problems in the manufacturing of such devices include adherence to concentricity tolerances, difficulties in sealing between the glow plug body and the glow tube and space problems in the area of the control spiral in rod glow plugs.
As an example, the prior art glow plug 100 as shown in FIG. 1 consists of the glow plug body 15 , into which glow plug tip tube 16 is installed. The glow tube 16 includes a heating element 4 and a control element 5 that are embedded in an electrically insulating material for conducting heat, such as MgO. In the terminal-side area in the body 15 , there is provided a connection lead 10 . This area of the glow plug 100 is sealed by a seal 2 relative to the glow plug tip tube 16 . The terminal-side area includes a cavity around the connection lead 10 which connects to an electric terminal 6 . This cavity is sealed by another seal 3 . This terminal-side of the glow plug body 15 has a thread 7 and a polyhedron 8 . An annular gap 14 is provided proximate to the glow plug tip tube 16 in the combustion space-side exit area between the glow plug tip tube 16 and the glow plug body 15 . As can be seen, the annular gap 14 is formed by increasing the diameter of the hole in the glow plug body 15 . As can be readily appreciated, such prior art glow plugs are relatively complicated with many parts which are difficult to manufacture and assemble.
SUMMARY OF THE INVENTION
One object of the present invention is to overcome the limitation of prior art devices by enabling slenderizing of glow plugs, heating plugs for preheating water, measurement and sensor elements without adversely affecting their operation.
Another object of the present invention is to reduce deviations from concentricity of these devices.
Still another object of the present invention is to reduce the number of parts used in such glow plugs, heating plugs for preheating water, measurement and sensor elements.
These and other objects and advantages of the subject invention are obtained by a glow plug including a glow plug body formed from a single piece tube, the single piece tube including a plug tip area with a glow element disposed therein, a control area with a control element disposed therein, and a connection area with an inside connection lead adapted to be connected to an electrical terminal where the plug tip area has a different diameter than the control area and/or the connection area of the single piece tube.
These and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the invention when viewed in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a prior art glow plug.
FIG. 2 is a partial cross-sectional view of a glow plug in accordance with one embodiment of the present invention.
FIG. 3 is a partial cross-sectional view of the terminal-side area of a glow plug in accordance with the present invention with a union nut.
FIG. 4 is a partial cross-sectional view of the terminal-side area of a glow plug in accordance with another embodiment of the present invention with a union nut.
FIG. 5 is a side profile view of a glow plug in accordance with the present invention with a union nut and annular ring as installed in an engine block.
FIG. 6 a is a side profile view of a glow plug in accordance with another embodiment of the present invention as installed in an engine block.
FIG. 6 b is a side profile view of a glow plug of FIG. 6 a removed from the engine block.
FIG. 7 is a partial cross-sectional view of the terminal-side area of a glow plug in accordance with another embodiment of the present invention including a rolled-on thread and a stamped-on polyhedron.
FIG. 8 shows yet another embodiment of a glow plug in accordance with the present invention but without the union nut.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described herein below together with the drawings as specifically applied to glow plugs. However, it should be noted that the present invention may also be readily applied to other tubular or sleeve-shaped heating and measurement devices, including heating plugs for preheating water, measurement and sensor elements. Therefore, the term Aglow plugs≃ is used in the general sense and should be construed to include tubular or sleeve-shaped heating and measurement devices including glow plugs, heating plugs for preheating water, measurement and sensor elements.
FIG. 2 shows a glow plug in accordance with one embodiment of the present invention including a single piece tube 1 . Initially, it is noted that in reference to the present invention in FIGS. 2 to 7 as well as in the prior art glow plug of FIG. 1, common numerals have been used for similar components for ease of comparison.
As can be seen in FIG. 2, the diameter of the single piece tube 1 in the glow plug 200 in accordance with the present invention is reduced in a step like manner into tube sections of decreasing diameters. In the present illustrated embodiment, the plug tip area 16 of the single piece tube 1 has the smallest diameter and houses the heating element 4 . The tube section with the control area 16 a adjacent to the plug tip area 16 in the terminal-side direction has a greater diameter than the plug tip area 16 . The transition between the two tube sections is characterized by a peripheral sealing surface 9 a . This sealing surface 9 a is provided to interact with a corresponding seal seat surface 9 b in a hole in the engine block (see FIG. 5) to provide sealing thereof. This tube section with the control area 16 a may be provided a control element 5 . Similarly, the tube section with the connection area 16 b which adjoins the control area 16 a in the terminal direction has a somewhat greater diameter than the control area 16 a and houses a connecting lead 10 which is connected to or is made integral with the electrical terminal 6 through a seal 2 on the terminal-side end of the single piece tube 1 . Preferably, the heating element 4 , the control element 5 and the connection lead 10 are supported in a heat conducting, electrically nonconductive material, such as MgO.
As shown in FIG. 3, the glow plug 200 in accordance with the present invention may be provided with a union nut 17 with an outside thread and optionally, an cutting ring 19 on the terminal-side end. The union nut 17 is used to fix the glow plug 200 into a hole in the engine block by screwing the union nut 17 into an inside thread 18 in the engine block 12 . The cutting ring 19 seals the free space between the inside wall of the hole and the outside wall of the single piece tube 1 under the pressure of the tightened union nut 17 .
In FIG. 4, the glow plug 400 in accordance with the present invention does not have an annular ring. Rather, in an manner otherwise similar to FIG. 3 a seal is achieved by the contact of the sealing surface 9 a on the single piece tube 1 as shown in FIG. 2 against a corresponding opposite seal seat surface in the hole of the engine block by tightening the union nut 17 into an inside thread 18 of the engine block 12 .
FIG. 5 shows another embodiment of a glow plug 500 in accordance with the present invention which can be fixed in a corresponding hole in the engine block 12 using a union nut 17 in a substantially similar manner as shown in FIG. 3, again, the common elements being enumerated with the same reference numerals. In this embodiment, the sealing surface 9 a of the glow plug 500 interacts to form a seal with the corresponding opposite seal seat surface 9 b in the hole in the engine block 12 . Because the diameter of the plug tip area 16 of the single piece tube 1 is somewhat smaller than the corresponding areas of hole in the engine block 12 , an air gap 13 is formed around the combustion space side of the single piece tube 1 . In a similar manner, an annular gap 14 a is formed between the remainder of the single piece tube 1 and the hole in the engine block 12 . Moreover, the annular gap 14 a is sealed relative to the air gap 13 by the sealing surface 9 a and the corresponding opposite seal seat surface 9 b in the hole.
The embodiment of the glow plug 600 installed in the engine block 12 as shown in FIG. 6 a corresponds essentially to the embodiment of FIG. 5 discussed above but with a rolled-on thread 7 . The glow plus 600 in accordance with this embodiment is more clearly shown in FIG. 6 b . In addition, the embodiment of the glow plug 700 as shown in FIG. 7 also corresponds essentially with the embodiment of FIGS. 5, 6 a and 6 b but with a stamped-on polyhedron 8 which is integral with the single piece tube 1 . FIG. 8 shows yet another embodiment of a glow plug 800 in accordance with the present invention but without the union nut. Again, the common components in these various figures have been enumerated using the same numerals but the discussions of these common components have been omitted to avoid repetition.
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto. These embodiments may be changed, modified and further applied by those skilled in the art. Therefore, this invention is not limited to the details shown and described previously but also includes all such changes and modifications which are encompassed by the appended claims
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A glow plug including a glow plug body formed from a single piece tube, the single piece tube including a plug tip area with a glow element disposed therein, a control area with a control element disposed therein, and a connection area with an inside connection lead adapted to be connected to an electrical terminal where the plug tip area has a different diameter than the control area and/or the connection area of the single piece tube.
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This is a continuation of application Ser. No. 08/385,004, filed Feb. 7, 1995, now issued as U.S. Pat. No. 5,625,680.
TECHNICAL FIELD
This invention relates to a method and apparatus for prioritizing telephone calls.
BACKGROUND OF THE INVENTION
There are existing methods of prioritizing telephone calls. For example, the name or telephone number of the caller party can be displayed on the recipient's telephone, a telephone can be provided with a function that blocks all incoming telephone calls on demand or telephone calls can be forwarded to an automated message center.
There also are existing methods of rerouting telephone calls. For example, call forwarding or automated answering systems that allow callers to reroute their telephone calls.
The existing methods of prioritizing and rerouting of telephone calls have several disadvantages. One distinct disadvantage with respect to prioritizing of telephone calls is that the caller does not have any control over the prioritizing of his telephone calls. Similarly, with respect to rerouting of telephone calls, the caller does not have any control over whether his call will be rerouted.
Existing methods of prioritizing and rerouting of telephone calls also have disadvantages from the recipient's perspective. For example, because the recipient does not know the nature of the call before answering, the recipient cannot prioritize or reroute calls based upon the nature of the call.
The deficiencies in the existing methods of prioritizing and rerouting of telephone calls is made readily apparent in telemarketing. Telemarketing is the use of telecommunication services to market and sell products and services and to provide customers with product and service information.
Often times, telemarketing agents expend time and effort calling potential customers only to be greeted by anger and irritation. Many people consider calls to their home during nonworking hours by nameless, faceless telemarketing agents to be an unwanted intrusion. In particular, potential customers often express anger and irritation when telemarketing agents call during dinner hour.
Thus, there is a need for a method and apparatus that allows the caller to designate the priority of a telephone call based on specified priority criteria and the recipient to designate treatment of telephone calls based on their specified priority criteria.
SUMMARY OF THE INVENTION
The above problems are solved according to the invention by providing a method and apparatus for prioritizing telephone calls. The invention allows a caller to designate the priority of his telephone call based upon specified priority criteria. The specified priority criteria follow the telephone call through the telephone network. The priority of the call is determined based on the specified priority criteria. The telephone call is connected, rerouted or terminated based upon the specified priority criteria.
More particularly a telephone service provider's network is equipped with an originating switch proximate to the caller. The originating switch is equipped with means for identifying specified priority criteria that the caller has assigned to his call. That specified priority criteria follows the call through the telephone service provider's network.
The telephone service provider's network is also equipped with a terminating switch proximate to the recipient. The terminating switch is equipped with means for identifying specified priority criteria that the recipient has assigned to incoming calls.
When the caller places a call to the recipient, the call arrives at the originating switch which undertakes to identify the specified priority criteria, if any, that the caller has assigned to the call. The originating switch then connects the call to the terminating switch. If the caller has assigned specified priority criteria to the call, that specified priority criteria follows the call through the telephone service provider's network from the originating switch to the terminating switch.
When the call arrives at the terminating switch, the terminating switch identifies the specified priority criteria, if any, that the recipient has assigned to incoming calls. If the recipient has assigned a specified priority criteria to incoming calls, the specified priority criteria that the recipient has assigned to incoming calls is compared to the specified priority criteria that the caller has assigned to the call. If the specified priority criteria that the recipient has assigned to incoming calls satisfies the specified priority criteria that the caller has assigned to the call, then the call is connected. If the specified priority criteria that the recipient has assigned to incoming calls does not satisfy the specified priority criteria that the caller has assigned to the call, then the call is either rerouted to an alternative destination or terminated.
The specified priority criteria that a caller can assign to a call and that the recipient can assign to incoming calls include any manner of denoting special treatment for a call. For example, the caller could specify that the call is a low priority call and the recipient could specify that low priority calls only be put through during certain times of the day. The specified priority criteria can be more particular. The caller could, for example, specify that the call relates to telemarketing or to a fund raising campaign and the recipient could specify that calls relating to telemarketing or fundraising not be put through at all or only be put through during certain times of the day.
The caller could, for example, designate that the call is of a personal nature. If the recipient, for example, is working at home and does not want to be interrupted by calls of a personal nature, the recipient could specify that all personal calls be directed to a answering machine device or a voice mail system. Similarly, if the recipient is out of his office and at home on vacation or with an illness, the recipient could, for example, specify that work related calls be directed to an answering machine or voice mail system. Alternatively if the recipient, for example, conducts business out of his home, and does not want business calls during evening hours, the recipient could specify that personal calls be put through during evening hours, but business calls received during evening hours be directed to an answering machine or voice mail.
As would be understood by a person of ordinary skill in the art, the invention can be used for prioritizing and directing of electronic data communication as well as telephone calls. For example, electronic mail ("E-mail") and facsimile transmissions can be prioritized and directed in the same manner as described above with respect to telephone calls.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram which illustrates an embodiment of the invention.
FIG. 2 is a flow diagram illustrating the processing of telephone calls in accordance with the invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a basic configuration of an embodiment of the invention. A caller 10 is connected through a telephone service provider's network 12 to the call recipient 14. The telephone service provider's network 12 includes an originating switch 20 and a terminating switch 22 which are connected via link 24.
The caller 10 is connected via link 26 to the originating switch 20. Similarly, the terminating switch 22 is connected via link 28 to the call recipient 14.
The originating switch 20 is connected via link 30 to an automatic number identification ("ANI") "trigger table" 32. An ANI trigger table contains a list of the telephone numbers of subscribers to various special services offered by the telephone service provider. The originating switch 20 is also connected via link 34 to a data base 36.
Similarly, the terminating switch 22 is connected via link 38 to an ANI trigger table 40. The terminating switch 22 is also connected via link 42 to a data base 44.
When the caller 10 places a call to the call recipient 14, the call proceeds via link 26 to the originating switch 20. The caller's telephone number, which is identified by the telephone service provider's system, is transmitted with the call to the originating switch 20. Using the caller's telephone number, the originating switch queries the ANI trigger table 32 as to whether the caller 10 subscribes to any of the special services offered by the telephone service provider.
If the caller's telephone number does not appear on the ANI trigger table 32, the ANI trigger table 32 signals the originating switch 20 that the caller 10 does not subscribe to any of the special services offered by the telephone service provider. The originating switch then connects the call to the terminating switch 22 via link 24 and the terminating switch 22 connects the call to the call recipient 14 via link 28.
If, however, the caller's telephone number appears on the ANI trigger table 32, the ANI trigger table 32 signals the originating switch 20 that the caller 10 subscribes to at least one of the special services offered by the telephone service provider. The originating switch 20 then queries the data base 36 as to the particular special service offered by the telephone service provider to which the caller subscribes. The database identifies the caller as a subscriber to the telephone call prioritization system and provides the caller's specified priority criteria. The originating switch 20 connects the telephone call to the terminating switch 22 via link 24. The specified priority criteria that the caller has assigned to the call is transmitted with the call from the originating switch 20 to the terminating switch 22 via link 24. The call recipient's telephone number, which is identified by the telephone service provider's system, also is transmitted with the call from the originating switch 20 to the terminating switch 22 via link 24. The call and specified priority criteria arrive at the terminating switch 22.
Using the recipient's telephone number, the terminating switch queries the ANI trigger table 40 as to whether the call recipient 14 subscribes to any of the special services offered by the telephone service provider. If the call recipient's telephone number does not appear on the ANI trigger table 40, the ANI trigger table 40 signals the terminating switch 22 that the call recipient 14, does not subscribe to any of the special services offered by the telephone service provider. The terminating switch 22 then connects the call to the call recipient 14 via link 28.
If, however, the call recipient's telephone number appears on the ANI trigger table 40, the ANI trigger table 40 signals the terminating switch 22 that the call recipient 14 subscribes to at least one of the special services offered by the telephone service provider. The terminating switch 22 then queries the data base 44 as to the particular special service offered by the telephone service provider to which the call recipient subscribes. The database identifies the call recipient as a subscriber to the telephone call prioritization system and provides the recipient's specified priority criteria and alternative treatment of calls that do not fall within the recipient's specified priority criteria.
Based on the caller's specified priority criteria transmitted with the telephone call and the recipient's specified priority criteria and alternative treatment information, the terminating switch 22 directs the telephone call. If the caller's specified priority criteria satisfies the recipient's specified priority criteria, the call is connected. If the caller's specified priority criteria does not satisfy the recipient's specified priority criteria, the call is rerouted to an alternative destination or terminated.
FIG. 2 is a flow diagram showing the processing of a telephone call in accordance with the principles of the invention. The caller 10 places a telephone call and the telephone call arrives at the originating switch 20 (step 100). Using the caller's telephone number, the originating switch queries the ANI trigger table 32 to check if the caller's telephone number appears (step 104).
If the caller's telephone number does not appear on the ANI trigger table 32, the ANI trigger table 32 signals the originating switch 20 that the caller 10 does not subscribe to any of the special services offered by the telephone service provider and the originating switch 20 then connects the call through the terminating switch 22 via link 24 to the call recipient 14 via link 28 (step 106). If, however, the caller's telephone number appears on the ANI trigger table 32, the ANI trigger table 32 signals the originating switch 20 that the caller 10 subscribes to at least one of the special services offered by the telephone service provider.
The originating switch 22 then queries the data base 36 as to the particular special service offered by the telephone service provider to which the caller subscribes. The database identifies the caller as a subscriber to the telephone call prioritization system and provides the caller's specified priority criteria (step 108). The originating switch 20 then routes the call to the terminating switch 22 with the caller's specified priority criteria in the signalling path (step 110).
The call arrives at the terminating switch 22 (step 112). Using the recipient's telephone number, the terminating switch 22 queries the ANI trigger table 40 to check if the recipient's telephone number appears (step 116).
If the recipient's telephone number does not appear on the ANI trigger table 40, the ANI trigger table 40 signals the terminating switch 22 that the recipient does not subscribe to any of the special services offered by the telephone service provider and the terminating switch 22 connects the call (step 118). If, however, the recipient's telephone number appears on the ANI trigger table 40, the terminating switch 22 queries the data base 44 for the particular special service offered by the telephone service provider to which the call recipient subscribes. The database identifies the call recipient as a subscriber to the telephone call prioritization system and provides the recipient's specified priority criteria and desired alternative treatment of calls that do not fall within the specified priority criteria (step 120).
Finally, based on the caller's specified priority criteria transmitted with the telephone call and the recipient's specified priority criteria and alternative treatment information, the terminating switch 22 directs the telephone call (step 122). If the caller's specified priority criteria satisfies the recipient's specified priority criteria, the call is connected (step 124). If the caller's specified priority criteria does not satisfy the recipient's specified priority criteria, the call is either terminated or rerouted based on the call recipient's alternative treatment information (step 126).
The following is an example of use of the method and apparatus for prioritizing telephone calls.
A telemarketing center subscribes to the telephone call prioritizing system and has specified that all calls originating from its telephone number are "low priority" calls. At 6:30 pm, a telemarketing agent calls a potential customer from that telemarketing center. The potential customer also subscribes to the telephone call prioritizing system and has specified that it does not wish to receive low priority calls between the hours of 5:00 pm and 9:00 am and that incoming low priority calls during those hours should be connected through to his answering machine.
The call arrives at the originating switch that handles the telemarketing center's telephone numbers. The originating switch, using the telephone number of the telemarketing center, queries the ANI trigger table. The ANI trigger table signals the originating switch that the telemarketing center subscribes to at least one of the special services offered by the telephone service provider.
The originating switch then queries the database for the special service offered by the telephone service provider to which the telemarketing center subscribes. The database identifies the telemarketing center as a subscriber to the telephone call prioritization system and provides the telemarketing center's specified priority criteria. The data base signals the originating switch that all calls originating from the telephone number of the telemarketing center are low priority. The originating switch connects the call to the terminating switch with telemarketing center's the low priority specified priority criteria in the signalling path.
The terminating switch queries the ANI trigger table as to whether the call recipient subscribes to any of the special services offered by the telephone service provider. The ANI trigger table signals the terminating switch that the call recipient subscribes to a special service offered by the telephone service provider.
The terminating switch then queries the database as the special service offered by the telephone service provider to which the call recipient subscribes. The database identifies the call recipient as a subscriber to the telephone call prioritizing system and provides the call recipient's specified priority criteria. The database signals the terminating switch that the call recipient does not wish to have low priority calls connected between the hours of 5:00 pm and 9:00 am and that incoming low priority call received during these hours should be connected to an answering machine. Per the call recipient's specified priority criteria and alternative treatment information, the terminating switch connects the call to the recipient's answering machine.
It is to be understood that the above description is only of one preferred embodiment of the invention. Numerous other arrangements may be devised by one skilled in the art without departing from the scope of the invention. The invention is thus limited only as defined in the accompanying claims.
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A method and apparatus for prioritizing telphone calls that enables a caller to specify priority criteria relating to the calls and a recipient to specify priority criteria relating to the treatment of the calls.
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FIELD OF THE INVENTION
[0001] The present invention relates to an electric coffee maker for the production of espresso coffee.
DESCRIPTION OF THE PRIOR ART
[0002] The traditional coffee maker for domestic use, of the type commonly known as moka or mocha, is formed by a lower vessel and an upper vessel generally screwed axially and tightly one to the other and communicating via an intermediate, substantially funnel-shaped vessel having a tubular portion. An axial duct, open at the upper end and if necessary provided with a dispensing member, extends from the base of the upper vessel. The coffee powder is placed in the intermediate vessel, while the lower vessel, which acts as a boiler, is filled with water as far as a preset level. The formation of steam in the boiler following the administering of heat causes an increase in pressure therein, sufficient for causing the hot water to rise up along the tubular portion of the intermediate vessel, forcing it to diffuse in the layer of coffee powder, traversing it and rising up along the axial duct of the upper vessel so as to pour into it, flowing from its free end.
[0003] In this type of domestic coffee maker the working pressure of the hot water that traverses the layer of coffee powder is generally very low and, since it is limited by a safety valve, the pressure drop through the layer of coffee powder cannot go beyond certain values. The low pressure of the hot water is responsible for the incomplete process of infusion whose effect influences the properties of the coffee produced.
[0004] Conventional domestic coffee makers generally use an external source of heat, for example a gas or other fuel cooker or an electric plate, although small coffee makers for domestic use with electrical heating are becoming increasingly widespread, that is to say coffee-makers provided with their own dedicated electric heater, in some cases integral with the boiler and in others separable therefrom. The success of electric coffee makers is due above all to their greater versatility of use, as they allow coffee to be prepared anywhere, even where a cooker is not available, for example in a bedroom or an office and, in the portable version, also in a car.
[0005] From the standpoint of the properties of the coffee produced, both traditional domestic coffee makers and those associated with dedicated electrical heating means, have the limitation, as referred previously, of not allowing preparation of real espresso coffee such as that which can be produced with professional machines for use in bars or also with espresso coffee makers for domestic use. The production of espresso coffee requires, as is known, in addition to a very fine grain size of the coffee powder used, also careful control of the temperature and pressure inside the boiler. In order to obtain the correct density of the infusion, it is important that diffusion of the water in the layer of coffee powder is as complete as possible and takes place at a constant temperature and for a preset time. These conditions cannot be observed in conventional domestic machines of the moka type wherein the contact time and the diffusion within the layer of coffee powder are controlled solely by the pressure of the steam which is formed in the boiler and which is responsible for the flow of hot water intended to traverse the layer of coffee powder.
[0006] In known machines for the production of espresso coffee, both domestic and professional, the pressure of the hot water inside the boiler is provided by a pump which feeds it over a filter filled with coffee powder and enclosed in a filter holder. The pressure of the water, associated with the finer grain size of the powder and a smaller section of the holes of the filtering plate, allows a more intense infusion process whereby the substances contained in the coffee powder, which confer to the infusion the typical properties of espresso coffee, are almost completely extracted.
[0007] On the other hand, for a number of reasons, including their simplicity of use and their established customary use, domestic moka coffee makers continue to be preferred over domestic machines for espresso coffee, despite the fact that the former do not succeed in achieving the typical quality features of espresso coffee. Their bulk in particular is considered to be one disadvantage of domestic machines for espresso coffee, which means they must be kept always on view on some furniture unit, and the fact that they traditionally do not allow preparation of more than two servings of coffee simultaneously, and therefore force replacement of the powder for each cup, or at most two cups, of coffee produced, whereas in moka coffee makers, according to their size, a much larger number of cups of coffee can be made.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] Therefore, the main object of the present invention is to provide a coffee maker for domestic use which has the structure of a moka coffee maker yet which enables coffee infusions to be made with the typical properties of espresso coffee.
[0009] A particular object of the present invention is to provide a coffee maker of the type mentioned above which is small in size and, in any case, only slightly larger in size than a traditional moka coffee maker.
[0010] Another object of the present invention is to provide a coffee maker of the type mentioned above which allows the production of several servings of espresso coffee.
[0011] A further object of the present invention is to provide a coffee maker of the type mentioned above wherein the ordinary maintenance operations (washing of the boiler and coffee collecting vessel, and emptying the used coffee powder) are simple and fast and the risks of soiling for the user and worktops are minimised.
[0012] The basic features of the coffee maker for domestic use according to the present invention are claimed in claim 1 . Further important features are claimed in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features, and advantages, of the coffee maker for domestic use according to the present invention will be made clearer by the following description of some embodiments thereof, given by way of a non-limiting example with reference to the accompanying drawings, wherein:
[0014] FIG. 1 is an elevational sectional view of a first embodiment of the coffee maker according to the invention;
[0015] FIG. 2 is a partially sectioned top plan view from above of the coffee maker of FIG. 1 ;
[0016] FIG. 3 is a sectioned view of the coffee maker of FIG. 1 along line III-III of FIG. 2 ;
[0017] FIG. 4 is a partial elevational sectional view of a variation of the coffee maker of FIG. 1 ;
[0018] FIG. 5 is an enlarged section of detail A of FIG. 4 ;
[0019] FIG. 6 is a detail view of a releasable coupling for connection of the water supply line to the boiler of the coffee maker of FIG. 1 ;
[0020] FIG. 7 is an elevational sectional view of a second embodiment of the coffee maker according to the invention;
[0021] FIG. 8 is a partial cross sectional view along line VIII-VIII of FIG. 7 ;
[0022] FIG. 9 is an axial sectional view along line IX-IX of FIG. 7 ;
[0023] FIG. 10 is an elevational sectional view of a third embodiment of the coffee maker according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring to FIGS. 1, 2 and 3 , the domestic coffee maker for producing espresso coffee according to the invention comprises a lower vessel 1 or boiler, an intermediate, substantially funnel shaped vessel 2 suitable for holding the coffee powder and tightly connected to the boiler 1 at its inlet, and an upper vessel 3 for collecting the coffee infusion, arranged coaxially to the boiler 1 and to the intermediate vessel 2 . More specifically the intermediate vessel 2 has a cylindrical portion 2 a and a tubular portion 2 b joined one to the other by a truncated cone portion 2 c , the tubular portion 2 b extending axially towards the bottom wall of the boiler 1 . The inlet of the boiler 1 is defined by a tubular wall 1 a whereto the cylindrical portion 2 a is connected tightly by means of an O ring 60 . A small perimetric edge 2 d projecting from the cylindrical portion rests on the edge of the tubular wall 1 a.
[0025] A disk-shaped body 4 extends above the intermediate vessel 2 and is bordered around its perimeter by a sleeve edge 5 which is screwed externally to the tubular wall 1 a . The disk 4 has a substantially conical shape slanting towards the upper vessel 3 above, and on the side of the intermediate vessel 2 holds a filtering plate 6 attached by means of an annular seal 7 engaged in a groove 8 formed on the internal face of the sleeve 5 immediately below the disk 4 . The seal 7 , in an elastic material, creates the hermetic tightness of the boiler 1 once the tubular sleeve 5 is screwed fully to the tubular wall 1 a of the boiler 1 .
[0026] Inside the cylindrical portion 2 a of the intermediate vessel 2 a container 9 is placed, with a finely perforated base 9 a which, together with the filtering plate 6 , defines a chamber 10 for containing the coffee powder. The container for the coffee powder 9 has a small projecting perimeter edge 9 b which is placed between the seal 7 and the corresponding small edge 2 d of the intermediate vessel 2 when the sleeve 5 is completely screwed to the tubular wall 1 a of the boiler 1 , in this way securing the container 9 inside the intermediate vessel 2 .
[0027] An elastic element 11 is provided inside the truncated cone portion 2 c of the intermediate vessel 2 . The elastic element 11 is placed between the truncated cone walls of portion 2 c and the bottom wall 9 a of the coffee powder container 9 . The elastic element 11 is compressed by the base 9 a when the sleeve 5 is fully screwed to the tubular wall 1 a , so that, when said sleeve is unscrewed and removed, the elastic reaction of the elastic element 11 pushes the container 9 axially, making it project partially from the intermediate vessel 2 and thus facilitating its grip for subsequent extraction and removal of the used coffee powder. Moreover raising of the container 9 creates a vacuum in the part below it which draws the water located between the disk 4 and the surface of the coffee powder. This water, mixed with coffee powder, would otherwise inevitably flow to the outside, when the disk-shaped body 4 is unscrewed from the lower vessel 1 .
[0028] A first tubular element 12 extends axially from the centre of the disk 4 inside the upper vessel 3 and a second tubular element 13 , extending coaxially from the bottom wall 3 a of the upper vessel 3 , engages slidingly on the first tubular element 12 . The base 3 a rests on the disk 4 , with the same configuration and slant, and along its perimeter a groove 14 is formed, wherein the tubular sleeve 5 engages, in this way removably securing the upper vessel 3 to the boiler 1 .
[0029] The tubular element 12 , which extends from the disk 4 , defines a duct 15 ending with a flared portion in which a truncated cone bush 16 is engaged, with the same slant, ending with a radially perforated head 16 a through which the coffee produced can flow. A skirt 17 extends radially from the bush 16 , immediately below its perforated head 16 a , and around the tubular element 13 at its free end. The bush 16 , forming a watertight connection with the tubular element 12 due to the conicity of the respective reciprocal contact walls, prevents infiltration of the coffee infusion between the upper vessel 3 and the disk 4 , assisted for this purpose also by the skirt 17 which covers the free ends of the two tubular elements 12 and 13 .
[0030] The upper vessel 3 is provided, as is customary, with a lid 18 , with a central knob 19 for its raising, and a side handle 20 .
[0031] The lower vessel 1 is mounted on a box-shaped body 21 provided with a removable base 22 . More specifically the box-shaped body 21 has a raised portion 23 which engages in a corresponding cavity 24 formed on the base of the lower vessel 1 . A water reservoir 25 , with a removable lid 26 , is also positioned on the box-shaped body 21 , alongside the lower vessel 1 . Inside the box-shaped body 21 a pump 27 is placed, supported by elastic vibration-preventing supports 28 and connected to the reservoir 25 via a suction duct 29 and to the boiler 1 via a discharge duct 30 . The connection between the duct 29 and the base of the reservoir 25 is formed by means of a valve 61 suitable for preventing the release of water from the reservoir when the latter is disengaged from the duct 29 so as to be removed from the box-shaped body 21 , for example for cleaning. The discharge duct 30 , in the present embodiment of the invention, is instead connected to the boiler 1 via a fixed coupling joint 31 , so that the boiler 1 is integral with the box-shaped body 21 and can be separated therefrom only by accessing its interior and adjusting a connection ring nut. The joint 31 is connected to a release nozzle 32 situated on the bottom wall of the boiler 1 , wherefrom the cold water flows out, preferably tangentially to the base of the boiler so as to eliminate, or at least limit, turbulence phenomena. In the present embodiment of the invention the water is heated by means of an electrical resistor 33 embedded in the metal of the boiler 1 on the bottom wall thereof and the temperature is controlled by means of a thermostat 52 .
[0032] The coffee maker according to the invention is also provided with a control panel, not shown, formed for example frontally on the box-shaped body 21 and provided with all the pushbuttons and the operation indicators required for operative control of the coffee maker.
[0033] When using the coffee maker according to the invention, after having filled with water the reservoir 25 and the boiler up to the level indicated therein, and after having placed the coffee powder in the container 9 , the chamber 10 is closed by screwing the disk 4 to the boiler 1 and positioning the upper reservoir 3 above it. The heating device is then switched on and remains in operation until the temperature of the water has reached the preset value (generally around 95° C.). At this point the user, by pressing the pushbutton for starting the pump 27 , causes water to flow into the boiler 1 which forces the hot water into the tubular portion 2 b , making it pass through the layer of coffee powder and from there rise up through the duct 15 until it flows out into the upper vessel 3 . The user will keep the pump 27 in operation until the level in the upper vessel 2 has risen to the level corresponding to the servings required. Preferably, for a direct check of the level in the upper vessel 3 , the latter will be made of a transparent material and a scale indicating the servings which correspond to the level reached by the coffee infusion will be provided on the vessel wall.
[0034] In order to ensure that the hot water traverses the layer of coffee powder at an optimal pressure (generally around 2-4 bars, according to the degree of compression of the powder and its grain size), a valve 34 is placed inside the tubular portion 2 b of the intermediate vessel 2 , illustrated by way of an example in the form of a rubber ball forced elastically against the aperture for access to the tubular portion 2 b . This valve avoids the pulsed feed of hot water at low pressure through the layer of coffee powder before the start of the pump. A further valve 35 , also illustrated by way of an example in the same way as the valve 34 , is provided at the inlet of the duct 15 with the triple function of ensuring discharge of the coffee infusion only after the pressure in the chamber 10 has reached a preset value sufficient for providing an optimal water-powder contact time, of forming in the duct 15 an orifice with restricted section for causing turbulence in the flow of liquid and with formation of the typical cream of espresso coffee, and finally of preventing the residual coffee remaining in the duct 15 from flowing out therefrom when the coffee maker is disassembled for cleaning.
[0035] Whereas the valve 35 is considered essential for the multiple functions it is called on to perform, the valve 34 is not strictly necessary for controlling the pressure inside the boiler. Although with a limited loss of working flexibility, this control too can be assigned to the valve 35 . In this case the hot water gradually fills the intermediate vessel as the pump feeds cold water into the lower vessel and dispensing of the coffee infusion only starts when the pressure of the infusion above the coffee powder exceeds the calibration pressure of the valve 35 .
[0036] FIGS. 4 and 5 show a variation of the coffee maker according to the invention. In these figures, the components identical to those of the embodiment previously described and illustrated will be denoted by the same reference numerals and will not be described again. The variation illustrated in FIGS. 4 and 5 relates to the intermediate vessel 2 which, in this case, is housed removably in a freely sliding manner in the inlet opening of the boiler 1 and is not provided with the container 9 for the coffee powder, but has an evenly perforated plate 36 on which the coffee powder is placed directly. The seal 7 has an axial edge 37 extending inside the cylindrical portion 2 a of the second vessel 2 and ending with an enlargement 37 a which engages in a groove 38 formed on the wall of the cylindrical portion 2 a . In this way engaging of the enlarged portion 37 a in the groove 38 makes the cylindrical portion 2 a integral with the seal 7 and therefore, by removing the disk 4 , the intermediate vessel 2 is also extracted simultaneously from the boiler 1 with its content of used coffee powder. Once extracted from the boiler 2 , it is easy to separate the intermediate vessel 2 from the seal 7 by a slight traction, in order to proceed subsequently with its emptying and washing. In addition to allowing easy removal of the intermediate vessel, with this solution too the leakage of liquid mixed with coffee powder is avoided when unscrewing the disk-shaped body 4 due to the vacuum created by raising of the intermediate vessel 2 .
[0037] FIG. 6 illustrates an example of coupling connection joint which allows the boiler 1 to be separated from the body 21 whenever required, for example for cleaning of the boiler, and which can be used as an alternative to a fixed coupling. In this case on the bottom wall 39 of the boiler a valve 40 is provided which intercepts the exit of a tubular element 41 , at the entrance whereof the discharge duct 30 of the pump is connected and which is fixed thereon by means of a tightening screw nut 42 screwed to the body of the tubular element 41 . The latter is attached, for example screwed, to the raised portion 23 of the base 21 in a special housing 23 a formed thereon. The tubular element 41 is tightly coupled in a housing 43 formed on the base 39 at the valve 40 .
[0038] FIGS. 7, 8 and 9 illustrate a second embodiment of the coffee maker according to the invention wherein components identical to those present in the first embodiment previously described and illustrated have the same reference numerals. In this embodiment of the invention the pump 27 is housed in a box-shaped body 46 integral with the lower vessel 1 and rests on a base 48 on which the reservoir 25 also rests. The pump 27 is mounted on vibration-preventing supports 28 and is connected to the reservoir 25 via a suction duct 29 and to the boiler 1 via a discharge duct 30 . The discharge duct 30 , in the present embodiment of the invention, flows into a spiral path 49 formed on the base of the boiler 1 , which can be seen in particular in FIG. 8 , and forming part of a known and so-called “Thermoblock” device, denoted by 50 , formed by armoured and co-moulded resistors 51 embedded in the metal of the boiler 1 and extending above the spiral path 49 . A pair of thermostats 52 are provided on the base of the boiler 1 to control the temperature of the water which in this case reaches almost instantaneously its optimal value while passing in the spiral duct 49 and then the production of coffee can begin automatically once the boiler 1 is filled.
[0039] A rapid electrical connection, generally indicated at 53 in FIG. 7 , known commercially by the name STRIX, which, since it is well known in the sector of small electric household appliances, is not illustrated in further detail.
[0040] Compared to the embodiment shown in FIGS. 2-3 , in this case the actual coffee maker with associated box-shaped body 46 can be separated from the reservoir 25 and from the base 48 whenever necessary, for example in order to remove the used coffee powder, allowing performance of the operation for example over the sink in order not to soil the worktop with sprays of water which inevitably come out of the boiler when it is separated from the disk 4 .
[0041] In the embodiment illustrated in FIG. 10 , the pump 27 for feeding water to the boiler 1 is housed in a cavity 55 formed in the lower part of the water reservoir 25 and its suction and discharge ducts 29 and 30 are connected in a fixed manner to the reservoir 25 and to the boiler 1 respectively. The base 48 contains only the electrical part of the appliance and the electrical connector 53 , of the STRIX type, and can be separated from the rest of the appliance. In this solution the reservoir 25 surrounds the boiler 1 , in this way recovering the volume lost due to the cavity 55 .
[0042] The heating device provided in one of the embodiments described and illustrated above can alternatively be used also in the other embodiments, and different heating devices and means from those illustrated can be used, provided they are functionally equivalent. The same applies for the valves illustrated only by way of an example.
[0043] Variants and/or modifications may be made to the coffee maker for domestic use for making espresso coffee according to the present invention without thereby departing from the scope and spirit of the invention as set forth in the following claims.
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An apparatus for the production of espresso coffee and the like is disclosed. The apparatus includes a lower vessel having an inlet opening, a substantially funnel-shaped intermediate vessel placed axially at the inlet opening to the lower vessel, and an electric heater in the lower vessel for heating water contained therein. The intermediate vessel comprises at least a perforated plate that defines a chamber for containing coffee in a finely ground or powder form. An upper vessel is mounted axially to the lower vessel in a desirable fashion and in communication with the lower vessel through the intermediate vessel. The intermediate vessel is reversibly connected to the lower vessel in a relatively tight fashion relative to the outside. The lower vessel is hydraulically connected to a water reservoir through a pump. The water reservoir is positioned alongside the lower vessel and on the same support. Water is fed into the lower vessel in close proximity to the heater. Further provided are valves for controlling the pressure of the heated water and/or coffee produced, whereby dispensing coffee in the upper vessel occurs only when the water and/or coffee pressure reaches a predetermined value.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to an exhaust muffler for an internal combustion engine, especially of a portable implement, comprising a catalyst which is arranged in a housing, which has at least one inlet opening and one outlet opening for an exhaust gas flowing from an internal combustion engine into an environment.
[0002] The exhaust gases from internal combustion engines generally enter the catalyst at an exhaust gas temperature of about 600 oC. A chemical conversion of the exhaust gases takes place inside the catalyst. In this case, three processes take place simultaneously adjacent to one another: NOx is reduced to nitrogen, releasing oxygen, CO is oxidized to CO2 and HC compounds are oxidized to CO2 and H2O, consuming oxygen at the same time. As a result of the chemical conversion processes, the temperature of exhaust gas “converted” by the catalyst is increased to about 1000 oC. When this heated exhaust gas emerges from the catalyst, there is a risk of afterburning if sufficient HC and O2 is present and the ignition temperature is exceeded.
[0003] This is especially disadvantageous in the case of portable implements since the operator of such an implement can be injured by flame formation or combustible materials located in the vicinity can be ignited.
[0004] Described from DE 79 25 614 U1 is an exhaust muffler which has an inlet space and an outlet space from which an exhaust gas is led away. In the area of the outlet a branched partial stream of cooling air is supplied to the exhaust gas stream, which is mixed with the exhaust gas at the outlet and provides for a reduction in temperature. It is disadvantageous however that a sufficient reduction in the temperature of the exhaust gas stream is not achieved in the area of the outlet.
[0005] Known in accordance with DE 1 98 34 822 A1 is an exhaust muffler which is mounted on an internal combustion engine of a hand-held implement. In this case, the exhaust muffler has a housing with a catalyst element which is positioned between an exhaust gas inlet and an exhaust gas outlet.
[0006] Furthermore, a first partial stream of the exhaust gas stream inflowing via the exhaust gas inlet is brought in contact with the catalyst element and a second partial stream flows substantially without contact with the catalyst element to the exhaust gas outlet. Before leaving the housing, the partial streams are brought together and mixed. In this case also no satisfactory reduction in the exhaust gas outlet temperature is achieved, whereby the afore-mentioned hazards could be avoided.
[0007] DE 38 29 668 C3 proposes an exhaust gas muffler in which a catalyst is arranged with a spacing on all sides [inside] a housing of the exhaust gas muffler, wherein the converted exhaust gas is led out of the catalyst to the outlet through an exhaust gas end pipe, wherein the exhaust gas end pipe lies inside the muffler housing over most of its length with spacing on all sides and is flushed with untreated exhaust gas, and the treated exhaust gas is led away from the muffler housing into the ambient air through a starting section of the exhaust gas end pipe. This cooling of the pipe behind the catalyst inside the muffler by unconverted exhaust gas is inferior to the additional cooling by ambient air and the muffler is expensive and costly to produce since the pipe must be made of stainless steel for example and there is a high degree of forming. In addition, the proposed solution merely leads to short pipe lengths since the length must be realized inside the muffler.
SUMMARY OF THE INVENTION
[0008] It is the object of the invention to provide an exhaust muffler in which the temperature of the exhaust gas is reduced substantially in the area of the outlet into the environment and/or a sufficiently long path length is made available so that flame development can be avoided especially in the outlet area of the exhaust muffler.
[0009] In order to solve this object, a device having the features of claim 1 is proposed. Preferred further developments of the exhaust muffler according to the invention are specified in the dependent claims.
[0010] For this purpose, it is provided according to the invention that the outlet opening has at least one means arranged inside and/or outside the housing whereby the flow path of the exhaust gas in the direction of the environment is lengthened. The means through which exhaust gas flows and which comprises an outlet facing the environment, can for example, have a wall which is constructed as a labyrinth-shaped channel in which the heated exhaust gas flowing from the catalyst is guided. The flow path of the exhaust gas to the environment is lengthened by the labyrinth-shaped construction of the channel so that any emergence of flames from the exhaust muffler is largely avoided. Whilst the exhaust gas flows through the means, residual hydrocarbons can still be burnt (oxidized) in the exhaust gas. In addition, as a result of heat conduction, the exhaust gas stays along the wall so that no ignition of the exhaust gas occurs in the outlet (opening region) of the exhaust muffler. In this case, it is unimportant whether part of the lengthening of the flow path is arranged inside and/or outside the housing. In addition to avoiding any flame formation and reducing the exhaust gas temperature in the outlet region, the lifetime of the exhaust muffler is further increased by the arrangement according to the invention. In this case, the arrangement of the means outside the housing has the advantage that the ambient air has a cooling effect on the exhaust gas flowing inside the means. From the aesthetic point of view, an arrangement of the means inside the housing can be preferred.
[0011] In a further embodiment of the invention, the means can be constructed as a bent pipe. The pipe can, for example, have a spiral-shaped or helical profile, preferably with a plurality of turns or with straight sections approximately at right angles to one another. In the case of the helical pipe, the pipe can be bent in different directions. One of the advantages of spiral or helical pipes, especially in the arrangement with sections constructed approximately
[0012] More appropriately, the means can have an outlet which has the form of a diffuser. The diffuser arrangement has the advantage that in the area of the outlet, thorough mixing of the cooler ambient air with the warmer exhaust gas flowing through the diffuser is favored, whereby a reduction in the exhaust gas temperature in the outlet region is achieved.
[0013] In a further alternative of the invention, the pipe is constructed with a plurality of openings. In this embodiment of the exhaust muffler, the pipe is preferably arranged outside the housing. The hot exhaust gas flows, for example, through the helical pipe, wherein an underpressure is formed from the flow technology point of view on the outside of the pipe in the area of the openings. Consequently, ambient air is sucked into the pipe through the openings so that the hot exhaust gas is mixed with the cooler ambient air inside the pipe and thus the exhaust gas temperature is further reduced in the outlet of the exhaust muffler. Thus, any flames formed in the exhaust gas can be extinguished.
[0014] The exhaust muffler according to the invention can have at least one bypass pipe which guides at least part of the exhaust gas flowing out of the internal combustion engine past the catalyst into the means. It is advantageous if non-converted “cold” exhaust gas is specifically brought together with the hot exhaust gas flowing out of the catalyst, which results in an appreciable reduction in the temperature of the exhaust gas in the opening area. The bypass pipe can for example be constructed as a pipe which has an exhaust gas inlet and an exhaust gas outlet wherein the exhaust gas inlet is preferably facing the inlet opening of the housing. The exhaust gas outlet is positioned behind the catalyst.
[0015] If the means according to the invention, for example, the helical pipe, is arranged outside the housing, it is advantageous that the exhaust muffler has a protective element extending above the pipe. This protective element serves as a type of contact protection and cooling air baffle plate which protects the user from the high temperatures of the pipe. To save weight, the protective element can be constructed as a perforated sheet. In this case, the protective element can be attached subsequently to the housing, for example, by means of a screw connection. In order that only minimal heat conduction takes place between the housing and the protective element, the protective element is preferably only affixed at a few points on the housing. Furthermore, the fixing points can have insulating elements which largely inhibit passage of heat. The insulating elements can, for example, be insulating spacers. The switching element can also be formed by the equipment cover/cover hood/air guiding hood or it can be affixed thereto.
[0016] In a further embodiment of the invention, a dividing wall can be provided in the housing so that a first and a second space is formed inside the housing. In this embodiment the catalyst is arranged on the dividing wall and represents the connection between the first and the second space. The dividing wall preferably has at least one bypass opening.
[0017] The exhaust gas on the one hand flows through the bypass opening from the first into the second space. On the other hand, a partial stream of the exhaust gas is guided through the catalyst in which the harmful components of the exhaust gas are converted. The hot exhaust gas emerging from the catalyst enters into the second space and mixes with the colder exhaust gas flowing into the second space through the bypass opening. The bypass opening further eliminates any throttle effect of the catalyst and any reduction in performance resulting therefrom.
[0018] Further advantages, features and details of the invention are obtained from the following description in which several embodiments of the invention are described in detail with reference to the drawings. In this case, the features mentioned in the claims and in the description can be important for the invention for themselves or in any combination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the figures, shown purely schematically:
[0020] FIG. 1 is a sectional view of an exhaust muffler with an internal combustion engine;
[0021] FIG. 2 is a perspective view of an exhaust muffler;
[0022] FIG. 3 is an exhaust muffler in an alternative embodiment;
[0023] FIG. 4 is a further embodiment of the exhaust muffler;
[0024] FIG. 5 is a further embodiment of the exhaust muffler;
[0025] FIG. 6 is a further embodiment of the exhaust muffler;
[0026] FIG. 7 is a further embodiment of the exhaust muffler;
[0027] FIG. 8 is a perpendicular sectional view of the exhaust muffler from FIG. 7 ;
[0028] FIG. 9 is a further embodiment of the exhaust muffler;
[0029] FIG. 10 is a further embodiment of the exhaust muffler, a perpendicular sectional view of the exhaust muffler from FIG. 9 ;
[0030] FIG. 11 is a sectional view of a further embodiment of the exhaust muffler with a bypass pipe; and
[0031] FIG. 12 is a sectional view of a further embodiment of an exhaust muffler.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] FIG. 1 shows an exhaust muffler 100 with an internal combustion engine 11 , which is a component of a hand-held tool which however is not shown, as an example. The tool can for example be a motor-driven chain saw, a disk grinder or the like. The exhaust muffler 100 has a housing 12 in which a catalyst 10 is arranged. Furthermore, the housing 12 is constructed with a plurality of inlet openings 13 through which exhaust gas is passed from the motor 11 into the exhaust muffler 100 . The exhaust gas enters the housing 12 at a temperature of around 600 oC. Inside the housing 12 the catalyst 10 converts the hydrocarbons contained in the exhaust gas large into carbon dioxide and water. The chemical conversion process involves an exothermic reaction process wherein the around 600 oC hot exhaust gas from the motor 11 can be further heated to temperatures above 1000 oC in the housing 12 .
[0033] The housing 12 is further constructed with an outlet opening 14 through which the exhaust gas is guided from the housing 12 . In this embodiment the catalyst 10 is arranged on an area of a housing wall which is constructed with the outlet opening 14 . Outside the housing 12 in the area of the outlet opening 14 , a means 16 in the form of a helical bent pipe 17 is arranged whereby the flow path of the exhaust gas in the direction of the environment 15 is lengthened (see FIG. 2 ). In this embodiment the pipe 17 has two ends, the first end facing the outlet opening 14 .
[0034] The second end is a free end through which the exhaust gas flows into the environment 15 .
[0035] The converted exhaust gas emerging from the catalyst 10 flows through the outlet opening 14 and enters into the bent pipe 17 . In the present embodiment the pipe 17 is bent at the first end in the direction of the housing wall.
[0036] Along the further profile the pipe 17 has a spiral profile and is constructed with an outlet opening 18 at the free end through which the exhaust gas enters the environment 15 . As a result of the lengthened flow path, the hot exhaust gas is cooled along the pipe wall 17 so that any flame effect formed inside the pipe 17 is counteracted. As a result of such a simple arrangement, a significant reduction in the temperature of the exhaust gas leaving the exhaust muffler 100 or the bent pipe 17 is achieved. It is possible to arrange a spark arrester screen (not shown) in the area of the outlet opening 18 .
[0037] Affixed above the pipe 17 is a protective element 22 ( FIG. 1 ) which prevents the user from contacting the hot pipe 17 and the housing wall 12 . In the present embodiment the protective element 22 is bent in a hood shape or U-shape and is affixed, for example, by means of a screw connection on the housing 12 which is not shown in the figures. The construction of the protective element not shown in FIG. 2 is such that incoming cooling air K is guided over the pipe wall 17 in order to additionally cool the pipe wall 17 .
[0038] FIGS. 3 and 4 show further alternative embodiments of the exhaust muffler 100 . In FIG. 3 the outlet 18 has the form of a diffuser 18 a . FIG. 4 shows a bent pipe 17 which has a plurality of openings 19 in the area of the free end. As a result of both alternative embodiments of the pipe 17 it is achieved that the exhaust gas temperature is reduced in the outlet 18 and flame formation is prevented as far as possible in the outlet region 18 . Naturally it is also possible to combine the aforesaid alternatives one with another.
[0039] In the embodiment of the exhaust muffler 100 shown in FIG. 5 , a labyrinth-shaped channel 29 , preferably constructed of a wall defined by longitudinal sections 29 a - 29 f parallel to the side edges, is arranged at the outlet opening 14 in order to maximally lengthen the flow path of the exhaust gas in the direction of the environment within the space available. More particularly, as illustrated in FIG. 5 , the wall 29 includes a plurality of angular bends along the length thereof, which are typically 90° so as to create the labyrinth-shaped exhaust outlet channel. The wall extends outwardly from the housing, and is of a lengthened path so as to cool the exhaust before it is finally emitted from an outlet of the channel. In this case, the channel is closed with a cover not shown in FIG. 5 in order to avoid short-circuiting flow into the environment.
[0040] It can also be provided to combine the channel 29 with a counterflow channel 129 to guide cooling air K through which the cooling air K is guided along on the walls of the channel 29 . This embodiment is shown in FIG. 6 . That is, a second wall extends outwardly from the housing in generally spaced relation to the first wall, the second wall defining the ambient air passageway 129 for cooling the exhaust gas passing through the exhaust outlet channel. Once again, the second wall includes a plurality of angular bends, typically 90° bends, along the length thereof such that sections of the wall are generally parallel to one another. It must then be provided that in the area of the channel end 130 a corresponding outlet opening is provided for the cooling air K in the cover not shown.
[0041] FIGS. 7 and 8 show a further embodiment of the exhaust muffler 100 whose fundamental construction corresponds to the embodiment according to FIG. 2 wherein the bent pipe 17 is constructed by constructing the housing 12 a in the area of the outlet opening 14 as a half-shell in which a channel with a hemispherical cross-section 17 a is stamped to form the pipe 17 . Placed hereon is a cover sheet 30 in which a corresponding channel 17 b having a likewise hemispherical cross-section is stamped so that overall the pipe 17 is formed which also has two ends, the first end overlapping into the outlet opening 14 not shown in FIGS. 7 and 8 and the other end being a free end through which the exhaust gas 15 flows into the environment. This embodiment has the advantage that the construction of the pipe 17 is relatively simple from the production technology point of view in that the desired shape of the pipe 17 is simply stamped into the top 12 a as a channel 17 a having a hemispherical or another desired cross section and especially the easily shaped arbitrary profile and the cover sheet 30 is placed thereon as a half-shell having a corresponding profile of the channel 17 b to form the pipe 17 . In this embodiment it is also appropriate to provide a protective element not shown in FIGS. 7 and 8 to avoid direct contact of the pipe 17 or the cover sheet 30 wherein it is advantageously also possible here to use this an air baffle plate for the guidance of cooling so that even more effective cooling of the exhaust gas is possible between the outlet opening 14 and the outlet 18 into the environment 15 .
[0042] Compared with the embodiment shown in FIGS. 7 and 8 , the embodiment shown in FIGS. 9 and 10 is shaped such that the muffler outer shell 21 is stamped outwards and the counterpiece 23 which then forms the channel together with the first stamping is incorporated in the muffler. The advantage is that gas leaks at the joints remain in the muffler. The counterpiece 23 can be welded in, clamped in or affixed in another suitable fashion. In this case, it is also feasible that the stamping of the housing wall and pipe shape is as in FIG. 1 . An advantage is that complete flow of cooling air around the pipe and a small overall height of the total muffler is achieved if the pipe is attached at sufficient distance from the stamping of the housing wall.
[0043] FIG. 11 shows the exhaust muffler 100 from FIG. 1 wherein a bypass pipe 20 is additionally arranged inside the housing 12 . The bypass pipe 20 extends from the inlet opening 13 to the outlet opening 14 of the housing 12 . As a result of this embodiment some of the non-converted exhaust gas flowing from the motor 11 is specifically guided past the catalyst 10 and mixed with the exhaust gas emerging from the catalyst 10 in the area of the outlet opening 14 of the housing 12 . The non-converted cool exhaust gas reduces the temperature of the treated exhaust gas flowing out of the catalyst 10 so that any flames formed can be extinguished by the cold exhaust gas.
[0044] In FIG. 12 a dividing wall 24 is arranged inside the housing 12 so that a first and a second space 26 , 27 are formed in the housing 12 . In contrast to the exemplary embodiment according to FIG. 1 or 5 the catalyst 10 is affixed to the dividing wall 24 which forms a connection between the first and the second space 26 , 27 . The catalyst 10 is arranged in an opening of the dividing wall 24 and is externally connected all the way round to the dividing wall 24 by means of a welded seam so that a gas-tight closure is provided. Naturally the catalyst 10 can be fixed to the dividing wall 24 by other known fixing alternatives. Among other things, it is achieved by the dividing wall 24 that the hot exhaust gas emerging from the catalyst 10 can no longer enter into the area of the inlet opening 13 of the housing 12 so that ignition of the overheated exhaust gas from the catalyst 10 which still has energy-rich constituents as a result of incomplete conversion, is prevented at the inlet opening 13 .
[0045] Arranged laterally at a distance from the catalyst 10 are bypass holes 25 in the dividing wall 24 through which the exhaust gas can flow from the first space 26 into the second space 27 . The partial streams which flow through the bypass holes 25 are not converted by the catalyst 10 . In the second space 27 the exhaust gases which flow from the catalyst 10 and from the bypass holes 25 are thoroughly mixed. As in the exemplary embodiment according to FIG. 5 , the exhaust gas located behind the catalyst 10 is cooled by the cold untreated exhaust gas which enters into the second space 27 through the bypass holes 25 .
[0046] The exhaust muffler 100 can have an insulating layer not shown which is preferably arranged on the housing wall 12 .
[0047] It is hereby achieved that the temperature of the housing 12 is kept as low as possible. Aluminum silicate which is a poor heat conductor, can be used as insulating material for example. However, other materials with similar insulating properties can also be used. A double-walled design is also possible.
[0048] It will be appreciated by those skilled in the art that the bypass means illustrated in FIGS. 11 and 12 can be applied to any of the exhaust muffler configurations illustrated and described herein. Moreover, the spark arresting cover, apertured pipe or channel, and insulating layer can also be incorporated into any of the embodiments illustrated and described herein.
[0049] Although several embodiments have been described in some detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
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In order to provide an exhaust muffler for an internal combustion engine, especially a portable implement, comprising a catalyst which is arranged in a housing which has at least one inlet opening and one outlet opening for exhaust gas flowing out from the internal combustion engine into the environment, in which the temperature of the exhaust gas in the area of the outlet into the environment is reduced substantially and/or a sufficiently long path length is made available so that flame development can be avoided especially in the outlet area of the exhaust muffler, it is proposed that the outlet opening has at least one means through which exhaust gas flows, which is arranged partially outside the housing and has an outlet facing the environment, whereby the flow path of the exhaust gas in the direction of the environment is lengthened.
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TECHNICAL FIELD
This invention relates generally to instruments used by the dental profession and in particular to dental matrix band retainers which are used to temporarily retain matrix bands tightly around a tooth following cavity preparation so that amalgams, composite resins, or temporary dressings may be inserted.
BACKGROUND OF THE INVENTION
When working on molars and bicuspids following cavity preparation, a dentist usually uses a dental matrix band which is held tightly around a tooth using a dental matrix band retainer so that the filling will restore the natural contour of the tooth. The matrix band, as described in U.S. Pat. No. 2,466,830 to Tofflemire, is a metal strip which is usually folded diagonally intermediate of its length to produce two ends that are arranged in diverging relation with one another when the strip is flat. The matrix band is slipped around the single tooth with the free ends extending in parallel and approximate relation with one another from the central portion of the buccal aspect and the fold arranged on the lingual side of the molar or bicuspid. The matrix band is pressed down until it is disposed close to the gingival border. Once slipped around the tooth, the matrix band is tightened around the tooth by using a matrix band retainer.
Over the years, many matrix band retainers has been developed. Most recently, U.S. Pat. No. 5,055,045 to Dickie et al. discloses a disposable plastic matrix band retainer which can be unlocked from its tightened position over a single tooth within a mouth quadrant without releasing the matrix band from the retainer. Once removed, the entire plastic matrix band retainer must be discarded.
U.S. Pat. No. 4,915,627 to Hirdes discloses a matrix band retainer comprising a frame, a threaded rod screwingly displaced in the frame, a coulisse block arranged which holds a matrix band and a tightening spring which is held on the threaded rod and acts upon a quick tightening nut. Once place around a single tooth, the matrix band is tightened by tilting a quick tightening nut which slides the coulisse block in the longitudinal direction. Once this coarse adjustment is made, a fine adjustment is available by rotating a knob located at one end of the threaded rod.
U.S. Pat. No. 3,613,245 to Knight discloses a similar matrix band retainer in which the looped matrix band is passed through a recess in a movable block. Simplicity of design allows the movable block to be easily removed and replaced. Rotation of a sleeve moves the block and decreases the size of the looped matrix band around a single tooth.
U.S. Pat. Nos. 3,462,841 and 3,516,162 to Ainsworth describe a similar matrix band retainer in which the matrix band is provided with enlargements on the ends such which are pulled in order to tighten the matrix band around a single tooth. The matrix band retainer incorporates a tubular body which protects the lips against moving parts within the body.
U.S. Pat. Nos. 2,439,703 and 2,502,903 describe the Tofflemire Matrix Retainer which consists of a slidably mounted clamping block with a diagonally extending slot into which the ends of the looped matrix band are inserted. The ends of the matrix band are clamped against the block by rotating a knob. Once the matrix band is clamped in the block, the matrix band is looped around a single tooth. A wedge may be inserted between the tooth being treated and an adjacent tooth to allow inserting the matrix band around the tooth easier. The tightness of the matrix band around the single tooth can be adjusted by rotating a sleeve which retracts the block.
Although many matrix band retainers have been developed, they all have the same limitation in that only a single tooth may be treated at one time. In other words, if a dentist needs to restore two posterior teeth with Class II, III or IV carious lesions in the same quadrant of a patient's mouth, the dentist must treat each tooth separately by performing the same procedure on each tooth in a sequential manner. As a result, the amount of time required to restore both teeth is approximately twice the amount of time needed to treat a single tooth which diminishes the work productivity of the dentist and the comfort to the patient.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a dual matrix band retainer which allows for the restoration of two posterior teeth with Class II, III or IV carious lesions simultaneously in the same quadrant of a patient's mouth.
It is another object of the invention to reduce the amount required for a dentist to treat two teeth in the same quadrant of a patient's mouth and thereby improving the work productivity of the dentist and maximizing the comfort to the patient.
In keeping with these objects and with others which will become apparent hereinafter, an embodiment of the invention resides, briefly stated, in a dual matrix band retainer which is formed by a fastening means connecting the first and second matrix band retainers. Preferably, the fastening means provides sufficient rigidity so that the first and second matrix band retainers can cooperate integrally as a dual matrix band retainer. The first and second matrix band retainers are aligned along a longitudinal axis so that the dual matrix band retainer can comfortably fit inside the oral cavity of a patient's mouth.
With the present invention, a dentist can restore two posterior teeth with Class II, III or IV carious lesions in the same quadrant simultaneously by looping the matrix bands from each matrix band retainer around each tooth to be restored. Once looped around each tooth, the matrix bands are then tightened by turning a knob near the end of each matrix band retainer. Once each tooth has been restored, the dentist removes each matrix band retainer by loosening the matrix bands around each tooth.
According to the embodiment of the present invention, the time necessary for restoring two posterior teeth with Class II, III or IV carious lesions in the same quadrant of a patient's mouth is greatly reduced. The reason is that it is no longer necessary for the dentist to completely restore one Class II, III or IV carious lesion before being able to restore another Class II, III or IV carious lesion. As a result, the work productivity of the dentist is increased, as well as, the comfort to the patient.
Other objects, features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the drawings wherein:
FIG. 1 is an isometric view of the dual matrix band retainer in use in accordance with an embodiment of the present invention;
FIG. 2 is a top plan view of a dual matrix band retainer in use, parts being shown in section, in accordance with an embodiment of the present invention.
FIG. 3 is another top plan view of a dual matrix band retainer in use, parts being shown in section, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A dual matrix band retainer 10 is illustrated in FIGS. 1 and 2. In general, the dual matrix band retainer 10 includes a first matrix band retainer 20 connected to a second matrix band retainer 50. In the preferred embodiment, each matrix band retainer 20 and 50, for example, are similar to the type as described in U.S. Pat. No. 2,502,903, which is herein incorporated by reference. However, it should be understood that other types of matrix band retainers, which are well known in the art, may be used without changing the scope and spirit of the present invention.
In a typical arrangement as shown in FIG. 1, the dual matrix band retainer 10 is in position for restoring, for example, two disto-occlusal cavity preparations situated between the lower right second bicuspid and third molar. Each matrix band retainer 20 and 50 includes a longitudinally extending bar 21 and 51 on which a matrix band clamping blocks 22 and 52 may be slidably mounted. As shown in FIG. 1, each block 22 and 52 are fashioned with a guideway 23 and 53 adapted to receive the bars 21 and 51, respectively. It should be noted that, in the present invention, bar 21 is much longer in the axial direction than bar 51 to enable the first matrix band retainer 20 to treat a different tooth than the second matrix band retainer 50. Each matrix band clamping block 22 and 52 has a diagonally-extending slot 31 and 61, respectively, in order to receive the end sections 32 and 62 of each matrix band 30 and 60.
Each bar 21 and 51 includes a head portion 24 and 54, respectively. Head portion 24 defines two fingers 25 and 28. Likewise, head portion 54 defines two fingers 55 and 58. As best seen in FIG. 2, fingers 25 and 28 of head portion 24 are longer than corresponding fingers 55 and 58 of head portion 54 so that the ends 29 and 59 of head portions 24 and 54 are aligned along the same longitudinal axis. Aligning the head portions 24 and 54 in the same longitudinal axis permits the dual matrix band retainer 10 to occupy a minimum amount of space and, in turn, allows the dual matrix band retainer be inserted in a patient's mouth comfortably. It should be noted that, in the present invention, the angle of head portions 24 and 54 is a design choice, since head portions 24 and 54 may be at any identical angle and still lie along the same longitudinal axis.
Each matrix band retainer 20 and 50 is designed to hold a matrix band that can encircle any two adjacent posterior teeth or two posterior teeth separated by another posterior tooth in the same quadrant of a patient's mouth. As shown in FIGS. 1 and 2, matrix band 60 encircles the lower right first molar and matrix band 30 encircles the lower right second molar. It should be understood that the relative length of each matrix band is not important and only needs to be of sufficient length to permit each band to be looped around the appropriate posterior tooth (bicuspid or molar) and allow the end sections 32 and 62 of each matrix band to be received in the slots defined between the fingers 25, 28 and 55, 58 and secured in each matrix band clamping block 22 and 52. When the ends of each matrix band 32 and 62 are received in the fingers of each matrix band retainer, the loops of each matrix band will extend laterally from each matrix band retainer 20 and 50.
As best seen in FIG. 2, each matrix band clamping block 22 and 52 has a longitudinally-extending threaded bore 33 and 63 which intersects the slots 31 and 61, respectively. Spindles 34 and 64 have a threaded portion 35 and 65 that is received in each bore 33 and 63, respectively, and each spindle has a conical end 36 and 66. Each spindle may be rotated in each bore, separately and independently of each other, by operating knobs 37 and 67 to cause each conical head to clamp the ends 32 and 62 of each matrix band in the matrix band clamping blocks 22 and 52. It should be noted that a movement of each matrix clamping block along each bar 21 and 51 will move the matrix ends 32 and 62 therewith. As best seen in FIG. 1, when each matrix band clamping block is moved to the right, each matrix band will tighten around each tooth, while movement to the left will loosen each matrix band around each posterior tooth.
The means for moving each matrix band clamping block 22 and 52 axially after it has clamped the matrix band ends 32 and 62 to each matrix band clamping block comprises tightening screws 38 and 68, respectively. Each tightening screw has a bore 39 and 69 with a threaded portion 40 and 70, respectively, for receiving each threaded spindle. Each tightening screw has an annular groove 41 and 71 therein for receiving the forks of U-shaped ends 42 and 72, respectively. Each tightening screw 38 and 68 may be rotated in one direction, separately and independently of each other, to advance each matrix clamping block 22 and 52 towards each head 24 and 54, respectively, while a rotation of each tightening screw in the opposite direction will retract each matrix band clamping block. It should be understood that each end 42 and 72 holds each tightening screw against longitudinal movement, but permits its free rotation.
As best shown in FIG. 1, the dual matrix band retainer 10 is formed by connecting a first matrix band retainer 20 to a second matrix band retainer 50. Preferably, bars 21 and 51 are connected by rods 43, 44, 73 and 74 so that the first matrix band retainer 20 and the second matrix band retainer 50 are rigidly affixed. Rods 43 and 44 are aligned on the same vertical plane, as well as, rods 73 and 74. The location of rods 43, 44, 73 and 74 on each bar 21 and 51 permit each matrix band clamping block to slide freely without interference from the rods. Connecting matrix band retainers 20 and 50 in this manner permits the integral cooperation necessary for the dual matrix band retainer 10 to act as a single device to treat two posterior teeth simultaneously in the same quadrant of a patient's mouth.
It should be noted that, in the present invention, the fastening means for connecting each matrix band retainer 20 and 50 may be connected at various other locations on each matrix band retainer by using any typical fastening means known in the industry to allow each matrix band retainer to rigidly cooperate as a dual matrix band retainer.
In a second embodiment, the dual matrix band retainer is capable of restoring two posterior non-adjacent teeth separated by another posterior tooth in the same quadrant of a patient's mouth. This is accomplished by varying the relative location of the first matrix band retainer head portion 24 with respect to the second matrix band retainer head portion 54 by changing the length of bar 21 and 51 on each matrix band retainer 20 and 50, respectively. As shown in FIG. 3, for example, the length of bar 21 allows matrix band 30 to encircle the lower right second molar and the length of bar 51 allows matrix band 60 to encircle the lower right second bicuspid. As a result, the dual matrix band retainer shown in FIG. 3, is in position for restoring, for example, a mesio-occlusal preparation in the second molar and a disto-occlusal cavity preparation in the second bicuspid.
It should be noted that the dual matrix band retainer as described above is capable of restoring posterior teeth in the lower right and, by inverting, the upper left quadrant of a patient's mouth. Furthermore, it can be appreciated by those skilled in the art that a dual matrix band retainer which is a mirror image of that described and shown in the figures above will be able to restore posterior teeth in the lower left and upper right quadrant of a patient's mouth.
Having identified the components of the dual matrix band retainer, its operation in the preferred embodiment can be described. Assuming that each matrix band 30 and 60 has been preshaped into substantially a loop and the dentist desires to apply the matrix to the right lower first molar and second molar, each tightening screw 38 and 68 are rotated, separately and independently of each other, so as to move each matrix band clamping block 22 and 52 toward each head portion 24 and 54, respectively. Next, the matrix band ends 32 and 62 are inserted into the slots provided between the fingers 25, 28 and 55, 58 and depressed into the diagonal slots 31 and 61 in each matrix band clamping block 22 and 52, respectively. Each knob 37 and 67 is rotated, separately and independently of each other, for bringing conical tips 36 and 66 of each spindle 34 and 64 into clamping relation with the matrix band ends 32 and 62.
Next, the loops of each matrix band 30 and 60 are arranged around each tooth. Each matrix band is pressed down until it is disposed close to the gingival border. The dentist rotates each tightening screw 38 and 68, separately and independently of each other, to retract each matrix band clamping block 22 and 52 relative to each head portion 24 and 54, respectively, until each matrix band is drawn tightly around the tooth.
It should be noted that the tightening screws 38, 68 and knobs 37, 67 project beyond the patient's mouth so that the dentist may operate any one without inserting his fingers into the mouth of the patient. A clear view of the tooth is assured and the dentist can observe each matrix band 30 and 60 as it is tightened or loosened around each tooth.
To remove each matrix band 30 and 60 from each matrix band retainer 20 and 50, respectively, knobs 37 and 67 are turned, separately and indepentently of each other, while holding each tightening screw 38 and 68 against rotation. This backs the conical ends 36 and 66 of each spindle 34 and 64 from the ends 32 and 62 of each matrix band 30 and 60, respectively. Each head portion 24 and 54 now may be freed from each matrix band 30 and 60. Each matrix band 30 and 60 may now be removed from each tooth. It may be noted that the manipulations of knobs 37, 67 and tightening screws 38, 68 are accomplished outside the oral cavity.
Although the invention has been described in detail with particular reference to a preferred embodiment thereof, it should be understood that the invention is capable of other and different embodiments, and its details are capable of modifications in various obvious respects. As is readily apparent ot those skilled in the art, variations and modifications can be affected while remaining within the spirit and scope of the invention. Accordingly, the foregoing disclosure, description, and figures are for illustrative purposes only, and do not in any way limit the invention, which is defined only by the claims.
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A dual dental matrix band retainer for use in dentistry comprising a first matrix band retainer which is connected to a second matrix band retainer. Each matrix band retainer is provided with a matrix band which is looped around a different posterior tooth in the same quadrant of a patient's mouth. Each matrix band retainer can be operated independently and separably of each other which allows for the dentist to restore two posterior teeth simultaneously. As a result, the time required for the dentist to restore both posterior teeth is greatly diminished improving the work productivity of the dentist while maximizing the comfort to the patient.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a fastening device for detachably joining together articles of clothing, such as a pair of socks or a pair of gloves.
[0002] It is recognized that there is difficulty in retaining together two individual socks belonging to a pair throughout the process of washing, drying and storing the socks after use. As an illustration, through the laundering process, pairs of socks can become separated or lost, thus leaving the launderer with the unwanted task of having to match up the pairs of socks afterwards. It is also generally appreciated that individual socks frequently become lost in this process.
[0003] In order to overcome this problem and difficulties associated in easily keeping together pairs of socks, or other articles of clothing, such as pairs of gloves, it is known to provide various devices for fastening such articles of clothing.
[0004] Boxer, in U.S. Pat. No. 4,058,853, for example, describes an article to hold a pair of socks together during laundering or the like, particularly, a flexible patch secured to each sock which adheres them to each other when pressed together. Such self-contained hook and loop VELCRO fasteners, however, are relatively inelastic while the shank portions of socks stretch.
[0005] In Klotz, U.S. Pat. No. 3,688,348, the use of special bands wrapped around the shanks of sock pairs to keep them together during washing is disclosed. However, such bands have the disadvantage of lack of availability at the time of discarding socks.
[0006] Ursino, U.S. Pat. No. 5,038,413, provides a snap type fastener device for securing socks, which includes decorative covers that concealed the fasteners while the socks are being worn. The removable covers, however, are especially dangerous, as they present a choking hazard to children. Furthermore, the fastening means attaches through the body of the socks, thereby requiring a plurality of circumferentially spaced axially extending ribs to engage an annular rim portion of the fastener. This configuration does not secure the snap fastener means securely through the sock, in that it could disengage easily while the socks are in wash.
[0007] Other related devices are shown in Bellet, U.S. Pat. No. 6,092,241; Dean, U.S. Pat. No. 6,032,294; Stubbs, U.S. Pat. No. 5,974,590; Smith, U.S. Pat. No. 5,357,660; Butler, U.S. Pat. No. 1,682,771; Bohman, U.S. Pat. No. 2,663,877; Hofmeister, U.S. Pat. No. 3,699,617; Sneider, U.S. Pat. No. 3,774,267; Ciuffo, U.S. Pat. No. 5,321,855; Hicks, U.S. Pat. No. 5,450,658; Hurst, U.S. Pat. No. 5,530,998; Christy, U.S. Pat. No. 5,579,541; and Messman, U.S. Pat. No. 5,740,558.
[0008] Accordingly, it is an objective of the present invention to provide a new and improved device for releasably, yet securely, fastening pairs of articles of clothing together without damaging the articles of clothing.
[0009] Another object is to provide a time and labor saving device in laundering pairs of clothing articles, such as socks.
[0010] Another object of the invention is to prevent the loss of one of a pair of articles of clothing, such as a single sock from a pair of socks or a single glove from a pair of gloves.
[0011] It is another object of the present invention to provide a simple device for releasably attaching two pieces of fabric together for any practical use intended by the user.
[0012] These and other objects and advantages of the present invention will become apparent to readers from a consideration of the ensuing description and the accompanying drawings.
BRIEF DESCRIPIION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of the male fastener portion of the present invention in an opened position.
[0014] FIG. 2 is a perspective view of the female fastener portion of the present invention in an opened position.
[0015] FIG. 3 is an exploded perspective view showing the male fastener portion of the present invention being affixed to an article of clothing, such as a sock.
[0016] FIG. 4 is a perspective view showing the male fastener portion of the present invention affixed to an article of clothing, such as a sock.
[0017] FIG. 5 is an exploded perspective view showing the female fastener portion of the present invention being affixed to an article of clothing, such as a sock.
[0018] FIG. 6 is a perspective view showing the female fastener portion of the present invention affixed to an article of clothing, such as a sock.
[0019] FIG. 7 is a perspective view of the male and female fastener portions of the present invention secured onto their respective socks and positioned opposite each other.
[0020] FIG. 8 is a perspective view of the male and female fastener portions of the present invention respectively secured onto a pair of socks with two positioning tabs removed.
[0021] FIG. 9 shows the male and female fastener portions of the fastening device as illustrated in FIG. 8 attached to each other.
[0022] FIG. 10 illustrates cross-sectional views of the male fastener portion secured onto a sock, taken across the lines B-B of FIG. 8 , and of the female fastener portion secured onto a sock, taken across the lines C-C of FIG. 8 .
[0023] Similar reference characters denote corresponding features consistently throughout the attached drawings.
[0024] Although every reasonable attempt is made in the accompanying drawings to represent the various elements of the embodiments in relative scale, it is not always possible to do so with the limitations of two-dimensional paper. Accordingly, in order to properly represent the relationship of various features among each other in the depicted embodiments and to properly demonstrate the invention in a reasonably simplified fashion, it is necessary at times to deviate from the absolute scale in the attached drawings. However, one of ordinary skill in the art would fully appreciate and acknowledge any such scale deviations as not limiting the enablement of the disclosed embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring now to FIGS. 1 and 2 , there is shown the fastening device of the present invention, which is generally comprised of two portions, a male fastener portion 10 ( FIG. 1 ) and a female fastener portion 10 ( FIG. 2 ). Together, the male fastener portion 10 and the female fastener portion 10 A comprise the present invention, a fastening device. Generally, the male and female fastener portions are each comprised of, respectively, a first end 12 , 12 A, an opposite second end 14 , 14 A, and a positioning tab 16 , 16 A therebetween. On the respective inner surfaces 22 , 22 A of the second ends 14 , 14 A of each respective male and female fastener portion 10 , 10 A, there are a plurality of fastening pins 24 , 24 A. (Referring to FIG. 7 , the “inner surface” refers to the surface which is adjacent to an article of clothing 34 , such as a sock, when the male and female faster portions 10 , 10 A of the fastening device are attached to the sock. See also FIGS. 3-6 . This will become evident as the preferred embodiments are described herein.) The respective inner surfaces 26 , 26 A of the first ends 12 , 12 A of each respective male and female portion 10 , 10 A, are further comprised with a plurality of fastening holes 28 , 28 A for receiving the respective and corresponding fastening pins 24 , 24 A from the second ends 14 , 14 A of each fastener portion 10 , 10 A. The fastening pins 24 , 24 A and the fastening holes 28 , 28 A of respective male and female fastener portions 10 , 10 A are complementary, in that the fastening pins 24 , 24 A, as demonstrated below, insert through the fastening holes 28 , 28 A when attaching the male and female fastener portions 10 , 10 A to separate articles of clothing.
[0026] With regard to the male fastener portion 10 , the fastening pins 24 on the inner surface 22 of the second end 14 are positioned away from the center of the inner surface 22 and near the periphery or outer circumference of the inner surface 22 . Conversely, the fastening pins 24 A on the corresponding inner surface 22 A of the corresponding second end 14 A of the female fastener portion 10 A are positioned near the center of the inner surface 22 A and away from the periphery or outer circumference of the inner surface 22 A. The purpose of such positioning of the fastening pins 24 , 24 A of each portion shall be obvious in view of further discussion on the preferred embodiments of the invention.
[0027] With respect to the male fastener portion 10 , the first end 12 has a raised circular-shaped male locking element 18 protruding from the outer surface of that portion, said male locking element 18 being further comprised of threads 20 on its outer surface. In a similar fashion, with respect to the female fastener portion 10 A, the first end 12 A also has a raised corresponding circular-shaped female locking element 18 A protruding from its outer surface, which is configured much like a “bottle cap” with corresponding receiving threads 20 A (not shown in FIG. 2 ; shown in FIGS. 5-8 , 10 ) formed therein, for engaging with and receiving the threads 20 on the male locking element 18 . This configuration thereby allows the male locking element 18 to be securely, yet releasably, attached to the female locking element 18 A by manually engaging and twisting those components in a “clockwise” or “tightening” fashion. That is, the inner threads 20 A on the female locking element 18 A are complementary to the outer threads 20 on the male locking element 18 , in that they are configured to achieve a tight lock by manually screwing together much like a plastic bottle cap is twisted onto the plastic bottle neck by means of interlocking threads. This allows for secure attachment of the male fastener portion 10 to the female fastener portion 10 and for de-attachment thereof.
[0028] Referring now to FIGS. 3 and 4 , there is shown the male fastener portion 10 of the present invention being affixed to an article of clothing 34 , such as a sock. The positioning tab 16 has a hinged means 30 between the first end 12 and the second end 14 . To facilitate folding of the male fastener portion 10 over the top edge of the sock 34 , the hinged means 30 may be a portion of the positioning tab 16 which has a reduced cross section. The male fastener portion 10 is attached to the sock 34 by first placing the positioning tab 16 on the outer edge of the sock 34 in such a manner that the male locking element 18 is directed outwardly from the sock 34 , i.e., away from the body of the wearer and on the outside of the sock when worn. The fastening pins 24 push through the sock 34 , and once the fastening pins 24 have penetrated the fabric of the sock 34 , the fastening pins 24 insert through the fastening holes 28 , thereby securely attaching the male fastener portion 10 to the sock 34 . The fastening pins 24 are relatively rigid, yet with enough flexibility and elasticity, that they are capable of being forced through the fastening holes 28 . Comprised of a resilient material, once the fastening pins 24 are fully inserted through the fastening holes 28 , the fastening pins 24 regain their original shape, and due to the larger diameter at the distal ends thereof relative to the diameter of the fastening holes 28 , the fastening pins 24 are prevented from disengaging from the fastening holes 28 . As such, this attachment by means of the fastening pins 24 and the fastening holes 28 is to securely attach the male fastener portion 10 to the fabric 34 . It shall be generally appreciated by those skilled in the art that any number of means may be utilized to attach the first and second ends of the male fastener portion 10 through a fabric 34 , and the present invention is meant to encompass such other attaching means.
[0029] Still referring to FIGS. 3 and 4 , when the male fastener portion 10 is securely attached to an article of clothing 34 , such as a sock, the fastening pins 24 of the male fastener portion 10 are enclosed within a ring-shaped protective shield 38 , thereby hiding from view and protecting the fastening pins 24 when the male fastener portion 10 is securely attached to the fabric. Due to the fact that the fastening pins 24 on the inner surface 22 of the second end 14 of the male fastener portion 10 are positioned away from the center of the inner surface 22 and in proximity to the periphery or outer circumference of the inner surface 22 , as described above, this protective shield 38 is configured in such a way that it creates a recess or cavity 39 within the male locking element 18 .
[0030] Referring now to FIGS. 5 and 6 , there is shown the female fastener portion 10 A of the present invention being securely affixed to an article of clothing 34 , such as a sock. Again, the positioning tab 16 A has a hinged means 30 A between the first end 12 A and the second end 14 A. To facilitate folding of the female fastener portion 10 A over the top edge of the sock 34 , the hinged means 30 A may be a portion of the positioning tab 16 A which, again, has a reduced cross section. The female fastener portion 10 A is attached to the sock 34 by first placing the positioning tab 16 A on the outer edge of the sock 34 in such a manner that the female locking element 18 A is directed outwardly from the sock 34 , i.e., away from the body of the wearer and on the outside of the sock when worn. The fastening pins 24 A push through the sock 34 , and once the fastening pins 24 A have penetrated the fabric of the sock 34 , the fastening pins 24 A insert through the fastening holes 28 A, thereby securely attaching the female fastener portion 10 A to the sock 34 in the same manner as described above. Again, this attachment by means of the fastening pins 24 A and the fastening holes 28 A is to securely attach the female fastener portion 10 A to the fabric 34 .
[0031] Still referring to FIGS. 5 and 6 , when the female fastener portion 10 A is securely attached to an article of clothing 34 , such as a sock, the fastening pins 24 A of the female fastener portion 10 A are also enclosed within a dome-shaped protective shield 40 , thereby hiding from view and protecting the fastening pins 24 A. Due to the positioning of the fastening pins 24 A on the inner surface 22 A of the second end 14 A and the fastening holes 28 A on the inner surface of the first end 12 A of the female fastener portion 10 A, the protective shield 40 is positioned in the center of the recessed area of the female locking element 18 A.
[0032] Referring now to FIGS. 7, 8 and 10 , it can be seen that, when the male and female locking elements 18 , 18 A are engaged, the protective shield 40 on the female locking element 18 A fits inside the complementary recess 39 formed by the protective shield 38 on the male locking element 18 . The respective protective shields 38 and 40 are preferably circular in shape, but they may assume other shapes so long as they do not interfere with each other when the male and female locking elements 18 , 18 A are engaged and twisted relative to each other to lock the male and female fastener portions 10 , 10 A together.
[0033] Although a preferred embodiment of the present invention employs the positioning tabs 16 , 16 A to facilitate positioning of the male and female fastener portions 10 , 10 A onto articles of clothing 34 , such as a pair socks, the present invention may optionally omit such use of the positioning tabs 16 , 16 A. That is, the fastening device in accordance with the present invention may be provided without the positioning tabs 16 , 16 A. With such alternative embodiment of the present invention, a user may be able to position and attach the first and second ends of the respective male and female fastener portions 10 , 10 A onto articles of clothing or other fabric materials without the assistance of the positioning tabs 16 , 16 A. It will therefore be appreciated by those skilled in the art, particularly with regard to fashion and clothing design, but not limited thereto, that the present invention may be adopted to fastening any two pieces of fabric together. As such, for example, the male and female fastener portions 10 , 10 A, with or without positioning tabs 16 , 16 A, may be used as a “screwable” button/snap for a shirt, and it would allow the user to place the buttons/snaps in any desired position on the shirt, thereby achieving functionality and design. The invention may be further widely adopted in other industries and uses—anywhere there is a need to securely, but releasably, attach two pieces of fabric together.
[0034] Referring now to FIGS. 7, 8 and 9 , once the male and female fastener portions 10 , 10 A are securely attached to the respective single socks 34 forming a pair of socks, the positioning tabs 16 , 16 A may be removed. The removal of the positioning tabs 16 , 16 A is facilitated by a plurality of perforations 32 , 32 A, or other convenient means generally known to those skilled in the art, whereby the user of the fastening device of the present invention can easily tear off the positioning tabs 16 , 16 A from the secured male and female fastener portions 10 , 10 A that form the fastening device. Although it is preferable that the positioning tabs 16 , 16 A be removed before the male and female locking elements 18 , 18 A are brought together, this step is not required to achieve full use and functionality of the invention. The male and female locking elements 18 , 18 A may then be securely attached to each other by simply engaging the complementary threads 20 , 20 A of each portion by screwing them together, much like a plastic bottle cap with internal threads is twisted onto the complementary threads on the top of the bottle neck. That is, by screwing the male locking element 18 clockwise relative to the female locking element 18 A (and vice versa), the male and female fastener portions 10 , 10 A are securely attached together; conversely, by turning the male locking element 18 counterclockwise relative to the female locking element 18 A (and vice versa), the male and female fastener portions 10 , 10 A are released from each other. This process is completely reversible. In a preferred embodiment, the corresponding threads 20 , 20 A on the respective male and female locking elements 18 , 18 A are sufficiently blunt so as to require a minimal turn of only between approximately 90 degrees to 180 degrees to achieve a tight lock between the male and female locking elements 18 , 18 A. In another preferred embodiment of the present invention, only a twist of between 45 degrees to 90 degrees is required, thereby requiring even less manual torque in order to achieve a fully fastened and secured state of the two portions. In a further preferred embodiment, the female locking element 18 A of the female fastener portion 10 A is equipped with a plurality of ribs 36 on its outer side for providing traction to the user for twisting the female fastener portion 10 A either on or off the male fastener portion 10 .
[0035] In a further preferred embodiment, the male and female fastener portions 10 , 10 A of the fastening device comprising the present invention are comprised of hypoallergenic and/or corrosion-resistant materials that can withstand the highest temperatures commonly used in home and commercial laundry and dry cycles and would not cause allergic skin reactions.
[0036] Referring now to FIGS. 3 and 5 , it is intended that, when the articles of clothing are worn, such as a pair of socks, the flat outer surfaces 15 , 15 A of the second ends 14 , 14 A of each portion will be immediately adjacent to the body of the wearer, i.e., those surfaces 15 , 15 A are between the sock and the skin of the wearer of said socks. Contrarily, it is intended that the male and female locking elements 18 , 18 A of each portion will be oriented outwardly from the body of the wearer, i.e., the locking elements 18 , 18 A are on the outside of the socks when worn by the user. As such, when the male and female portions are attached to articles of clothing, such as a pair of socks, the locking elements 18 , 18 A will be on the outside of each sock.
[0037] In another embodiment of the invention, optional indicia means may be used. Specifically, an indicia means 17 , 17 A may be incorporated on the flat surfaces 15 , 15 A of the second ends 14 , 14 A of each portion. The indicia means 17 , 17 A may be a letter of the alphabet, a number, a geometric design, combinations thereof, or any other means. Preferably, the indicia means 17 , 17 A is flush with the flat surfaces 15 , 15 A. In addition, the indicia means 17 , 17 A may be a color, wherein the entire fastening device or both portions of the fastening device are colored. The indicia means 17 , 17 A may serve to identify the clothing item or the owner of the clothing. For those items such as socks, and other items which are normally comprised of pairs, the identical indicia means may be applied to both members of the pair so that the pair is more readily and rapidly identified. This is especially helpful for individuals who, for example, have several pairs of socks closely resembling one other in color (e.g., blue, navy blue, black) or pattern, or for individuals who may be color blind.
[0038] The fastening device in accordance with the present invention can be used not only for connecting together fabric materials, such as pairs of socks, during the washing and drying cycles, but whenever it is desired to keep the two socks of a pair together, such as when storing them. In addition, colors, raised Braille indicia, and other indicia having numbering, letters and designs, such as animal figures, symbols or other logos may be placed on the male and female fastener portions of the present invention for providing information and/or for aesthetic purposes.
[0039] Due to the large number of indices and combination of indices which may be used, the fastening device has many institutional uses and applications.
[0040] Furthermore, the fastening device in accordance with the present invention is easily attached to an article of clothing 34 without special equipment. It is quickly attached in seconds by hand and without the need for any tool. The fastening device in accordance with the present invention can be attached to the article of clothing 34 when initially purchased or at any time subsequently.
[0041] Although various preferred embodiments of the present invention and the method of using the same have been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the present invention pertains will be considered infringement of this invention when those modified forms fall within the claimed scope of this invention.
[0042] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0043] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A fastening device for detachably joining together paired articles of clothing, such as socks or gloves, is described. The device includes male and female fastener portions that are adapted for attaching to the articles of clothing and provided with complementary threads for detachably coupling to each other. In applications, the device protects the article of clothing from loss or mismatch during their laundering or storing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of a prior application entitled “A SYSTEM AND PROCESS FOR REGRESSION-BASED RESIDUAL ACOUSTIC ECHO SUPPRESSION”, which was assigned Ser. No. 11/097,548 and filed Mar. 31, 2005 now U.S. Pat. No. 7,813,499.
BACKGROUND
1. Technical Field
The invention is related to residual echo suppression in a microphone signal which been previously processed by an acoustic echo canceller (AEC), and more particularly to a regression-based residual echo suppression (RES) system and process for suppressing the portion of the microphone signal corresponding to a playback of a speaker audio signal that was not suppressed by the AEC.
2. Background Art
In teleconferencing applications or speech recognition, a microphone picks up sound that is being played through the speakers. In teleconferencing this leads to perceived echoes, and in speech recognition, reduction in performance. Acoustic Echo Cancellers (AECs) are used to alleviate this problem.
However, the echo reduction provided by AEC is often not sufficient for applications that require a high level of speech quality, such as speech recognition. The insufficient echo reduction is caused by, among other things, adaptive filter lengths in AEC that are much shorter that the room response. Short AEC filters are used to make AEC computationally feasible and to achieve reasonably fast convergence. Various methods have been employed to suppress the residual echo. For example, techniques such as coring (also referred to as center clipping) were used. However, this can lead to near-end speech distortion.
Other methods to remove the residual echo tried to achieve this goal by estimating its power spectral density (PSD), and consequently removing it using Weiner filtering [1,2] or spectral subtraction [3]. However, most of those methods either need prior information about the room, or make unreasonable assumptions about signal properties. For example, some methods estimate PSD based on long-term reverberation models of the room [3]. Parameters of the model are dependent on the room configuration and need to be calculated in advance based on the behavior of the room impulse response.
There are some techniques that estimate the residual echo PSD via a so-called “coherence analysis” which is based on the cross-correlation between the speaker signal (sometimes referred to as the far-end signal in teleconferencing applications) and the residual signal. In a sub-band system, only the discrete Fourier transforms (DFTs) of the windowed signals are available, so the cross-correlations can be only approximately calculated [1]. In [2], the coherence function is computed based on a block of a few frames of data; in [1] it is based on multiple blocks. The latter assumes that the frames of the speaker signal are uncorrelated, which is almost never true. The performance of these algorithms is dictated by the accuracy of the PSD estimate and their ability to track it accurately from one frame to another. The accuracy decreases when near-end speech is present or when the echo path changes.
It is noted that in the preceding paragraphs, as well as in the remainder of this specification, the description refers to various individual publications identified by a numeric designator contained within a pair of brackets. For example, such a reference may be identified by reciting, “reference [1]” or simply “[1]”. A listing of references including the publications corresponding to each designator can be found at the end of the Detailed Description section.
SUMMARY
The present invention is directed toward a system and process for suppressing the residual echo in a microphone signal which been previously processed by an acoustic echo canceller (AEC), which overcomes the problems of existing techniques. In general, the present system and process uses a regression-based approach to modeling the echo residual. In other words, a parametric model of the relationship between the speaker and the echo residual after AEC is built and then these parameters are learned online. Thus, instead of estimating the power spectral density (PSD), a prescribed signal attribute (e.g., magnitude, energy, or others) of the short-term spectrum of the AEC residual signal is directly estimated in terms of the same attribute of the short-term spectra of the speaker signal using the parameterized relations. This scheme is powerful since, regression models can easily capture complex empirical relationships while providing flexibility. Tracking the parameters can be easily done using stochastic filters. Prior knowledge about room reverberation is not needed.
In one embodiment of the present system and process, the residual echo present in the output of an acoustic echo canceller (AEC) is suppressed using linear regression between the spectral magnitudes of multiple frames of the speaker signal and the spectral magnitude of the current frame of the echo residual as found in the output of an acoustic echo canceller AEC, per sub-band. The sub-bands are computed using a frequency domain transform such as the Fast Fourier Transform (FFT) or the Modulated Complex Lapped Transform (MCLT). In the tested embodiment, the MCLT is used to convert the time domain signals to the frequency domain. This model automatically takes into consideration the correlation between the frames of the speaker signal. The regression parameters are estimated and tracked using an adaptive technique.
The present regression-based echo suppression (RES) system and process is both simple and effective. Preliminary results using linear regression on magnitudes of real audio signals demonstrate an average of 8 dB of sustained echo suppression in the AEC output signal under a wide variety of real conditions with minimal artifacts and/or near-end speech distortion.
As indicated previously, in the present RES system and process, a portion of a microphone signal corresponding to a playback of a speaker audio signal sent from a remote location and played back aloud in a near-end space is suppressed. In one embodiment, this involves first processing the microphone signal using an AEC module that suppresses a first part of the speaker signal playback found in the microphone signal and generates an AEC output signal. A RES module is then employed. This module inputs the AEC output signal and the speaker signal, and suppresses at least a portion of a residual part of the speaker signal playback found in the microphone signal, which was left unsuppressed by the AEC module. The output of the RES module can be deemed the final RES output signal. However, additional suppression of the remaining portion of the speaker signal playback may be possible by employing one or more additional RES modules. In the multiple RES module embodiments, one or more additional RES modules are added, with each inputting the signal output by the preceding RES module and the speaker signal. The additional module then suppresses at least a portion of a remaining part of the speaker signal playback found in the microphone signal, which was left unsuppressed by the AEC module and all the preceding RES modules. The output of the last RES module is designated as the final RES signal.
The process used by each RES module is the same, only the input signals change. More particularly, in the case of the first (and perhaps only) RES module, the following suppression process is used for each segment of the AEC output signal, one by one, in the order in which the frame is generated. A segment can correspond to a single frame of the AEC output, as in tested embodiments of the present invention. However, in alternative embodiments, a segment can comprise multiple frames or fractions of frames, perhaps depending on external parameters, such as room size. Within each frame, a pre-defined range of sub-bands found within the overall frequency range are processed. First, a previously unprocessed sub-band within a prescribed overall frequency range is selected. The desired signal attribute of this band is calculated (e.g. magnitude, energy). The echo residual component associated with the selected sub-band as exhibited in the prescribed signal attribute is then predicted using a prescribed regression technique, based on a prescribed number of past periods of the speaker signal and a current set of regression coefficients. The result of this prediction is subtracted from a measure of the same signal attribute in the segment of the AEC output signal currently under consideration, to produce a difference. In addition, the noise floor of the segment of the AEC output signal currently under consideration is computed in terms of the prescribed signal attribute. It is next determined if the aforementioned difference is lower than the computed noise floor. If not, then the difference is designated as a RES output for sub-band pertaining to the segment of the AEC output signal currently under consideration, and otherwise the noise floor is designated as the RES output. The RES output signal component for the selected sub-band and the segment of the AEC output signal currently under consideration is generated from the designated RES output.
As mentioned previously, the regression coefficients can be adaptively updated as the suppression process continues. If so, it is next determined if the segment of the AEC output signal currently under consideration contains human speech components that originated in the near-end space. Whenever this is not the case, a smoothed speaker signal power is estimated for the same time period and selected sub-band. This is followed by computing a normalized gradient and updating the regression coefficients. If the regression coefficients have been updated or it was determined that the segment of the AEC output signal currently under consideration contains near-end speech components, the last computed regression coefficients are designated as the coefficients that are to be used for the associated sub-band to predict the AEC output signal echo residual component for the next segment of the AEC output signal to be considered.
The process continues by determining if there are any remaining previously unselected sub-bands. If so, another one of the sub-bands is selected and the foregoing process is repeated until there are no previously unselected sub-band-ranges remaining. At that point, the RES output signal components generated for each previously selected sub-band are combined and the combined signal components are designated as the RES output for the segment of the AEC output signal currently under consideration.
It is noted that the same process is used if the RES module in question is not the first, except that the output from the preceding RES module is used as an input in lieu of the AEC output signal.
The present RES system and process is also applicable to stereo residual suppression as well. Current stereo AEC techniques have problems with correlations between the right and left channels, however, the present RES approach can naturally handle these correlations by removing them in two passes. Thus, at least two RES modules are employed. Essentially, there is no difference in the processing itself, only a difference in which signals are input to the RES modules.
More particularly, in one embodiment of the present RES system and process applicable to stereo, a portion of a microphone signal corresponding to a playback of the right and left channels of a far-end stereo audio signal sent from a remote location, and each of which is played back aloud via separate loudspeakers in a near-end space, is suppressed. Alternatively, the stereo audio signal can be generated on the near end computer (e.g. playing music from a CD). This processing involves first processing the microphone signal using a stereo AEC module that suppresses a first part of the playback of the left and right channels of the speaker signal found in the microphone signal and generates an AEC output signal. A first RES module is then employed, which inputs the AEC output signal and one of the channels of the speaker signal. The first RES module suppresses at least a portion of a residual part of the speaker signal playback of the input channel found in the microphone signal which was left unsuppressed by the AEC module, to produce a first RES output signal. Then, a second RES module inputs the first RES output signal and the other channel of the speaker signal (i.e., the one not input by the first RES module). This second RES module suppresses at least a portion of a residual part of the speaker signal playback of the input channel found in the microphone signal which was left unsuppressed by the AEC module and the first RES module, to produce a final RES output signal. This method is also applicable to multi-channel playback where the number of playback channels is greater than 2 (e.g. 5.1, 7.1, and so on).
In an alternate embodiment of the present RES system and process applicable to stereo, the foregoing modules operate in the same way, except in this case, the first RES module inputs either the sum or difference of the two channels of the speaker signal and the second RES module inputs the sum or difference of the speaker signal—whichever one was not input by the first RES module.
In addition to the just described benefits, other advantages of the present invention will become apparent from the detailed description which follows hereinafter when taken in conjunction with the drawing figures which accompany it.
DESCRIPTION OF THE DRAWINGS
The specific features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a diagram depicting a general purpose computing device constituting an exemplary system for implementing the present invention.
FIG. 2 is a block diagram depicting an overall echo reduction scheme including a regression-based residual echo suppression (RES) module in accordance with the present invention.
FIG. 3 shows a flow chart diagramming one embodiment of a RES process according to the present invention employed by the RES module of FIG. 2 for suppressing the portion of the microphone signal corresponding to a playback of the speaker audio signal that was not suppressed by the AEC module.
FIG. 4 is a block diagram depicting an overall echo reduction scheme including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention.
FIG. 5 is a block diagram depicting an overall echo reduction scheme for stereo playback scenarios including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention, where the first RES module handles the left channel and the second RES module handles the right channel.
FIG. 6 is a block diagram depicting an alternate overall echo reduction scheme for stereo playback scenarios including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention, where the first RES module inputs a sum of the left and right stereo channels and the second RES module inputs a difference of the left and right stereo channels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description of the preferred embodiments of the present invention, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
1.0 THE COMPUTING ENVIRONMENT
Before providing a description of the preferred embodiments of the present invention, a brief, general description of a suitable computing environment in which portions of the invention may be implemented will be described. FIG. 1 illustrates an example of a suitable computing system environment 100 . The computing system environment 100 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing environment 100 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 100 .
The invention is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
The invention may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
With reference to FIG. 1 , an exemplary system for implementing the invention includes a general purpose computing device in the form of a computer 110 . Components of computer 110 may include, but are not limited to, a processing unit 120 , a system memory 130 , and a system bus 121 that couples various system components including the system memory to the processing unit 120 . The system bus 121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus.
Computer 110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 110 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer 110 . Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media.
The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . A basic input/output system 133 (BIOS), containing the basic routines that help to transfer information between elements within computer 110 , such as during start-up, is typically stored in ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 120 . By way of example, and not limitation, FIG. 1 illustrates operating system 134 , application programs 135 , other program modules 136 , and program data 137 .
The computer 110 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 1 illustrates a hard disk drive 141 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 151 that reads from or writes to a removable, nonvolatile magnetic disk 152 , and an optical disk drive 155 that reads from or writes to a removable, nonvolatile optical disk 156 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 141 is typically connected to the system bus 121 through a non-removable memory interface such as interface 140 , and magnetic disk drive 151 and optical disk drive 155 are typically connected to the system bus 121 by a removable memory interface, such as interface 150 .
The drives and their associated computer storage media discussed above and illustrated in FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computer 110 . In FIG. 1 , for example, hard disk drive 141 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 , and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 110 through input devices such as a keyboard 162 and pointing device 161 , commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 120 through a user input interface 160 that is coupled to the system bus 121 , but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor 191 or other type of display device is also connected to the system bus 121 via an interface, such as a video interface 190 . In addition to the monitor, computers may also include other peripheral output devices such as speakers 197 and printer 196 , which may be connected through an output peripheral interface 195 . A camera 192 (such as a digital/electronic still or video camera, or film/photographic scanner) capable of capturing a sequence of images 193 can also be included as an input device to the personal computer 110 . Further, while just one camera is depicted, multiple cameras could be included as input devices to the personal computer 110 . The images 193 from the one or more cameras are input into the computer 110 via an appropriate camera interface 194 . This interface 194 is connected to the system bus 121 , thereby allowing the images to be routed to and stored in the RAM 132 , or one of the other data storage devices associated with the computer 110 . However, it is noted that image data can be input into the computer 110 from any of the aforementioned computer-readable media as well, without requiring the use of the camera 192 .
The computer 110 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 . The remote computer 180 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 110 , although only a memory storage device 181 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 171 and a wide area network (WAN) 173 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
When used in a LAN networking environment, the computer 110 is connected to the LAN 171 through a network interface or adapter 170 . When used in a WAN networking environment, the computer 110 typically includes a modem 172 or other means for establishing communications over the WAN 173 , such as the Internet. The modem 172 , which may be internal or external, may be connected to the system bus 121 via the user input interface 160 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 110 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 1 illustrates remote application programs 185 as residing on memory device 181 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
The exemplary operating environment having now been discussed, the remaining parts of this description section will be devoted to a description of the program modules embodying the invention.
2.0 REGRESSION-BASED RESIDUAL ECHO SUPPRESSION
The role of the present regression-based residual echo suppression (RES) system in an overall echo reduction scheme is illustrated in FIG. 2 . The speaker signal x(t) 202 coming from a remote location is received and played back in the space represented by near-end block 200 via loudspeaker 204 . The far end signal playback 206 , as well as the ambient noise n(t) 208 in the near-end space and near-end speech s(t) 210 is picked up by the microphone 212 which produces a microphone signal 214 . This microphone signal 214 is fed into a conventional AEC module 216 which suppresses a part of the speaker signal playback picked up by the microphone. The output of the AEC module 216 is the AEC signal m(t) 218 , which is in turn fed into the RES module 220 . The RES module 220 uses this signal and the speaker signal 202 (which is also fed into the AEC module 216 ) to produce the final RES output signal b(t) F 222 in the manner that will be described next.
In RES it is desired to directly estimate the amount of residual echo energy in each frame of AEC output. This is achieved by modeling the empirical relationship between the speaker signal and the echo residual. The output of the AEC m(t) can be expressed as
m ( t )= x ( t )* h l ( t )+ s ( t )+ n ( t ) (1)
where s(t) is the near-end signal at the microphone, x(t) is the far-end or speaker signal, n(t) is the ambient noise, and h l (t) is the uncompensated part of the room impulse response. The echo residual after AEC, r(t), is
r ( t )= x ( t )* h l ( t ), (2)
where * denotes convolution. In the frequency domain, this is expressed as:
R ( f )= X ( f ) H l ( f ). (3)
This expression holds true only when infinite duration signals are considered. In reality, the signals are processed on a frame-by-frame basis (typically of 20 ms duration) and the true relationship between the short-term frames is complex. In general, the current frame of the residual signal can be expressed in terms of the current and past speaker signal frames:
R ( f,t )= g Θ ( X ( f,t ), X ( f,t− 1), . . . , X ( f,t−L+ 1)), (4)
where f and t represent the frequency and time index respectively, g represents an unknown function, Θ is the set of parameters of the model, and L depicts the model order. Once a good estimate of R(f,t) is obtained, it can be subtracted from the AEC signal.
Typically, a room impulse response lasts a few hundred milliseconds. Depending on the number of taps, the AEC is able to model and cancel the effect of the relatively early echoes. The AEC residual can reasonably be assumed to be a part of the early echo and most of the late-echoes, also called long-term room response, or late reverberation. The late reverberation consists of densely packed echoes that can be modeled as white noise with an exponentially decaying envelope [4]. This, combined with the belief that the AEC captures a significant part of the phase information, leads to the belief that whatever phase information is left behind will be very difficult to track. Instead, the present system and process uses attributes of the signal (e.g., magnitude, energy) of the short-term spectrum of the echo residual expressed in terms of the same attribute of the current and previous frames of the speaker signal.
The present invention can employ any appropriate regression model (e.g., linear regression, kernel regression, decision tree regression, threshold linear models, local linear regression, and so on including non-linear models). However, it has been found that a simple linear model is quite effective, especially if the RES is applied more than once, as will be discussed later. In addition, of the aforementioned signal attributes, it has been found that magnitude is particularly effective. Thus, the following description will describe the invention in terms of a linear regression magnitude model. However, it is not intended that the present invention be limited to just this embodiment. Rather any appropriate regression model and any signal attribute could be employed instead without exceeding the scope of the invention.
Given the use of a linear regression model and magnitude as the signal attribute under consideration:
R ( f , t ) ≈ ∑ i = 0 L - 1 w i X ( f , t - i ) ( 5 )
where w i are the regression coefficients for the magnitude model.
Adaptive RES
More particularly, the present RES system and process involves predicting the echo residual signal magnitude {circumflex over (R)}(f,t) in the AEC output signal for each frequency sub-band of interest, identified by a frequency index f, and for each time period identified by a time index t (which in tested embodiments was each frame of the AEC output signal), as:
R ^ ( f , t ) = ∑ i = 0 L - 1 w i ( t ) X ( f , t - i ) . ( 6 )
In tested embodiments f ranges from 2-281 (starting at band 0) with each index number representing a 25 Hz span, t ranges from 1 to the last frame of interest output by the AEC, L is the regression order, w i (t) for i=[0 . . . L−1] are the regression coefficients for time period t, and |X(f,t−i)| is the magnitude of the speaker signal for sub-band f over prior time period t−i for i=[0 . . . L−1]. The regression order L is chosen according to the room size. Since higher frequency signal components are absorbed better than lower frequency signal components [4], a relatively smaller value of L is used at higher frequencies. For example, in tested embodiments of the present RES system and process, L=10, 13 and 16 was chosen for sub-bands 2-73 (lower frequencies) and L=6, 8 and 10 for sub-bands 74-281 (higher frequencies), for small, medium, and large rooms respectively. The initial regression coefficients (i.e., w i (1)) are set to zero. These coefficients are adapted thereafter as will be described shortly. Finally, it is noted that |X(f,t)| is deemed to be 0 for t≦0.
Once {circumflex over (R)}(f,t) is predicted for the current time period t and a particular sub-band, it can be used to remove some or all of the residual echo in the AEC signal. This removal can be accomplished in a number of ways, including spectral subtraction and Weiner filtering. The spectral subtraction method is the simplest and is described herein. First, {circumflex over (R)}(f,t) is subtracted from the magnitude of the current frame of the AEC signal |M(f,t)| associated with the same time period and sub-band, to produce an error signal E(f,t), as:
E ( f,t )=| M ( f,t )|− {circumflex over (R)} ( f,t ). (7)
It is noted that whenever the difference between |M(f,t)| and {circumflex over (R)}(f,t) becomes lower than the noise floor, E(f,t) is set to the noise floor. This helps in reducing any artifacts such as musical noise in the RES output. The noise floor can be calculated using any appropriate conventional method, such as a minimum statistics noise estimation technique like the one described in [6].
The RES output signal component B(f,t) is then generated as:
B ( f,t )= E ( f,t )exp( j φ) (8)
where φ=∠M(f,t) is the current phase of the AEC output signal. This procedure is performed for the current time period t and all the remaining sub-bands of interest, and the resulting RES output signal components B(f,t) associated with each sub-band are combined in a conventional manner to produce the RES output signal b(t). The net result is to suppress at least part of the echo residual component in the current frame of the AEC output signal.
After the initial frame of the AEC output signal is processed, the foregoing process is repeated for each new frame generated. However, the regression coefficients w i are a function of the room environment and change as the room environment changes. Thus, it is advantageous to update them on a frame-by-frame basis to ensure they more accurately reflect the current conditions. In the embodiment of the present RES system and process employing magnitude as the signal attribute of interest, a magnitude regression-based normalized least-mean squares (NLMS) adaptive algorithm is used, such as described in [5]. However, it is noted that other adaptive algorithms could be used instead, such as recursive least squares (RLS), Kalman filtering or particle filters.
More particularly, before generating the aforementioned RES output for each frame after the initial one, a decision is made as to whether to adaptively update the regression coefficients before moving on. This is done by determining if the current AEC output frame contains near end speech components, using a conventional method such as double-talk detection. If so, the regression coefficients cannot be accurately adapted and the values employed for the current frame are re-used for the next. If, however, near-end speech is absent from the current frame, then the regression coefficients are updated as follows.
First, a smoothed speaker signal power P(f,t) is estimated using a first order infinite impulse response (IIR) filter for the current frame and a particular sub-band f, as:
P ( f,t )=(1−α) P ( f,t− 1)+α∥ X ( f,t )∥ 2 (9)
where α is a smoothing constant which in tested embodiments was set to a small value, e.g., 0.05□0.1, and where ∥X(f,t)∥ 2 is the energy associated with the speaker signal for the same time period t (e.g., frame) and at the same sub-band. It is noted that in order to improve convergence, P(f,t) is initialized with the energy in the initial frame of the speaker signal. Thus, P(f,0)=∥X(f,1)∥ 2 . In order to prevent the smoothed estimate from attaining a zero value (and thus causing a divide by zero in further computation), a small value can be added to the P(f,t), or if P(f,t) falls below a threshold, P(f,t) can be set to that threshold. These readjustments can be considered to be part of the first-order filter.
The smoothed speaker signal power P(f,t) is used to compute a normalized gradient for the current time period and sub-band under consideration, as:
∇ ( t ) = - 2 E ( f , t ) X ( f , t ) P ( f , t ) ( 10 )
This normalized gradient is then used to update the regression coefficients employed in the current frame for the sub-band under consideration. Namely,
w ( t+ 1)= w ( t )−μ∇( t ) (11)
where w(t) is a regression coefficient vector equal to [w 0 w 2 . . . w L-1 ] T for the current time period (e.g., frame) at the sub-band under consideration, and μ is a small step size. The value of μ is chosen so that the residual signal estimate {circumflex over (R)}(f,t) is mostly smaller than |M(f,t)|. In tested embodiments, μ was in a range of 0.0025 and 0.005. In addition, if it is determined that {circumflex over (R)}(f,t) exceeds |M(f,t)|, the step size μ is multiplied by a small factor λ, e.g., 1<λ<1.5. This is to ensure the positivity of E(f,t) as much as possible.
RES Process
Referring to FIGS. 3A and 3B , the foregoing RES process can be summarized as follows. First, the current segment (e.g., frame) of the AEC output signal is selected (process action 300 ). In addition, a previously unselected one of the pre-defined sub-bands within a prescribed overall frequency range is selected (process action 302 ). The AEC output signal echo residual component as exhibited in a prescribed signal attribute (e.g., magnitude, energy, and so on) is then predicted in process action 304 using a prescribed regression model (e.g., linear, kernel based regression, and so on) based on a prescribed number of past periods (e.g., frames) of the speaker signal. Next, the prediction results are subtracted from the same attribute of the current AEC output period (e.g., frame) in process action 306 and the noise floor of the current AEC output period is computed in regards to the signal attribute under consideration (process action 308 ). It is then determined if the difference is lower than the noise floor (process action 310 ). If not, the difference is designated as the RES output for the currently selected time period (process action 312 ). However, if the difference is lower, then the noise floor is designated as the RES output for the time period (process action 314 ). A RES output signal component for the selected sub-band and time period is then generated from the designated RES output (process action 316 ).
The process continues in FIG. 3B by first determining if the AEC output associated with the currently selected time period contains near-end speech components (process action 318 ). If not, the smoothed speaker signal power is estimated for the selected time period and sub-band (process action 320 ). This is followed by computing the normalized gradient for the selected time period and sub-band (process action 322 ) and updating the regression coefficients employed in predicting the AEC output signal echo residual component for the selected time period and sub-band (process action 324 ). Once the regression coefficients are updated, or if it was determined in process action 318 that the AEC output associated with the currently selected time period contained near-end speech components, the last computed regression coefficients are designated as the coefficients that are to be used for the associated sub-band to predict the AEC output signal echo residual component for the next time period selected (process action 326 ).
It is next determined if there are any remaining previously unselected sub-bands (process action 328 ). If so, process actions 302 through 328 are repeated until there are no unselected ranges left. The RES output signal components generated for each previously selected sub-band are then combined, and the resulting signal is designated as the RES output signal for the selected period (process action 330 ). At that point, the entire process is repeated for the next time period by repeating process action 300 through 330 as appropriate.
Repeated Application of Adaptive RES
Based on the cursory analysis, it can be intuitively presumed that repeated application of RES, will lead to successive reduction in echo residual. This is borne out empirically from experimentation, with a second RES application supplying an echo reduction of about 2-5 dB beyond a first RES application. Thus, when the extra processing time and costs are acceptable it is envisioned that the forgoing RES technique would be run at least twice. This modified RES technique is illustrated in FIG. 4 in an embodiment having two RES stages. As before, the speaker signal x(t) 402 is received and played back in the space represented by near-end block 400 via loudspeaker 404 . The speaker signal playback 406 , as well as the ambient noise n(t) 408 in the near-end space and near-end speech s(t) 410 is picked up by the microphone 412 which produces a microphone signal 414 . This microphone signal 414 is fed into a conventional AEC module 416 , which suppresses a part of the speaker signal playback picked up by the microphone. The output of the AEC module 416 is the aforementioned AEC signal m(t) 418 , which is in turn fed into the first RES module 420 . The first RES module 420 uses this signal and the speaker signal 402 (which is also fed into the AEC module 416 ) to produce the initial RES output signal b(t) 422 in the manner described previously. This initial RES output signal 422 is then fed into a second RES module 424 along with the speaker signal 402 . The second RES module 424 repeats the present RES technique, except using the initial RES output signal b(t) 422 in lieu of the AEC output signal m(t) 418 . The output of the second RES module 424 is the final RES output signal b(t) F 426 . However, as indicated there could also be more than two RES stages (not shown). In that case, additional RES module(s) are added with the output of the immediately preceding RES module being fed into the next module, along with the speaker signal. The final RES output signal is then output by the last RES module in the series.
Application to Stereo AEC
The present RES system and process can also be applied to stereo AEC in two ways, both involving two passes of the regression procedure, similar to the repeated application embodiment just described. Stereo AEC has problems with correlations between the right and left channels, however, the present RES approach naturally handles these correlations by removing them in two passes. Essentially, there is no difference in the processing itself, only a difference in which signals are input to the RES modules. In the first approach illustrated in FIG. 5 , the present RES technique is applied to the AEC output based on the left channel speaker signal x L (t) 506 in the first pass, and then the right channel speaker signal x R (t) 502 in the second pass. More particularly, the right channel speaker signal x R (t) 502 is received and played back in the space represented by near-end block 500 via loudspeaker 504 , while the left channel speaker signal x L (t) 506 is received and played back in the space via loudspeaker 508 . The right and left channel far end signal playbacks 510 , 512 , as well as the ambient noise n(t) 514 in the near-end space and near-end speech s(t) 516 are picked up by the microphone 518 , which produces a microphone signal 520 . This microphone signal 520 is fed into a conventional stereo AEC module 522 , along with both the right and left channel speaker signals 502 , 506 . The stereo AEC module 522 suppresses a part of the left and right speaker signal playback picked up by the microphone 518 . The output of the AEC module 522 is the AEC signal m(t) 524 , which is in turn fed into the first RES module 526 . The first RES module 526 uses this signal and the left channel speaker signal x L (t) 506 to produce the first RES output signal b 1 (t) 528 in the manner described previously. This first RES output signal 528 is then fed into a second RES module 530 along with the right channel speaker signal 502 . The second RES module 530 repeats the present RES technique, except using the first RES output signal b 1 (t) 528 in lieu of the AEC output signal m(t) 522 . The output of the second RES module 530 is the final RES output signal b(t) F 532 . This method is also applicable to multi-channel playback where the number of playback channels is greater than 2 (e.g. 5.1, 7.1, and so on).
In the second approach illustrated in FIG. 6 , the present RES technique is applied to the stereo AEC output based on the sum of the left and right channel speaker signals in the first pass and on the difference between the left and right channel speaker signals in the second pass. More particularly, as in the first embodiment, the right channel speaker signal x R (t) 602 is received and played back in the space represented by near-end block 600 via loudspeaker 604 , while the left channel speaker signal x L (t) 606 is received and played back in the space via loudspeaker 608 . The right and left channel speaker signal playbacks 610 , 612 , as well as the ambient noise n(t) 614 in the near-end space and near-end speech s(t) 616 are picked up by the microphone 618 which produces a microphone signal 620 . This microphone signal 620 is fed into a conventional stereo AEC module 622 , along with both the right and left channel speaker signals 602 , 606 . The stereo AEC module 622 suppresses a part of the left and right speaker signal playback picked up by the microphone 618 . The output of the AEC module 622 is the AEC signal m(t) 624 , which is in turn fed into the first RES module 626 . In addition, the right and left channel speaker signals 602 , 606 are summed in summing module 634 and the resulting summed signal 636 is fed into the first RES module 626 . The first RES module 626 uses the AEC signal m(t) 624 and the summed channel signal 636 to produce the first RES output signal b 1 (t) 628 in the manner described previously. This first RES output signal 628 is then fed into a second RES module 630 . In addition, the right and left channel speaker signals 602 , 606 are subtracted in the difference module 638 and the resulting difference signal 640 is fed into the second RES module 630 . The second RES module 630 uses the first RES output signal b 1 (t) 628 and the difference signal 642 to produce the final RES output signal b(t) F 632 in the manner described previously.
It is noted that the order in which the left and right channel far end signals are processed in the RES modules in the first stereo RES embodiment or the order in which the summed and difference signals are processes in the RES modules in the second stereo RES embodiment could be reversed from that described above if desired.
3.0 REFERENCES
[1] G. Enzner, R. Martin and P. Vary, “Unbiased residual echo power estimation for hands free telephony”, ICASSP '02, pp. 1893-1896, Orlando, Fla., May 2002.
[2] M. Kallinger and K. Kammeyer, “Residual echo estimation with the help of minimum statistics”, IEEE Benelux Signal Processing Symposium, Leuven, Belgium, March 2002.
[3] K. Lebart, et. al., “A New Method Based on Spectral Subtraction for the Suppression of Late Reverberation from Speech Signals”, Audio Engineering Society Issue 4764, 1998.
[4] J-M. Jot, et. al., “Analysis and Synthesis of Room Reverberation Based on a Statistical Time-Frequency Model”, Audio Eng. Soc. 103rd Convention, New York, 1997.
[5] S. Haykin, “Adaptive Filter Theory”, Prentice Hall, 4th Edition, September 2001.
[6] R. Martin, “Spectral subtraction based on minimum statistics,” Proc. EUSIPCO-94, pp. 1182-1185, Edinburgh, 1994.
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A regression-based residual echo suppression (RES) system and process for suppressing the portion of the microphone signal corresponding to a playback of a speaker audio signal that was not suppressed by an acoustic echo canceller (AEC). In general, a prescribed regression technique is used between a prescribed spectral attribute of multiple past and present, fixed-length, periods (e.g., frames) of the speaker signal and the same spectral attribute of a current period (e.g., frame) of the echo residual in the output of the AEC. This automatically takes into consideration the correlation between the time periods of the speaker signal. The parameters of the regression can be easily tracked using adaptive methods. Multiple applications of RES can be used to produce better results and this system and process can be applied to stereo-RES as well.
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FIELD OF THE INVENTION
This invention relates to a storage cabinet having a plurality of drawers arranged one above the other, and more particularly to an autolock mechanism in such a cabinet, for locking the remaining drawer(s) shut when one of them is opened.
DESCRIPTION OF THE PRIOR ART
Storage cabinets are known, including drawers arranged one above the other, in which the drawers can be opened and closed independently of one another. A disadvantage is that more than one drawer can be opened at once and if the drawers are sufficiently laden, this can result in the cabinet toppling over about the front edge of its base. This presents a serious hazard to users of such storage cabinets.
SUMMARY OF THE INVENTION
According to the invention, there is provided, in a storage cabinet having a plurality of drawers arranged one above the other, an autolock mechanism for locking the remaining drawer(s) shut when one of them is opened, the mechanism comprising an upright locking bar which is displaceable longitudinally of itself between upper and lower positions, one of which is a drawer-locking position and the other a drawer-releasing position, means associated with the drawers and operative to bring about locking bar displacement to lock the remaining drawer(s) shut during the initial part of opening one of the drawers, and retaining mechanism, including a spring, operable by the locking bar and arranged so that when the locking bar is moved from the drawer-releasing position to the drawer-locking position the spring passes through an over-centre position from a first state in which it tends to hold the locking bar in the drawer-releasing position to a second state in which it retains the locking bar in the drawer-locking position, the retaining mechanism being arranged so that the spring returns to the first state when the locking bar is returned to the drawer-releasing position. Preferably the spring is connected to a point in the retaining mechanism that undergoes augmented movement relatively to the movement of the locking bar.
In a preferred construction the retaining mechanism comprises a pinion whose teeth are engaged with complementary teeth on the locking bar and which bears an arm to which the spring is connected.
Conveniently, the upper and lower positions are respectively the drawer-locking and drawer-releasing positions.
In one preferred embodiment of the invention, the storage cabinet additionally includes a key-lock mechanism which is operatively coupled to the locking bar and which is so constructed and arranged as to permit the bar to be raised and lowered when the key-lock mechanism is unlocked but to raise the bar to lock all the drawers shut when the key-lock mechanism is locked.
It has been found that when the drawers have not been locked shut by the key-lock mechansim and when, for example, the cabinet is being carried up or down stairs in a position in which it is turned from the upright position to a position in which the locking bar can slide under its own weight or inertia towards its locking position, all the drawers will be locked shut by this movement. Then when the cabinet is returned to the upright position, the drawers will remain locked and cannot be unlocked by the lock because this will be held in the unlocked position by the locking bar in its raised position. It is therefore, a further object of the present invention to provide simple means whereby this action can be avoided.
Advantageously, therefore, a gravity responsive device operative on the retaining mechanism may be provided to inhibit longitudinal movement of the locking bar if the cabinet is tilted in such a way as to cause the locking bar to travel to its drawer locking position, the gravity responsive device thereby preventing all the drawers from becoming locked by such movement of the locking bar. The gravity responsive device may conveniently comprise a ball arranged to run along a track to a position in which it obstructs the operation of toothed gearing which would otherwise transmit the movement of the locking bar to the spring, this obstruction occurring when the locking bar is moved towards the horizontal position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of part of a drawer autolock mechanism;
FIG. 1A is an exploded perspective view showing details of a drawer key-lock device;
FIG. 1B is a perspective view of part of a cabinet drawer,
FIG. 1C is an elevation of a detail of the mechanism shown in FIG. 1;
FIGS. 2 and 3 are respectively a front elevation and plan of part of the mechanism shown in FIG. 1;
FIGS. 4 and 5 illustrate diagrammatically the operation of the drawer autolock mechanism;
FIG. 6 illustrates different working positions of the details shown in FIG. 1A; and
FIGS. 7 and 8 respectively show different operative conditions of a portion of the mechanism shown in FIG. 1; and
FIG. 9 is an isometric view of a four-drawer cabinet embodying autolock mechanism as described with reference to FIGS. 1 and 8 and shown with part of its wall broken away to disclose the mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1, 1B and 3 to 5, filing cabinet shown in FIG. 9 and only diagrammatically in FIGS. 4 and 5 comprises a number of drawers 1 arranged one above the other, the top drawer being shown open in FIGS. 5 and 9. It is to be understood that the following description of the top drawer and its associated components of the autolock mechanism applies equally to all the drawers 1.
Arranged just inside the drawer opening in the front of the filing cabinet, on one side (e.g., the right-hand side) of the opening, is an upright channel member 2 which has outwardly directed side wing portions providing feet 3 on opposite sides of the channel by which the channel member is secured to the inside surface of the side wall of the filing cabinet that is the portion of the side wall shown broken away in FIG. 9. Only the lower portion of the channel member 2 is shown in FIG. 9.
Arranged within the channel of the channel member along one of its sides so as to lie between the base wall of the channel member and the facing wall of the filing cabinet is a locking bar 4 which is U-shaped in cross-section and can slide vertically within the channel member the locking bar 4 being shown in longitudinal section in FIG. 9. One of the side walls of the locking bar is cut at locations spaced along its length to provide actuating tags 5 for the drawers, respectively. As can be seen in FIG. 1, the tag 5 for the top drawer is bent outwardly at right angles to the locking bar 4 to project through an aperture in the base wall of the channel member 2.
Each actuating tag 5 cooperates with an associated cam track 7, secured to the side wall of the associated drawer 1, in certain positions of the drawer as will be explained hereinbelow, and for this purpose, the upper and lower faces of the tag are inclined downwardly at a small angle, typically 15 degrees, to the horizontal for good bearing contact with the cam track 7. Conveniently, the cam track can be formed from a sheet metal blank which is bent to provide the required shape and then welded, for example, to the drawer side.
The locking bar 4 is formed along one edge with teeth 8 (FIG. 2) engaged with the teeth of a pinion 22 which is rotatably mounted on the channel member 2 and which bears a radially projecting arm 33. Conveniently, the pinion and arm can be formed by a single sheet steel pressing. The free end of the arm 33 is bent over to form a tag 24 around which is fitted one end of a tension spring 13 whose other end is fitted around a tag 25 which is stamped from the base wall of the channel member and then bent out of the plane of the base wall.
When all the drawers of the filing cabinet are shut but not locked by a key-lock mechanism to be described hereinbelow, the bar 4 is in its lower position and the spring 13 is in the position illustrated in FIG. 4. As the bar 4 is raised by the cam track 7 on opening one of the drawers, the bar rotates the pinion 22 anit-clockwise, and thereby causes the arm 33 to move from the broken line position of FIG. 2 so that the spring 13 goes beyond its over-centre position. As the drawer is opened further, the locking bar 4 arrives at its uppermost position, in which the spring 13 adopts the position shown in FIGS. 2 and 5. Then the spring, still under tension, exerts by way of a substantial turning moment on the arm 33 a sufficient upward force on the locking bar to retain it in that position as the drawer is opened further.
Referring to FIGS. 1, 1A and 6 a key-lock mechanism comprises a flag 16 welded to the top end of the locking bar 4, this flag being formed from a length of strip metal bent to the required shape. A roller 18 eccentrically mounted relative to a barrel 19 of a key-operated lock 20, on an arm 21, cooperates with the flag as will be explained in detail hereinbelow with reference to FIG. 6.
Operation of the autolock mechanism will now be described in detail with particular reference to FIGS. 4 and 5. In FIG. 4, both drawers 1 of the filing cabinet are closed. It will be seen that the actuating tags 5 are positioned at the entrances to their cam tracks 7. As the top drawer is opened, relative movement between its inclined cam track 7 and actuating tag 5 causes the locking bar 4 to slide vertically in the channel member, thereby bringing the actuating tag 5 associated with the lower drawer into the position shown in FIG. 5 where it is opposite a shoulder 9 at the entrance to the cam track. The spring 13 holds the locking bar 4 in its raised position even when the upper drawer 1 is opened fully and the actuating tag 5 is no longer urged upwardly by the cam track 7. It will be noted that any attempt to open the bottom drawer of the filing cabinet will fail because the shoulder 9 abuts with the actuating tag 5 associated with the lower drawer. Thus, while the drawer 1 is open, the lower drawer is locked shut.
When the upper drawer 1 is pushed back towards its closed position, the cam track 7 comes into engagement with the actuating tag 5, a lower boundary 15 of the cam track ensuring that even if the locking bar should drop at all whilst the drawer is fully open, the necessary engagement between the cam track and actuating tag can be guaranteed as the drawer is shut. Owing to the engagement the cam track forcibly displaces the locking bar 4 downwardly and in so doing causes the tension in spring 13 to increase and to pass eventually through its centre state and finally return to the position shown in FIG. 4. Then the bottom drawer can be opened, if desired, since the actuating tag 5 associated with it is no longer opposite the shoulder 9 but is in fact aligned with the entrance to its cam track 7. Clearly, the autolock mechanism functions in an analogous way, when the bottom drawer is opened, to lock the top drawer shut.
The key-lock mechanism will now be described with reference to FIGS. 1 and 6. The roller 18 is shown in its unlocked position in FIG. 1A. With all the drawers shut as shown by a broken line in FIG. 6, the roller 18 is positioned at the entrance to a channel 23 formed in the flag. If one of the drawers is opened, the resulting vertical displacement of the locking bar causes the flag 16 to move into the position 16' indicated in full lines, while the roller 18 remains stationary. On closing the drawer, the flag 16 returns to its original position with the roller at the entrance to the channel 23.
When (with all the drawers shut) a key is inserted into the lock 20 and turned, the arm 21 rotates through a half revolution clockwise so that the roller 18 follows the arcuate path 26 to arrive at the position 18'. It will be appreciated from FIG. 6 that as the roller 18 moves along the path 26 it initially enters the channel 23, then it moves right to the bottom of the channel and then returns to a position 18' at the entrance to the channel 23. During this time, the flag has been raised by the roller 18 from the position indicated in broken lines to the position 16'. Thus, all the actuating tags on the locking bar are positioned opposite their respective shoulders 9 alongside the entrances to the cam tracks 7 and so none of the drawers can be opened. To unlock the cabinet, it is merely necessary to rotate the arm 21 through a half-revolution in the anti-clockwise sense to lower the locking bar and thereby release the drawers.
Of course, although the description of FIGS. 4 and 5 herein relate to a two-drawer cabinet, the autolock mechanism can be adapted to a filing cabinet with many more drawers (e.g., four as shown in FIG. 9) merely by providing additional actuating tags on the locking bar and cam tracks on the additional drawers. Then, opening of any one drawer will cause all the others to be locked shut.
In addition to the described autolock mechanism having a positive over-centre locking action, it is simple and cheap to produce in mass production, in particular because the pinion and its arm, and also the locking bar formed with its teeth, can be made in a sheet metal stamping process. In the case of the locking bar, the stamping process is followed by an appropriate bending operation.
It will be appreciated that when, for example, the cabinet is being carried up or down stairs in a position in which it is turned from the upright position to a position in which the locking bar 4, in the absence of some restraining device, can slide under its own weight or inertia towards what is normally the top end of the cabinet, all the drawers will be locked shut by this movement, it being assumed that the drawers have not previously been locked by the lock 20. Then when the cabinet is returned to the upright position, the drawers will remain locked and cannot be unlocked by the lock 20 because this will be held in the unlocked position by the locking bar 4 in its raised position.
A gravity actuated device is, therefore, mounted adjacent the pinion 22 for holding the locking bar down in such conditions. This gravity actuated device comprises a plastics member 40 fixed to the channel member 2 and formed with a bush 41 for the pinion 22. When the channel member 2 is upright a metal ball 42 lies at the bottom of a recess 43 in the member 40, the ball then being in the position A in FIGS. 7 and 8. The recess 43 lies between a depression 44 formed in the channel member and a depression 45 in the member 40. Depending on whether the channel member 2 happens to be at the top of the tilted cabinet (FIG. 7) or at the bottom of the tilted cabinet (FIG. 8), when the cabinet is turned over to the horizontal or nearly horizontal position, the ball 42 will run along one or other of the sides 46, 47 (FIG. 1C) of the recess 43 into one of the depressions 44, 45 to take up the position B or C. When in a depression 44 or 45, the ball locks the pinion against rotation because the ball projects slightly out of the depression to engage a pinion tooth 48 so that the ball is held between the tooth and one side of the depression. The locking bar 4 is, therefore, held against longitudinal movement so that the actuating tags 5 cannot engage the shoulders 9.
The inclination of the sides 46, 47 of the recess 43 is such that the ball 42 reaches its locking position before the locking bar 4 reaches the horizontal position.
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Initial opening movement of a drawer in a cabinet by cam action raises a locking bar to lock the other drawers closed. In so doing the locking bar rotates a pinion having an arm which stresses a spring carrying it past an over-center position to maintain the bar in locking position while the moving drawer travels to the fully open position. The end of the closure of this drawer by cam action returns the bar, arm and spring to their initial state. A key-lock mechanism can raise the bar to lock all the drawers shut. If the cabinet is tilted forward substantially, gravity causes a ball to run to a position to hold the pinion against rotation thereby preventing all the drawers from automatically becoming locked due to the bar running to the locking position under gravity or inertia.
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This application is a divisional of application Ser. No. 10/755,930 filed Jan. 13, 2004, which is a divisional of application Ser. No. 10/078,121, filed Feb. 19, 2002, now U.S. Pat. No. 6,675,914.
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
FIELD OF THE INVENTION
The invention relates to a method and apparatus for the removal of undesirable materials on the wall of an earth formation so as to allow the measurement of formation characteristics such as pressure. More particularly, the invention relates to a device that creates a wave discharge by pulsing a volume of fluid so as to produce a resonant oscillation in the fluid. The wave discharge is directed in the form of a concentrated beam against at least partially non-permeable membranes formed on the earth wall of a borehole in order to remove these materials from the wall of the borehole. Still more particularly, the described device creates oscillations that produce the wave discharge by using a Helmholtz resonance frequency in pulsing a fluid volume. The wave discharge will disintegrate mudcake formed on the earth formation borehole wall to allow the unobstructed measurement of formation pressure within the formation.
BACKGROUND OF THE INVENTION
The efficient recovery of subterranean hydrocarbons such as oil and gas is assisted by obtaining reliable data about the physical conditions in a formation of interest. For example, a target formation typically includes hydrocarbon fluids that are under high pressure. Accurately measuring the formation pressure where such pressurized materials reside promotes safe and cost-effective operations in nearly all phases of hydrocarbon recovery. However, techniques for measuring formation pressure must overcome a number of technical challenges. One obstacle to pressure measurement is the mudcake that drilling mud tends to deposit on the wall of the wellbore.
A wellbore is typically filled with a drilling fluid such as water or a water-based or oil-based drilling fluid. The density of the drilling fluid is usually increased by adding certain types of solids that are suspended in solution. Drilling fluids containing solids are often referred to as drilling muds. The drilling fluids cool and lubricate the drill bit and carry the cuttings uphole to the surface. The solids in drilling fluids also increase the hydrostatic pressure of the wellbore fluids. By selecting drilling fluids weighted to a particular density, the column of drilling fluids creates a pressure downhole, which is greater than the pressure of the fluids in the formation. When the drilling fluid pressure is greater than the formation fluid pressure, the well is said to be in an over balanced condition. Conversely, if the formation pressure is greater than the fluid column, then the well is said to be in an under balanced condition. Control of formation fluids flowing into the well under high pressure minimizes the risk of a well blowout.
While an over balanced condition prevents well blowouts, it also has disadvantages, such as increased drilling costs due to slower penetration into the formation. Drilling fluid pressure in excess of formation pressure slows the penetration of the drill bit into the formation. In certain well environments it is preferred to maintain a neutral or slightly under balanced condition so as to achieve drilling speeds faster than those achieved while drilling in an over balanced condition. Drilling Practices Manual, Preston Moore, P. 18–22 Pennwell Publishing, 1974. Consequently, it is desirable to maintain a neutral balance or a slightly under balanced condition to maximize drilling penetration into the formation.
Drilling fluids create a mudcake as they flow into a formation by depositing solids on the inner wall of the wellbore. The mudcake on the wall of the wellbore tends to act like a filter and tends to isolate the high-pressure fluids of the wellbore from the relatively lower pressures of the formation. The mudcake helps prevent excessive loss of drilling fluid into the formation. The static pressure in the wellbore and the surrounding formation is typically referred to as hydrostatic pressure. Pressure in the formation beyond the mudcake gradually tapers off with increasing radial distance outward from the wellbore.
The measurement of formation pressures during drilling operations assists in locating strata most likely to produce hydrocarbons efficiently. Typically after the borehole is drilled, the well is logged by lowering a package of sensors downhole that gather data about the formation. Pressure data is useful in judging when a formation contains hydrocarbons and when such a formation may economically produce hydrocarbons. Often a wellbore may pass through more than one hydrocarbon-bearing formation, and formation pressure data assists the drilling engineer in determining whether to halt or continue drilling.
Further, the ability to monitor formation pressure during drilling is important to the desired practice of continuously adjusting the drilling mud density. This facilitates drilling through the maximum amount of formation in the shortest amount of time
To maintain the proper condition during drilling, whether neutral, over balanced or under balanced, it is necessary to measure the pressure of the formation fluids at the vicinity of the drill bit. However, the dynamic environment near the drill bit makes measurement of the formation fluids particularly difficult during logging while drilling (LWD) operations. In addition, the mudcake that forms on the wall of the borehole presents a further difficulty in determining formation fluid pressure at the bit during drilling. This mudcake forms a relatively non-permeable barrier between the instrument on the one side and the formation fluids on the other. The mudcake barrier hinders accurate measurement of the pressure of the formation fluids.
Prior art sensors are generally not capable of measuring formation fluid pressure during drilling. Consequently, rig personnel must closely monitor the drilling fluids flowing from the borehole for signs of increased formation fluid pressure. This often entails temporarily halting the drilling operation to allow pressure measurement of the formation. Once the drilling fluids show evidence of formation fluids flowing up the borehole, drilling is stopped and corrective measures are taken. However, this approach has particular drawbacks; and, it would be desirable to determine formation fluid pressure at the bit during drilling.
One such prior art instrument is a reservoir description tool (RDT) such as that disclosed in U.S. Pat. No. 5,644,076 (the '076 patent) entitled “Wireline Formation Tester Supercharge Correction Method”, incorporated herein by reference in its entirety. The RDT of the '076 patent includes a pressure sensing element mounted within a chamber of a housing having a piston to create a vacuum within the housing chamber. Hydraulic pads force the housing against the borehole wall; and, as the piston retracts to create a pressure reduction, a drawdown pressure removes the mudcake lining from the borehole wall. Fluids in the formation then enter the housing chamber allowing the pressure-sensing element to take a pressure reading. This tool allows only stationary measurements because drawdown pressure requires a tight seal between the housing and the borehole wall. This is undesirable because, aside from being time consuming, stationary measurements provide only discrete data points, not a continuous log. The drawback to discrete data points is that the fluid pressure between the discrete data points may vary dramatically and unpredictably.
Another borehole tool for removing the mudcake to measure the pressure of the formation fluids is disclosed in U.S. Pat. No. 5,969,241 (the '241 borehole tool) incorporated herein by reference. The '241 borehole tool measures pressure from within the borehole. A portion of the borehole wall is isolated from the surrounding borehole fluids by placing the chamber of the '241 borehole tool against the borehole wall. The chamber comprises a recess in an exterior surface of the '241 borehole tool. This patent describes an acoustic horn as the mechanism by which to excite fluids in a chamber. The mudcake present on the isolated portion of the borehole wall is disintegrated by an ultrasonic transducer, actuated by a piezoelectric stack, housed within the chamber. A pressure gauge then measures the pressure of the chamber to indicate the pressure of the earth formation.
Such a prior art tool also has deficiencies. For example, this borehole tool is inefficient because its vibrational energy does not transfer directly to the fluid. The vibrating horn is limited in the efficiency by which it transfers electrical energy to acoustical wave energy. Excitation of the piezoelectric stack creates a longitudinal wave resonance within the ultrasonic transducer. As the ultrasonic transducer resonates longitudinally, the vibrational energy is transferred to the fluid. However, the mechanical coupling of the ultrasonic transducer to the fluid is poor, thus much of the vibrational energy imparted by the piezoelectric stack remains in the ultrasonic transducer. This inefficient energy transfer is expected to reduce the vibrational energy available to break down the mudcake. Further, such tools are not compact and arel not easily installed in the drill string, which must pass through the confined area of the borehole.
Notwithstanding the foregoing described prior art, there remains a need for a device that possesses the features of efficiently transferring vibrational energy to create a focused wave discharge that may be used to remove mudcake from a borehole wall. Further, it is desired that such a device may be utilized so as to minimize any interruption to the drilling process. It is also desired that such a tool be capable of use on different down hole assemblies such as wire line operations and near the drill bit in drilling operations. Additionally, the tool should be able to take pressure measurements on a continuous or near-continuous basis as the drill string descends the well bore.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned deficiencies of the prior art by providing a device that generates rhythmic pressure pulsations within a fluid-filled chamber, thereby producing a pressure wave discharge, which exits through an orifice of the chamber in a focused beam. The pulsations produced by the device include Helmholtz resonant frequencies for the geometry of the chamber; Helmholtz resonant frequencies efficiently transfer energy from pulse elements of the device to the fluids in the chamber. The device directs pressure waves in the fluids in the chamber through an orifice that focuses the waves against the borehole wall in the form of a concentrated beam. The wave discharge removes mudcake from the borehole wall, thereby opening a passage from the interior of the formation to the device chamber. In this manner pressure transducers associated with the device may accurately measure pressure from the formation. The device of the present invention operates with a speed that allows it to be used on a continuous to near-continuous basis. If disposed on a drill string, the drilling operation need not be slowed or halted in order for the present acoustic jet to function. Further the device may be used on both wireline operations and drilling operations.
The pressure reading tool of the present invention overcomes the deficiencies of the prior art by applying a fundamentally different approach to the removal of mudcake from borehole walls. For example, the '241 borehole tool induces vibrational frequencies in an acoustic horn to transfer the vibratory energy to the fluid. The tool of the present invention induces a resonance in the fluid itself. Thus, the poor energy transfer between the acoustic horn and fluid is eliminated. Further, the tool of the present invention concentrates and focuses the wave energy so as to minimize the loss of energy while simultaneously maximizing the energy brought to bear against the borehole wall.
One embodiment of the present invention includes pressure reading tool having a housing with an interior chamber and an orifice extending from the chamber to the exterior of the housing. A pulse member with a magnetostrictive ring and excitation source is disposed within the housing chamber to produce a highly agitated fluid discharge through the orifice. The magnetostrictive ring, chamber volume, and orifice may be designed to cooperate to induce Helmholtz resonance frequencies in the fluid in the chamber to thereby enhance the agitation of the fluid discharge. A sheathing may be used to encapsulate the pulse member to protect it from contact with the fluid. A dampening element may also be interposed between the pulse member and housing to isolate vibration.
In operation, the tool is disposed in the wall of the drill stem having a drill bit for penetrating the formation and forming a borehole. An impermeable membrane in the form of mudcake forms on the borehole wall due to the drilling fluids. A portion of the borehole wall is isolated by placing the tool against the borehole wall. The pulse member is actuated to modulate the chamber volume to produce agitated fluids within the chamber. The fluids are agitated at a high frequency within the chamber. The tool directs a stream of pressure waves through the orifice and against the impermeable membrane to remove the impermeable membrane. A pressure transducer communicates with the chamber to read the pressure of the formation fluids. These pressure readings are communicated with the surface to direct the drilling of the bit through the formation. The readings may be continuous while drilling.
Thus, the present invention comprises a combination of features and advantages that enable it to overcome various problems of prior art pressure measuring devices. The various characteristics described above, as well as other features, objects, and advantages, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of a preferred embodiment of the present invention, reference will now be made to the accompanying drawings, which form a part of the specification, and wherein:
FIG. 1 is a cross-sectional close-up view of a drill string and well bore;
FIG. 2 is a cross-sectional view of a preferred embodiment of the present invention;
FIG. 3 is a cross-sectional close-up view of the preferred embodiment of FIG. 2 ; and
FIG. 4 is a cross-sectional view of three pressure reading tools positioned in three stabilizer blades of a down hole assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It should be appreciated that the invention may be embodied in many different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention. However, the present disclosure is an exemplification of the principles of the invention. It is not intended to limit the invention to the particular illustrated embodiments, which can be modified in the practice of the invention. For example the present invention may be used while logging on a wireline cable or in logging while drilling. The present invention is particularly advantageous in logging while drilling as further described below. The term “logging” is used herein in its broadest sense to include recording any type of data representing characteristics of the formation as a function of depth, including particularly the measurement of formation fluid pressure.
Referring initially to FIG. 1 , there is shown the use of an embodiment of the present invention for logging while drilling. The pressure reading tool 60 is shown disposed in a bottom hole assembly 10 for drilling a borehole 12 . The borehole 12 extends from the surface down through a plurality of different earth formations such as exemplary formation 14 . Formation 14 may include various formation fluids 16 such as water, gas and hydrocarbons. These formation fluids 16 are under pressure. The logging while drilling embodiment of the bottom hole assembly 10 includes various members including a drill collar or drill stem 18 with a drill bit 20 connected thereto. It can be seen that the drill bit 20 is penetrating the formation 14 at the bottom 22 of the borehole 12 .
Drilling fluids 24 are pumped down through the drill string on which the bottom hole assembly 10 is disposed, to the bottom 22 of the borehole 12 and then return up the annulus 26 , formed by the drill string and wall 28 of borehole 12 , to the surface. The drilling fluids 24 lubricate and cool the bit 20 and remove the cuttings to the surface. As the column of drilling fluids circulates through borehole 12 , some of the drilling fluid solids 24 accumulate on wall 28 of borehole 12 forming a mudcake 30 . Mudcake 30 forms a relatively impermeable membrane between the drilling fluids and earth formation 14 . A pressure drop typically occurs across mudcake 30 .
The present pressure reading tool 60 is schematically shown disposed in aperture 32 of one of the drilling string members, such as drill stem 18 . Alternatively, the tool may be disposed on various pieces of downhole machinery. For example, in the embodiment shown in FIG. 4 pressure reading tools are placed in stabilizer blades 40 . Alternatively, the pressure reading tools may be placed on the drill stem 18 or on the drill collar. Alternatively, pressure reading tools may be positioned on a dedicated piece of machinery that is itself attached to the drill string. Similarly, the tool may be employed on a wireline.
While FIG. 1 portrays a single pressure reading tool disposed within the drilling apparatus, it should also be understood that more than one such tool may be included in any particular down hole assembly. For example, in one embodiment three pressure reading tools are disposed within the same drill collar or drill stem. As shown in FIG. 4 , a particular drill collar has three stabilizer blades 40 . There is a tool of the present invention disposed in each of the three stabilizer blades. In that embodiment, each of the three tools is at the same horizontal position on the drill stem; however, each tool is separated radially. In this manner, the three tools record formation pressure from sections of the formation at differing azimuthal positions. In an alternative embodiment a drill collar or drill stem may be arrayed with multiple tools at differing horizontal positions. There is an advantage associated with the use of multiple pressure reading tools. As the number of such tools increases, so does the chance of successfully obtaining an accurate formation pressure reading at a particular location. Conditions inherent in drilling, such as the vibrations and mechanical shocks found in the drilling environment, raise the possibility that mechanical equipment such as the pressure reading tool may be rendered inoperable. Likewise, a poor seal between the borehole wall 28 and orifice 76 of the tool may affect the pressure reading taken by the tool. In both these instances, the placement of multiple tools on the drill string increases the chance of a successful reading.
In both FIG. 1 and FIG. 4 tool 60 is directed radially outward toward mudcake 30 . In this manner, tool 60 produces and directs a wave discharge for removing the mudcake to allow the measurement of formation fluid pressure while drilling as hereinafter described in detail.
Referring now to FIG. 2 , there is shown a preferred embodiment of the tool 60 , which includes a pressure reader 64 , a housing 66 , and pulse device 70 for producing an agitated fluid discharge using Helmholtz resonance frequencies, thus enabling pressure readings of the earth formation. Housing 66 is generally defined by a cylindrical wall 82 , an outer cap 74 , and an inner cap 75 . The generally hollow interior of housing 66 forms a chamber 84 . Chamber 84 itself is generally cylindrical in shape, as it is defined by cylindrical wall 82 , outer cap 74 , and inner cap 75 . Outer cap 74 includes an orifice 76 . Outer cap 74 may be at least partially hardened against frictional wear caused by movement across borehole wall 28 . Hardening of outer cap 74 may be through a surface treatment or a “wear plate” mounted on outer cap 28 . Inner cap 75 is adjacent the inside diameter of drill stem 18 and includes a conduit 78 at its center, which is substantially opposite orifice 76 in outer cap 74 . Inner cap 75 also includes one or more feed-through holes 80 , 81 for receiving electrical conduits 83 , 85 . Outer cap 74 or inner cap 75 may be removable to allow access to chamber 84 .
The tool has been described as having a chamber with a generally cylindrical interior geometry. While such a shape is believed to be advantageous for the transfer of energy from an electrical form to an acoustic form, the chamber may nevertheless assume other configurations. Any chamber geometry is possible, including, but not limited to, conical, spherical, cubic, rectangular, tetragonal, pyramid-shaped, elliptical, ovoid, parabolic, and polygonal.
Conduit 78 is also preferably substantially opposite orifice 76 . While this is believed advantageous, alternative placements of conduit 78 are also possible. For example, conduit 78 could be placed in cylindrical wall 82 . Also, conduit 78 could be placed in an off-center position on inner cap 75 . These examples are for illustrative purposes only and are not meant to be limiting.
According to the embodiment as shown in FIG. 2 , outer cap 74 is curved so as to follow the shape of borehole wall 28 . Outer cap 74 would be disposed adjacent the borehole wall. In this embodiment, outer cap 74 may be hardened to withstand the contact with borehole wall 28 . In alternative embodiment, however, outer cap 74 is positioned some distance from borehole wall 28 so as to avoid direct contact with borehole wall 28 . As shown in FIG. 4 , the pressure reading tool is positioned in a stabilizer blade of the downhole assembly. In this configuration, stabilizer blade 40 contacts borehole wall. Outer cap 74 is slightly recessed so that it does not directly contact borehole wall. In the configuration of FIG. 4 , outer cap 74 need not assume a curved shape; nor does it need to be hardened.
Preferably, housing 66 is sufficiently compact to fit into a drill collar, drill stem 18 , stabilizer blade 40 , or wireline device. The pressure reading tool may be preassembled and installed as a unit in a machined or precut aperture 32 of a selected drill piece. Some known attachment means may be used in order to affix the pressure reading tool to the drill piece. Known attachment methods include, but are not limited to, a pressure fitting, pins, threading, bolting or gluing. Preferably, a threaded lock ring 42 , shown in FIG. 4 , secures the pressure reading tool to the drill piece. The body of housing 66 may also seal aperture 32 so as to prevent the interior of the drill string passing fluids to or from the exterior of the drill string. This is preferably accomplished by o-ring seals 44 . Material selection for housing 66 is largely driven by downhole environment conditions. Generally, a corrosion resistant steel will provide the necessary ruggedness for borehole applications. Acceptable materials include steels such as 17-4PH or MP-35N.
Referring now to FIGS. 2 and 3 , cylindrical wall 82 of chamber 84 is preferably at least partially lined with dampening element 86 . Preferably, dampening element 86 is made of a relatively soft material such as lead. Because tool 60 may be used along with an array of wireline instruments, it is preferred that the operation of tool 60 be dampened to prevent the transmission of vibrations along the drill string. This serves to minimize interference with other drill string instruments. Thus, cylindrical wall 82 of chamber 84 is lined on its interior preferably with a layer of lead to absorb much of the vibrations. In lieu of a lining, dampening element 86 may be a lead ring formed to seat at least partially along interior cylindrical wall 82 . It is emphasized that these are only two non-limiting examples of elements suitable for dampening. It is also emphasized that the dampening element is a convenient feature and may not be essential to the satisfactory operation of tool 60 . Alternatively any members that constitute housing 66 such as cylindrical wall 82 , outer cap 74 , and inner cap 75 may be selected of a material and dimension sufficient to perform any needed dampening function.
Pulse device 70 is disposed within chamber 84 and comprises a member or members that can physically oscillate in response to a signal. In the preferred embodiment of FIG. 2 , pulse device is a generally annular or ring-shaped member disposed within chamber 84 . Pulse device 70 seats substantially contiguously along the interior surface of cylindrical wall 82 , or, if present, along the interior surface of dampening element 86 . Preferably, pulse device 70 extends along the length of cylindrical wall 82 such that the ends of pulse device 70 rest against the interior surfaces of outer cap 74 and inner cap 75 .
In the preferred embodiment, pulse device 70 seats substantially contiguously along the interior surface of cylindrical wall 82 . In this manner, the physical oscillations of pulse device 70 efficiently transfer energy to fluid in chamber 84 at all positions along the interior surface of pulse device 70 . However, it is possible to configure pulse device 70 in an alternative manner. For example, rather than being configured as a single, ring-shaped body, pulse device 70 could comprise any number of discrete units, of any geometry. These separate units could be placed at different locations within chamber 84 . A plurality of individual pulse device units could approximate the form and function of a ring-shaped pulse device when such individual units are placed in proximity to one another along the interior surface of cylindrical wall 82 . Alternatively, discrete pulse device units could be placed on the interior surfaces of outer cap 74 and inner cap 75 . Additionally, pulse device units could even be placed at some interior position of chamber 84 . If housing 66 is selected such that it defines chamber 84 to have a non-cylindrical geometry, then pulse device 70 may also have an alternative configuration and placement in the chamber. It would also be possible, and would be within the scope of this invention, to construct housing 66 with recesses or voids so as to have a honeycombed configuration. In such a configuration, pulse device units could be disposed within the recesses of housing 66 .
Pulse device 70 may itself be composed of separate elements. In the ring-shaped, preferred embodiment, shown in FIG. 3 , pulse device 70 has pulse elements 88 at its core. Excitation source 90 wraps around pulse elements 88 , and sheathing 72 wraps around excitation source 90 . Sheathing 72 thus forms the external surfaces of the preferred pulse device 70 .
Sheathing 72 is preferably made of an elastomeric material to insulate the pulse device 70 from harmful contact with borehole fluids and particulates. Accordingly, the material for sheathing 72 should be selected to provide a impermeable barrier between the borehole environment and pulse device 70 . Another consideration in material selection is the need to efficiently couple the energy of pulse device 70 to the fluid in chamber 84 . Thus, sheathing 72 should be a resilient medium that provides efficient transfer of pulsing motion from pulse device 70 to the fluid. Generally, the modulus of elasticity of the material for sheathing 72 should be closer to that of rubber than that of steel. Materials with relatively high material stiffness will tend to limit the motion of pulse device 70 . Rubber meets the requirements of elasticity and impermeability. Other materials such as Teflon may also be designed to have the requisite material properties. Further, sheathing 72 also provides a resilient support for pulse device 70 in housing chamber 84 . Preferably, the thickness of sheathing 72 should secure pulse device 70 within housing 66 without unduly impeding the oscillating motion of pulse device 70 .
Still referring to FIG. 3 , pulse device 70 includes a plurality of pulse elements 88 wrapped within excitation source 90 . Pulse elements 88 physically distort in response to an excitation signal. As pulse elements 88 physically distort, the volume of chamber 84 rhythmically increases and decreases, thereby producing a pulsation of the fluid within chamber 84 . Preferably, pulse elements 88 are a ring of magnetostrictive elements capable of radial oscillatory expansion and contraction when activated. Excitation source 90 can include windings that are capable of transferring magnetic flux signals. Magnetic flux is the excitation signal that causes magnetostrictive elements to physically distort. The windings of excitation source 90 are wrapped around the magnetostrictive elements and exit housing 66 via housing feed-through holes 80 , 81 . Outside the housing, the wires may connect with an external signal source. While feed-through holes 80 , 81 allow the winding wires of excitation source 90 to exit, it is otherwise sealed to segregate fluid within chamber 84 . Pressure boots may provide one mechanism by which to make the electrical connection from wiring to the pressure reading tool.
Alternatively, pulse elements 88 may be a plurality of piezoelectric elements. As with the magnetostrictive ring, the piezoelectric elements are formed into an annular or ring shape. A preferred piezoelectric material is PZT-5A Piezoelectric Material, available from EDO Corporation, Salt Lake City, Utah, 84115. Whether piezoelectric elements or magnetostrictive elements are used depends on the demands of a particular application. For example, it is generally understood that piezoelectric elements are more brittle than magnetostrictive elements and may be more easily damaged. However, a particular situation may require the higher frequency oscillations that are more efficiently provided by piezoelectric elements. In any event, magnetostrictive and piezoelectric elements are given as illustrative examples of a material that can produce harmonic pulsation of the fluids in chamber 84 . Pulse elements 88 are not intended to be limited to these two materials.
Orifice 76 will focus the pressure wave discharge into a concentrated beam. However, one skilled in the art will understand that the profile of orifice 76 can be easily modified for alternate fluid discharges. Thus, nearly any profile may be utilized for chamber 84 and orifice 76 . If a Helmholtz chamber is desired, the resulting volume and geometry must satisfy the Helmholtz resonance frequency requirements. In certain downhole applications, it is foreseeable that it may not be possible to design housing 66 to create Helmholtz resonance frequencies. In such cases, it will be apparent to one skilled in the art to adjust the geometry of housing 66 and orifice 76 to produce an agitated fluid discharge.
A Screen 68 is preferably positioned within chamber 84 on outer cap 74 proximate to orifice 76 . Screen 68 can prevent borehole particulates from entering chamber 84 . When the fluid in chamber 84 is vibrated, fluid in the immediate vicinity of orifice 76 develops the highest fluid velocity. It is preferable not to restrict such fluid movement. However, if screen 68 is placed too far from orifice 76 , it may allow borehole particulates to enter chamber 84 and damage pulse device 70 . Preferably, screen 68 is placed to allow the highest velocity fluid movement through orifice 76 . Further, screen 68 includes a plurality of openings designed to minimize impedance to fluid movement. Preferably, screen 68 is formed of stainless steel and secured to outer cap 74 . While particulates capable of damaging tool 60 are often present in a borehole environment, it is emphasized that satisfactory operation of tool 60 is not dependant on the presence of screen 68 .
A pressure reader 64 is mounted to housing 66 . Conduit 78 provides fluid communication between pressure reader 64 and chamber 84 . Pressure reader 64 preferably includes a threaded portion that may engage mating threads within conduit 78 . Alternatively, pressure reader 64 may be secured to housing 66 by some alternative means. Because conduit 78 provides access to chamber 84 , the fluids in chamber 84 pass through conduit 78 and contact a surface of pressure reader 64 such that the pressure of the fluids can be measured. It is preferable to locate pressure reader 64 as closely as possible to chamber 84 . A remotely mounted pressure reader 64 requires a longer conduit 78 , which may be more susceptible to plugging by borehole particulates. Commercially available pressure transducers can be utilized as the pressure reader 64 in the present invention. One such pressure transducer is a strain gage based pressure transducer manufactured by Paine, Inc. Quartz gage pressure transducers are more accurate and may be used. Such devices are usually more bulky and thus of limited suitability to borehole applications.
While it is not essential to the invention, in the preferred tool 60 , the geometry of housing 66 , chamber 84 , orifice 76 , and pulse device 70 are selected to produce Helmholtz resonance frequencies in the fluid expected to be encountered in the drilling environment. Helmholtz resonance is a well-known scientific principle. The shape and design of Helmholtz cavities or Helmholtz resonators is also known in the industry. One kind of Hehnholtz resonator is an enclosed cavity of fluid with an open port. If the volume of fluid in the cavity is compressed, the fluid attempts to spring back to its original volume. Physical oscillations in the fluid within a ported cavity tend to resonate at specific frequencies.
The natural resonant frequency for a spherical Helmholtz resonator ported with a cylindrical neck in an atmospheric environment may be represented by the following equation: where
f
r
=
c
2
π
A
L
V
c=speed of sound in the fluid
V=cavity volume
A=cross sectional area of the neck, and
L=length of the neck
This equation necessarily changes as the fluid is changed from air to another medium. Likewise, as other factors such as the geometry of the chamber and neck become more complicated, the classical equation breaks down. Hence the selection of an optimal frequency in the pressure reading tool must also be guided by trial-and-error methods. Given the changing environment in an active wellbore arising from factors such as changing pressures and the changing densities of fluids present in the wellbore, it is sometimes necessary to design a resonating chamber that can function across a variety of frequencies.
A preferred design of the present invention was tested in laboratory conditions. The fluid was a drilling mud with density of approximately 1500 kg/M 3 . The speed of sound in this material was estimated at 1500 m/s. At approximately 42 kHz the preferred embodiment of the present invention displayed a relatively low impedance while retaining good sound pressure levels. At this frequency the design was found to generate a cylindrical standing wave in laboratory testing.
One preferred embodiment of pressure reading tool 60 previously described has the following dimensions. The diameter of the chamber 84 in the fully assembled tool, i.e., the chamber diameter as defined when pulse device 70 is in place, is approximately 1.10 in. The diameter of chamber 84 with pulse device 70 removed is approximately 1.75 in. No dampening element 86 was present. The annular pulse device 70 thus has a ring thickness of approximately of 0.325 in. The depth of chamber 84 is approximately 1.00 inch. Outer cap 74 has a thickness of approximately 0.250. Inner cap 75 has a thickness of approximately 0.50 in. The cylindrical interior wall is approximately 0.25 in. thick. Orifice 76 , centered in outer cap 74 , has an opening diameter, measured at the exterior wall of outer cap 74 , of approximately 0.50 in.; and orifice 76 widens toward the interior of chamber 84 at an angle of approximately 28°.
In this preferred embodiment, pulse device 70 , with an annular ring thickness of approximately 0.325 in., was further designed as follows. Sheathing 72 was as long as the interior length of chamber 84 , approximately 1.00 in., and assumed the ring thickness of the pulse device 70 , approximately 0.325 in. An annular-shaped magnetostrictive assembly, composed of a magnetostrictive ring with windings, was approximately 0.75 in. long and approximately 0.10 in. in thickness. The magnetostrictive assembly formed the interior of pulse device 70 . The magnetostrictive assembly had an interior diameter of approximately 1.30 in. and an exterior diameter of approximately 1.50 in. Given the differences in diameters, the magnetostrictive assembly was thus placed in sheathing 72 in a slightly off center position. The distance from the interior surface of sheathing 72 to the interior surface of the magnetostrictive assembly was approximately 0.20 in. However, the distance from the exterior surface of sheathing 72 to the exterior surface of the magnetostrictive assembly was approximately 0.25 in. In the assembled pulse device the magnetostrictive assembly was placed equidistant from the interior surfaces of outer cap 74 and inner cap 75 , approximately 0.125 in. from each.
In operation, rig personnel will install preferred tool 60 into a drilling structure such as a drill stem 18 , on a stabilizer blade 40 , or drill collar. The appropriate electrical connections are made to link pulse device 70 with a signal source. Pressure reader 64 may also be linked with an appropriate display device or recording device, usually located at a control point on the surface. Such a link is preferably done through an electronic data connection.
To take pressure readings during LWD, the assembled tool is lowered into borehole 12 . When the drill string approaches a formation region of interest, several steps will take place. Of initial importance is the seal between orifice 76 of tool 60 and borehole wall 28 . The measuring of formation pressure with the pressure reading tool is best accomplished when the tool is placed firmly against the formation wall. In one embodiment, the face, or outer cap 74 , of tool 60 is curved so as to make full contact against the curved face of the borehole wall 28 . Outer cap 74 seals against borehole wall 28 and traps fluids, such as drilling fluids within chamber 84 . Alternatively, where outer cap 74 is recessed relative to stabilizer blade 40 , it is stabilizer blade 40 or alternate drill string structure that forms a seal with borehole wall 28 . A tight seal is provided between preferred tool 60 and borehole wall 28 to ensure that pressure reader 64 receives the pressure of formation 14 , and not the fluids in borehole 12 . Placement of multiple tools on a drill string, each tool placed at a differing radial position, increases the probability that the orifice of at least one such tool will be in sufficiently sealed contact with the borehole wall to assure an accurate pressure reading.
The procedure for obtaining a pressure reading continues with electrical signals of a chosen frequency or frequencies delivered to tool 60 . These signals activate pulse device 70 at a corresponding mechanical frequency. Activation of pulse device 70 causes it to oscillate, thereby imparting a rhythmic expansion and contraction of the volume of chamber 84 . The rhythmic expansion and contraction of the volume in chamber 84 imparts pressure waves in the fluid. This wave energy flows through the only point of discharge, orifice 76 . Orifice 76 focuses the wave discharge into a concentrated beam. Because the pulsation frequency causes the fluid to resonate at a Helmholtz frequency, pulse device 70 efficiently transfers energy to the fluid discharge.
The near instantaneous result is a flow of wave energy expelled from the tool. Orifice 76 directs the wave discharge toward borehole wall 28 layered with mudcake 30 . The fluid pulsations strike mudcake 30 , flush away the mudcake 30 , and thereby restore permeability to borehole wall 28 .
At this point electrical signals to the tool can stop, and the fluid oscillation thereby ceases. The necessary period is allowed for the hydrocarbons in formation 14 to pressurize tool chamber 84 . The time period needed to pressurize chamber 84 will vary depending on factors such as the permeability of the formation and the pressure in the formation. The fluids in formation 14 seep through borehole wall 28 and into chamber 84 through orifice 76 . With hydraulic communication established via conduit 78 , chamber 84 and orifice 76 , pressure reader 64 can measure formation fluid pressure. As is known in the art, it is possible to estimate formation pressure without the need for the pressure to equalize between that of the formation and that of the chamber. Pressure reader 64 transmits the pressure data to the surface.
The tool allows for continuous or near-continuous readings of formation pressure. In the logging while drilling embodiment, the movement of the drill string downward as drilling progresses also moves the tool vertically downward. However, the tool receives pressure readings from a given point on the borehole wall prior to the time that the tool descends past this point of the borehole wall. The tool clears mudcake from the borehole wall and records the formation pressure associated with the cleared area of borehole wall, prior to the orifice moving past that cleared point. Once the orifice does descend past a point on the borehole wall that has been cleared and measured for pressure, the process can begin anew. At a new, lower point on the borehole wall, the tool clears mudcake and again records formation pressure. The points of pressure measurement can be closely spaced so as to allow recording of pressure data in a continuous or near-continuous fashion. In this manner the tool will take formation pressure readings at a series of points, in an ongoing fashion, while the drill string makes its normal descent in the formation. There is no need to halt drilling in order to make these pressure readings.
Preferred tool 60 provides a direct reading of formation fluid pressure that can be used to adjust the borehole pressure. That is, rig personnel can select a borehole pressure that prevents formation fluid from invading the borehole 12 without creating an excessive borehole pressure that slows drilling speed. Referring back to FIG. 1 , during LWD, preferred tool 60 can be linked with a downhole telemetry system 100 to transmit formation pressure data uphole. For example, downhole telemetry system 100 could include control circuitry 102 to energize preferred tool 60 and a drive circuitry/transmitter 104 to receive pressure data from preferred tool 60 to transmit the pressure data to the surface. Drive circuitry/transmitter 104 may utilize a mud siren to transmit data in the form of pressure pulses in the drilling mud flowing uphole. Monitors 106 on the surface receive and process the pressure data transmitted by downhole telemetry system 100 . Such a system could be configured to provide continuous transmission of pressure data. Alternatively, the drive circuitry could be designed to transmit pressure data only after a threshold pressure is sensed by pressure transducer. In any event, data transmission systems for LWD in the prior art are well known, and one of ordinary skill in the art will understand how to relay pressure readings obtained from preferred tool 60 to monitoring systems on the surface. Further, one of ordinary skill in the art will know how to modify drilling mud to create a specific borehole pressure.
A similar approach is followed for deploying preferred tool 60 during wireline logging operations. For wireline logging, a preferred tool 60 is usually one of several tools in a package lowered downhole. Thus, preferred tool 60 may transmit pressure data via the wireline cable to the surface. A continuous log requires that preferred tool 60 be dragged along borehole wall 28 . While it is believed that tool 60 will remove mudcake nearly instantaneously, a similarly instantaneous pressure reading may not be possible. A lag time may be involved with wireline logging. Lag time calculations are discussed in the '076 patent referenced above and incorporated by reference in its entirety. Thus, pressure reader 64 provides pressure data that allows an accurate reading of formation fluid pressure even though the fluid pressure in chamber 84 and formation 14 have not equalized.
While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. In the claims, the recitation of steps in a sequential order is not intended to require that the steps be performed in that order, unless explicitly so stated.
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The pressure reading tool includes a housing with an interior chamber and an orifice extending from the chamber to the exterior of the housing. A pulse member with a magnetostrictive ring and an excitation source are disposed within the chamber to produce a highly agitated fluid discharge through the orifice. The magnetostrictive ring, chamber volume, and orifice cooperate to induce Helmholtz resonance frequencies in the fluid in the chamber to thereby enhance the agitation of the fluid discharge. A sheathing encapsulates the pulse member to protect it from contact with the fluid. A dampening element is also interposed between the pulse member and housing to isolate vibration.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed generally to the field signal processing and, more particularly, to the field of video signal processing.
2. Description of the Background
It is known in the art to use color as a basis for merging pixel by pixel, two video signals. Chroma-keying, as the process is known, uses color information to control a switching process. A person, for example a weatherperson, stands in front of a blue screen while a first video signal is made. A second video signal is provided which is to be combined with just the weatherperson from the first video signal. The first video signal is analyzed pixel by pixel for the key, i.e., the blue of the background screen. For each blue pixel, the corresponding pixel from the second video signal is selected for the final image. Each non-blue pixel from the first video signal is selected for the final image. Through that simple process, the weatherperson is extracted from the background screen and superimposed on top of the images in the second video signal. The chroma-key process is simple enough to be performed in real time. However, the extracted image is always considered to be in front of the images from the second video signal. That may or may not result in a realistic looking final product. Furthermore, because the extracted image is always in front of the images from the second video signal, there is no physical or geometrical interaction allowed between the extracted image and the images of the second video signal.
Other methods for combining video signals are disclosed in U.S. Pat. No. 5,400,080 entitled Apparatus And Method For Combining Video Signals Representing Images Having Different Depths, U.S. Pat. No. 5,353,068 entitled Video Signal Combining Apparatus And Method, and U.S. Pat. No. 5,280,337 entitled Depth-Based Video Combining. Each of those patents discloses a method which uses depth information for combining one or more video signals. However, the patents do not disclose how to obtain the needed depth information, which is a non-trivial problem if pixel by pixel depth information is to be provided in real time for standard video signals having a frame rate of thirty frames per second. Moreover, there is no recognition in the aforementioned patents of how images from the combined video signals might interact, e.g. one image might cast a shadow on an image which is behind it in the combined video. Thus, the need exists for a method of using depth as the key for merging two video signals in real time in a way which enables the images from the combined video to interact with one another.
SUMMARY OF THE INVENTION
The present invention is directed to a method, and to an apparatus for carrying out the method, by which objects in real images and synthetic images can dynamically interact with each other in a geometrically correct manner. In this invention, a 3-D camera is used for acquiring video images and depth information for each pixel of a video image in real time. The 3-D geometry of every pixel obtained in real time is used for calculation of the geometrical relationship with objects in a synthetic image. The method is comprised of the steps of providing a first signal containing depth and image information per pixel about a real image. A second signal containing depth and image information per pixel about a synthetic image (which may include virtual images) is provided. The depth information corresponding to the real image and the depth information corresponding to the virtual or synthetic image for each pixel is compared. Based on the comparison, either the image information corresponding to the real image or the image information corresponding to the synthetic image is selected. The selected information is then combined on a per pixel basis
The method and apparatus of the present invention allow for the combination, based on depth information, of two (or more) images, one real and one synthetic, in real time. Because the depth information for each pixel is known, any interaction between pixels can be determined. For example, if two pixels have the same depth information, they occupy the same point in space, which means that the sound of a collision may be generated. By knowing the relationship of a synthetic object with respect to a light source, the synthetic object may cast a shadow on a real object, or vice versa. By having real time depth information for the images to be combined, the images can be combined in a much more realistic manner. Those advantages and benefits of the present invention, and others, will become apparent from the Description of the Preferred Embodiments hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures wherein:
FIG. 1 is a diagram illustrating an implementation of the merging and interaction of a real image and a synthetic image according to the present invention;
FIGS. 2A and 2B are examples of an intensity map and a depth map, respectively, for a synthesized image;
FIGS. 3A and 3B are examples of an intensity map and a depth map, respectively, for a real image;
FIG. 4 is an example of an output image;
FIG. 5 is a diagram illustrating an implementation of the present invention using a pixel-by-pixel depth key switch.
FIG. 6 is a diagram illustrating an implementation of the present invention using a pixel-by-pixel depth key switch and a image mask for a real object;
FIG. 7 is a block diagram illustrating the process for calculating a shadow cast by a synthetic image onto a real image;
FIG. 8 is an example of an image with a shadow cast by a synthetic object;
FIG. 9 is a diagram illustrating the process for calculating the generation of a sound resulting from the collision of a synthetic object and a real object;
FIG. 10 is a diagram illustrating the creation of a reflection in a synthetic mirror; and
FIG. 11 is a diagram which aids in the description of the process of creating a reflection in a synthetic mirror.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, the present invention is directed to a system 10 and method of combining, in real time, objects in real images and synthetic images. The system 10 is comprised of an image rendering system 12 which may be a commercially available CAD system for producing images for which depth information is available for each pixel. The synthetic image may be comprised of a depth image or depth map 14 (an example of which is seen in FIG. 2B) and a map 15 (an example of which is seen in FIG. 2A) which contains color, intensity, or other image information.
A 3-D camera 17 is provided to produce real time images of a real object 19. The 3-D camera 17 outputs video images and 3-D geometry in real time. The real-time acquisition of images and depth information is essential for dynamic interaction between real and synthetic objects. At the output of the 3-D camera 17 the 3-D geometry of a real scene is represented by a pixel-by-pixel depth map 20 (an example of which is seen in FIG. 3B) while the color, intensity, etc. is represented by a pixel-by-pixel map 21 (an example of which is seen in FIG. 3A). A video rate stereo machine is one type of device which may be used for such a 3-D camera 17. Such machines are disclosed in, for example, T. Kanada et al., A Stereo Machine for Video Rate Dense Depth Mapping and Its New Applications, CVPR 96, 1996, which is hereby incorporated by reference.
The 3-D coordinate (x,y,z) of an object at image coordinates (i,j) can be calculated by the following equation:
x=XR (i,j,DR(i,j))
y=YR (i,j,DR(i,j))
z=ZR (i,j,DR(i,j))
where DR(i,j) is the depth value of the real object 19 at (i,j) and XR, YR, and ZR are the camera geometry functions of the 3-D camera 17. Those camera geometry functions can be determined by existing camera calibration procedures. See, for example, R. Tsai, A versatile camera calibration technique for high-accuracy 3D machine vision meteorology using off-the-shelf TV cameras and lenses, IEEE Journal of Robotics and Automation, Vol. RA-3, No. 4, August 1987, and S. Kimura, et al., CMU Video-Rate Stereo Machine, Mobile Mapping Symposium, Columbus, Ohio, May 24-26, 1995, both of which are hereby incorporated by reference. If the z axis is parallel to the camera direction, then the z component can be simply written as:
z=DR(i,j)
As mentioned, synthetic images with their own 3-D geometry can be created by existing computer graphics technique. At the output of the image rendering system 12, the 3-D geometry of a synthetic scene is represented by pixel-by-pixel depth information DS(i,j). The viewing conditions of the synthetic images should be the same as the viewing conditions of the 3-D camera 17. In other words, the "camera geometry functions" of the synthetic image (XS, YS, ZS) have to be the same as those of the 3-D camera's (XR, YR, ZR). The synthesized images should be synthesized in real time if objects in the images move or the3-D camera geometry changes. Surface features of synthetic objects such as transparency FS1, reflectivity FS2, etc. are defined explicitly, so that kind of information can be output pixel-by-pixel if needed and stored with map 15.
If there is a specific object in a synthetic image which to be combined, an image mask MS(i,j) with the following definition can be created by the image rendering system 12: ##EQU1## If there is no specific object for processing, and the entire image is to be used, an image mask value should be set at "1" for all values of (i,j).
If there is a specific object in a real image which is to be combined, an image mask MR(i,j) with the following definition can be created by an image mask generator 22, which may be a specific software routine: ##EQU2## An image mask for an object in a real image can be created using color information or depth information from the 3-D camera 17.
A typical method of creating a mask image with color information is chroma keying which extracts the region which is not in the specific color. An image mask MR(i,j) also can be created by comparing the depth information DR(i,j) and a background depth information DRb(i,j) which is captured by a 3-D camera without the specific real object: ##EQU3## If there is no specific object for processing and the entire image is to be used, an image mask value should be set at "1" for all values of (i,j).
After the maps 14, 15, 20, 21 have been created, the geometrical relationship between objects in the real and the synthetic images is examined and interaction between objects is determined as shown by box 23 in FIG. 1. The typical output is one or more output images IO28 (an example of which is seen in FIG. 4) where real and synthetic images are merged and a real object and a synthetic object interact with each other. Other output signals 28 such as sounds, lights, etc., are also possible. Sounds and other output signals can be generated with existing signal generators 29. The images IO28, whether they are individual frames or a series of frames forming a video, can be displayed using any suitable monitor 27.
In the most general form, the output image IO(i,j) is determined with the following function:
IO (i,j)=io (i,j,IR,IS,DR,DS,MR,MS,FS.sub.1,FS.sub.2, . . . )(1)
where IR is a real image from the 3-D camera 17, DR is the pixel-by-pixel depth information corresponding to IR, IS is the synthetic image, DS is the pixel-by-pixel depth information corresponding to IS, MR is the image mask of an object in the real image, MS is the image mask of an object in the synthetic image, and FS 1 , FS 2 . . . are additional pixel-by-pixel information attached to the synthetic image. Note that on the right hand side of equation (1), IR, IS, etc. are arrays which have dimensions of image size and not the local values at (i,j) (IR(i,j), IS(i,j), etc.). IR, IS, etc. also can be sequences arrays if needed. If IR and IS are color images, IR is the bundle of three image arrays IRr, IRg, and IRb which stand for red, green, and blue bands of the image IR, respectively, and is the bundle of three image arrays ISr, ISg, and ISb.
Examining objects in the real and the synthetic images can be accomplished because both the real and synthetic images have pixel-by-pixel depth information. Therefore, each pixel of the real and the synthetic images can have 3-D coordinates. That means that an output image can be created to reflect the 3-D relationship of all image pixels of the real and the synthetic images. Inputs are received from both the real and synthetic world in real time. Therefore, an object (typically a person) in the real world can dynamically interact with the synthetic (or virtual) world in real time.
The following illustrates some examples of how the geometrical relationship may be calculated.
Depth Keying
Depth keying is a technique to merge real and synthetic images in a geometrically correct manner by using the pixel-by-pixel depth information (depth map) to control the image information used in the final image. As shown in FIG. 5, this technique is implemented by a depth key switch 24 which performs the function of determining the geometrical relationship of box 23. For each pixel, the depth key switch 24 compares depth information of the real and the synthetic images and routes the pixel value of the image which is nearer to the camera. Thus, the foreground image for each pixel can be determined and image created where each part of a real and a synthetic object occlude each other correctly as illustrated in the output image 28 of FIG. 4.
The function of the depth key switch 24 can be written in the following form. ##EQU4## As shown in FIG. 6, the depth key switch 24 can also be used with the image mask generator 22. Thus, when there is some specific object in the real image, equation (2) can be written as following: ##EQU5## An example of a software routine, written in C language, for implementing the functionality of equations (2) and (3) is four in Appendix A.
Creating a Shadow Cast by a Synthetic Object onto a Real Object
A shadow cast by a synthetic object onto a real object can be created by considering the geometrical relationship between a synthetic object, a real object, and a light source. FIG. 7 is a diagram of that process. In FIG. 7, the function of the block 23 is performed by a software routine 38, an example of which, written in C language, is found in Appendix B. Basically, the shadow is created by exchanging the relevant portions of the real and synthetic images.
In FIG. 7, the routine 38 begins at step 40 where the position of the shadow on the real image IR is determined. A pixel on a real object is considered as being in the shadow of a synthetic object when a pixel on a synthetic object lays in the direction to a light source. If V rs (i,j,s,t) is a 3-D vector from the position of IR(i,j) to the position of IS(s,t), and V ro (i,j) is a 3-D vector from the position of IR(i,j) to the position of the light source, then a mask Msh(i,j) can be created which has a value of "1" if IR(i,j) is in the shadow of a synthetic object: ##EQU6## where the operator (⊕) is the inner product and ⊖ th is a threshold angle.
A new image IR' containing the shadow is created at step 42 with the following equation. ##EQU7## where Sh is a function for calculating a pixel value in a shadow. For example, Sh can be as below:
Sh (IR (i,j))=k·IR (i,j)
where k is a constant value between 0 and 1.
Finally, at step 44, IR' and IS are merged by, for example, the depth keying method described above. An example of such an image 46 is illustrated in FIG. 8.
Generating Sound Resulting from the Collision of a Real Object and a Synthetic Object
In the geometrical calculation process, it is possible to compute the geometrical condition for generating signals other than images. For example, a sound can be generated when a collision between a synthetic and a real object occurs. That process is illustrated in FIG. 9 wherein the computation of the geometrical condition for generating signals other than images is performed by a software routine 48 which may be incorporated into the functionality of box 23.
The condition of the collision of a real object and a synthetic object can be denoted with a pixel count threshold N th and a collision distance threshold D th :
N.sub.th <ΣMR (i,j)·MD (i,j)
where ##EQU8## A sound generator 50, or other appropriate signal generator, may be provided to produce an audible output.
Creating a Reflection in a Virtual Mirror
A virtual mirror which reflects both real and synthetic objects can be created by considering the geometrical relationship between a synthetic object, a real object, a virtual mirror, and the camera position. That process can be implemented as a software routine 52 as part of the functionality of box 23 as shown in FIG. 10. The process begins at step 54 by defining a virtual mirror (56 in FIG. 11), which contains the following information:
Mm(i,j): an image mask which is 1 if a pixel (i,j) is on the mirror, otherwise 0.
Vm(i,j): unit vectors of a mirror surface direction at a pixel (i,j).
Dm(i,j): depth information of a mirror surface at a pixel (i,j).
Each 3-D position of a mirror surface at a pixel (i,j) is calculated with the camera geometry functions and depth information. Referring to FIG. 11, Vcm(i,j) is a vector from the camera position to the mirror's 56 surface. If Mm(i,j)=1, a unit vector Vref(i,j) of the direction from the mirror's 56 surface to an object which is supposed to be reflected by the mirror 56 is: ##EQU9## Thus, we can denote the condition that an image pixel whose position from the camera (V) is on the direction Vref(i,j) from the mirror's 56 surface (Vcm(i,j)) as follows: ##EQU10## where ⊖ th is a threshold angle. That condition can be examined for each pixel of IR(i,j) and IS(i,j) using pixel-by-pixel depth information DR and DS, respectively. That examination can be eliminated for the pixels whose image mask value MR(i,j) or MS(i,j) is 1. The reflected image pixel is the pixel which has the smallest value of |V-Vcm(i,j)] among the pixels which satisfies that condition. Applying that condition for all IR and IS, we get a reflected image Im(i,j) at step 58. If no pixel of IR or IS satisfies that condition, Im(i,j) is assigned a default intensity (or color), for example, zero (or black).
With an image mask Mm and pixel-by-pixel depth information Dm, the reflected image IM can be merged with a synthetic image IS by, for example, depth keying as shown by step 60. The image information IS', DS' output by step 60 may then be merged, for example, by depth keying as shown by step 62. This time, the depth information of IS' (i.e., DS') has the following definition: ##EQU11##
The same principals may be used to enable synthetic images to be reflected in real mirrors or other similarly reflective objects.
Set forth in the Appendices hereto is specific software, i.e. specific program code segments, that are employed to configure a general purpose microprocessor to create specific logic circuits. Those circuits are intended to be "means" corresponding to any claimed means limitations. Those of ordinary skill in the art will recognize that many aspects of the present invention such as the image rendering system 12, image mask generator 22, and the functionality of box 23, as well as the generation of appropriate output signals, may be implemented in software. When implemented in software, the software may be carried by any appropriate computer media, such as disks, CD ROMs, tapes, etc.
While the present invention has been described in conjunction with preferred embodiments thereof, many modifications and variations will be apparent to those of ordinary skill in the art. The foregoing description and the following claims are intended to cover all such modifications and variations.
APPENDIX A__________________________________________________________________________Depth-Key C__________________________________________________________________________#include <stdio.h> #include <stdlib.h> /* z keying */ /* This code is for using with mr. */ z.sub.-- key(orig,depth,mr,origs,depths,out,II.sub.-- OUT,JJ.sub.--OUT)unsigned char *orig; /* a real image (intensity) IR */ float *depth; /* depth information for the real image DR */ int *mr; /* an image mask for a real image MR */ unsigned char *origs; /* a synthetic image (intensity) IS */ float *depths; /* depth information for the synthetic image DS */ unsigned char *out; /* output image (intensity) IO */ int II.sub.-- OUT; /* image row size */ int JJ.sub.-- OUT; /* image column size */ {int i; unsigned char *orgptr,*orgsptr,*outptr; float *dptptr,*dptsptr; int *mrptr; orgptr = orig; dptptr = depth; orgsptr = origs; dptsptr = depths; outptr = out; mrptr = mr; for(i=0;i<JJ.sub.-- OUT*II.sub.-- OUT;i++) { if((*dptptr)<=(*dptsptr)&&(*mrptr)==1) *outptr = *orgptr;else *outptr = *orgsptr;/* if you do not want to use mr, please use following code */ /* if((*dptptr)<=(*dptsptr)) *outptr = *orgptr;else *outptr = *orgsptr;*/ dptptr++; orgptr++; orgsptr++; dptsptr++; outptr++; mrptr++;}__________________________________________________________________________
APPENDIX B__________________________________________________________________________shadow c__________________________________________________________________________#include <stdio.h> #include <stdlib.h> #include <math.h> #define ANGLE.sub.-- THRESHOLD 0.05 #define SHADOW.sub.-- COEF 0.50 typedef struct { float x; float y; float z; } XYZ; typedef XYZ CRD; extern convCrdToXyz(); /* convert column, row, depth information to 3-d coordinates (x,y,z) (Not disclosed here. Use some proper function) convCrdToXyz(crd,xyz)CRD *crd; Column, Row, and Depth information (input) XYZ *xyz; X,Y,Z (output) { } *//* calculate the inner product of v1 and v2 */ double inner.sub.-- product(v1,v2) XYZ *v1,*v2; { return((double)((v1->x)*(v2->x)+(v1->y)*(v2->y)+(v1->z)*(v2->z))); /* subtract xyz2 from xyz1 */ subXyz(xyz1,xyz2,outxyz) XYZ *xyz1,*xyz2,*outxyz; { outxyz->x = (xyz1->x) - (xyz2->x); outxyz->y = (xyz1->y) - (xyz2->y); outxyz->z = (xyz1->z) - (xyz2->z);} /* calculate the length of vec */ double vabs(vec) XYZ *vec; { return((double)((vec->x)*(vec->x)+(vec->y)*(vec->y)+(vec->z)*(vec->z)));} /* Determination of pixels in shadow on IR */ makeMsh(orgdpt,mr,backdpt,ms,xyzlight,II.sub.-- OUT,JJ.sub.-- OUT,msh)float *orgdpt; /* depth information for a real image */ int *mr; /* an image mask for a real image */ float *backdpt; /* depth information for a synthetic image */ int *ms; /* an image mask for a synthetic image */ XYZ xyzlight; /* coordinates of a light origin */ int II.sub.-- OUT; /* image row size */ int JJ.sub.-- OUT; /* image column size */ int *msh; /* an image mask for a virtual shadow (output) */ {int i,j,k,l; CRD crd; XYZ xyz,xyz2; XYZ vrs,vro; /* Vrs, Vro */ double avrs,avro; double costh; /* Cos(ANGLE.sub.-- THRESHOLD) */ double inp;costh = cos(ANGLE.sub.-- THRESHOLD); for(i=0;i<II.sub.-- OUT;i++) { for(j=0;j<JJ.sub.-- OUT;j++) { if(mr[i*JJ.sub.-- OUT+j]==1) { msh[i*JJ.sub.-- OUT+j]=0;/* calculation of Vro */ crd.z = orgdpt[i*JJ.sub.-- OUT+j]; crd.x = j; crd.y = i; convCrdToXyz(&crd,&xyz); subXyz(&xyz,&xyzlight,&vro); for(k=0;k<II.sub.-- OUT;k++) { for(1=0;1<JJ.sub.-- OUT;1++) {/* calculation of Vrs */ crd.z = backdpt[k*JJ.sub.-- OUT+1]; crd.x = l; crd.y = k; convCrdToXyz(&crd,&xyz2); subXyz(&xyz,&xyz2,&vrs); inp = inner.sub.-- product(&vrs,&vro); avrs = vabs(&vrs); avro = vabs(&vro); if(((inp/avrs/avro)>costh)&&(ms[k*JJ.sub.-- OUT+1]==1)) msh[i*JJ.sub.-- OUT+j]=1; } }} }}} /* creation of a shadow on IR */ addShadow(org,msh,II.sub.-- OUT,JJ.sub.-- OUT)unsigned char *org; /* a real image (intensity) */ int *msh; /* an image mask for a virtual shadow (output) */ int II.sub.-- OUT; /* image row size */ int JJ.sub.-- OUT; /* image column size */ {int i,j; for(i=0;i<II.sub.-- OUT;i++) { for(j=0;j<JJ.sub.-- OUT;j++) { if(msh[i*JJ.sub.-- OUT+j]==1) org[i*JJ.sub.-- OUT+j] = (unsigned char)((org[i*JJ.sub.-- OUT+j])*SHADOW.sub.-- COEF);} }} /* making a virtual shadow cast by a synthetic object on a real object*/ makeShadow(org,orgdpt,mr,back,backdpt,ms,xyzlight,II.sub.-- OUT,JJ.sub.-- OUT,msh,out)unsigned char *org; /* a real image (intensity) */ float *orgdpt; /* depth information for the real image */ int *mr; /* an image mask for a real image */ unsigned char *back; /* a synthetic image (intensity) */ float *backdpt; /* depth information for the synthetic image */ int *ms; /* an image mask for a synthetic image */ XYZ xyzlight; /* coordinates of a light origin */ int II.sub.-- OUT; /* image row size */ int JJ.sub.-- OUT; /* image column size */ int *msh; /* an image mask for a virtual shadow (output) */ unsigned char *out; {/* Determination of pixels in shadow on IR */ makeMsh(orgdpt,mr,backdpt,ms,xyzlight,II.sub.-- OUT,JJ.sub.-- OUT,msh);/* creation of a shadow on IR */ addShadow(org,msh,II.sub.-- OUT,JJ.sub.-- OUT);/* z keying */ z.sub.-- key(org,orgdpt,mr,back,backdpt,out,II.sub.-- OUT,JJ.sub.-- OUT);} /* z keying */ z.sub.-- key(orig,depth,mr,origs,depths,out,II.sub.-- OUT,JJ.sub.--OUT)unsigned char *orig; /* a real image (intensity) */ float *depth; /* depth information for the real image */ int *mr; /* an image mask for a real image */ unsigned char *origs; /* a synthetic image (intensity) */ float *depths; /* depth information for the synthetic image */ unsigned char *out; /* output image (intensity) */ int II.sub.-- OUT; /* image row size */ int JJ.sub.-- OUT; /* image column size */ {int i; unsigned char *orgptr,*orgsptr,*outptr; float *dptptr,*dptsptr; int *mrptr; orgptr = orig; dptptr = depth; orgsptr = origs; dptsptr = depths; outptr = out; mrptr = mr; for(i=0;i<JJ.sub.-- OUT*II.sub.-- OUT;i++) { if((*dptptr)<=(*dptsptr)&&(*mrptr)==1) *outptr = *orgptr;else *outptr = *orgsptr;dptptr++; orgptr++; orgsptr++; dptsptr++; outptr++; mrptr++; }}__________________________________________________________________________
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A method for merging real and synthetic images in real time is comprised of the steps of providing a first signal containing depth and image information per pixel about a real image. A second signal containing depth and image information per pixel about a synthetic image is provided. The depth information corresponding to the real image and the depth information corresponding to the synthetic image for each pixel are compared. Based on the comparison, either the image information corresponding to the real image or the image information corresponding to the synthetic image is selected and combined. Because the image information is compared based on depth, any interaction such as occluding, shadowing, reflecting, or colliding can be determined and an appropriate output generated
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a granular biomass burning heating system. Any type of granular biomass can be used as fuel. Grains, such as corn and wheat, have become popular fuel sources for furnaces and stoves. Various stoves and furnaces of a type to burn such materials are known.
[0002] In any type of solid fuel burning system, regardless of the type of fuel being used, it is desired to increase the efficiency of the system so that the amount of heat produced and utilized by the system is relatively high. It is further desired to decrease the lag time between unit start up and when heat is evident to the user. Further, some known biomass fuel furnaces have problems with incomplete burning of the fuel. Therefore it is desirable to provide a biomass furnace which provides for complete burning of the fuel.
[0003] One of the problems associated with some grain burning heating systems is back burning. Many granular biomass burning heating systems include an auger-type fuel feed. Back burning occurs when fuel located in this auger begins to burn before it is introduced to the burn pot. It is desirable to provide a granular biomass burning heating system with a fuel feed designed to prevent back burning.
[0004] Some known biomass furnaces have problems associated with the controls. For example, the heat of the furnace can be difficult to control. It is therefore desirable to provide a user friendly furnace, which utilizes a computer control unit to function on its own with very little human intervention. It is further desirable to provide a system which utilizes a smart logic thermal controller to reduce the human intervention necessary to keep the output of the furnace at a consistent or desirable temperature.
[0005] Additional problems included fly ash build up in previous furnaces. Fly ash can decrease the efficiency of the system, so it is desirable to include a way to remove the build up of ash from a biomass furnace. Additionally, incomplete combustion can clog the system by creating clinkers, or hardened lumps of unburned material, and can also decrease efficiency. Therefore it is desirable provide a biomass furnace which removes clinkers and also promotes complete combustion.
[0006] Although many designs for granular biomass burning heating systems have been considered, improved designs are continually being sought to improve the technology. It is an object to the present invention to provide a novel granular biomass burning heating system.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved granular biomass burning heating system. The apparatus includes a three stage heat exchanger, wherein the heat exchanger stages are connected in parallel relation to each other.
[0008] The apparatus may further include a linear fuel infeed system including a self closing door to minimize back burning. The apparatus may also include a venturi design to direct smoke and fire away from the self closing door when the unit is in operation.
[0009] The apparatus may further include an air inducement system by which air is supplied to the burn pot from the side, center, and bottom of the burn pot.
[0010] The apparatus may further include a wash down system which includes a water supply pump, a water filter, a baffled water sediment tank, and a rotatable shaft with a plurality of holes formed there to remove ash and other debris from the furnace. The apparatus may recycle water and cleaning solution within the process.
[0011] The invention may include a computer controller which automatically controls features of the furnace to automatically operate the system.
[0012] The invention may include a smart thermostat and a variable speed air inducer fan. The unit may utilize the smart thermostat to determine when and how long to use the high burn status before selecting the intermediate burn, low burn, burnout, or wash down status. This allows the unit to adjust itself to use the minimum amount of fuel to achieve maximum heating results. The computer chooses the heat status required for to further increase efficiency of the unit. The computer also decreases the lag time between the call for heat and actual heat. This units starts at high burn to generate maximum heat initially and through the process the unit turns down heat output when necessary to limit wasted heat.
[0013] The invention may further include a plurality of sensors connected to the computer controller such that the system is controlled based on input from the plurality of sensors.
[0014] Additional objects and advantages of the invention will be set forth in the following description, or may be learned through practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a simplified side plan view of the furnace of the present invention.
[0016] FIG. 2 is an interior view of lower portion of the furnace of the present invention, including the fuel infeed system.
[0017] FIG. 3 is an interior view of the top portion of the furnace of the present invention.
[0018] FIG. 4 is an interior view of the furnace of the present invention.
[0019] FIG. 5 is an interior view of the bottom portion of the furnace of the present invention showing the air intake system.
[0020] FIG. 6 is an interior view of the bottom portion of the furnace of the present invention showing the water intake system, the ash auger, and the baffled sediment tank.
[0021] FIG. 7 is a simplified interior view of the furnace of the present invention which shows the locations of the system sensors.
[0022] FIG. 8 is an interior view of the fuel hopper attached to the fuel infeed system.
[0023] FIG. 9 is a top view of a portion of the air intake system.
[0024] FIG. 10 is an interior view from the top of the baffled sediment tank and the ash auger.
[0025] FIG. 11 is a top view of the ignition plate.
[0026] FIG. 12 is a flow chart depicting the initial safety protocol.
[0027] FIG. 13 is a flow chart depicting the ignition sequencing protocol.
[0028] FIG. 14 is a flow chart depicting the high burn sequencing protocol.
[0029] FIG. 15 is a flow chart depicting the choosing sequence.
[0030] FIG. 16 is a flow chart depicting the low burn sequencing protocol.
[0031] FIG. 17 is a flow chart depicting the intermediate burn sequencing protocol.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0033] FIG. 1 shows the furnace 2 of the presenting invention in a very simplified form. The furnace 2 has a lower portion 54 and an upper portion 52 . Within the lower portion 54 of the furnace 2 is a burn pot 6 and a first stage heat exchanger 10 . A second stage heat exchanger 12 lies in both the lower portion 54 and the upper portion 52 of the furnace. The upper portion 52 of the furnace 2 also includes a third stage heat exchanger 14 . The furnace 2 is preferably controlled by a computer 16 . A plurality of sensors (shown in FIG. 7 ) are located throughout the furnace 2 to measure conditions. The data from these sensors is utilized by the computer 16 to run the furnace 2 . The furnace 2 includes an ash removal system 18 , an air inlet system 20 , and a fuel inlet system 22 . The furnace 2 is optionally surrounded by an insulated jacket 24 .
[0034] The furnace 2 is preferably cylindrical in shape. Attached to the furnace 2 is a computer controller 16 , an air infeed 20 , a fuel infeed 22 , a water infeed 62 , a water outlet 28 , a water pump 30 , fuel and ash rotator 32 , a washdown pipeshaft motor 34 , a wash down and ash removal caseway 36 , and a baffled sediment tank 38 .
[0035] The preferred embodiment of the present invention includes three stages of heat exchangers which can best be seen in FIG. 4 . The first stage of the heat exchanger is a spiral shaped water jacket 40 surrounding the burn pot 6 . The second stage is a set of heat exchanger heli-coils 42 which are strapped to ash funnels 44 or heli-coils 42 supported by tripod legs 46 located in the furnace 2 . The third stage is a fine finned heat exchanger 48 open at the bottom and baffled at the top. The third stage heat exchanger is located at the top of the furnace 2 . The use of a three stage heat exchanger system increases the efficiency of the heat transfer of the system.
[0036] The furnace 2 preferably also includes condensation collectors. One bushel of corn at 10 percent moisture produces 5.6 pounds of water. This water can douse the flames if it is not removed from the system. The condensation collectors carry water away from the center of the burn pot 6 . The first and third ash funnels 44 can additionally suffice as a condensation collector. The condensation travels along the funnel 44 to the ash caseway 36 . In the preferred embodiment, an ash/condensate trough 50 located at the point where the lower portion 54 and upper portion 52 of the furnace 2 connect collects condensation as it travels towards and down the ash caseway 36 . An ash wiper 56 associated with the trough 50 pushes the condensation towards the ash caseway 36 . A third condensation tray 58 which is cupped upward can be located underneath the fine finned heat exchanger 48 so that water hits the tray 58 and is removed from the system by a pipe 60 which deposits the condensation in the baffled sediment tank 38 . It is desirable to remove the condensation from the furnace 2 to increase the efficiency of the furnace 2 .
[0037] Each stage of heat exchanger is supplied with water. The water inlet system is shown in FIG. 6 . The water is provided to the furnace inlet pipe 62 which is connected to the heating system. It is contemplated that this water may come from a coil within a forced air furnace or heating pipes within the floor of the area to be heated by the furnace (not shown). The furnace inlet pipe 62 serves a water pump 30 which is located outside of the furnace 2 , near the bottom of the burn pot 6 . A system drain valve is preferably located in the furnace inlet pipe 62 near the water pump 30 . The water is pumped into the furnace 2 through the furnace inlet pipe 62 . In the preferred embodiment, the furnace inlet pipe 62 splits into a first supply pipe 66 and an inlet manifold 68 . The first supply pipe 66 supplies the spiral water jacket 40 . The inlet manifold 68 continues up the side of the furnace 2 on the outside of the furnace 2 , but underneath the optional insulating jacket 24 . The inlet manifold 68 supplies each heat exchanger heli-coil 42 . As seen in FIG. 3 , near the top of the furnace 2 the inlet manifold 68 supplies the fine finned heat exchanger 48 . Through this configuration the heat exchangers are set up in parallel relation to each other such that each heat exchanger stage is provided with fresh heating system water. The inlet manifold 68 continues past the fine finned heat exchanger 48 and exits the optional insulated jacket 24 . The inlet manifold 68 ends in an air bleed off valve 70 .
[0038] This inlet configuration puts the stages of the heat exchanger in parallel rather than in series. Because each stage of the heat exchanger is getting fresh heating system water, rather than water which has been utilized in a previous stage heat exchanger, the efficiency of heat exchange in the system is increased. As discussed above, condensation problems are overcome by condensation collection system. This is because the efficiency of a heat exchanger depends in part on the temperature differential between the two fluids in the system. Water which has been used in a previous stage of the heat exchanger would be warmer than fresh heating system water entering the system, and therefore is able to accept less heat from the air in the furnace 2 , resulting less efficient heat exchange. The water flowing through some of the heli-coils 42 may be temperature regulated. In this case, a device would be present which would allow water to heat up in the heli-coils 42 before being allowed to flow out of the heli-coils 42 . This improves the efficiency of the system because water which is too cold can cause condensation, which if not properly removed, can douse the fire in the burn pot 6 .
[0039] The first stage heat exchanger is a spiral water jacket 40 . The water jacket 40 is formed on the inner wall of the burn pot 6 and extends around the lower portion 54 of the furnace 2 . The water jacket 40 forms a spiral path for the water flowing through the system. A water jacket pressure relief valve 41 is located at the top of the water jacket 40 , near the area where the lower portion 54 and the upper portion 52 of the furnace mate.
[0040] As seen in FIG. 4 , the second stage heat exchanger includes a plurality of heat exchanger heli-coils 42 . The preferred embodiment includes eleven heli-coils 42 , four lower heli-coils 42 in the lower portion 54 of the furnace 2 and seven upper heli-coils 42 in the upper portion of the furnace 2 . However, it is contemplated that any other suitable number of heli-coils 42 could be utilized. Each heli-coil 42 is made of a pipe which is tightly wound, such that the rings of the heli-coils 42 are almost touching. The pipe is wound until it becomes too tight and would kink if further wound, leaving the center portion of the heli-coil 42 open (not shown).
[0041] Each of the heli-coils 42 in the lower portion 54 of the furnace 2 are strapped to the bottom side of an ash funnel 44 . The ash funnels 44 are attached to the internal wall of the furnace 2 . The ash funnels 44 are removable for maintenance of the furnace 2 . Each heli-coil 42 is fed from the inlet manifold 68 . After the water flows through a heli-coil 42 , the water flows to the outlet manifold 80 . The lower portion 54 of the furnace 2 also includes heat deflectors 72 attached to the second and fourth sets of ash funnels 44 . The heat deflectors 72 have a shape similar to a funnel, and force the air from the furnace 2 to take a less direct path, thus exposing the air to more of the heat exchanger heli-coils 42 , which will increase the efficiency of the furnace 2 .
[0042] The upper portion 52 of the furnace 2 includes several upper heli-coils 42 ; in the preferred embodiment seven heli-coils 42 are utilized. The upper portion 52 heli-coils 42 are strapped to three tripod legs 46 which rest into recessed notches formed in the furnace 2 inner wall. The tripod legs 46 rise upward toward the washdown rotator shaft sleeve 74 . The tripod legs 46 are also attached to washdown rotator sleeve 74 . The tripod legs 46 are hingedly attached to the rotator sleeve 74 . Each heli-coil 42 is fed from the inlet manifold 68 . After the water flows through a heli-coil 42 , the water flows to the outlet manifold 80 .
[0043] A plurality of heat deflecting baffles 76 are also located in the upper portion 52 of the furnace 2 . In the preferred embodiment of this invention, seven baffles 76 are disclosed. The baffles 76 are aligned such that each baffle 76 is located just below a heli-coil 42 . The configuration of the baffles 76 and heli-coils 42 is such that the air in the furnace 2 does not have a straight path up the height of the furnace 2 . Rather, the air will be deflected by the baffle 76 and forced to flow around the baffles 76 . In this manner, the hot air from the furnace 2 will have more contact with the heat exchanger heli-coils 42 , which will result in more efficient heat transfer.
[0044] In the preferred embodiment of the invention, the third stage of the heat exchanger system is a fine finned heat exchanger 48 . However, it is contemplated that any other suitable type of heat exchanger could be utilized as a third stage heat exchanger. The fine finned heat exchanger 48 is formed of a pipe which has a diameter which is smaller than the diameter of the heli-coils 42 . This pipe is bent to create banks of finned tubes. The fine finned heat exchanger 48 is surrounded around its circumference by a removable shroud 78 . This shroud 78 forces the air from the furnace 2 to flow through the fine finned heat exchanger 48 , rather than flow around it. Water enters the fine finned heat exchanger 48 from the inlet manifold 68 . After the water has flowed through the heat exchanger it flows into the outlet manifold 80 . After the air from the furnace 2 flows through the fine finned heat exchanger 48 , the air exits the system through a pitched down exhaust 82 .
[0045] FIG. 5 shows the air inlet system 20 . The preferred embodiment of the furnace 2 has a three part air inducer system. A variable speed blower 84 is located on the outside of the furnace 2 . The blower 84 is connected to an air duct 86 . The air duct 86 extends around the diameter of the burn pot 6 . The air duct 86 is located near the bottom of the burn pot 6 , within the water jacket 40 , but below the spirals of the water jacket 40 . An air inducing donut 88 is formed with a plurality of air holes such that air is inducted to the burn pot 6 from the outer walls of the burn pot 6 . The air inducing donut 88 is immersed in the water jacket 40 and stands up from bottom of the water jacket 40 approximately ½ inch away from water jacket 40 to provide a cooling effect on three sides or the air inducing air inducing donut 88 . This configuration eliminates warping of the steel. The air duct 86 is provided with a split union 90 before the air inducing donut 88 , such that air is supplied through a secondary air duct 86 to the ash tray 92 below the burn pot 6 .
[0046] The air which is supplied to the ash tray 92 below the burn pot 6 is induced to the burn pot 6 in two manners. First, a central air inducer pipe 94 extends through the ignition plate 96 into the base of the burn pot 6 . This air inducer pipe 94 is preferably 1½ inches in diameter and has a pattern of small air holes thereon. The air holes are preferably ¼ inch holes which introduces air to the center of the burn pot 6 . Second, the ignition plate 96 is formed with a plurality of slots 98 . The air can travel up from the ash tray 92 through the slots 98 to enter the burn pot 6 . The ignition plate 96 stands off ⅛ inch from the water jacket 40 . This gap also allows air to enter the burn pot 6 . By this configuration, air is introduced from the sides, bottom, and center of the burn pot 6 . This configuration provides air nearest to the combustion, which increases efficiency. The speed of the blower 84 rotation is determined by desired heat output set forth by smart thermostat or by the manual setting.
[0047] A safety door 100 stops air flow in event of system malfunction. The safety door 100 is controlled by a normally closed solenoid 102 which opens the safety door 100 for operation. An electromagnet 104 holds the safety door 100 open during operation. By utilizing an electromagnet, rather than the solenoid to hold the safety door 100 open for extended periods of time, the amount of noise created by the unit is reduced. If power is cut, the electromagnet 104 will release the safety door 100 and the safety door 100 is returned to its normally closed position which will prevent air infeed.
[0048] The preferred embodiment of the fuel inlet system is shown in detail in FIG. 2 . The fuel inlet system has a linear actuator dosing mechanism. A furnace hopper 108 feeds fuel into a fuel channel 112 . The fuel channel 112 extends from the furnace hopper 108 into the burn pot 6 . A deflecting shroud 114 is formed inside the burn pot 6 and is connected to the inner wall of the burn pot 6 near the outside of the fuel channel 112 . The deflecting shroud 114 extends from the sidewall of the burn pot 6 and is angled up towards the center of the furnace 2 . The shroud 114 extends past the door 116 to the fuel channel 112 , and then has a slight cutback before extending vertically upward past the fuel channel door 116 . After the fuel channel door 116 , the shroud 114 extends back towards the inner wall of the furnace 2 . This configuration deflects the air from the door 116 of the fuel channel 112 , and increases the airspeed until the air is past the door 116 of the fuel channel 112 . A plunger 118 is disposed within the channel 112 to advance the fuel into the burn pot 6 . The plunger 118 is attached to a lead screw 120 which is in turn connected to a motor 122 . The motor's 122 function is to rotate the lead screw 120 in a first direction to advance the plunger 118 and to rotate in a second direction to retract the plunger 118 . The fuel channel 112 includes a pair of plunger stop sensors 124 , 125 . The fuel inlet further includes a fuel channel door 116 hingedly attached to the end of the fuel channel 112 disposed within the furnace 2 . The fuel channel door 116 is attached to a closure rod 126 by means of a pivotal linkage 128 . The closure rod 126 is attached to a compression spring 130 .
[0049] In use, a dose of fuel is delivered to the fuel channel 112 from the furnace hopper 108 . The fuel channel 112 is pitched upward toward the burn pot 6 to prevent fire from entering the fuel channel 112 . In the preferred embodiment, the angle of the fuel channel 112 is 22 degrees. The motor 122 rotates the lead screw 120 to advance the plunger 118 . As the plunger 118 advances the fuel dose is advanced within the fuel channel 112 . The fuel channel door 116 is pushed open by the force from the advancing dose and plunger 118 . The dose of fuel is pushed into the furnace 2 and lands on the ignition plate 96 at the bottom of the burn pot 6 . When the plunger 118 reaches the plunger advancement stop sensor 124 , the motor 122 reverses its direction and rotates the lead screw 120 in the opposite direction to retract the plunger 118 . As the plunger 118 retracts the fuel channel door 116 returns to its sealed closed position by the force of the compression spring 130 pulling on the door closure rod 126 . As a measure of safety the door 116 has a weight 129 attached thereon, such that if the closure rod linkage 128 were to break, the weight of the door 116 will force it to close. The plunger 118 continues to retract into the until the plunger 118 reaches the plunger retraction stop sensor 125 at which point the plunger 118 is at its original position and the fuel channel 112 is ready to again receive a dose of fuel.
[0050] Safety sensors on the lead screw 120 and dose motor 122 provide elements of safety and will shut down the motor 122 if the unit is malfunctioning. Specifically, a strike 132 is associated with the motor end of the dosing channel 112 . The strike 132 engages a normally closed limit switch 134 . A mechanical malfunction will move the strike 132 and open the limit switch 134 will causes the motor 122 to stop. There are three mechanical failures which will cause the limit switch 134 to be opened. First, if the door closure rod linkage 128 breaks, the compression spring 130 will force the door closure rod 126 into the strike 132 to open the limit switch 134 . Second, if the dose plunger 118 retracts too far a tab 119 on the plunger 118 will push against the strike 132 and open the limit switch 34 . Third, a holddown bearing 136 is located on the lead screw 120 of the dose plunger 118 . If the dose plunger 118 exceeds the shearing force for the holddown bearing bolts and the lead screw 120 will move towards the strike 132 , and the limit switch 134 will be opened. As an additional measure of safety, the lead screw 120 includes a lobe 121 near the end of the screw 120 which is associated with a rotation limit switch counter 138 . This rotation limit switch counter 138 will measure the number of times the lead screw 120 has been rotated anticipate the number of rotations in a cycle so that if there is a mechanical problem and the lead screw 120 is rotating too many times, the motor 122 will be shut down.
[0051] The hinged self closing fuel channel door 116 minimizes back burning in the fuel channel 112 . The deflecting shroud 114 also aids in minimizing back burning in the fuel channel 112 by causing a vacuum effect which prevents air from the furnace 2 from being pushed into the fuel channel 112 . The channel 112 is pitched up towards the burn pot 6 , further preventing fire from entering the fuel channel 112 . It should be noted that although the preferred fuel for this unit is grain, it is also contemplated that this invention could utilized with any biomass fuel.
[0052] Additionally, the furnace hopper 108 attached to the furnace 2 could also be automatically filled by a larger maxi-bin 140 . The furnace hopper 108 includes a sensors which would actuate an auger 144 affixed to the furnace hopper 108 . The furnace hopper 108 includes a funnel 146 which is attached to a pivoting arm 148 and a limit switch 150 located above the pivoting arm 148 . That pivoting arm 148 is attached to a pull spring 152 . When the furnace hopper 108 is full of fuel, the funnel 146 is depressed and which pushes the end of the pivoting arm 148 up against the limit switch 150 . When the fuel in the furnace hopper 108 reaches a low level, the funnel 146 is lifted up and the end of the pivoting arm 148 is pulled down by the spring 152 , removing the pivoting arm 148 from contact with the limit switch 150 which activates an auger 144 in an associated maxi-bin (not shown) to provide fuel to the furnace hopper 108 . The top of the furnace hopper 108 has a plastic covering 154 and a limit switch 156 held above the furnace 108 hopper by an arm 155 . As the furnace hopper 108 is filled with fuel, the plastic cover 154 rises. When the plastic cover 154 engages the limit switch 156 , the auger 144 supplying fuel from the maxi-bin is turned off. The furnace hopper 108 may also include a sliding door 157 near the fuel channel 112 , in order to easily remove the fuel from the furnace hopper 108 if maintenance to the furnace 2 is required.
[0053] As described above, the ignition plate 96 is located at the bottom of the burn pot 6 . The ignition plate 96 is shown in FIG. 11 . The ignition plate 96 includes two annular recesses 158 which house an electrical ignition mechanism 159 . Four tabs 160 are located on the surface of the ignition plate 96 to loosely hold the ignition elements 159 in place. These tabs 160 are installed in recesses in the plate 96 , such that the tabs 160 are flush with the surface of the ignition plate 96 . The ignition plate 96 also includes a plurality of slots 98 . In the preferred embodiment, these slots 98 are beveled such that the slot is wider on the lower side of the ignition plate 96 . In the preferred embodiment, the slots 98 are approximately 9/64 of an inch. The bevels improve the ash drop out which will be described below. The ignition plate 96 must be of a material that is tolerant to reach combustion temperatures of 1600 degrees F. The material must also be tolerant to abrasion and the impact of the biomass fuel. In the preferred embodiment, the ignition plate 96 is made of a metal material, however any other suitable material could also be used, as would be obvious to one of skill in the art.
[0054] The ash removal system can be best seen in FIG. 2 . An ash tray 92 is located beneath the ignition plate 96 . As the fuel is burned, ashes fall through the slots 98 in the ignition plate 96 into the ash tray 92 . A shaft 162 extends through the bottom of the furnace 2 , the ash tray 92 , and the ignition plate 96 and extends into the burn pot 6 . A fuel stirrer 32 is located just above the ignition plate 96 and is attached to the shaft 162 . The fuel stirrer 32 has two sets of arms 164 , 165 . The first set of arms 164 is located just above the surface of the ignition plate 96 . The second set of arms 165 is located approximately halfway up the shaft 162 . The blades on the arms 164 , 165 are beveled and sharp and extend close to, but not touching the water jacket 40 to avoid damaging the water jacket 40 . The fuel stirrer 32 includes rotatable cutting wheels or projections 166 which engage the slots 98 of the ignition plate 96 to clean the slots 98 during rotation of the fuel stirrer 32 . The fuel stirrer 32 is attached to the shaft 162 at the T-head 168 at the top of the shaft 162 . There is an air gap between the top of the shaft 162 and the T-head 168 to give a margin of flexibility to the shaft 162 in a vertical direction. The shaft 162 is attached to a small spring in the bottom of the ash tray 92 . This allows the shaft 162 to move slightly up and down and allows the cutter wheels or projections 166 to engage and disengage the slots 98 . The shaft 162 is connected by a drive mechanism 173 to a rotator motor 174 . When the motor 174 drives the shaft 162 to rotate, the fuel stirrer 32 is rotated which causes additional ashes to fall through slots 98 in the ignition plate 96 . Removal of debris from the ignition plate 96 ensures proper air flow for combustion. The fuel stirrer 32 also serves to agitate the fuel to increase complete combustion of the fuel and further increase efficiency of the furnace 2 and break up any clinkers which may form. A clinker is a fragment of incombustible matter left after a wood, coal or charcoal fire.
[0055] Inside the ash tray 92 , an ash arm 176 is attached to the shaft 162 just above the bottom surface of the ash tray 92 . When the shaft 162 is rotated the ash arm 176 rotates and pushes any ashes which have accumulated into the removable ash slide 178 . The removable ash slide 178 may include a mechanism such as an auger 180 to remove the ashes from the furnace 2 . In the preferred embodiment, the ash auger 180 would run for approximately 30 seconds after 60 minutes of cumulative furnace 2 operation. The auger is located near the baffled sediment tank 38 and the base of the auger 180 is constantly immersed in water. This water acts as a dam to prevent unwanted air to flow to or from the furnace 2 . The auger 180 runs relatively slowly, so that the debris is dried by the time it reached the end of the auger 180 . However, it is also contemplated that the ash slide 178 may simply deposit ashes into an appropriate disposal container.
[0056] The furnace 2 includes a wash down system which can best be seen in FIG. 4 . The wash down system functions to clean ash and other debris from the furnace 2 . The wash down system includes a pipeshaft 182 which is attached to a pipeshaft motor 34 . The pipeshaft motor 34 is provided outside of the furnace 2 to rotate the pipeshaft 182 . The pipeshaft 182 is attached to a water supply 184 ; the water supply pipe 184 includes electric solenoid valves(not shown). The pipeshaft 182 has numerous washdown holes provided thereon. The holes can be of any size which provides adequate volume and pressure of fluid to achieve sufficient washdown of the furnace 2 ; however the preferred embodiment provides holes which are approximately 1/16″ in diameter. The water supplied to the washdown cycle can optionally include an additive, such as a cleaning agent, to aid in cleaning the unit. The water solution is pumped, filtered, and reused in subsequent cycles.
[0057] In the preferred embodiment, the water solution is stored in a baffled sediment tank 38 of approximately 18 gallons, shown in FIGS. 6, 7 and 10 . It is important to use enough water for adequate cleaning of the system without using too much water, which can flood out key components of the system. The baffled sediment tank 38 allows the ash to sink in the tank. In this manner, most of the solids are removed from the water solution before reaching the filters and pump 190 . The baffled sediment tank 38 includes a removable cover for access to clean the tank 38 . The washdown cycle can be initiated either manually or automatically.
[0058] As described above, the furnace 2 is formed with a number of ash funnels 44 and tripod legs 46 to which the heat exchanger heli-coils 42 are attached. In the preferred embodiment four sets of ash funnels 44 are provided in the lower portion 54 of the furnace 2 and seven sets of tripod legs 46 are provided in the upper portion 52 of the furnace 2 . The ash funnels 44 and tripod legs 46 are attached to the inner wall of the furnace 2 .
[0059] Each set of ash funnels 44 in the lower portion 54 of the furnace 2 has an ash wiper 56 located in close proximity thereto. In the preferred embodiment the ash wipers 56 are magnetic; however it is also contemplated that the ash wipers 56 could have a different configuration, such as having metal bristles attached to the wiping surface. The ash wipers 56 are attached to the pipeshaft 182 , such that when the pipeshaft 182 rotates, the ash wiper 56 rotates. The ash caseway 36 is a tube positioned just inside the water jacket 40 surrounding the furnace 2 . The caseway 36 includes magnetic doors 196 located just above the point where the first and third ash funnels 44 are attached to the caseway 36 . An additional magnetic door 196 is provided at the top of the caseway 36 in the area where the lower portion 54 and the upper portion 52 of the furnace 2 are mated. This door 196 is an exit point for condensate during operation of the furnace 2 . Additionally, the debris and fluid from the washdown cycle are discharged through this door 196 .
[0060] In use, the pipeshaft motor 34 is operated to rotate the pipeshaft 182 . Water is supplied to the pipeshaft 182 through the water supply pipe 184 . When water is supplied to the pipeshaft 182 and the pipeshaft 182 is rotated water is flung from the pipeshaft holes to clean the furnace 2 . As the pipeshaft 182 is rotated, the ash wipers 56 which are hingedly attached to the pipeshaft 182 also rotate. The rotation of the ash wipers 56 causes any debris on the ash funnel 44 to be pushed away. The second and fourth lower funnels 44 are attached to tripod legs 46 which protrude from the funnel 44 to mate with notches formed in the inner wall of the furnace 2 . The configuration of the ash funnels 44 is such that as the water and debris from the second and fourth set of ash funnels 44 will fall onto the first and third set of ash funnels 44 . The debris and water on the first and third ash funnels 44 are pushed towards the ash caseway 36 . The trough 50 at the connection area of the lower portion 54 and upper portion 52 of the furnace 2 also collects water and debris and, as described above, contains a additional magnetic door 196 . The magnetic doors 196 of the ash caseway 36 are pushed open as the wipers 56 from the rotating shaft come in close proximity with the door. Each door 196 includes a protrusion. As the wiper 56 rotates, the wiper 56 engages the protrusion and opens the door 196 and allows the water and debris to fall down the ash caseway 36 and into the ash tray 92 . The magnetic door 196 is biased such that when the force of the water and debris recedes, the door 196 returns to its closed position. Sensors show door 196 position. An open door during burn status can be closed manually or by automatic means. A small electric solenoid is connected to each magnetic door 196 to push the door 196 shut if necessary. The steps of operation of the wash down system will be described in more detail below.
[0061] As is seen in FIG. 1 the furnace 2 includes a computer 16 which controls the system. A number of sensors throughout the system provide data to the computer 16 . The locations of the primary sensors are shown in FIG. 7 ; however additional sensors may be utilized. The sensors includes a limit switch on a normally closed electric solenoid 202 , an exhaust temperature sensor 204 , an outlet temperature sensor 206 , a plurality of monitoring temperature sensors 208 , a plurality of door position limit switches 210 , a removable burn pot temperature probe 212 , an air door position sensor 214 , an air inlet temperature sensor 216 , a water column sensor 218 , a torque clutch with reversing sensor 220 , an ignition plate current sensor 222 , a fuel channel temperature sensor 224 , a water inlet temperature sensor 226 , a door closure sensor 228 , a plunger advancement stop sensor 124 , a plunger retraction stop sensor 125 , a normally closed limit switch 134 , a rotation limit switch counter 138 .
[0062] There are six main sequences: a start up sequence, an ignition sequence, a high burn sequence, a selection sequence which selects between low burn, intermediate burn, burnout, and washdown, a low burn sequence, and an intermediate burn sequence. Each of the sequences combines activities including, but not limited to rotating the fuel stirrer, activating the air blower 84 , activating the igniter 159 , administering doses of fuel, ash dispensing, washdown, and selection of burn status. The computer 16 and program utilize the sensor data to determine which step of the program is to be completed. The unit also includes a smart logic thermal controller.
[0063] FIGS. 12-17 are flowcharts which show the various sequencing series by which the furnace 2 operates. FIG. 12 is the First Sequencing Series, which is the initial start up and safety check protocol. FIG. 13 is the Second Sequencing Series, which is the ignition sequencing protocol. FIG. 14 is the Third Sequencing Series, which is the high burn sequencing protocol. FIG. 15 is the Sequence Series, which is the low burn, intermediate burn, burnout, and/or wash down selection sequence. FIG. 16 is the low burn sequencing protocol. FIG. 17 is the intermediate burn sequencing protocol. FIGS. 12-17 use a number of abbreviations of parts of the system. For example, B.P. stands for burn pot, L.S. stands for limit switch, W.D. stands for wash down, W.C. stands for water column, and SLTC stands for smart logic thermal controller.
[0064] As illustrated in FIG. 12 , the computer 16 tests various elements of the unit as an initial safety protocol. Specifically, when the main power is manually on, the computer 16 tests whether the furnace hopper 108 has fuel. Whether the furnace hopper 108 has fuel is tested by the limit switch associated with the furnace hopper 108 . If the furnace hopper 108 does not have fuel, a limit switch activates the auger 144 to rotate. When the furnace hopper 108 is full an additional limit switch turns off the auger 144 to the furnace hopper 108 . The computer 16 also turns the circulator pump 30 on, tests whether it is functioning, and then turns it off. The computer 16 tests whether all water, exhaust, dose tube, and fan duct temperatures are 180 degrees F. or less. The computer 16 tests, by means of separate limit switches, whether the fuel plunger 118 is retracted, the combustion release door 201 is closed, the wash down solenoid valves are closed, and whether the wash down ash caseway doors 196 are closed. The computer 16 also rotates the fuel stirrer 32 for one minute and or greater than or equal to 12 revolutions and tests to see if it is complete. The computer 16 activates the ash auger 180 for 30 seconds, and then tests whether the cycle is complete. The computer 16 also activates the blower 84 to 100 percent power then turns off the fan and tests whether the wash down caseway sensors are ok. The computer 16 then tests whether there is a call for heat. If there is a call for heat the computer 16 proceeds to the second sequence. If there is no call for heat, the unit is put in stand by mode. If the unit fails any of the tests above, the computer 16 either attempts to solve the failure, or deactivates the unit and activates an associated alarm. If the computer 16 attempts to solve the failure and still fails, the unit is deactivated and the associated alarm is activated.
[0065] As illustrated in FIG. 13 , the second sequence is the ignition sequence. The computer 16 provides three consecutive doses of fuel to the furnace 2 , and tests whether this has been completed using a limit switch with an event counter. Motor rotation is verified at each does. If the three doses are complete, the fuel stirrer 32 is then rotated for 5 seconds or greater than or equal to one revolution. Motor rotation is verified at each operation. If the fuel stirring step is complete, the computer 16 turns on the water pump 30 . If the water pump 30 has properly tuned on, the computer 16 turns the igniter 159 on. The computer 16 tests whether there is current to the igniter plate 96 . If the current sensor shows there is current to the plate 96 , the computer 16 activates the air fan 84 to 100% and tests whether the fan 84 is at 100%. If the air fan 84 is at 100% the computer 16 then tests whether the air cut out door 100 is open. This is tested via a limit switch. If the air cut out door 100 is open, the computer 16 tests whether the burn pot 6 temperature of 300 degrees F. or higher and rising within approximately 10 minutes of turning the fan 84 on. If this condition is satisfied the computer 16 turns the igniter 159 off at a burn pot 6 temperature of 300 degrees F. or more. While the burn pot 6 temperature is rising, the computer 16 proceeds to the third sequence. If the unit fails any of the tests described above, the computer 16 either deactivates the unit and activated an appropriate alarm, or attempts to fix the problem through the steps shown in FIG. 13 . If the problem cannot be fixed by the steps shown in FIG. 13 , the computer 16 deactivates the unit and activates an appropriate alarm. As illustrated in FIG. 14 , the third sequence is a high burn protocol. In the high burn protocol the computer 16 tests whether the burn pot 6 temperature is 1010 degrees F. and rising. If the burn pot 6 temperature is 1010 degrees F. and rising, the computer 16 waits until the burn pot 6 temperature has fallen to 1000 degrees F. then rotates the fuel stirrer 32 for 5 seconds or greater than or equal one rotation. If the fuel stirrer 32 has successfully been rotated for 5 seconds, or greater than or equal one rotation, the computer 16 tests whether the burn pot 6 temperature has risen above 1010 degrees F. If the burn pot 6 temperature has risen above 1010 degrees F., the computer 16 repeats the previous step of rotating the fuel stirrer 32 when the burn pot 6 temperature falls to 1000 degrees F. If the burn pot 6 temperature has not risen to 1010 degrees F., the computer 16 has a dose of fuel delivered to the burn pot 6 when the burn pot 6 temperature falls to 950 degrees F. Within 30 seconds, the computer 16 tests whether the temperature has risen to over 1010 degrees F. If the temperature has reached more than 1010 degrees F., the computer 16 returns to the step of waiting for the burn pot 6 temperature to falls to 1000 degrees F. and rotating the fuel stirrer 32 for five seconds or at least one revolution and repeats above described procedure. At that point, if there is a call for low or medium burn and more than five doses have been administered in the high burn sequence, the computer 16 runs the low or medium burn sequence. The selection of burn status is determined by the smart logic thermal controller or by manual selection. As described with regard to the previous sequences, if the unit fails any of the tests described above, the computer 16 either deactivates the unit and activated an appropriate alarm, or attempts to fix the problem through the steps shown in FIG. 14 . If the problem cannot be fixed by the steps shown in FIG. 14 , the computer 16 deactivates the unit and activates an appropriate alarm.
[0066] As illustrated in FIG. 15 , the fourth sequence is the choosing sequence after high burn protocol. In this sequence the computer 16 , with input from either the smart logic thermal controller or manual input, determines whether to run the low burn, intermediate burn, burn out status or wash down sequence. The computer 16 uses either manual input or a smart logic thermal controller to determine whether the unit is to activate low burn status. If the unit is to activate low burn status, the unit runs the low burn sequence. If the unit is not to activate low burn status, the computer 16 tests whether the unit to activate intermediate burn status. If the unit is to activate intermediate burn, the intermediate burn sequence is run. In the unit is not told to activate intermediate burn, the computer 16 goes to the burnout sequence.
[0067] The burnout sequence can be initiated either manually or by the smart logic thermal controller. The burnout cycle is also shown in FIG. 15 . In the burn out sequence when the burn pot 6 temperature falls to 300 degrees F., the fan 84 is turned off and the fuel stirrer 32 is rotated for 5 minutes or 60 revolutions. The water pump 30 is turned off at 200 degrees F. The optimum washdown time is determined based on the differential between the output water temperature and the exhaust air temperature. As the differential between the two temperatures increases, the inefficiency of the unit is also increasing. The controller makes a decision on the optimum time for washdown based on the temperature differential as well as other factors. For example, if the ambient air temperature is too low, the unit will not go through the washdown process. The burnout sequence is also described in FIG. 15 .
[0068] If the smart logic controller determines that it is not an appropriate time to run the washdown cycle, the computer 16 tests whether there is a call for heat. If there is a call for heat the computer 16 runs the first sequence, the safety protocol. If there is no call for heat the unit is put to standby. The wash down cycle is also shown in FIG. 15 . In the washdown sequence, the ash auger 180 is activated for 30 seconds. If this is completed successfully the water solenoid 186 , washdown water pump 190 , washdown pipeshaft motor 34 , wash down pipeshaft 182 , fuel stirrer 32 , and ash auger 180 are activated for 15 minutes. Water pump 190 is deactivated for 5 minutes before the next step. This allows water within the furnace 2 to drain out. This allows the unit to dry out. The fan 84 is activated and the igniter plate 96 is activated to prevent corn from entering wet furnace 2 . If this is completed successfully, the air blower 84 is activated at 100 percent for 45 minutes, the fuel stirrer 32 for 45 minutes and ash auger 180 are activated for 5 minutes and the igniter 159 is activated for 45 minutes. If this is completed successfully, the computer 16 tests whether there is a call for heat. If there is a call for heat the first sequence is run. If there is no call for heat the unit is put to standby. As described with regard to the previous sequences, if the unit fails any of the tests described above, the computer 16 either deactivates the unit and activated an appropriate alarm, or attempts to fix the problem through the steps shown in FIG. 15 . If the problem cannot be fixed by the steps shown in FIG. 15 , the computer 16 deactivates the unit and activates an appropriate alarm.
[0069] The low burn protocol is shown in FIG. 16 . In the low burn protocol the computer 16 tests whether the burn pot 6 temperature is 410 degrees F. and rising. If the burn pot 6 temperature is 410 degrees F. and rising, the computer 16 waits until the burn pot 6 temperature has fallen to 400 degrees F. then rotates the fuel stirrer 32 for five seconds or greater than or equal one rotation. If the fuel stirrer 32 has successfully been rotated for 5 seconds, or greater than or equal one rotation, the computer 16 tests whether the burn pot 6 temperature has risen above 410 degrees F. If the burn pot 6 temperature has risen above 410 degrees F., the computer 16 repeats the previous step of rotating the fuel stirrer 32 when the burn pot 6 temperature falls to 400 degrees F. If the burn pot 6 temperature has not risen to 410 degrees F., the computer 16 has a dose of fuel delivered to the burn pot 6 when the burn pot 6 temperature falls to 375 degrees F. Within 30 seconds, the computer 16 tests whether the temperature has risen to over 410 degrees F. If the temperature has reached more than 410 degrees F., the computer 16 returns to the step of waiting for the burn pot 6 temperature to fall to 400 degrees F. and rotating the fuel stirrer 32 for five seconds or at least one revolution and repeats above described procedure. At that point, if there is a call for high or medium burn and more than five doses have been administered in the low burn sequence, the computer 16 runs the high or medium burn sequence. The selection of burn status is determined by the smart logic thermal controller or by manual selection. As described with regard to the previous sequences, if the unit fails any of the tests described above, the computer 16 either deactivates the unit and activated an appropriate alarm, or attempts to fix the problem through the steps shown in FIG. 16 . If the problem cannot be fixed by the steps shown in FIG. 16 , the computer 16 deactivates the unit and activates an appropriate alarm.
[0070] FIG. 17 shows the intermediate burn sequence. In the intermediate burn protocol the computer 16 tests whether the burn pot 6 temperature is 710 degrees F. and rising. If the burn pot 6 temperature is 710 degrees F. and rising, the computer 16 waits until the burn pot 6 temperature has fallen to 700 degrees F. then rotates the fuel stirrer 32 for five seconds or greater than or equal one rotation. If the fuel stirrer 32 has successfully been rotated for five seconds, or greater than or equal one rotation, the computer 16 tests whether the burn pot 6 temperature has risen above 710 degrees F. If the burn pot 6 temperature has risen above 710 degrees F., the computer 16 repeats the previous step of rotating the fuel stirrer 32 when the burn pot 6 temperature falls to 700 degrees F. If the burn pot 6 temperature has not risen to 710 degrees F., the computer 16 has a dose of fuel delivered to the burn pot 6 when the burn pot 6 temperature falls to 650 degrees F. Within 30 seconds, the computer 16 tests whether the temperature has risen to over 710 degrees F. If the temperature has reached more than 710 degrees F., the computer 16 returns to the step of waiting for the burn pot 6 temperature to fall to 700 degrees F. and rotating the fuel stirrer 32 for 5 seconds or at least one revolution and repeats above described procedure. At that point, if there is a call for low or high burn and more than five doses have been administered in the intermediate burn sequence, the computer 16 runs the low or high burn sequence. The selection of burn status is determined by the smart logic thermal controller or by manual selection. As described with regard to the previous sequences, if the unit fails any of the tests described above, the computer 16 either deactivates the unit and activated an appropriate alarm, or attempts to fix the problem through the steps shown in FIG. 17 . If the problem cannot be fixed by the steps shown in FIG. 17 , the computer 16 deactivates the unit and activates an appropriate alarm.
[0071] If at any time during a call for heat, whether high, intermediate, or low burn sequence, if the burn pot 6 tem falls to 300 degrees F. or less, the igniter 159 will activate and the fan speed 84 will increase to 100 percent. Both will activate for approximately 10 minutes. At this point one dose of fuel will also be administered. If the burn pot 6 temp rises to 410 degrees F. and rising within the 10 minutes the igniter 159 will be deenergized and the fan 84 speed will resume its speed based on the burn status which was its related burn status. The burn status will then continue as previously described. If combustion does not occur, an appropriate alarm will be indicated.
[0072] It should be noted that the entire furnace 2 can be taken apart for maintenance purposes. The top of the furnace 2 has a removable cover 200 . All of the heat exchangers can be disconnected and removed from the system. The heli-coil tripod legs 46 are hinged to allow the legs 46 to be pulled out of the furnace 2 .
[0073] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
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A granular biomass burning furnace for use with any appropriate granular biomass, such as grains, cherry pits, etc. The furnace includes a three stage heat exchanger, a fuel injector, a fuel stirrer, an ash ejector, a wash down system, a three stage air inducer, a fuel igniter, and supporting components. The unit includes a computer controller which controls all aspects of the operation of the unit based on information from sensors located throughout the unit. The unit includes a smart logic thermal controller to adjust the output heat of the unit via a variable speed air inducer. The three stage heat exchanger system includes a spiral water jacket surrounding the burn pot, a plurality of heat exchanger baffles in the unit, and a fine finned heat exchanger at the top of the unit. The air inducer provides air to the burn pot from three directions to promote complete combustion.
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BACKGROUND OF THE INVENTION
The present invention relates to a false twisting roll of the type used in a false twist crimping machine to impart false twist to a manmade, continuously advancing endless yarn. A false twisting roll of this general type is disclosed in German OS 24 60 031.
The false twisting roll as disclosed in German OS 24 60 031 is arranged so that the angle of lead of the yarn (epsilon) at the beginning of the line of contact with the false twist roll is approximately equal to half the acute angle of the cone of contact (gamma Epsilon) at the point of entry. In order to meet this condition, yarn guides precede the false twist roll. Optimal twist imparting conditions are preset by these yarn guides thus associated to the roll. A change of the twist level while maintaining the optimal twist imparting conditions is not possible
It is the object of the present invention to design and construct a false twisting roll, which permits the desired twist level to be adjusted, while maintaining the optimal twist imparting conditions.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are achieved in the embodiments illustrated herein by the provision of a false twisting roll which has a concave yarn contacting surface portion, and which defines a central roll axis. The twisting roll is mounted for rotation about the roll axis and for pivotal movement about a pivot axis which is perpendicular to the roll axis, and the roll may be set in a selected pivotal position. Yarn guide means is provided for guiding an advancing yarn along a predetermined yarn path leading into contact with the yarn contacting surface portion, and the concave yarn contacting surface portion is configured, and the pivotal axis is located, so that in all pivotal positions of the roll the angle alpha is equal to the angle gamma, with the angle alpha being defined as the angle between the predetermined yarn path and a circumferential tangent to the roll at the point of contact of the yarn path to the roll, and with the angle gamma being defined as the angle between the roll axis and a tangent to the concave surface portion at the point of contact of the yarn path to the surface portion and which intersects the roll axis.
The present invention is based upon the discovery that the angle condition, according to which the angle of lead of the yarn at the beginning of the line of contact with the body of rotation, i.e. the angle alpha as defined above, is approximately equal to the half the acute angle of the contact cone at the point of entry, i.e. the angle gamma, is not the cause for an optimal operation of the false twist roll, but is a consequence occurring independently in the operation of the false twist roll. Resulting therefrom is the further discovery that the aforesaid angle condition is maintained when changing the inclination of the roll, but that the looping conditions change on the preceding yarn guide. This disadvantage of the known false twist roll is eliminated by the present invention.
More particularly, in the present invention, the position of the pivotal axis is adapted to the contour of the roll, so that in the predetermined path of the yarn the angle alpha between the contacting yarn and the circumferential tangent of the roll in the point of first contact is always equal to the angle gamma between the roll axis and the tangent of the contour line at the point of first yarn contact, irrespective of the inclination of the roll axis. To this end, the position of the pivotal axis is determined by geometric construction, calculation and/or test, with the contour and yarn path being given. Conversely, with the yarn path and axis of rotation being given, the contour is determined by geometric construction, calculation and/or test. Thereafter, the ideal surface line (contour line) extending in an axial plane of the roll can be approximated by a circular, parabolic, hyperbolic or any mathematically determinable function.
In order to make the yarn path independent of the inclination of the roll, it is further suggested that the end of the roll, from which the yarn leaves, is cylindrically shaped or increases again slightly in diameter. As a result, the point of delivery remains constant.
In accordance with the invention, a false twisting roll is created, which imparts a twist which is exclusively dependent on the inclination of the roll. The invention make it possible to provide the false twisting rolls for a plurality of yarns on a common, pivotable mounting support, so that a common adjustment is made possible, without having a different twist insertion in the individual yarns. Contributory to this end is also a common drive of the rolls.
In a second embodiment of the invention, the twisting roll is mounted for both axial displacement along its central axis and for pivotal movement about a pivot axis which is perpendicular to the axis of the roll. This results in the advantage that, irrespective of the selection of the roll contour, the pivotal axis can be placed at a location favorable from the viewpoint of machine engineering. The axial displacement of the roll thus assures that the desired condition for the first contact, i.e. the angle of inclination of the roll is equal to the angle of the contour cone, is produced without resulting in a change of the looping conditions on the yarn guide preceding the roll--be it a cooling plate or a special yarn guide. Although DE-OS 24 60 031 provides likewise for an axial displacement of the false twist roll, which is intended to bring about a change in the twist level, the latter being based on the change of the looping conditions on the preceding yarn guide, the present invention, however, avoids such a change of the looping conditions by the combination of pivoting and axial displacement.
As can be seen, for the purpose of optimizing the twist insertion, the contour cannot only be adapted to the arbitrarily given position of the pivotal axis. Rather, the profiling of the contour also calls for consideration of the adhesive and sliding properties of the yarn necessary for an optimal twist insertion. Thus, the contour on the thicker receiving end should not be so steep that the contacting yarn slides downwardly without any adhesion, solely as a result of its tension. Consequently, in the zone of the first contact, the angle of the contour cone preferably should be smaller than the angle of static friction of the yarn relative to the false twist roll, and greater than the angle of sliding friction of the yarn. On the other hand, in the delivery zone, the angle of the contour cone should become smaller than the angle of sliding friction, it being provided by the invention, as aforesaid, that the end zone of the roll is cylindrical. Likewise, the smallest and the largest diameter should be determined by test so that an optimal twist insertion occurs. The selection of the position of the pivotal axis is to be subordinated to these requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when taken in conjunction with the accompanying drawings, in which
FIG. 1 is a schematic cross sectional view of a false twist crimping machine which embodies the present invention;
FIG. 2 is a fragmentary view of the false twisting roll shown in FIG. 1;
FIG. 3 is a schematic representation of the geometric construction of the contour of the false twisting roll;
FIG. 4 illustrates a second embodiment of a false twist roll in accordance with the present invention; and
FIG. 4A is a sectional view of one embodiment of the mounting of the drive motor for the false twisting roll.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the false twist crimping machine as shown in FIG. 1, a yarn 3 advances from a supply package 1. The supply package 1 is creeled on a holder. The yarn is drawn off overhead, via a yarn guide 4, by means of a feed system 5. The yarn is then guided over a hot plate 6 and subsequently over a cooling plate 7. The extension of the cooling plate 7 determines the path of the yarn contacting a false twisting roll 9. A yarn guide 8 preceding the false twisting roll serves only to ensure the yarn path. There occurs no deflection on the guide 8, so that the twist, which is produced by the false twisting roll, does not accumulate on the yarn guide 8. It is possible, though, to provide for a certain deflection also on the yarn guide. However, according to the invention, this deflection remains constant, so that the twist accumulation and thus also the twist conditions of the yarn do not change on the heater 6 and the cooling plate 7. The yarn loops about the false twisting roll 9 in a predetermined direction. Likewise this direction of looping determines the direction of the twist at the same time, the appearance of the yarn on the roll corresponding to an S or Z twist pattern. The yarn is withdrawn from the false twisting roll 9 by a second feed system 13, reciprocated by a traversing system 14, and wound onto a package 15 of a takeup system.
The false twisting roll 9 is supported on a mounting support 10. The mounting support 10 is pivotable about an axis 12. A motor 11 drives the false twisting roll 9 at a constant speed, which is adapted to the yarn speed.
FIG. 2 illustrates a view of the roll 9 with the yarn 3. It is assumed that the yarn 3 advances in a plane which is parallel to the plane of the paper. The yarn contacts the roll at the point A. Line 20 indicates the circumferential tangent of the roll to point A in the normal plane to the roll extending through the point A (and simultaneously the projection of this normal plane to the plane of the paper). The yarn path 3 forms with the tangent 20 an angle alpha. This angle alpha is equal to the angle of inclination of the roll axis 17 to a plane perpendicularly intersecting the yarn path, and thus represents the inclination of the roll axis 17 relative to the yarn path. Line 21 represents the contour tangent, which is the tangent to the contour line 22 of the roll extending in the plane of the paper. The roll is shaped by the rotation of the contour line 22 about the roll axis 17. The contour line is convex relative to the roll axis 17 and can technically be represented, for example, as a segment of a circle, hyperbola, parabola, or any similar, mathematically determinable curve. The contour tangent 21 forms with the roll axis 7 an angle gamma, which is described within the scope of the present application as the angle of the contour cone.
At the yarn delivery end, the contour line 22 terminates as smoothly as possible in a straight line parallel to the roll axis 17. In other words, the delivery end 18 of the roll is cylindrically shaped.
The path of the yarn 3 advancing onto the false twisting roll 9 always adjusts itself, so that the angle of inclination alpha of the roll is equal to the angle of the contour cone gamma of the point of first contact A.
FIG. 3 schematically illustrates the geometric construction of the contour line with a given pivot 12, which is here indicated at D. The mounting support of the false twisting roll is indicated by the numeral 10. The zero position of the mounting support is plotted by a solid double line. The zero position of the axis 17 of the false twisting roll is shown in a dash-dotted line and fully spelled out. The path of the yarn 3 is shown by a solid line. In the construction of the contour line, both the position of the pivot D and the yarn path 3 are given. This results in the zero position of the axis and the desired point of first contact AO, which, according to the invention, should lie on the cylindrical delivery end 18 of the false twist roll. In the zero position of the false twist roll, no twist is imparted. A radius RO may be determined for the cylindrical delivery end, so that optimal diameters develop on the false twist roll for the twist insertion. As a result, the first point UO of the contour line is predetermined.
Only two additional points will be constructed hereinbelow, in that the mounting support 10 is pivoted by an angle alpha and by an angle alpha 2 . As can be seen, a very accurate construction of the contour line is possible when the angles alpha 1 and alpha 2 differ only little.
When the mounting support 10 is pivoted by the angle alpha, it assumes the position 10.1 indicated by a dashed double line. As a result of this pivoting, the axis of the false twisting roll is at the position 17.1. According to the invention, the yarn path 3 should not change as a result of the inclination of the roll. At an inclination by the angle alpha 1 the point of first contact of the yarn on the roll is thus in point A1, which when projected on the plane of the paper is the intersection of the yarn path 3 with the axis 17.1. According to the invention, the tangents to the contour line form now in the yarn contact point A1 with the axis 17.1 an angle of the contour cone gamma 1 , which is equal to the angle of inclination of the roll and thus equal to the pivotal angle alpha 1 . Consequently, a line is drawn through the first contour point UO of the contour line, which has the inclination gamma 1 relative to the zero position of the axis. At the same time, a straight line between H1 and A1, which represents the axial position of the point of first contact A1, is plotted on the zero position of the axis starting from point H. This results in the point A1' on the zero position of the axis. From the point A1' a perpendicular line is extended. The intersection of this perpendicular line with the line which has the inclination gamma 1 relative to the axis, forms the further contour point U1.
The mounting support 10 is now pivoted by the angle alpha 2 . As a result, the mounting support assumes the position of the dashed double line 10.2, and the roll axis has the position 17.2. The intersection or the roll axis 17.2 with the yarn path 3 results in the yarn contact point A2. Now the straight line H2-A2 is plotted on the zero position of the axis starting from point H. This results in point A2'. Further, a line is drawn through the second contour point U1, which has an inclination gamma 2 (which equals alpha 2 ) relative to the zero position of the axis. Another contour point U2 is located in the point where the perpendicular line extended from the point A2' on the zero position of the axis 17 intersects this line.
The perpendicular lines on the zero position of the axis in the respective points A1' and A2' represent each the radii R1 and R2 of the roll in the normal plane, the projection of which is represented by the respective perpendicular lines.
If only two pivotal angles are given, the false twist roll will obtain a discontinuous contour line. However, a steady contour line may be obtained if the pivotal angles are closely stepped.
FIG. 4 discloses a second embodiment of the invention. In this embodiment, the roll is supported in a mounting support 10 rotatable about a pivot 12. The roll is driven by a motor 11. The pivoted position of the roll can be secured by a locking mechanism 16 in a slot 23, which is concentric to the pivotal axis and provided in base plate 27. A yarn advances from cooling plate 7 and travels without deflection over yarn guide 8 onto false twisting roll 9. At the same time, the false twisting roll is axially displaceable on the mounting support 10 in the roll axis 17. This allows to always adapt the yarn contact point A to the path of the yarn given by line 3 in any pivoted position.
The axial displacement may be done by hand. However, it is also possible to automatically couple the axial displacement with the pivotal motion by means of a transmission gearing.
To this end, the mounting support 10 may be provided with a longitudinal groove 25, which has a dovetailed cross section as shown in FIG. 4A. Aligned in the longitudinal groove is a guide rail 26 having the same cross section. The upper side of the guide rail 26 projects from the groove 25, so that the motor casing 11 with the false twist roll can be mounted thereon. A threaded bore is formed in the underside of the mounting support 10 facing the base plate 27 and in alignment with the slot 23. Inserted into this threaded bore is an adjusting screw 28 which is provided with a knurled head. Upon screwing the adjusting screw 28 into the threaded hole of the mounting support 10, the guide rail can be clamped in the longitudinal groove 25, thereby securing any desired axial position of the false twist roll. The adjusting screw projects from the slot so that a special adjustment is possible in any pivoted position.
In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A false twisting roll for imparting false twist to an advancing yarn of manmade fibers is disclosed. The roll has a generally conical and somewhat concave surface configuration, and the angle of inclination of the roll axis is adjustable with respect to the yarn path leading into contact with the roll. To insure optimal twisting conditions at all adjustable inclinations of the roll, the position of the pivotal axis of the roll, and the shape of the surface of the roll are adapted to each other so that the yarn path leading into contact with the roll is predetermined and remains constant. This in turn assures that the upstream twisting conditions of the yarn are unchanged.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to the field of well monitoring. More specifically, the invention relates to equipment and methods for real time monitoring of wells during various processes.
[0003] 2. Related Art
[0004] There is a continuing need to improve the efficiency of producing hydrocarbons and water from wells. One method to improve such efficiency is to provide monitoring of the well so that adjustments may be made to account for the measurements. Other reasons, such as safety, are also factors. Accordingly, there is a continuing need to provide such systems. Likewise, there is a continuing need to improve the placement of well treatments.
SUMMARY
[0005] In general, according to one embodiment, the present invention provides monitoring equipment and methods for use in connection with wells. Another aspect of the invention provides specialized equipment for use in a well.
[0006] Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0008] [0008]FIG. 1 illustrates a well having a perforating gun with a control line therein,
[0009] [0009]FIG. 2 illustrates a perforating gun in a well having a control line positioned in a passageway of the gun housing.
[0010] [0010]FIG. 3 illustrates a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
[0011] [0011]FIG. 4 is a cross sectional view of a perforating gun housing of the present invention showing numerous alternative designs.
[0012] [0012]FIG. 5 is a side elevational view of a perforating gun housing of the present invention.
[0013] [0013]FIG. 6 shows an alternative embodiment of the present invention.
[0014] [0014]FIG. 7 illustrates another embodiment of the present invention.
[0015] [0015]FIG. 8 is a partial cross sectional view of an alternative embodiment of the present invention.
[0016] [0016]FIGS. 9 through 16 illustrate various other alternative embodiments of the present invention.
[0017] [0017]FIG. 17 shows an intergun housing of the present invention.
[0018] [0018]FIG. 18 illustrates an embodiment of the present invention in which an instrumented perforating gun is provided with a completion.
[0019] [0019]FIG. 19 illustrates an embodiment of the present invention in which the well may be perforated and gravel packed in a single trip into the well.
[0020] [0020]FIG. 20 shows an embodiment of the present invention in which the perforating charges are provided in the casing.
[0021] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0023] In this description, the terms “up” and “down”; “upward” and downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
[0024] One aspect of the present invention is the use of a sensor, such as a fiber optic distributed temperature sensor, in a well to monitor an operation performed in the well, such as a perforating job as well as production from the well. Other aspects comprise the routing of control lines and sensor placement in a perforating gun and associated completions. Yet another aspect of the present invention provides a perforating gun 20 which is instrumented (e.g., with a fiber optic line 24 or an intelligent completions device 26 ). Referring to the attached drawings, FIG. 1 illustrates a wellbore 10 that has penetrated a subterranean zone that includes a productive formation 14 . The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 formed therein that allow fluid communication between the wellbore 10 and the productive formation 14 . Firing a perforating gun 20 having shaped charges 22 at the desired position in the well forms the perforations. The perforating gun 20 embodiment of FIG. 1 is a wireline-conveyed perforating gun and is instrumented with a control line 24 extending the length of the gun 20 . FIG. 1 also illustrates one embodiment in a cased hole although the present invention may be utilized in both cased wells and open hole completions.
[0025] Although shown with the control line 24 outside the perforating gun 20 , other arrangements are possible as disclosed herein. Note that other embodiments discussed herein will also comprise intelligent completions devices 26 on or the perforating gun 20 or the associated completion.
[0026] Examples of control lines 24 are electrical, hydraulic, fiber optic and combinations of thereof. Note that the communication provided by the control lines 24 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement (as in a distributed temperature system), pressure measurement, sand detection, seismic measurement, and the like. Additionally, the fiber optic line may be used to detect detonation of the guns.
[0027] In the case of a fiber optic control line, the control line 24 may be formed by any conventional method. In one embodiment of the present invention, a fiber optic control line 24 is formed by wrapping a flat plate around a fiber optic line in a similar manner as that shown in U.S. Pat. No. 5,122,209. In another embodiment, the fiber optic line is installed in the tube by pumping the fiber optic line into a tube (e.g., a hydraulic line) installed in the well. This technique is similar to that shown in U.S. reissue Pat. No. 37,283. Essentially, the fiber optic line 14 is dragged along the conduit 52 by the injection of a fluid at the surface, such as injection of fluid (gas or liquid) by pump 46 . The fluid and induced injection pressure work to drag the fiber optic line 14 along the conduit 52 .
[0028] Examples of intelligent completions devices 26 that may be used in the connection with the present invention are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, detonation detectors, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, locks, release mechanisms, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, locators, devices to determine the orientation, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as mentioned above. In one example, the fiber optic line provides a distributed temperature and/or pressure functionality so that the temperature and/or pressure along the length of the fiber optic line may be determined.
[0029] In an embodiment of FIG. 1 in which the control line 24 is a fiber optic line, the fiber optic line 24 is connected to a receiver 12 that may be located in the vehicle 13 . Receiver 12 receives the optical signals through the fiber optic line 14 . Receiver 12 , which would typically include a microprocessor and an opto-electronic unit, converts the optical signals back to electrical signals and then delivers the data (the electrical signals) to the user. Delivery to the user can be in the form of graphical display on a computer screen or a print out or the raw data. In another embodiment, receiver 12 is a computer unit, such as laptop computer, that plugs into the fiber optic line 24 . In each embodiment, the receiver 12 processes the optical signals or data to provide the chosen data output to the operator. The processing can include data filtering and analysis to facilitate viewing of the data.
[0030] [0030]FIG. 2 shows a wireline-conveyed perforating gun 20 having a hollow-carrier gun housing 28 and a plurality of shaped charges 22 . The housing 28 has a passageway 30 (control line passageway) formed in the wall thereof with a control line 24 extending through the passageway 30 . The passageway 30 provides protection for the control line 24 and reduces the overall size of the perforating gun 20 when compared to a perforating gun in which the control line 24 is provided on an outer surface of the housing 28 .
[0031] [0031]FIG. 3 is a cross sectional view of the housing 30 showing alternative positions for the passageway 30 , the control line 24 , and the intelligent completions device 26 . The housing 28 has a scallop 32 therein. A scallop 32 , or recess, is a thinned portion of the gun housing 28 . A shaped charge 22 within the housing 28 is aligned with the scallop 32 to minimize the energy loss required to penetrate the housing 28 . The passageway 30 , the control line 24 and the intelligent completions device 26 are spaced from the scallop 32 to prevent damage to the instrumentation (i.e., the control line 24 and intelligent completions device 26 ) when the shaped charges 22 are fired. However, in some applications it may be desirable to fire through a control line 24 or a component of an intelligent completions component 26 to, for example, detect detonation or for other purposes.
[0032] In one alterative embodiment shown in FIG. 3, a control line 24 a is provided in a passageway 30 a formed in the outer surface 34 of the housing 28 . In another alternative embodiment shown in FIG. 3, a passageway 30 b is formed in an inner surface 36 of the housing 28 . An intelligent completions device 26 and a control line 24 b are positioned in the passageway 30 b.
[0033] [0033]FIG. 4 illustrates one alternative embodiment in which a passageway 30 c formed in the housing outer surface 34 has a control line 24 c therein. A cover 38 is provided over at least a portion of the length of the passageway 30 c to maintain the control line 24 c in the passageway 30 c . The cover 38 may be removeably or fixedly attached to the housing 28 such as by welding, screws, rivets, by snapping into mating grooves in the housing 28 , or by similar means. Alternatively, the perforating gun 20 may comprise one or more cable protectors, restraining elements, clips, adhesive, epoxy, cement, or other materials to keep the control line 24 in the passageway 30 .
[0034] In one embodiment, shown in FIG. 3, a material filler 40 is placed in the passageway 30 a to mold the control line 24 a in place. As an example, the material filler 40 may be an epoxy, a gel that sets up, or other similar material. In one embodiment, the control line 24 a is a fiber optic line that is molded to, or bonded to, the perforating gun 20 . In this way, the stress and/or strain applied to the perforating gun 20 may be detected and measured by the fiber optic line 24 a.
[0035] Another embodiment shown in FIG. 4 provides an internal passageway 30 d within the wall of the housing 28 . A control line 24 d extends through the internal passageway 30 d.
[0036] [0036]FIG. 4 also shows an embodiment for positioning of an intelligent completions device 26 (e.g., a sensor). As in the embodiment shown, the intelligent completions device 26 may be placed within the wall of the housing 28 .
[0037] [0037]FIG. 5 shows a perforating gun 20 having a housing 28 with a passageway 30 (e.g., a recess, or indentation) formed in the outer surface 34 thereof. Brackets 42 , or clips, secure the control line 24 within the passageway 30 . The passageway 30 and control line 24 are offset from the gun scallops 32 .
[0038] [0038]FIG. 6 illustrates a perforating gun 20 that comprises a housing 28 and a loading tube 44 . The loading tube 44 has a plurality of openings 46 for holding shaped charges 22 . A detonating cord 48 is routed along the back of the shaped charges to fire the shaped charges 22 . The loading tube is placed in the housing 28 with the shaped charges 22 aligned with the housing scallops 32 . One embodiment of the invention illustrated in FIG. 6 has a control line 24 extending the length of the loading tube 44 . As discussed above with respect to the housing 28 , the control line 24 may extend through a passageway 30 provided on the loading tube 44 (e.g., the interior surface, the exterior surface, or internal to the wall). Another embodiment of FIG. 6 shows a control line 24 provided on the housing 28 of the perforating gun 20 .
[0039] Note that, in each of the embodiments discussed herein, the control line 24 may extend the full length of the perforating gun 20 or a portion thereof. Additionally, the control line 24 may extend linearly along the perforating gun 20 or follow an arcuate, or nonlinear, path. FIG. 6 illustrates a perforating gun 20 having a control line 24 that is routed in a helical path along the perforating gun 20 (both the loading tube embodiment and the housing embodiment). In one embodiment, the control line 24 comprises a fiber optic line that is helically wound about the perforating gun 20 (internal or external to the perforating gun 20 ). In this embodiment, a fiber optic line 24 that comprises a distributed temperature system, or that provides other functionality (e.g., distributed pressure measurement), has an increased resolution. Other paths about the perforating gun 20 that increase the length of the fiber optic line 24 per longitudinal unit of length of perforating gun 20 will also serve to increase the resolution of the functionality provided by the fiber optic line 24 .
[0040] [0040]FIG. 7 discloses another embodiment of the present invention in which a control line 24 is provided adjacent a shaped charge 22 . In the embodiment shown, the shaped charge 22 has a case passageway 52 provided in the shaped charge case 50 . The control line 24 extends through the case passageway 52 . In one embodiment, the control line 24 is a fiber optic line used for shot detection. When the shot fires, the fiber optic line is broken at that point. Light reflected through the fiber optic line indicates the end of the fiber optic line and point at which the line was broken.
[0041] [0041]FIG. 8 shows a wireline-conveyed perforating gun 20 having a control line 24 in the housing 28 and extending the length thereof.
[0042] [0042]FIG. 9 shows an alternative embodiment in which the passageway 30 is routed in an arcuate path (e.g., helical) along the loading tube of a high shot density perforating gun 20 .
[0043] [0043]FIG. 10 is a cross sectional view of a loading tube 44 showing additional alternative embodiments for instrumenting a perforating gun 20 . One embodiment shows a passageway 30 extending along the loading tube 44 . A pair of control lines 24 are routed through the passageway 30 . Another embodiment illustrated in FIG. 10 provides an intelligent completions device 26 mounted in the wall of the loading tube 44 , such as in a recess provided in the wall, or inside the loading tube 44 . Yet another embodiment shown in FIG. 10 provides a control line 24 inside the loading tube.
[0044] Although the aforementioned perforating guns 20 have been described as wireline-conveyed, tubing could also convey the guns 20 .
[0045] [0045]FIGS. 11 through 16 illustrate embodiments of the present invention in which the perforating gun 20 comprises a plurality of shaped charges 22 mounted on a carrier 54 . FIG. 11 shows a semi-expendable perforating gun 20 having a linear carrier 54 . A control line 24 is mounted to the carrier 54 . Similarly, FIG. 12 shows a semi-expendable carrier 54 having a plurality of capsule shaped charges 22 mounted thereon and a control line 23 mounted to the carrier 54 . Expendable guns may also be used with the present invention.
[0046] As used herein, the housing 28 , loading tube 44 , and carrier 54 are generically referred to as a “carrier component” of the perforating gun 20 .
[0047] In the perforating gun 20 of FIG. 13, the carrier 54 is a hollow tube. A control line 24 extends through the carrier 54 , hollow tube.
[0048] [0048]FIGS. 14 and 15 show an alternative embodiment of the present invention used in conjunction with a pivot perforating gun 20 . The pivot gun 20 has a carrier 54 and a pull rod 58 . The shaped charges 22 are mounted to the pull rod 58 in a first position in which the axis of the shaped charges 22 generally pointed along the axis of the perforating gun 20 . Once downhole, the pull rod 58 is caused to move relative to the carrier 54 . A retainer 56 connecting each of the shaped charges to the carrier cause the shaped charges 22 to rotate to a second firing position. The pivot gun 20 may use a variety of other schemes to achieve the pivoting of the shape charges 22 .
[0049] [0049]FIG. 14 illustrates alternative embodiments of the present invention. In one embodiment, the pull rod 58 is a hollow tube having a control line 24 extending therein. In another embodiment, the carrier 54 has a control line 24 mounted therein (see also FIG. 15).
[0050] [0050]FIG. 16 shows another embodiment in which the perforating gun 20 comprises a spiral strip carrier 54 in which the carrier 54 is formed into a helical shape. A control line 24 extends along the carrier strip 54 .
[0051] It should be noted from the above that the shaped charges may be oriented in a variety of phasing patterns as illustrated in the figures.
[0052] [0052]FIG. 17 shows another embodiment of the present invention in which adjacent perforating guns are interconnected by an intergun housing 60 . The intergun housing 60 may contain one or more intelligent completions devices 26 that may be used, for example, to measure reservoir parameters, production characteristics, gun orientation, and gun performance metrics. Additionally, the intelligent completions device 26 in the intergun housing 60 may comprise safety devices that prevent detonation until certain conditions are satisfied (e.g., certain downhole parameters, like pressure, temperature, location, or orientation). Further, the intergun housing may comprise a swivel, a motor, or other device that will facilitate orientation of the perforating gun 20 . Also, the intergun housing 60 may contain other devices that inflate to isolate sections of the wellbore, to shut off zones, or devices that choke back production from sections of the well.
[0053] [0053]FIG. 18 illustrates an alternative embodiment of the present invention in which the perforating guns 20 are run as part of a permanent completion 62 . A completion 62 may comprise a large variety of components and jewelry such as packers, safety valves, sand screens, flow control valves, pumps, intelligent completions devices, and the like. In some circumstances, it is desirable to run the perforating gun 20 with the completion 62 to reduce the number of trips into the well and for other reasons. FIG. 18 shows a permanent completion 62 having a perforating gun 20 and a control line extending along the completion 62 and the perforating gun 20 .
[0054] [0054]FIG. 19 shows another embodiment of the present invention in which the well is perforated and gravel packed in a single trip into the well. The completion 62 has a perforating gun 20 connected thereto and comprises packers 64 , a sand screen 66 , and a crossover port 68 . The assembly of the completion 62 and the perforating gun is run into the well on a service string 70 . A control line 24 extends along the completion 62 and the perforating gun 20 . Once the perforating gun 20 is aligned with the formation 14 , the perforating gun 20 is fired. Generally, the perforating gun 20 is dropped into the rathole. The completion 62 is then moved into place and the packers 64 are set to isolate the formation 14 . Next, the annulus between the sand screen 66 and the wellbore wall is gravel packed and the service string 66 is removed from the well and replaced with a production tubing. In alternative systems, the gravel pack operation is performed using a through-tubing service tool so that the run-in string may also serve as the production string.
[0055] However, if a through-tubing gravel pack operation is not used and the service string 70 is replaced with a production tubing, the control line 24 extending above the packer 64 may need to be replaced. Accordingly, in one embodiment, the present invention uses a connector 72 at or near the upper packer 64 that allows the control line 64 to separate so that the upper portion of the control line 24 (the portion above the packer 64 ) may be removed from the wellbore 10 . When the production tubing is placed in the well 10 , a control line attached to the production tubing has a connector 72 that completes the connection downhole of the control line below the upper packer 64 that was previously left in the well 10 with the control line 24 attached to the production tubing.
[0056] In the embodiment of FIG. 20, the perforating gun 20 is a casing-conveyed perforating gun 20 . In this embodiment, the casing 16 has one or more shaped charges 22 mounted thereto. The shaped charges 22 may be mounted in the wall of the casing 16 , inside the casing 16 , or attached to the outside of the casing 16 . A control line 24 extends along the perforating gun 20 (the portion of the casing having the shaped charges 22 therein). In the disclosed embodiment, the control line 24 has a ‘U’ configuration and extends from the surface into the well and returns to the surface. Such a ‘U’ configuration is particularly useful when the control line 24 is a fiber optic line that is blown into the well as previously described. In such a case, the control line may provide redundancy.
[0057] In some embodiments, the perforating gun 20 uses alternative forms of initiators 74 (see FIG. 11) for activating the shaped charges 22 . As an example, the initiator 74 may be an exploding foil initiator (EFI) which is electrically activated. As used here, “exploding foil initiator” may be of various types, such as exploding foil “flying plate” initiators and exploding foil “bubble activated” initiators. In addition, in further embodiments, exploding bridgewire initiators may also be employed. Such initiators, including EFIs and EBW initiators, may be referred to generally as high-energy bridge-type initiators in which a relatively high current is dumped through a wire or a narrowed section of a foil (both referred to as a bridge) to cause the bridge to vaporize or “explode.” The vaporization or explosion creates energy to cause a flying plate (for the flying plate EFI), a bubble (for the bubble activated EFI), or a shock wave (for the EBW initiator) to detonate an explosive. Some electrical initiators are described in described in commonly assigned copending U.S. Pat. No. 6,385,031, issued May 7, 2002, entitled “Switches for Use in Tools” and U.S. Pat. No. 6,386,108, issued May 14, 2002, entitled “Initiation of Explosive Devices,” which are hereby incorporated by reference.
[0058] When using an EFI or other electrically activated initiator, it is possible to selectively fire a sequence of perforating strings or even a series of shaped charges. As an example, if a plurality of control devices including a microcontroller and detonator assembly are coupled on a wireline, switches within the perforating gun may be controlled to selectively activate control devices by addressing commands to the control devices in sequence. This allows firing of a sequence of perforating strings or shaped charges in a desired order. Selective activation of a sequence of tool strings is described in commonly assigned copending U.S. Pat. No. 6,283,227, issued Sep. 4, 2001, entitled “Downhole Activation System That Assigns and Retrieves Identifiers” and U.S. patent application Ser. No. 09/404,522, filed Sep. 23, 1999 and published as WO 00/20820 on Apr. 13, 2000, entitled “Detonators for Use with Explosive Devices,” which are hereby incorporated by reference.
[0059] Accordingly, a perforating gun 20 having electrically activated initiators 74 may be instrumented in the manner previously described. In such a system, the instrumentation (e.g., the fiber optic line 24 or the intelligent completions device 26 ) may provide data during the perforation job. For example, the instrumentation may provide information relating to shot confirmation, pressure, temperature, or flow, among other information, between individual gun 20 or shaped charge 22 detonations. Therefore, in one example, a perforating gun 20 having a plurality of shaped charges 22 and electrically activated initiators is run into a well 10 . The shaped charges 22 are fired in a particular sequence while providing the option of moving the perforating gun 20 between shots, skipping defective charges 22 , as well as other features. The instrumentation 24 , 26 provides feedback regarding shot confirmation. In another example, the instrumentation 24 , 26 measures the temperature and pressure in the well following each shot.
[0060] In another embodiment of the present invention, the instrumentation 24 , 26 of the perforating gun 20 is used to determine the placement of a fracturing treatment, chemical treatment, cement, or other well treatment by measuring the temperature or other well characteristic during the injection of the fluid into the well. The temperature may be measured during a strip rate test in like manner. In each case remedial action may be taken if the desired results are not achieved (e.g., injecting additional material into the well, performing an additional operation). It should be noted that in one embodiment, a surface pump communicates with a source of material to be placed in the well. The pump pumps the material from the source into the well. Further, the instrumentation 24 , 26 in the well may be connected to a controller that receives the data from the intelligent completions device and provides an indication of the placement position using that data. In one example, the indication may be a display of the temperature at various positions in the well. In another example, the remedial action comprises firing a perforating gun 20 . In this example, the remedial action may comprise perforating a particular zone again, perforating a longer interval of the wellbore, perforating another zone, or the like.
[0061] The instrumented perforating gun 20 of the present invention should not be confused with prior perforating guns which have sensors placed above or below the perforating gun. Accordingly, in the present invention the term “instrumented” and the like shall mean that the instrumentation is provided on the perforating gun 20 itself, such as attached to a housing 28 , loading tube 44 , or carrier 54 of the gun 20 , positioned below the uppermost shaped charge 22 of the perforating gun 20 and above the lowermost shaped charge 22 , between shaped charges 22 , or in the substantially the same cross sectional portion of the well 10 as the shaped charges 22 . Thus, the instrument 24 , 26 is provided on the same shaped charge region of the perforating gun 20 as the shaped charges 22 .
[0062] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses 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.
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An instrumented perforating gun and associated methods. One aspect provides a recess for placement of instruments on the perforating gun. Another aspect provides methods for perforating and completing a well in a single trip. The present invention also provides an instrumented intergun housing. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority in U.S. Provisional Patent Application No. 61/148,995, filed Feb. 1, 2009, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to telemetry apparatus and methods, and more particularly to acoustic telemetry isolation apparatus and methods for the well drilling and production (e.g., oil and gas) industry.
[0004] 2. Description of the Related Art
[0005] Acoustic telemetry is a method of communication used, for example, in the well drilling and production industry. In a typical drilling environment, acoustic extensional carrier waves from an acoustic telemetry device are modulated in order to carry information via the drillpipe as the transmission medium to the surface. Upon arrival at the surface, the waves are detected, decoded and displayed in order that drillers, geologists and others helping steer or control the well are provided with drilling and formation data. In production wells, downhole information can similarly be transmitted via the well production tubing.
[0006] The theory of acoustic telemetry as applied to communication along drillstrings has a long history, and a comprehensive theoretical understanding has generally been backed up by accurate measurements. It is now generally recognized that the nearly regular periodic structure of drillpipe imposes a passband/stopband structure on the frequency response, similar to that of a comb filter. Dispersion, phase non-linearity and frequency-dependent attenuation make drillpipe a challenging medium for telemetry, the situation being made even more challenging by the significant surface and downhole noise generally experienced.
[0007] The design of acoustic systems for static production wells has been reasonably successful as each system can be modified within economic constraints to suit these relatively long-lived applications. The application of acoustic telemetry in the plethora of individually differing real-time drilling situations, however, presents other challenges and this is primarily due to the increased noise due to drilling and the problem of unwanted acoustic wave reflections associated with downhole components, such as the bottom-hole assembly (or “BHA”), typically attached to the end of the drillstring, which reflections can interfere with the desired acoustic telemetry signal. The problem of communication through drillpipe is further complicated by the fact that drillpipe has heavier tool joints than production tubing, resulting in broader stopbands; this entails relatively less available acoustic passband spectrum, making the problems of noise and signal distortion relatively more severe.
[0008] To make the situation even more challenging, BHA components are normally designed without any regard to acoustic telemetry applications, enhancing the risk of unwanted and possibly deleterious reflections caused primarily by the BHA components.
[0009] When exploring for oil or gas, in coal mine drilling and in other drilling applications, an acoustic transmitter is preferentially placed near the BHA, typically near the drill bit where the transmitter can gather certain drilling and geological formation data, process this data, and then convert the data into a signal to be transmitted up-hole to an appropriate receiving and decoding station. In some systems the transmitter is designed to produce elastic extensional stress waves that propagate through the drillstring to the surface, where the waves are detected by sensors such as accelerometers, attached to the drill string or associated drilling rig equipment. These waves carry information of value to the drillers and others who are responsible for steering the well. Examples of such systems and their components are shown in: Drumheller U.S. Pat. No. 5,128,901 for Acoustic Data Transmission through a Drillstring; Drumheller U.S. Pat. No. 6,791,474 for Reducing Injection Loss in Drill Strings; Camwell et al. U.S. Patent Publication No. 2007/0258326 for Telemetry Wave Detection Apparatus and Method; and Camwell et al. U.S. Patent Publication No. 2008/0253228 for Drill String Telemetry Methods and Apparatus. These patents and publications include common inventors with the present application and are incorporated herein by reference.
[0010] Exploration drilling in particular has become a highly evolved art, wherein the specification and placement of the BHA components is almost entirely dictated by the driller's need to drill as quickly and accurately as possible while gathering information local to the drill bit. A large variety of specialized BHA modules or tools are available to suit local conditions, and their inclusion in a BHA usually takes priority over the requirements of telemetry methods, acoustic or otherwise. The diversity of these BHA tools and the decision regarding whether or not to even include them in a drillstring, pose major issues for consideration; these issues have a significant impact when dealing with acoustic energy questions. Cyclic acoustic waves suffer multiple reflections and amplitude changes even in a very simple BHA, and the net effect of these changes may destructively interfere with the required acoustic telemetry broadcast signal. The reflections are caused by impedance mismatches which are the result of mechanical discontinuities present in all BHAs presently in use.
[0011] An initial response to this problem would be to place the acoustic telemetry device above the BHA and simply direct the acoustic energy up the drillstring, away from the BHA components. Unfortunately, this does not fully address the problem because typical acoustic transmitters emit waves of equal magnitude both up-hole and down-hole, and the downward travelling waves in particular may be reflected, thereby potentially resulting in destructive interference with the upward travelling waves. In the worst cases, this can cause virtually complete cancellation of the upward travelling communication signal.
[0012] It is known in other fields, for example in radio frequency (RF) transmitter design and electrical transmission lines, that wave reflections can be controlled by inserting simple specific impedance changes at certain distances from a transmitter, such that the combination of the original wave and the reflected wave combine constructively to produce a single wave travelling in one direction with increased amplitude. The standard approach is to insert a “quarter wave” (λ/4) impedance change (or odd multiples thereof) adjacent to the transmitter so that one wave (the “down” wave) is reflected in phase with the intended transmitted wave (the “up” wave) and constructively aids the intended transmitted wave by increasing its amplitude.
[0013] Downhole applications typically employ transmitters that emit stress waves of nearly equal, but not necessarily equal, magnitude in both directions. Moreover, each wave has the same sign in stress but opposite sign in material velocity. In such cases, the appropriate reflection device would be a λ/4 tuning bar (pipe section) placed below the transmitter. However, such a simple solution is often impractical because the equipment below the acoustic transmitter is designed to drill and steer the well rather than to aid telemetry. Equipment such as drill collars, crossover pipes, drilling motors and bits can easily nullify the benefit of simply introducing a λ/4 section of pipe below the acoustic transmitter because the equipment will generally be of differing lengths and impedances that can add to the λ/4 section and eliminate the intended benefit. This discussion assumes the reader is familiar with the phase change differences associated with waves passing from a given medium to that of greater or less acoustic impedance.
[0014] Other styles of transmitters which emit waves in both directions, but by design have different relationships between their stresses and material velocity would require tuning bars of different lengths, not necessarily λ/4 sections, further complicating the problem.
[0015] As mentioned above, downhole noise is also of concern in acoustic telemetry. The problem of downhole noise is addressed to some extent in U.S. Pat. No. 6,535,458 to Meehan, wherein is taught a baffle filter comprising a periodic structure of typically 20 m length interposed above or below the acoustic source; this is intended to cause stopbands over a certain range of frequencies, the position of the baffle being to protect the acoustic transmitter from the sources of the noise from the drill bit and motor. This teaching, however, does not address or anticipate the more serious problem of energy propagating in a “down” direction being reflected in a relatively unattenuated manner back to the transmitter where it may combine in a destructive manner with the energy propagating in an “up” direction, thereby causing possibly significant destruction of the signal intended to reach the surface.
[0016] As can now be seen, the required upward travelling acoustic telemetry waves are often interfered with by unwanted reflections from impedance mismatches below the transmitter. The known art of inserting a tuning bar of appropriate length is usually ineffective because the local conditions often necessitate the addition of further BHA components that cause further reflections that can often destructively interfere with the upward travelling wave.
BRIEF SUMMARY OF THE INVENTION
[0017] It is an object of the present invention to control wave reflections, in particular, in such a manner as to mitigate the otherwise potentially destructive reflections. Specifically, the present invention comprises an apparatus for placement adjacent to the transmitter, and a method for using same, that will beneficially reflect waves, such that:
A. the apparatus can be configured to be effective over a certain broadcast bandwidth, such that all the desired frequencies in a modulated telemetry signal are significantly and beneficially reflected at known places; and B. the apparatus aids the transmitted wave by adding in phase, providing up to a 3 dB gain in the amplitude of the wave motion amplitude and a 6 dB gain in the wave energy.
[0020] An isolator according to the present invention seeks to effectively isolate essentially all down waves from the subsequent (i.e. downhole) BHA components, thus curtailing the possibility of waves that would have entered the BHA and returned with potentially destructive phases. Positioning an isolator according to the present invention below the transmitter can, in effect, make the lower BHA components essentially “acoustically invisible” over a bandwidth useful for acoustic telemetry.
[0021] The present invention is also intended to be applicable in situations other than real-time drilling with drillpipe or production wells with production tubing. For example, many relatively shallow wells are drilled with coiled tubing. Although coiled tubing drilling systems do not have the passband/stopband features of drillpipe sections connected by tool joints, they do have BHA components similar to those in jointed pipe applications. Thus, the isolator and the isolation method taught herein are intended to apply equally to the situation of coiled tubing.
[0022] It is intended that the present invention be applicable in still further applications. For example, an isolation/reflection means as described herein can also be beneficial in production wells where there may not be a BHA as such, but there may instead be production components such as valves, manifolds, screens, gas lift equipment, etc., below the acoustic source. Thus, the apparatus and method taught herein are intended to apply equally to this situation.
It is not intended that an exhaustive list of all such applications be provided herein for the present invention, as many further applications will be evident to those skilled in the art.
[0024] According the present invention, then, there is provided an acoustic isolator for use with tubular assemblies comprising:
[0025] a first tubular member of first physical length, first acoustic impedance, and first acoustic transit time;
[0026] a second tubular member of second physical length, second acoustic impedance, and of second acoustic transit time;
[0027] the first and second members not making contact or exchanging acoustic energy directly to each other;
[0028] a first upper coupling placed at the upper end of the first and second members, said coupling restricting the motions of said members and said coupling to be equal at their common points of contact thereby allowing exchange of acoustic energy between the drilling components above said coupling and said tubular members below said coupling;
[0029] a second lower coupling placed at the lower end of the first and second members said coupling restricting the motions of said members to be equal at their common points of contact thereby allowing exchange of acoustic energy between the drilling components below said coupling and said tubular members above said coupling;
[0030] the lengths, acoustic impedances, and transit times of said tubular members being adjusted so that by means of constructive and destructive wave interference the acoustic energy transmitted through the upper coupling results in reduced motion and force in the lower coupling and likewise acoustic energy transmitted through the lower coupling results in reduced motion and force in the upper coupling.
[0031] Thus it is to be understood that downward traveling acoustic energy may be reflected upward, and upward traveling acoustic energy may be reflected downward. Moreover, it is to be understood that acoustic energy could be arriving simultaneously from both directions and the acoustic isolator is simultaneously reflected back towards the drilling components that originally injected the energy.
[0032] A detailed description of an exemplary embodiment of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as limited to this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the accompanying drawings, which illustrate the principles of the present invention and an exemplary embodiment thereof:
[0034] FIG. 1 is a diagram of a typical drilling rig, including an acoustic telemetry isolation system embodying an aspect of the present invention;
[0035] FIG. 2 is a fragmentary, side elevational view of the acoustic telemetry isolation system, particularly showing an isolator thereof;
[0036] FIG. 3 is a fragmentary, enlarged side elevational view of the isolator, particularly showing the propagation of acoustic energy waves;
[0037] FIG. 4 is a plot of a pole equation over a frequency range from 0 to 1200 Hz;
[0038] FIG. 5 is a plot of a transfer function for different acoustic impedance values for the drillpipe sections and
[0039] FIG. 6 is a corresponding plot of the pole equation;
[0040] FIG. 7 shows the results for the transmitted wave amplitudes obtained from harmonic analysis;
[0041] FIG. 8 is a fragmentary, side elevational view of an isolator comprising a first modified aspect of the invention with an inner mandrel of beryllium copper;
[0042] FIG. 9 is a plot of a pole equation therefore over a frequency range from 0 to 1000 Hz;
[0043] FIG. 10 is a plot of the transfer function therefor;
[0044] FIG. 11 is a side elevational of a portion of a drillstring with an acoustic isolation system comprising another modified aspect of the present invention with a tuning pipe section; and
[0045] FIG. 12 shows the results for the transmitted wave amplitudes obtained from harmonic analysis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] In the following description, reference is made to “up” and “down” waves, but this is merely for convenience and clarity. It is to be understood that the present invention is not to be limited in this manner to conceptually simple applications in acoustic communication from the downhole end of the drillstring to the surface. It will be readily apparent to one skilled in the art that the present invention applies equally, for example, to subsurface stations in drilling applications, such as would be found in telemetry repeaters, or non-drilling applications as would be found in production wells.
[0047] Referring to the drawings more detail, the reference numeral 2 generally designates a parallel-path acoustic isolation system embodying an aspect of the present invention. Without limitation on the generality of useful applications of the system 2 , an exemplary application is in a drilling rig 4 as shown in a very simplified form in FIG. 1 . For example, the rig 4 can include a derrick 6 suspending a traveling block 8 mounting a kelly swivel 10 , which receives drilling mud via a kelly hose 11 for pumping downhole into a drillstring 12 . The drillstring 12 is rotated by a kelly spinner 14 connected to a kelly pipe 16 , which in turn connects to multiple drill pipe sections 18 , which are interconnected by tool joints 19 , thus forming a drillstring of considerable length, e.g. several kilometers, which can be guided downwardly and/or laterally using well-known techniques. The drillstring 12 terminates at a conventional bottom-hole apparatus (BHA) 20 , typically comprising a drill bit, bit sub, mud motor, crossover, non-magnetic drill collar, etc., thence connecting to the drillpipe. FIG. 1 shows acoustic modules (isolator 26 and transmitter 22 ) as separate from the conventional BHA simply for clarity. Other rig configurations can likewise employ the acoustic isolation system of the present invention, including top-drive, coiled tubing, etc.
[0048] FIG. 2 shows the components of the acoustic isolation system 26 which is incorporated along the drillstring 12 , e.g., just above the BHA 20 , or at other desired locations therealong. An upper, adjacent pipe section 18 a is connected to a parallel-path acoustic isolator 26 at an upper interface 28 a . The isolator 26 is also connected to a downhole adjacent pipe section 18 b at a lower interface 28 b . Without limitation, the isolator 26 can be located below a piezoelectric transducer (PZT) transmitter 22 . Examples of such acoustic transducers and their construction are shown in Drumheller U.S. Pat. No. 5,703,836 for Acoustic Transducer and Drumheller U.S. Pat. No. 6,188,647 for Extension Method of Drillstring Component Assembly, which are incorporated herein by reference.
[0049] The focus of the present invention is to implement designs of isolators 26 comprising inner and outer tubular, coaxial isolation members 30 , 32 (pipes of various types) such that judicious control of their impedances and transient times may result in a useful and necessary apparatus, i.e. the parallel-path acoustic isolator 26 which can be incorporated in the acoustic isolation system 2 .
[0050] First, it should be understood that the wave speed c and characteristic acoustic impedance z of a pipe section i of uniform material properties and wall area are:
[0000] c i =√{square root over ( E i /ρ i )} [1]
[0000] z i =√{square root over (ρ i E i )} A i =ρ i c i A i [2]
[0051] where
ρ i =material mass density E i =material stiffness (Young's modulus) A i =wall area of the pipe
[0055] Also note that pipe section i with wave speed c i and length L has a transit time of
[0000] Δt i =L/c i [3]
[0056] The basic principle of operation of this invention can be understood through an examination of an upwardly traveling incident simple wave W. 1 (see FIGS. 2 , 3 ). Typically, as this wave encounters the lower interface 28 b it gives rise to a reflected wave W. 1 in pipe section 18 and transmitted waves W. 3 , W. 2 in pipes 30 and 32 respectively. Subsequent interactions of waves W. 3 and W. 2 with upper interface 28 a give rise to reflections W. 5 , W. 4 in pipes 30 and 32 respectively as well as a transmitted wave W. 6 in upper pipe section 18 a . As time progresses wave reflections continue at interfaces 28 a and 28 b , producing ever more complex modifications of the waves in pipes 30 and 32 as well as additional modifications to the reflected wave W. 7 and transmitted wave W. 6 . When the primary incident wave W. 1 is a harmonic wave of frequency f it is possible to analyze these wave interactions and thereby derive the following expression:
[0000] I=G ( f ) T [4]
[0057] where
[0058] I=amplitude of material velocity of the incident wave W. 1
[0059] T=amplitude of material velocity of the transmitted wave W. 6
[0060] G(f)=transfer function of parallel-path isolator, which is a function of f.
[0061] The object of designing an isolator is to make the transmitted amplitude T zero or nearly zero for arbitrary finite values of the amplitude I. This occurs in the neighbourhood of the poles of the transfer function G(f). The locations of the poles are given by:
[0000] z 2 (1− P 1 2 ) P 2 +z 1 (1− P 2 2 ) P 1 =0 [5]
[0000] where
[0000] P i =exp( ik i L ) [6]
[0062] Controlling the locations of the roots of [5] is key to designing an isolator, and this is best achieved by examining the function
[0000] S ( f )=| z 2 (1− P 1 2 ) P 2 +z 1 (1− P 2 2 ) P 1 | [7]
[0063] which will be referred to as the pole equation. A plot of this equation reveals the frequencies f r where S(f r )=0. These frequencies are the solutions of [5]. Another simplified expression yields the solution for the reflected wave W. 7 at the root frequencies f r :
[0000]
R
=
1
+
K
(
f
r
)
1
-
K
(
f
r
)
I
[
7
a
]
K
(
f
)
=
z
2
(
1
+
P
2
)
z
4
(
1
-
P
2
)
+
z
2
(
1
+
P
1
)
z
4
(
1
-
P
1
)
[
7
b
]
[0064] where R=amplitude of wave W. 7 .
[0065] It is now instructive to examine a special case of [5] in which both the pipes 30 and 32 have the same impedance. Indeed for z 1 =z 2 equation [5] yields:
[0000] ( P 1 +P 2 )(1− P 1 P 2 )=0. [8]
[0000] The roots of [8] are obviously:
[0000] P 1 =−P 2 [9]
[0000] P 1 P 2 =1. [10]
[0066] Substitution of [6] in these expressions yields the following frequency pairs
[0000]
f
r
=
2
n
+
1
2
L
1
/
c
1
-
1
/
c
2
[
11
]
f
r
=
n
+
1
L
(
1
/
c
1
+
1
/
c
2
)
[
12
]
[0067] where n is an arbitrary integer including zero, and
[0000] L=length of pipes 30 and 32
Each value of n yields a pair of frequencies from [11] and [12]. The pair of frequencies obtained for n=0 are of particular use. Solving this specific pair of frequencies for L yields:
[0000]
L
=
1
2
f
r
1
/
c
1
-
1
/
c
2
[
13
]
L
=
1
f
r
(
1
/
c
1
+
1
/
c
2
)
[
14
]
[0068] Considering an incident wave W. 1 whose frequency satisfies [9] will now provide an instructive discussion of the operation of the isolator. Upon initially encountering interface 28 b a wave of this frequency produces transmitted waves W. 2 , W. 3 in pipes 30 and 32 respectively. Waves W. 2 and W. 3 are in phase as they leave interface 28 b , and because z 1 =z 2 their forces and material velocities are equal. However, each wave travels at a different velocity upwardly towards interface 28 a.
[0069] Because the frequency satisfies [9], waves W. 2 and W. 3 are caused to arrive at interface 28 a with values of force and velocity that are opposite in sign to each other. Thus the total force and motion exerted by pipes 30 and 32 on interface 28 a is ideally at or near zero, and little or no transmitted wave W. 6 is produced in pipe segment 18 a.
[0070] Parallel path isolators 26 can be designed from these expressions. The following examples illustrate how.
Example 1
[0071] Table 1 contains material specifications and dimensions for pipes 30 and 32 of a parallel-path isolator. The sizes would be compatible with typical 6.5″ oilfield drilling tools. Notice that both pipes are chosen such that they have the same characteristic impedance z. The center frequency of the required isolation band is specified to be 660 Hz.
[0000]
TABLE 1
Material
Pipe 30 (Lead)
Pipe 32 (Stainless steel)
OD (in)
5.7
6.5
ID (in)
2.5
5.76
A (m 2 )
0.009
0.0046
ρ (Mg/m 3 )
11200
7760
E (GPa)
15.8
191
c (m/s)
1188
4961
z (Mg/s)
177
177
[0072] We are now able to employ solutions to [13] and [14]. They yield the following values for the length of pipes 30 and 32 respectively:
L=1.18 m (pipe 30 ) L=1.45 m (pipe 32 )
[0075] Setting the length of the isolator to the average of these two values (L=1.32 m) will center the pair of poles about 660 Hz.
[0076] FIG. 4 is a plot of the pole equation [7] over the range of frequencies from 0 to 1200 Hz. The zero points at 590 Hz and 730 Hz are the frequencies given by [13] and [14]. Notice that the two poles are centered about the desired frequency: 660 Hz.
[0077] The harmonic analysis using equation [4] is shown in FIG. 5 , illustrating the magnitude |T| of wave W. 6 due to an incident wave W. 1 of unit magnitude |I|=1 is provided by |T|=|G(f)| −1 .
[0078] Note that at the frequencies corresponding to the zero points, 590 Hz and 730 Hz, there is no transmitted wave because |T|=|G(f)| −1 =0 at these frequencies. However, if the frequency of the wave is unequal to either of the two pole frequencies it will not be completely reflected by the isolator, and some wave energy will enter pipe 18 a.
[0079] In FIG. 5 the transfer function is determined for two cases. In the first case the acoustic impedances of pipe segments 18 b and 18 a are 700 Mg/s. In the second case they are 354 Mg/s. Note that this latter case represents an impedance match to the parallel-path isolator as z 3 =z 4 =z 1 +z 2 . FIG. 5 shows the amplitude of the wave that passes through the isolator to pipe 18 a from pipe segment 18 b . Curve 43 represents the response for the matched impedances of 354 Mg/s. Curve 42 represents the response when pipe segments 18 a and 18 b have impedances of 700 Mg/s. For an ineffective isolator these curves would be flat with constant amplitude of 1. Indeed both curves again confirm that waves with the pole frequencies of 590 and 730 Hz are completely blocked by the isolator 26 (see points 44 and 45 in FIG. 5 ) and in the passband between these two frequencies the isolator remains effective.
[0080] Note the similarity in the plots of the pole equation [7] in FIG. 4 and the plots of the transmitted amplitude T in FIG. 5 , particularly in the neighbourhood around and between the pole frequencies themselves. This is particularly useful in the design of an isolator due to the simplicity of the pole equation. The pole equation also has another interesting feature. To illustrate this, suppose the impedance of pipe 32 is reduced from 177 Mg/s to 159 Mg/s. FIG. 6 is the corresponding plot of the pole equation. Note the two pole frequencies have merged to form a tangent point at the center frequency: 660 Hz, thereby improving the bandwidth of total isolation. This is evident in FIG. 7 which contains the results for the transmitted wave amplitudes obtained from harmonic analysis.
Example 2
[0081] FIG. 8 shows an isolator 52 comprising an alternative aspect of the present invention with an inner mandrel 54 of beryllium copper (BeCu). The isolator 52 is otherwise similar to the isolator 26 of Example 1. It is then necessary to increase the inner diameter of an inner pipe 56 to allow room for the modified mandrel. The lead could be attached directly to the mandrel 54 to form a composite structure that functions similarly to inner pipe 30 of the first isolator 26 discussed above. In this new isolator 52 the lead of the inner pipe 30 can be replaced by another material, such as “High Gravity” particle-filled nylon in the inner pipe 56 , which can be molded to the features on the mandrel 54 . The properties of these materials are listed in Table 2 below:
[0000]
TABLE 2
Composite
High Gravity
(HG Nylon +
Stainless
Material
Nylon
BeCu
BeCu)
Steel
OD (in)
5.45
3.4
5.45
6.5
ID (in)
3.4
2.5
2.5
5.76
A (m 2 )
0.0092
0.0027
0.0119
0.0046
ρ (kg/m 3 )
8000
8370
8083
7760
E (GPa)
11.7
131
38.7
191
c (m/s)
1209
3956
2188
4961
z (Mg/s)
88.9
89.1
210
177
[0082] The column labelled Composite contains the averaged properties of the High Gravity/BeCu composite pipe 54 / 56 , which also includes the averaged density and the parallel-coupled stiffness. The composite wave speed and impedance are computed from [1] and [2] using the listed composite values of stiffness, density and area. The isolator 52 is constructed of the mandrel 54 and the inner pipe 56 with the properties listed in the composite column and an outer pipe 58 (tubular member) with properties listed in the Stainless Steel column of Table 2. The length L of this isolator is 2.65 m.
[0083] This length as well as the outside diameter of the High Gravity Nylon inner pipe 56 is determined by iteration of parameters in the pole equation [7] until the plot in FIG. 9 is obtained. The outside diameter of the High Density Nylon inner pipe 56 is adjusted to achieve convergence of the poles, and the length is adjusted to place the center isolation frequency at 660 Hz. The transfer function of this isolator is shown in FIG. 10 .
Example 3
[0084] FIG. 11 shows an acoustic energy isolation system 62 comprising another alternative aspect of the present invention with a piezoelectric transducer (PZT) transmitter 64 , which is adapted for use with an isolator 66 , which can be constructed similarly to the isolators 26 and 52 described above. Tuning a transmitter is another important use of an isolator. To illustrate how this can be accomplished consider the isolator 66 and the PZT transmitter 64 attached to each other with a tuning pipe 68 . The isolator 66 is defined as in Example 2. The assembly of 64 , 66 and 68 is bounded by two semi-finite pipe sections 70 a and 70 b , located respectively above and below 64 , 66 . The transmitter 64 , bounding pipes 70 a and 70 b and the tuning pipe 68 all have impedances of z 4 =700 Mg/s. A harmonic voltage is applied to the PZT transmitter 64 of sufficient amplitude to cause it to emit upwardly and downwardly traveling waves in pipes 70 a and 68 respectively. These waves have unit amplitude when measured with respect to their material velocity. Note that when the frequency of the waves is 660 Hz the isolator 66 will reflect the downwardly traveling wave and cause it to combine with the upwardly traveling wave to form a combined wave W. 8 . Depending on the physical length of the isolator 66 this combination will either be constructive or destructive producing amplitudes in wave W. 8 that may range between 0 and 2. It is desired to adjust the length of the isolator 66 to a value that yields an amplitude of approximately 2 for wave W. 8 . It is known that the two original waves emitted by the PZT transducer are out of phase by π radians. Thus if the downwardly traveling wave is delayed by another π radians (i.e. net 2π radians) before it is combined with the upwardly traveling wave they will combine constructively. Before combining with the upwardly traveling wave, this wave must travel down the tuning pipe 68 , undergo reflection by the isolator 66 , travel back up pipe 68 and travel up the PZT transmitter 64 . Therefore the required length of the tuning pipe 68 is determined as follows:
[0085] A phase shift of π radians is achieved when the total delay equals half the period of a 660 Hz wave i.e. 758 μs.
[0086] The time for a wave to travel up transmitter 64 is a known property and for this particular example it is 20.5 μs.
For this isolator equation [7a] yields a value of R/I=∠−0.555 radians. This is interpreted as the reflection is equal in amplitude to the downwardly traveling wave but delayed in phase by 0.555 radians. As the period of a 660 Hz wave is 1515 μs the delay due to the isolator reflection is
[0000]
1515
=
0.555
2
π
=
133.8
μs
.
[0088] The additional delay required for constructive combination is:
[0000] 758 − 20 . 5 − 133 . 8 = 603 . 7 μs.
[0089] This delay must be achieved by a double transit of the steel tuning pipe 68 , which has a known wave speed of 4961 m/s.
[0090] Thus the length of the tuning pipe 68 is
[0000]
4961
×
0.0006037
2
=
1.5
m
.
[0091] Using this length for the tuning pipe 68 , harmonic analysis of the system yields the amplitude for waves W. 8 and W. 9 . FIG. 12 contains plots of the upwardly traveling wave W. 8 (see curve 73 ) and the downwardly traveling wave W. 9 that is able to proceed past the isolator (see curve 74 ). Note that at 660 Hz the amplitude of curve 73 is 2, and the amplitude of curve 74 is 0, thus a complete constructive combination of the waves occurs at this frequency.
[0092] The foregoing explains the innovative method by which an isolator can be built with bandstop properties determined by causing acoustic telemetry waves to travel along specific parallel tubular members such that the ensemble set of reflected and transmitted waves combine with phases that aid unidirectional requirements of an isolating filter.
[0093] It is shown how the components of the isolator may be tuned to respond to certain frequency bandpass structures inherent in drillpipe. This enables an acoustic transmitter incorporated in the BHA in a drilling environment to beneficially transmit in a net upward direction, thereby doubling its wave amplitude in that direction.
[0094] It is also shown how the components of the isolator may be tuned to respond to certain frequency bandpass structures inherent in downhole production strings, also aiding the transmission of acoustic telemetry signals in a specified direction of benefit to said telemetry.
[0095] A notable advance on the previous art is afforded by this invention is to be to provide impressive filter functionality in tubular mechanical materials appropriate to oil and gas drilling and production in a relatively small length considering that the wavelength in drill pipe at 660 Hz is approximately 8 m.
[0096] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that the disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention.
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An acoustic telemetry isolation system and method for use with tubular assemblies such as drillpipe and production tubing includes an acoustic wave transmitter and an acoustic isolator. A “down” wave propagated toward the isolator is reflected back substantially in phase with an “up” wave propagated from the acoustic wave source away from the isolator. Furthermore, the acoustic isolator is similarly effective in reflecting “up” propagating waves originating from below the isolator, hence further protecting the acoustic wave source from possible deleterious interference. The construction of the isolator utilizes a specified combination of waves traveling in parallel in materials whose properties aid the beneficial combination of reflected and transmitted waves. The design of the isolator is to generally provide a bandstop filter function, thereby aiding the frequency isolation of an acoustic transmitter over a passband that may be constrained by the geometry of drill pipe or components of production tubing. It causes substantially all of the emitted wave energy to travel in a chosen direction along the drill pipe, thus aiding the efficiency of acoustic telemetry in the pipe.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a technique allowing communications between a computer and a network such as a switched telephone network.
[0003] 2. Description of the Related Art
[0004] With the widespread use of personal computers (PCs), the demands for voice communication between personal computers through a telephone network are growing. Conventionally, voice data communication is performed using telephone terminal equipment connecting a personal computer to the telephone network. More specifically, the telephone terminal equipment is provided with a phase-locked loop circuit that is used to synchronize to a clock signal extracted from the telephone network.
[0005] It is necessary to synchronize all devices connected to the same communication line and therefore the USB (universal serial bus) interface is used to synchronize the clock of a PC to the clock signal extracted from the telephone network. However, the clock of a PC cannot be controlled from outside. Accordingly, it is difficult or almost impossible to establish synchronization of a PC.
[0006] When clock synchronization is not perfectly established, the clock of a PC that is used to digitize a voice signal and the transmission clock of the telephone network are independently running. In the case where the PC clock frequency is higher than the transmission clock frequency of the telephone network, the digital signal generated by the PC cannot be transmitted to the telephone network. Contrarily, when the PC clock frequency is lower than the transmission clock frequency of the telephone network, data to be transmitted to the telephone network is partly lost, which causes noise due to slips of voice data.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide a clock adjustment method and apparatus allowing stable and reliable voice communication between a computer and a network without generating noise due to slips of voice data.
[0008] According to an aspect of the present invention, an apparatus connecting a first network and a second network to transfer data between them, wherein the first and second networks operate at different clock frequencies, respectively, includes: a first interface to the first network; a second interface to the second network; a buffer memory connected to the first interface, for storing data to be transferred to one of the first and second networks; a clock converter connected between the buffer memory and the second interface, performing a clock conversion according to a controlled clock signal corresponding to the first network and an extracted clock signal that is extracted from the second network; a buffer monitor for monitoring an amount of data stored in the buffer memory to produce a buffer status signal; and a clock adjuster for adjusting the controlled clock signal depending on the buffer status signal.
[0009] The clock adjuster may change a frequency of the controlled clock signal so that the amount of data stored in the buffer memory is kept at a predetermined level. The clock adjuster may change a frequency of the controlled clock signal by an amount within a permissible frame clock error which may occur in the first interface.
[0010] According to another aspect of the present invention, an apparatus includes: a USB (universal serial bus) interface to a USB bus connected to the personal computer; a network interface to the switched telephone network; a transmission buffer memory for storing transmission digital voice data that the personal computer transmits; a reception buffer memory for storing reception digital voice data received from the switched telephone network via the network interface; a PCM modulator for modulating the transmission digital voice data to produce a transmission PCM signal; a PCM demodulator for demodulating a reception PCM signal to produce the reception digital voice data; a transmission clock converter connecting the PCM modulator to the network interface, performing a clock conversion according to a controlled clock signal corresponding to the USB interface and an extracted clock signal that is extracted from the second network; a reception clock converter connecting the network interface to the PCM demodulator, performing a clock conversion according to the controlled clock signal and the extracted clock signal; a buffer monitor for monitoring an amount of data stored in each of the transmission and reception buffer memories to produce a buffer status signal; and a clock switching controller for switching a frequency of the controlled clock signal to one selected from a plurality of predetermined frequencies depending on the buffer status signal.
[0011] The clock switching controller may switch a frequency of the controlled clock signal so that the amount of data stored in the buffer memory is kept at a predetermined level. The plurality of predetermined frequencies may be a normal frequency, a lower frequency, and a higher frequency, wherein a difference between each of the lower and higher frequencies and the normal frequency falls into a range within a permissible frame clock error which may occur in the USB interface. The permissible frame clock error may be 5% of a normal frame clock of the USB bus.
[0012] The transmission clock converter may include: a first coder for coding the transmission PCM signal to produce a transmission analog voice signal according to the controlled clock signal; and a first decoder for decoding the transmission analog voice signal to produce network-side transmission PCM signal according to the extracted clock signal. The reception clock converter may include: a second coder for coding network-side reception PCM signal to produce a network-side reception analog voice signal according to the extracted clock signal; and a second decoder for decoding the network-side reception analog voice signal to produce the reception PCM signal according to the controlled clock signal.
[0013] The digital voice data may be transferred through the USB bus in an isochronous mode.
[0014] The transmission buffer memory and the reception buffer memory may be FIFO (first-in-first-out) memories, respectively.
[0015] The transmission buffer memory may include a plurality of FIFO memories and the reception buffer memory comprises a plurality of FIFO memories.
[0016] A control method for a telephone terminal connecting a personal computer and a switched telephone network to transfer voice data between them, includes the steps of: storing digital voice data to be transferred to one of the personal computer and the switched telephone network in a buffer memory; monitoring an amount of data stored in the buffer memory to produce a buffer status signal; adjusting a frequency of a controlled clock signal corresponding to the personal computer depending on the buffer status signal; extracting an extracted clock signal from the switched telephone network; and converting an operation clock between the personal computer and the switched telephone network according to the controlled clock signal and the extracted clock signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a block diagram showing the configuration of a clock adjustment apparatus according to an embodiment of the present invention;
[0018] [0018]FIG. 2 is a diagram showing a clock adjustment operation of the embodiment when transferring data from a PC to a telephone network; and
[0019] [0019]FIG. 3 is a diagram showing a clock adjustment operation of the embodiment when transferring data from the telephone network to the PC.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to FIG. 1, a personal computer (PC) 1 and a telephone terminal 3 are connected via a USB bus 2 . The telephone terminal 3 includes a clock adjustment apparatus according to an embodiment of the present invention and is connected to a switched telephone network 4 .
[0021] The telephone terminal 3 is provided with a USB interface 11 allowing isochronous communication with the PC 1 through the USB bus 2 . Here, it is assumed that the USB bus 2 allows 16-byte voice data to be transferred for each frame of 1 msec in the isochronous mode. The output terminal of the USB interface 11 is connected to a PCM (pulse code modulation) modulator 12 through a FIFO (first-in first-out) memory section 101 - 104 . The input terminal of the USE interface 11 is connected to a PCM demodulator 13 through a FIFO memory section 201 - 204 .
[0022] Each FIFO memory section may be composed of a single FIFO memory or a plurality of FIFO memories connected in series. Here, the FIFO memory section between the USE interface 11 and the PCM modulator 12 is composed of 16-byte FIFO memories 101 - 104 and the FIFO memory section between the USB interface 11 and the PCM demodulator 13 is composed of 16-byte FIFO memories 201 - 204 .
[0023] As described later, when 16-byte transmission voice data enters the FIFO memory section 101 - 104 for the first time,, the transmission voice data is sequentially transferred through the FIFO memories 101 - 103 and stored in the FIFO memory 104 , In this manner, transmission voice data is sequentially stored in the FIFO memory section starting from the FIFO memory 104 .
[0024] Contrarily, when 16-byte reception voice data enters the FIFO memory section 201 - 204 for the first time, the reception voice data is sequentially transferred through the FIFO memories 204 - 202 and stored in the FIFO memory 201 . In this manner, reception voice data is sequentially stored in the FIFO memory section starting from the FIFO memory 201 .
[0025] The PCM modulator 12 and PCM demodulator 13 are connected to a USB-side coder/decoder (CODEC) 14 , which is connected to a line-side CODEC 15 . The line-side CODEC 15 is connected to the switched telephone network 4 via a line interface 16 . Here, it is assumed that the line interface 16 transmits and receives an 8-bit PCM signal for each frame of 125 μsec to and from the switched telephone network 4 .
[0026] The USB-side CODEC 14 receives a transmission PCM signal from the PCM modulator 12 and converts it into a transmission analog signal. The line-side CODEC 15 receives the transmission analog signal from the USB-side CODEC 14 and converts it into a line-transmission PCM signal to be transmitted to the switched telephone network 4 . When receiving a reception PCM signal from the line interface 16 , the line-side CODEC 15 converts it into a reception analog signal. The USE-side CODEC 14 receives the reception analog signal from the line-side CODEC 15 to convert it into a USB-reception PCM signal and outputs it to the PCM demodulator 13 .
[0027] The USB-side CODEC 14 converts a transmission PCM signal into analog according to a controlled clock signal supplied from a clock generation switch 17 . The line-side CODEC 15 converts the transmission analog signal into digital according to an operation clock signal supplied from a clock supplier 18 connected to a clock extractor 19 . The clock extractor 19 is connected to the line interface 16 to extract a line clock signal from the switched telephone network 4 . The clock supplier 18 produces the operation clock signal from the line clock signal to operate the line-side CODEC 15 . In this manner, clock conversion is performed such that a PCM signal is converted into an analog signal according to one clock signal and the resultant analog signal is converted into a PCM signal according to the other clock signal.
[0028] The telephone terminal 3 is further provided with a FIFO status monitor 20 that monitors the statuses of respective ones of the FIFO memory sections 101 - 104 and 201 - 204 . More specifically, the FIFO status monitor 20 monitors the amount of transmission data storing in the FIFO memory section 101 - 104 and monitors the amount of reception data storing in the FIFO memory section 201 - 204 . For example, each of the FIFO memories 101 - 104 and 201 - 204 outputs a full-status signal to the FIFO status monitor 20 when the FIFO memory becomes full and outputs an available/empty-status signal until the FIFO memory is full. The details will be described later (see FIGS. 2 and 3).
[0029] The FIFO status monitor 20 outputs a FIFO status signal to a clock controller 21 , which controls the clock generation switch 17 depending on the FIFO status so that an appropriate clock frequency is supplied to the USB-side CODEC 14 . Hereafter, a clock adjustment operation according to the present embodiment will be described in detail.
CLOCK ADJUSTMENT
[0030] Referring to FIG. 2, each of the 16-byte FIFO memories 101 - 104 outputs a full-status signal to the FIFO status monitor 20 when the FIFO memory has stored 16-byte transmission voice data for each frame and outputs an empty-status signal when the FIFO memory stores no data. Here, the FIFO status monitor 20 outputs one of four FIFO status signals to the clock controller 21 depending on the amount of transmission voice data stored in the FIFO memories 101 - 104 .
[0031] As shown in FIG. 2, when the FIFO memories 103 and 104 are full and the remaining FIFO memories 102 and 101 are empty, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 . Here, the period of the normal-frequency clock is 125 μsec. In other words, the clock generation switch 17 supplies the USB-side CODEC 14 with a frame pulse signal having a period of 125 μsec.
[0032] When only the FIFO memory 104 is full and the remaining FIFO memories 101 - 103 are empty, it means that the frequency of the PC-side clock is lower than that of the controlled clock generated by the clock generation switch 17 . Accordingly, the clock controller 21 controls the clock generation switch 17 so that a lower-frequency (lower-speed) clock signal with respect to the normal-frequency clock signal is supplied to the USB-side CODEC 14 to increase the amount of data stored in the FIFO memory section. When the amount of data stored in the FIFO memory section becomes normal, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 .
[0033] The lower frequency is lower than the normal frequency by an amount within a permissible frame clock error of ±5% which may occur in the USB interface 11 and the PC clock can accommodate. For example, the lower-frequency clock signal has a period of 132 μsec. In other words, the clock generation switch 17 switches the period of a frame pulse signal supplied to the USB-side CODEC 14 from 125 μsec to 132 μsec.
[0034] When the FIFO memories 102 - 104 are full and only the FIFO memory 101 is empty, which is caused by frame pulse jitter on the USB bus 2 and/or by the frequency of the PC-side clock higher than that of the controlled clock generated by the clock generation switch 17 . Accordingly, the clock controller 21 controls the clock generation switch 17 so that a higher-frequency (higher-speed) clock signal with respect to the normal-frequency clock signal is supplied to the USB-side CODEC 14 to decrease the amount of data stored in the FIFO memory section. When the amount of data stored in the FIFO memory section becomes normal, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 .
[0035] The higher frequency is higher than the normal frequency by an amount within a permissible frame clock error of ±5% which may occur in the USB interface 11 and the PC clock can accommodate. For example, the higher-frequency clock signal has a period of 117 μsec. In other words, the clock generation switch 17 switches the period of a frame pulse signal supplied to the USB-side CODEC 14 from 125 μsec to 117 μsec.
[0036] When the PC 1 starts data transmission in the isochronous mode, transmission voice data sequentially store into the FIFO memories 101 - 104 as described before. When the FIFO memories 104 and 103 become full, the clock generation switch 17 starts supplying the normal-frequency clock signal to the USB-side CODEC 14 under control of the clock controller 21 as described before. If the transmission voice data are stored in the FIFO memories 104 to 102 , the clock controller 21 switches the normal-frequency clock signal to the higher-frequency clock signal. Contrarily, when the FIFO memories 101 - 103 become empty, the clock controller 21 switches the normal-frequency clock signal to the lower-frequency clock signal.
[0037] Referring to FIG. 3, each of the 16-byte FIFO memories 201 - 204 outputs a full-status signal to the FIFO status monitor 20 when the FIFO memory has stored 16-byte reception voice data for each frame and outputs an empty-status signal when the FIFO memory stores no data. Here, the FIFO status monitor 20 outputs one of four FIFO status signals to the clock controller 21 depending on the amount of reception voice data stored in the FIFO memories 201 - 204 .
[0038] As shown in FIG. 3, when the FIFO memories 201 and 202 are full and the remaining FIFO memories 203 and 204 are empty, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 . Here, the period of the normal-frequency clock is 125 μsec. In other words, the clock generation switch 17 supplies the USB-side CODEC 14 with a frame pulse signal having a period of 125 μsec.
[0039] When only the FIFO memory 201 is full and the remaining FIFO memories 202 - 204 are empty, it means that the frequency of the PC-side clock is higher than that of the controlled clock generated by the clock generation switch 17 . Accordingly, the clock controller 21 controls the clock generation switch 17 so that a higher-frequency (higher-speed) clock signal with respect to the normal-frequency clock signal is supplied to the USB-side CODEC 14 to increase the amount of data stored in the FIFO memory section. When the amount of data stored in the FIFO memory section becomes normal, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 .
[0040] As described before, the higher frequency is higher than the normal frequency by an amount within a permissible frame clock error of ±5% which may occur in the USB interface 11 and the PC clock can accommodate. Here, the higher-frequency clock signal has a period of 117 μsec.
[0041] When the FIFO memories 201 - 203 are full and only the FIFO memory 204 is empty, it means that the frequency of the PC-side clock is lower than that of the controlled clock generated by the clock generation switch 17 . Accordingly, the clock controller 21 controls the clock generation switch 17 so that a lower-frequency (lower-speed) clock signal with respect to the normal-frequency clock signal is supplied to the USB-side CODEC 14 to decrease the amount of data stored in the FIFO memory section. When the amount of data stored in the FIFO memory section becomes normal, the clock controller 21 controls the clock generation switch 17 so that a normal-frequency (normal-speed) clock signal is supplied to the USB-side CODEC 14 .
[0042] The lower frequency is lower than the normal frequency by an amount within a permissible frame clock error of ±5% which may occur in the USE interface 11 and the PC clock can accommodate. Here, the lower-frequency clock signal has a period of 132 μsec.
[0043] When the line-side CODEC 15 starts operating in response to reception of data from the switched telephone network 4 , the clock generation switch 17 starts supplying the USB-side CODEC 14 with the normal-frequency clock signal. Accordingly, reception voice data sequentially store into the FIFO memories 201 - 204 as described before. When the FIFO memories 201 and 202 become full, the USB interface 11 starts sequentially transferring the stored voice data to the PC 1 through the USB bus 2 in the isochronous mode. When the reception voice data are stored in the FIFO memories 201 to 203 , the clock controller 21 switches the normal-frequency clock signal to the lower-frequency clock signal. Contrarily, when the FIFO memories 202 - 204 become empty, the clock controller 21 switches the normal-frequency clock signal to the higher-frequency clock signal.
[0044] As described above, data transmission and reception can be performed by the telephone terminal 3 according to the clock adjustment operations as shown in FIGS. 2 and 3, respectively. Accordingly, even in the case where the PC clock is not synchronized to the line clock of the switched telephone network 4 , the clock adjustment allows continuous voice data transmission without data slip or noise, resulting in improved stability and reliability on voice data communication.
[0045] In the above embodiment, the FIFO memory section is composed of a plurality of FIFO memories connected in series. It is also possible to use a single FIFO memory having a necessary capacity.
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An apparatus allowing stable and reliable voice communication between a computer and a network without generating noise due to slips of voice data is disclosed. A FIFO memory section temporarily stores voice data. A clock converter performs a clock conversion between the computer and the network according to a controlled clock signal and a network-extracted clock signal. The amount of data stored in the FIFO memory section is monitored. A frequency of the controlled clock signal is changed depending on the amount of data stored in the FIFO memory section so that the voice data is continuously transferred.
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BACKGROUND OF THE INVENTION
This application relates to a scroll compressor wherein a back pressure pocket is provided with a fluid supply from a discharge pressure chamber.
Scroll compressors are becoming widely utilized in fluid compression applications. In a scroll compressor, a pair of scroll elements each have a base and a generally spiral wrap extending from their base. The wraps interfit to define compression chambers. One of the two scroll elements is caused to orbit relative to the other, and as this orbiting occurs, compression chambers define between the wraps decrease in volume and an entrapped fluid is compressed.
There are many challenges with a scroll compressor. One challenge is that the internal pressure in the compression chambers tends to force the two scroll members away from each other. To address this challenge, a bias force is applied to urge the two scroll members together.
Scroll compressors are formed with a thrust bearing that acts in opposition to the bias force. The bias force is known to be behind a non-orbiting scroll member in some scroll compressors, and behind the orbiting scroll member in other scroll compressors. In scroll compressors wherein the bias force is placed behind the non-orbiting scroll member, the thrust bearing is on a rear face of the base of the orbiting scroll member. In scroll compressors wherein the bias force is behind the rear face of the orbiting scroll member, the thrust bearing is positioned at radially outer locations on a forward face.
It is known to use a seal that receives a partially compressed fluid as part of the thrust bearing. Typically, a tap taps fluid at an intermediate compression point to a seal chamber.
There are deficiencies with this arrangement. In particular, there are losses due to the cyclic feeding and draining of this back pressure pocket across the tap hole, as the tap hole orbits relative to the pocket. The fluid can actually be bypassed from one compression pocket to the next, with resulting efficiency losses. In addition, the width of the seal chamber must be sufficiently wide so the tap will always be in communication throughout the orbiting cycle.
SUMMARY OF THE INVENTION
A face of a base of an orbiting scroll member is in contact with a thrust bearing. The thrust bearing includes a back pressure pocket and a seal for sealing the back pressure pocket to entrap a compressed fluid. There is a tap for tapping fluid at the discharge pressure into said back pressure pocket.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view through a scroll compressor incorporating the present invention.
FIG. 2 is an enlarged view of a portion of the FIG. 1 compressor.
FIG. 3 shows a detail of a seal element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a compressor 20 incorporating a shaft 22 that is driven to rotate by a motor (not shown). FIG. 2 shows a portion of the compressor 20 . The shaft causes an orbiting scroll member 24 to orbit through a non-rotation coupling, as known. The orbiting scroll member 24 has a wrap which interfits with a wrap on a non-orbiting scroll member 26 . As shown, a force F biases one of the scroll elements toward the other. In the FIG. 1 embodiment, the bias force F is directed to urge the non-orbiting scroll member 26 toward the orbiting scroll member 24 . The bias force may be created by a tapped compressed fluid, or by a mechanical element such as a spring. The bias element is disclosed here schematically by the letter F, and a worker of ordinary skill in the art would recognize how to provide such a bias force.
As the two scroll members 24 and 26 orbit relative to each other, fluid is compressed in compression chambers defined between the wraps of the two scroll members 24 and 26 . This fluid is compressed toward a central discharge port 27 , and discharged into a discharge pressure chamber 28 .
While this application will refer to the scroll wraps as being “generally spiral,” it should be understood that this term would extend to so-called “hybrid” wrap scroll compressors wherein the shape of a scroll wrap is a series of connected curves, rather than a pure spiral. Still, all scroll wraps do extend along curves from a central point radially outwardly, and wrapping around each other. The term “generally spiral” as used in this application extends to all such shapes. While the force is shown behind the non-orbiting scroll member 26 , it is also known to apply a bias force behind the orbiting scroll member 24 , and the teachings of this invention would extend to such a scroll compressor.
As shown, a tap 30 taps this discharge pressure fluid downwardly, and radially inward through a crankcase passage 32 , into a passage 33 through a thrust bearing 34 . As shown, passage 30 is radially outwardly of the scroll members 24 and 26 . This fluid passes into the back pressure pocket 36 .
As shown in FIGS. 2 and 3 , a ring 38 has o-rings 42 at radially outer and radially inner locations to seal the pocket 36 . As can be appreciated, the pocket 36 is internal to the thrust bearing 34 . Of course, other seal types may be used. A passage 48 is provided through the ring 38 to connect its lower and its upper face. The upper face of the ring is provided with a groove defining two lips 50 and 52 able to seal the pocket when the ring is in contact with the wear plate 44 arranged in a recess 46 formed in the base of orbiting scroll member 24 . Pressure distribution on both sides of the ring maintain it in contact with the wear plate, and allow fluid at discharge pressure to act at the rear of the orbiting scroll. In this manner, a force is provided to resist a thrust of an orbiting scroll member 24 downwardly, and away from the non-orbiting scroll 26 .
The thrust bearing 34 may be a sintered impregnated bronze thrust bearing.
With the invention, the radial width of the back pressure chamber 36 may be made smaller than in the prior art. The back pressure chamber 36 will always communicate with its pressure source, and the orbit radius will not matter. Also, the discharge pressure will be at a more constant pressure than the intermediate pressure as used in the prior art.
While the thrust bearing 34 is shown on a rear face of the base of an orbiting scroll member 24 , scroll compressors are also known which have the thrust bearing on a radially outer location of the forward face of the base of the orbiting scroll member. Such an application is typically used when the bias force F is provided to urge the orbiting scroll member 24 upwardly and toward the non-orbiting scroll member. This invention would apply to such arrangements also.
Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A face of a base of an orbiting scroll member is aligned with a thrust bearing. The thrust bearing includes a back pressure pocket and a seal for sealing the back pressure pocket to entrap a compressed fluid. There is a tap for tapping fluid at a discharge pressure into said back pressure pocket.
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TECHNICAL FIELD
[0001] The present invention relates to a method and arrangement in a telecommunication system, in particular to a technique for handling the aggregation of multiple frequency resources in an evolved Universal Terrestrial Radio Access Network or similar telecommunication network.
BACKGROUND
[0002] The Long-Term Evolution (LTE) of the Universal Terrestrial Radio Access Network (UTRAN), also denoted E-UTRAN, as standardized in Rel-8 of the 3rd Generation Partnership Project (3GPP) specifications supports transmission bandwidths up to 20 MHz. In the downlink, LTE uses conventional Orthogonal Frequency Division Multiplexing (OFDM) as the transmission scheme. OFDM provides benefits, e.g. it is robust to time dispersion, but has also some drawbacks, most notably a relatively high peak-to-average power ratio (PAR) of the transmitted signal.
[0003] Power amplifiers have to be designed to meet peak transmission power requirements while still meeting network requirements regarding the average output power (for example, determining the achievable data rate and coverage). The difference between the peak power and the average power determines the so-called amplifier back-off and is thus a measure on how much the power amplifier needs to be “over dimensioned” (or, equivalently, how much is lost in coverage when using the same amplifier but a lower-performance transmission scheme).
[0004] A high PAR implies a larger power back-off in the power amplifier, that is, the power amplifier cannot be used to its full extent. The Cubic Metric (CM) is another, generally more accurate metric, that can be used to represent the amount of back-off required in the power amplifier. In the following, the term “power amplifier metric” (denoting, e.g., PAR, CM, or any other appropriate measure) is used which shall be generally understood as a measure representing the impact of the difference or ratio between the peak power and the average power on the power amplifier design.
[0005] In the uplink, a high power amplifier metric can lead to reduced coverage, higher battery consumption, and/or more expensive implementation. Therefore, for the uplink, LTE has adopted a single-carrier transmission scheme with low power amplifier metric known as DFT (Discrete Fourier Transform)-spread OFDM (DFTS-OFDM) or DFT-precoded OFDM (sometimes also referred to as Single-Carrier Frequency Division Multiple Access, or SC-FDMA). SC-FDMA exhibits a significantly lower PAR than OFDM.
[0006] FIG. 1 is a schematic illustration of an example of an SC-FDMA transmitter stage 100 operable to transmit on a single carrier according to the LTE transmission scheme. In transmitter stage 100 , DFT coder 105 is coupled to OFDM modulator 110 which in turn is coupled to power amplifier 120 through a cyclic-prefix insertion stage 115 operable to insert a cyclic prefix in the output from OFDM modulator 110 before the output is amplified by power amplifier 120 for transmission over carrier 125 . As shown in FIG. 1 , carrier 125 has a bandwidth of 20 MHz. Carrier 125 may be referred to as a frequency resource for the transmission of a set of data blocks. While in FIG. 1 , carrier 125 is shown as having a 20 MHz bandwidth, other bandwidths are possible in the LTE transmission scheme, and the bandwidth may vary (e.g., depending on the number of symbols to be transmitted via carrier 125 ).
[0007] Modulation symbols 101 , shown in FIG. 1 as M modulation symbols, are input to DFT coder 105 and the output of DFT coder 105 is mapped to selective inputs of OFDM modulator 110 . Examples of OFDM modulators comprise an Inverse Fast Fourier Transform (IFFT). The output of OFDM modulator 110 contains the data of modulation symbols 101 (“OFDM symbols”) and is amplified by power amplifier 120 for transmission over carrier 125 .
[0008] The DFT size, for example the size of the DFT performed by DFT coder 105 , determines the instantaneous bandwidth of the transmitted signal while the exact mapping of the DFT coder output to the input of the OFDM modulator 110 determines the position of the transmitted signal within the overall uplink transmission bandwidth. Similar to conventional OFDM, a cyclic prefix is inserted subsequent to OFDM modulation. The use of a cyclic prefix allows for straightforward application of low-complexity frequency-domain equalization at the receiver side.
[0009] In order to meet requirements for International Mobile Telecommunications-Advanced (IMT-Advanced), 3GPP has initiated work on LTE-Advanced. One aspect of LTE-Advanced is to develop support for bandwidths larger than 20 MHz. Another aspect is to assure backward compatibility with LTE Rel-8. Backward compatibility also includes spectrum compatibility. Thus, in one exemplary implementation, to allow for backwards compatibility with LTE Rel-8, an LTE-Advanced spectrum or carrier that is wider than 20 MHz may appear as a number of separate LTE carriers to an LTE Rel-8 terminal. Separate LTE carriers may be referred to as different frequency resources. Thus, each Rel-8 LTE carrier can be referred to as a single frequency resource.
[0010] For early LTE-Advanced deployments, it can be expected that there will be a smaller number of LTE-Advanced-capable terminals compared to many LTE legacy terminals. Therefore, it is desirable to enable the use of frequency resources such that legacy terminals can be scheduled in all parts of the available wideband LTE-Advanced bandwidth. The straightforward way to allow for such optimal backwards compatibility would be by means of frequency resource aggregation. Frequency resource aggregation implies that an LTE-Advanced terminal can receive and transmit on multiple frequency resources, where each frequency resource may have, or may be modified to have, the same structure as a Rel-8 LTE carrier.
[0011] An example of the aggregation of multiple frequency resources is illustrated in FIG. 2 . Frequency resources 210 in FIG. 2 are all located next to each other so as to be contiguous. In the specific example of FIG. 2 , each frequency resource has a bandwidth of 20 MHz. Together, the five frequency resources 210 shown in FIG. 2 aggregate to an aggregated bandwidth of 100 MHz. The frequency resource aggregation shown in FIG. 2 requires that the operator has access to a contiguous spectrum allocation which can be divided to achieve the number of aggregated frequency resources. While in the drawings frequency resources are shown having a bandwidth of 20 MHz, this is for purpose of illustrating a backwards compatible spectrum allocation. Generally, individual frequency resources may have any bandwidth depending upon the number of included subcarriers.
[0012] To provide additional spectrum flexibility, LTE-Advanced may also support aggregation of non-contiguous spectrum fragments, which may be referred to as spectrum aggregation, an example of which is illustrated in FIG. 3 . In the particular example of FIG. 3 , five frequency resources 210 are spectrum aggregated to provide an aggregated bandwidth of 100 MHz. One or more frequency resources 210 are separated by spectrum gaps 320 which separate the one or more frequency resources 210 such that those frequency resources 210 separated by spectrum gaps 320 are not contiguous. Spectrum aggregation allows for the flexible addition of spectra for transmission. For example, an operator may bring into use different spectrum fragments over time depending upon availability for use by the operator.
[0013] The DFTS-OFDM property of a relatively low power amplification metric should be maintained as much as possible when extending the transmission bandwidth across multiple frequency resources, as for example, part of achieving or adding spectra to an LTE-Advanced system (e.g., having a spectrum allocation such as that shown in FIG. 3 ). To achieve a system operable to implement LTE-Advanced by extending the transmission bandwidth across multiple frequency resources, the structure of transmitter stage 100 of FIG. 1 may be generalized to transmit on one or more distinct frequency resources as shown in FIG. 4 .
[0014] FIG. 4 is a schematic illustration of an example of such a generalized transmitter stage 400 operable to be compliant with LTE-Advanced by transmitting on multiple frequency resources. In transmitter stage 400 , DFT coder 105 is coupled to OFDM modulator 110 which in turn is coupled to power amplifier 120 through a cyclic-prefix insertion stage 115 operable to insert a cyclic prefix in the output from OFDM modulator 110 before the output is amplified by power amplifier 120 for transmission over different frequency resources 410 a, 410 b.
[0015] As shown in FIG. 4 , transmitter stage 400 may be operable to receive modulation symbols 401 for transmission on frequency resources 410 a, 410 b substantially simultaneously. As can been seen from FIG. 4 , frequency resources 410 a and 410 b are separated by spectrum gap 420 and are hence non-contiguous. As also shown in FIG. 4 , each frequency resource 410 has a bandwidth of 20 MHz, thus the spectrum aggregation of the two frequency resources yields a total bandwidth of 40 MHz.
[0016] In the system of FIG. 4 , DFT coder 105 and OFDM modulator 110 are scaled to match the larger bandwidth. The output of DFT coder 105 is connected to the input of OFDM modulator 110 . Because the two frequency resources 410 are not contiguous in frequency, zeros will be input to OFDM modulator 110 to allow for gap 420 . In one embodiment of a possible future extension, the control signaling on the Physical Uplink Control Channel (PUCCH) may be located at each of the band edges of the LTE uplink, that is, for example, at the band edges of each frequency resource.
[0017] The structure shown in FIG. 4 is sometimes referred to as Clustered DFTS-OFDM (CL-DFTS-OFDM), where the term clustered refers to the fact that the frequency resources are not necessarily contiguous in frequency but located close to each other. The power amplifier metric of the generated signal is higher than that of conventional DFTS-OFDM, as shown, for example, in FIG. 1 , but still low compared to OFDM and increases with the number of clusters.
SUMMARY
[0018] Accordingly, it is an object to provide a technique to reduce the power amplifier metric in an LTE-Advanced or similar system relying at least in part on non-contiguous frequency resources.
[0019] To this end, according to a first aspect, a method of transmitting modulation symbols on multiple frequency resources is described. The method includes applying a DFT coding per set of modulation symbols of two or more sets of modulation symbols, wherein a first set of modulation symbols from the two or more sets of modulation symbols is to be transmitted on a set of frequency resources handled by the same power amplifier. Then, OFDM modulation is applied to the sets of DFT coded modulation symbols to output a first set of OFDM symbols for transmission on a set of frequency resources, and to output another set of OFDM symbols for transmission on at least one frequency resource distinct from the set of frequency resources used to transmit the first set of modulation symbols. The output of the OFDM modulator carrying the first set of modulation symbols to be transmitted over the set of frequency resources is amplified by a power amplifier exclusive of the power amplification of the output to be transmitted over other frequency resources. Thus, power amplification per set of frequency resources is achieved.
[0020] According to another aspect, a system operable to implement the above method includes a transmitter stage adapted to transmit modulation symbols on multiple frequency resources. The functionality of the transmitter stage may be implemented with multiple stages and components.
[0021] For example, in one aspect, the transmitter stage may include a first DFT coder operable to receive modulation symbols to be transmitted and a second DFT coder operable to receive modulation symbols to be transmitted on a set of frequency resources. A first OFDM modulator is associated with said first DFT coder and coupled to said first DFT coder to receive output from the first DFT coder, and operable to output OFDM symbols for transmission on at least one frequency resource distinct from the set of frequency resources. The transmitter stage further includes a second OFDM modulator associated with the second DFT coder and coupled to the second DFT coder to receive output from said second DFT coder, and operable to output OFDM symbols for transmission on the set of frequency resources. A first power amplifier is coupled to receive output of the first OFDM modulator and is operable to amplify said output for transmission on said at least one frequency resource. A second power amplifier is coupled to receive said output of the second OFDM modulator to and operable to amplify the output for transmission on the set of frequency resources.
[0022] Further aspects, which may or may not be included in particular implementations of the techniques disclosed herein, may serve to provide further functionality and additional features.
[0023] For example, each frequency resource may have a spectrum bandwidth spanning a frequency range compatible in bandwidth to a telecommunication system spectrum bandwidth. The spectrum bandwidth may be defined by the spectrum (e.g., carrier) bandwidth of a legacy telecommunication system. In the exemplary case of an LTE-Advanced system, each frequency resource may thus be defined by the spectrum bandwidth of an LTE system (of typically 1.25/2.5, 5, 10, 15 or 20 MHz).
[0024] In a further example, which may or may not be implemented, the above-described transmitter stage may further comprise a third DFT coder operable to receive modulation symbols to be transmitted on a second set of frequency resources, wherein the frequency resources of the second set of frequency resources are distinct from the other frequency resources, and a third OFDM modulator coupled to said third DFT coder to receive output from said third DFT coder, and operable to output OFDM symbols for transmission on the second set of frequency resources. A third power amplifier may be coupled to receive the output of the third OFDM modulator and operable to amplify the received output for transmission.
[0025] For example, a terminal comprising the above-described transmitter stage may be operable to negotiate with the network, be instructed by the network or decide autonomously to use the second (or any further) DFT coder and/or transmit on a set of frequency resources. In addition, in some implementations, the second DFT coder is coupled to receive modulation symbols from a demultiplexing stage. The second power amplifier may further be coupled to receive the output of the second OFDM modulator through a cyclic-prefix insertion stage operable to insert cyclic-prefixes in said output from said second OFDM modulator.
[0026] Demultiplexing one or more inputs may be used to input modulation symbols to DFT coders. Because frequency resources may be aggregated across a frequency spectrum in a discontinuous manner, a set of frequency resources may be non-contiguous with other frequency resource(s).
[0027] In an aspect, each set of frequency resources comprises a limited number of frequency resources. Thus, a DFT coding may be applied per a limited number of frequency resources and output to be transmitted over the limited number of frequency resources may be amplified by an associated power amplifier. According to another, optional, aspect, a set of frequency resources comprises contiguous frequency resources in the same frequency band.
[0028] Furthermore, aspects of the present invention also support the use of non-contiguous spectrum fragments. Non-contiguous frequency resources may be allocated from non-contiguous spectrum fragments (in, e.g., different frequency bands) as spectrum is used by or made available to an operator. Individual power amplifiers may be associated with individual continuous or non-contiguous frequency resources or sets of continuous, non-contiguous frequency resources. Thus, in one example, OFDM modulator output for transmission over a non-contiguous frequency resource or a set of non-contiguous frequency resources may be amplified per power amplifier, thus yielding a relatively low power amplifier metric per power amplifier.
[0029] The techniques presented herein may be realized in the form of software, in the form of hardware, or using a combined software/hardware approach. As regards a software aspect, a computer program product comprising program code portions for performing the steps presented herein when the computer program product is run on one or more computing devices may be provided. The computer program product may be stored on a computer-readable recording medium such as a memory chip, a CD-ROM, a hard disk, and so on. Moreover, the computer program product may be provided for download onto such a recording medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Further aspects and advantages of the techniques presented herein will become apparent from the following description of embodiments and the accompanying drawings, wherein:
[0031] FIG. 1 schematically illustrates an example transmitter implementation for transmitting on a frequency resource.
[0032] FIG. 2 illustrates an example of carrier aggregation over a contiguous spectrum.
[0033] FIG. 3 illustrates an example of carrier aggregation over a non-contiguous spectrum.
[0034] FIG. 4 schematically illustrates an example transmitter implementation for transmitting on multiple frequency resources.
[0035] FIG. 5 shows a flow diagram of a method embodiment for implementing a transmitter operable to transmit on multiple frequency resources.
[0036] FIG. 6 schematically illustrates an embodiment of a transmitter implementation for transmitting on multiple frequency resources.
[0037] FIG. 7 shows a flow diagram of a method embodiment for transmitting on multiple frequency resources.
DETAILED DESCRIPTION
[0038] In the following description of preferred embodiments, for purposes of explanation and not limitation, specific details are set forth (such as particular transmitter stage components and sequences of steps) in order to provide a thorough understanding of the present invention. It will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. It is evident that the techniques presented herein are not restricted to be implemented in LTE-Advanced systems exemplarily described hereinafter but may also be used in conjunction with other telecommunication systems.
[0039] Moreover, those skilled in the art will appreciate that the functions and steps explained herein below may be implemented using software functioning in conjunction with a programmed microprocessor, an Application Specific Integrated Circuit (ASIC), a Digital Signal Processor (DSP) or a general purpose computer. It will also be appreciated that while the following embodiments will primarily be described in context with methods and devices, the invention may also be embodied in a computer program product as well as in a system comprising a computer processor and a memory coupled to the processor, wherein the memory is encoded with one or more programs that may perform the functions and steps disclosed herein.
[0040] LTE-Advanced systems are designed to transmit across bandwidths and spectra exceeding 20 MHz. In order to allow for backwards compatibility, the bandwidth or spectrum transmitted upon by an LTE-Advanced system is separated into frequency resources (sometimes called “component carriers”) which are themselves backwards compatible. In one scenario, a frequency resource may be a component carrier as utilized by an LTE legacy system. In an implementation example, a component carrier, and thus a frequency resource, may have a bandwidth up to 20 MHz and may be composed of resource blocks (comprising sub-carriers) which may be transmitted over.
[0041] More generally, a frequency resource may be thought of as a series of resource blocks having a bandwidth spanning a portion of a spectrum and existing for a span of N consecutive symbols in the time domain. Such time domain symbols may be OFDM (e.g., SC-FDMA) symbols, and the bandwidth of the resource block may span or include M consecutive subcarriers. Thus a resource block is a block of N×M resource elements. Accordingly, LTE-Advanced systems have the potential to transmit upon multiple frequency resources, the individual frequency resources having the potential for different bandwidths. Examples of resource blocks are further discussed in the 3GPP Technical Specification 36.211 V8.7.0 (2009-05).
[0042] As described previously in the Background Section, to achieve an LTE-Advanced system, transmitter stage 100 depicted in FIG. 1 may be generalized to allow for transmission on multiple frequency resources substantially simultaneously, as, for example, shown in FIG. 4 . As further previously discussed, a generalized transmitter stage, such as that shown in FIG. 4 , exhibits an increasing power amplifier metric as the number of frequency resources scheduled for or handled by the transmitter increases. The increasing power amplifier metric requires that a correspondingly larger power back-off has to be built into the power amplifier of the generalized transmitter stage shown in FIG. 4 . Building such a larger power back-off into a transmitter stage increases the overall size of the transmitter stage, thus undesirably bulking up the transmitter and causing increased power consumption.
[0043] To overcome the problem of an LTE-Advanced system transmitter exhibiting an increasing power amplifier metric as the number of frequency resources which are scheduled for the transmitter stage increases, the following embodiments apply a DFT coding per set of frequency resources as will be discussed below with reference to FIGS. 5 to 7 . Because numerous frequency resources are divided into sets of frequency resources, each set of frequency resources has a limited number of frequency resources. Thus, DFT coding applied to a set of frequency resources is applied to a limited number of frequency resources.
[0044] The transmitter stage may also include multiple power amplifiers. Output for transmission over each set of frequency resources may be amplified at different power amplifiers such that each set of frequency resources is associated with an individual power amplifier and output transmitted over the set of frequency resources amplified by that amplifier. By amplifying output to be transmitted on sets of frequency resources per associated power amplifier, the power amplifier metric per power amplifier may be kept relatively low. Thus, the power back-off built into the power amplifier(s) may be reduced. In one aspect, reducing the number of non-contiguous frequency resources that are encoded by a single DFT reduces the power amplifier metric for the associated power amplifier.
[0045] A terminal operable to transmit on multiple frequency resources, such as, for example, in the uplink, is provided. The frequency resources are divided into sets such that a limited number of frequency resources form a set: output to be transmitted on each set will later be amplified for transmission using different power amplifiers, one power amplifier per set, as discussed above. Frequency resources in each set are transmitted on utilizing clustered DFTS-OFDM (CL-DFTS-OFDM) with different CL-DFTS-OFDM modulators used for the different sets. Such a structure can be referred to as Multi-Carrier CL-DFTS-OFDM (MC-CL-DFTS-OFDM). FIG. 6 schematically illustrates an example of such an MC-CL-DFTS-OFDM system that may be implemented in a terminal such as a mobile telephone, a data card or a portable computer.
[0046] FIG. 5 is a flow diagram of a method embodiment for operating a transmitter stage 600 as shown in FIG. 6 . At step 501 , multiple DFT coders 605 are provided. At step 502 , multiple OFDM modulators 610 are likewise provided. At step 503 , the DFT coders 605 are coupled to their respective associated OFDM modulators 610 . At step 504 , multiple power amplifiers are provided and at step 505 , the OFDM modulators 610 are coupled to their respective associated power amplifiers 620 . Thus yielding the transmitter stage 600 shown in FIG. 6 .
[0047] Referring to FIG. 6 , in transmitter stage 600 , each DFT coder 605 is coupled to an associated OFDM modulator 610 which in turn is coupled to an associated power amplifier 620 through a cyclic-prefix insertion stage 615 . Each cyclic-prefix insertion stage 615 is operable to insert a cyclic prefix in the output from the respective OFDM modulator 610 before the output is amplified by the power amplifier 620 associated with the respective OFDM modulator 610 .
[0048] As can be seen from FIG. 6 , each individual power amplifier 620 amplifies OFDM modulator output for transmission over a set of frequency resources. As can further be seen from FIG. 6 , the DFT coding of DFT coders 605 is applied per set of frequency resources such that modulation symbols coded by a DFT coder 605 are transmitted on a set of frequency resources located closely to each other in frequency (e.g., in the same frequency band). Thus, a DFT coding is applied per set of frequency resources and data output on a set of frequency resources is individually amplified by an associated power amplifier. Each set of frequency resources can have a limited number of frequency resources such that a DFT coding and corresponding OFDM modulation is applied per a limited set of frequency resources. By applying DFT coding and OFDM modulation per a limited number of frequency resources, the power amplification metric is reduced. More particularly, in one aspect, reducing the number of non-contiguous frequency resources coded with a DFT reduces the power amplification metric. This reduces the amount of back-off required in individual power amplifiers 620 receiving output from OFDM modulators 610 .
[0049] In one optional aspect, the frequency resources forming a set of frequency resources are contiguous frequency resources in the same frequency band. This may also reduce the power amplification metric.
[0050] As shown in FIG. 6 , a stream of modulation symbols is provided to DFT coders 605 by a demultiplexing stage 601 . In an optional aspect, demultiplexing stage 601 can supply modulation symbols to each of DFT coders 605 such that each DFT coder 605 may be operable to output coded modulation symbols to its associated OFDM modulator 610 to allow the OFDM modulators 610 to output OFDM symbols for transmission on frequency resources substantially simultaneously. For example, demultiplexing stage 601 may supply modulation symbols to DFT coder 605 b. DFT coder 605 b may apply a DFT coding to the modulation symbols and pass the DFT-coded modulation symbols on to associated OFDM modulator 610 b. OFDM modulator 610 b may then output OFDM symbols for transmission on frequency resources 650 b and 650 c.
[0051] FIG. 7 is a flow diagram of a method embodiment for transmitting modulation symbols, which may be performed utilizing a transmitter stage such as transmitter stage 600 shown in FIG. 6 .
[0052] At step 701 , a DFT coding is applied by DFT coders 605 per set of symbols to be transmitted on the associated set of frequency resources. At step 702 , OFDM modulation is applied by the respective OFDM modulators 610 per set of DFT coded symbols to output sets of OFDM symbols for transmission on sets of frequency resources. At step 703 , a cyclic-prefix is inserted at cyclic-prefix insertion stage 615 . At step 704 , power amplifiers 620 amplify modulator output for transmission over sets of frequency resources such that each power amplifier 620 amplifies output for transmission over an associated set of frequency resources.
[0053] Referring to FIG. 6 , power amplifier 620 a amplifies output from OFDM modulator 610 a for transmission over frequency resource 650 a. Power amplifier 620 b amplifies output from OFDM modulator 610 b for transmission over the set of frequency resources comprising frequency resource 650 b and frequency resource 650 c. Power amplifier 620 c amplifies output from OFDM modulator 610 c for transmission over the set of frequency resources comprising frequency resource 650 d and frequency resource 650 e. Because the sets of frequency resources include a limited number of frequency resources, each DFT coding, OFDM modulation and power amplification is applied per a limited number of frequency resources, reducing the power amplification metric per power amplifier.
[0054] Frequency resource 650 a is separated from the frequency resources associated with power amplifier 650 b by gap 660 a. Similarly, the frequency resources associated with power amplifier 650 b are separated from the frequency resources associated with power amplifier 650 c by gap 660 b. Thus, frequency resources 650 may be spectrum aggregated to achieve an aggregated bandwidth for the transmission of modulation signals or other data utilizing transmission stage 600 of FIG. 6 .
[0055] According to a further aspect, a transmitter stage can be selected or configured which approximates one of the transmitter stages shown in FIG. 4 or FIG. 6 . The selection of which structure to use for an uplink transmission may depend on the number of frequency resources that a terminal is scheduled to transmit upon. For example, in the event that a terminal has sufficient individual power amplifiers to amplify modulation output for transmission on each scheduled frequency resource individually, output to be transmitted on the frequency resources may be individually amplified, one frequency resource per power amplifier, as opposed to being amplified per sets of more than one frequency resources. In an alternative embodiment, the structure to be used is determined based on the number of power amplifiers allocated per user.
[0056] In addition to or as yet another aspect, the terminal and the network may negotiate which structure to use for different scenarios. For example, in a scenario where the number of frequency resources a terminal is scheduled to transmit on is less than or equal to the available power amplifiers, the power amplifiers may each amplify modulator output for transmission over a single frequency resource, even if the spectrum is contiguous.
[0057] By applying DFT coding per set of limited number of frequency resources, for example to a limited number of non-contiguous frequency resources, or amplifying sets of frequency resources per power amplifier, the advantage of a minimized power amplifier metric is achieved, thus allowing for smaller power amplifiers and allowing for a reduction in power consumption and power amplifier size. Thus the techniques disclosed herein provide an approach for transmitting and a transmitter stage yielding a power amplifier metric that is low when transmitting utilizing multiple frequency resources in an LTE-Advanced system. Further advantages of the disclosed techniques include maintaining a low power amplifier metric when transmitting over either frequency resource or spectrum aggregation aggregated spectra.
[0058] The achievement of a low power amplifier metric over the addition of multiple frequency resources allows for an inherently scalable system. Furthermore, because individual frequency resources are themselves backwards compatible in that they allow for use with legacy devices which may utilize a single frequency resource, a backwards compatible and scalable system which minimizes the power amplifier metric is achieved. In addition, this allows for the utilization of non-contiguous spectrum segments, thus enabling for the flexible addition of spectra or changing spectrum use, enhancing system flexibility.
[0059] It is believed that many advantages of the present invention will be fully understood from the forgoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the exemplary aspects thereof without departing from the scope of the invention or without sacrificing all of its advantages. Because the invention can be varied in many ways, it will be recognized that the invention should be limited only by the scope of the following claims.
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The present disclosure relates to a technique for transmitting modulation symbols on multiple frequency resources. A method aspect of this technique includes applying a Discrete Fourier Transform (DFT) coding per set of modulation symbols of two or more sets of modulation symbols, wherein a first set of modulation symbols from the two or more sets of modulation symbols is transmitted on a set of frequency resources handled by the same power amplifier. Then, Orthogonal Frequency Division Multiplexing (OFDM) modulation is applied to the sets of DFT coded modulation symbols to output a first set of OFDM symbols for transmission on the set of frequency resources, and output another set of OFDM symbols for transmission on at least one additional frequency resource distinct from the set of frequency resources. Power amplification is then applied per set of frequency resources at the power amplifier.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electromechanical drive system that includes a transmission, a brushless variable speed electric motor having velocity sensing instrumentation, and an industrial programmable controller. More particularly, this invention pertains to such a system for operating the displaceable carriages of way and transfer units used in automatic machining operations.
2. Description of the Prior Art
Conventional electromechanical slide drive systems employ two motors. One operates at high speed for rapid traverse of the distance between the position of the slidable carriage when the workstation receives the workpiece from the conveyor system to its position before the cutting operation begins. The other motor operates at a much lower speed to feed the cutting tool slowly toward the workpiece during the machining operation. Typically, the two motors operate through an elaborate mechanical transmission employing clutches and brakes to selectively connect the motors through appropriate gear reduction ratios to a lead screw that produces the linear motion of the slide. During the operating cycle, the transitions from rapid forward speed to feed speed, from feed speed to rapid reverse, and from reverse to dwell are controlled by a number of electromechanical limit switches. The clutches, brakes and limits switches and the many gears, belts, bearings used in such systems are susceptible of premature failure and high rates of wear.
Furthermore, the uncertain nature of brake performance requires that the slide position defining conclusion of the high speed traverse and commencement of the low speed feed be located substantially ahead of the point where the cutting tool engages the workpiece. The location of the transition from high speed to feed speed has been found to vary in drive systems according to current practice as much as three-eights of an inch from the intended point of transition. As a consequence of this wide tolerance range and the need to slow the slide unit well away from the workpiece, a considerable amount of lost time is spent in transporting the cutting tool at the slow feed rate into engagement with the workpiece.
Conventional d.c. motors can produce variable speed, high torque and precise control, but the brushes of such motors require frequent maintenance, particularly in the environment of a manufacturing plant. For this reason it is preferable that a brushless motor be used to power the drive system. In addition to providing reliable maintenance-free operation, the preferred motor must produce sufficient torque to move heavy objects at high speed and to feed them against the force of the cutting tool. Furthermore, the motor must develop a high rate of acceleration in order that the cutting tool can be moved quickly toward the workpiece and returned to its rest position. Of course, it is essential that the motor conforming to these specifications consumes as little power as possible.
With conventional slide drives the way units must be decelerated from fast speed to feed speed approximately one-quarter to three-eights of an inch from the work surface to prevent the cutting tool from impacting the workpiece due to slower than normal braking action. The result of premature slowdown is known as "air cutting", i.e., the process during which the tool is advanced slowly enough to cut metal but in reality is merely rotating in air. It is preferable that a slide drive system initiate the feed speed position of the motion cycle closer to the cutting tool, perhaps within 0.002 inches of the work surface.
In conventional slide drives, the feed speed is limited to one of a number of discrete speeds determined by the available gear ratios of the transmission. In order to vary the rate of feed speed, the gear ratios of the transmission must be changed. If the feed rate were infinitely adjustable and could be varied by a simple programming modification made to the control system, variations in the material of the workpiece and quality of the cutting tool could be accommodated to facilitate production. For example, if the hardness varied between batches of workpieces or the sharpness of the cutting tool deteriorated as machining time accrued, conventional slide drives could not automatically change the feed rate. By simple modifications to the programmed feed rate, the control according to this invention can deal with such subtle yet predictable process variations.
The controls for systems heretofore available require complicated mechanical assemblies whose reliability is low and whose repair is difficult, time consuming and costly. Further, these controls are inflexible and not readily adaptable to permit changes in a production line that require alterations in the forming process, variations in the workpiece material or the processing thereof. Highly automated, modern manufacturing production lines require great flexibility in adapting the controls of the forming tools to a wide variety of conditions, processes, and dimensional changes. It is preferable that the controls for operating the mechanical drive be suitable with this requirement for simple and easy changeover. Furthermore, the controls should be adaptive controls to adjust the working cycle to variations in dimensions or machinability between workpieces of the same kind.
SUMMARY OF THE INVENTION
The control system according to our invention is adapted for use with a variable speed electric motor whose rotation produces cyclical forward and reverse movement of a slide. The system includes a proximity switch that produces a signal indicating the location of the slide at a reference position, which when actuated initializes the control system for the next cycle of slide motion. An encoder produces a constant number of electrical pulses during each revolution of the motor shaft and a signal representing the absolute number of rotor shaft revolutions that occur following the initialization signal. The position control produces a signal representing the actual position of the slide relative to the reference position according to the number of encoder pulses that occur after the initialization signal. The position control includes a binary counter that counts the number of pulses received from the encoder after initilization. The binary counter inputs its register value sequentially to a comparator whose other input is a binary number representing the target position of the slide corresponding to a particular slide velocity. The target count and its corresponding velocity are recalled by the microprocessor from a lookup table wherein ordered pairs of slide position and velocity are stored to define the desired relationship between these variables during certain portions of the motor cycle of the slide. When the binary counter register and target count are equal, the comparator issues a signal to the microprocessor, which then transmits an updated signal of the slide velocity command that corresponds to the next target slide position. This signal is received by a binary digital-to-analog converter that produces an analog voltage signal whose polarity represents the sense of direction of the motor rotation and whose magnitude is proportional to the motor speed.
Power from the variable speed electric motor is transmitted through a speed reducer that drives a ball screw turning within a ball nut. The nut is fixed to the slide and moves axially on the ball screw as the shaft is turned. In this way, the position of the slide varies in either direction along the slide path and has a velocity that corresponds directly with the speed of the motor shaft. The mechanical drive system may include a worm gear speed reducer that produces a speed reduction from the motor speed of approximately 6 to 1 , although other speed ratios and speed reducers of other kinds may be used.
The variable speed motor used in connection with this control system is preferably of the d.c. brushless motor type. However, a variable frequency a.c. induction motor, or a variable frequency a.c. synchronous motor having either a soft iron salient pole rotor (reluctance synchronous) or a permanent magnet rotor could be used. In conventional slide drives the choice of feed rate is limited to one of discrete steps determined by the gear ratios available. Alteration of drive hardware is needed to change from one feed rate to another. A substantial gain in productivity is realized with the use of this invention because the feed rate can accommodate infinite adjustments by simply altering program steps or the position-velocity relationship defining slide motion along its path. These parameters are easily modified by changing the lookup tables that are stored in the computer access memory.
Control software can retain in memory many different operating cycles that can be selected by remote control if desired. Machining of different workpieces arriving at the workstation in identical batches or randomly mixed is possible. The control can be adapted to adjust the working cycle to variations in dimensions or machinability variations among workpieces of the same kind.
The control and drive system of this invention represents an advancement in industrial motor technology and provides a powerful and rugged programmable servo-controlled drive unit. The unit is adaptable to applications other than the machine tool slides. It can execute numerically programmable, precisely controlled displacement-time or velocity profile relationship commands with a force of many thousand pounds. The system can be used to replace mechanical drives which employs specially designed cams and offers great adaptability to product changes and the manufacturing installation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the slide driven by a ball screw and nut through a speed reduction gearbox that is powered by a variable speed electric motor.
FIG. 2 is a graphical representation of the desired or target velocity-position relationship over a full cycle of forward and rearward motion for a slide whose position and velocity so defined can be controlled by the system according to this invention.
FIG. 3 is a schematic block diagram of the motor control system for a mechanical slide assembly showing the position control, the microprocessor and the motor servo-control.
FIG. 4 shows the operating relationship of the computer software with the control signals received by and transmitted from the data processor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a variable speed electric motor 12 has its output shaft splined to the worm pinion shaft of a speed reduction gear box 16. An adaptor plate 18 is mounted on the face of the gearbox casting 16 and has a rubber bumper pad 20 abutting the end face of a slide table 22. The slide 22 is mounted on tracks to facilitate its linear movement forwardly away from the electric motor-gearbox assembly and rearwardly toward the assembly.
The slide may have a machine tool mounted thereon adapted to perform a metal cutting operation on a workpiece that is located at the forward end of the slide path. The drive system can be adapted to way units or to transfer units that carry workpieces from one conveyor system to another or between the conveyor and the work station in an automated manufacturing line. The variable speed motor control system of this invention can be used to power any variable speed drive, but is particularly adapted for use with machine slide units. Generally, the slide operates over a repetitive cycle of forward and rearward motion. The cycle begins from the rest or reference position of FIG. 1 where the slide has its rear face abutting the bumper pad 20 of adaptor plate 18.
The mechanical drive system transmits the power from the electric motor 12 through a ball screw 32 that turns within a ball nut 34 fixed driveably at 36 to the slide. The worm and worm gear that drive the ball screw are on non-intersecting, perpendicular shafts, the worm shaft being colinear with the motor shaft and worm gear shaft being colinear with the ball screw 32. The worm and worm gear are formed with the same hand of helix. An arrangement of bumpers 20 and Belleville washers 38 mounted on the inner end of the ball screw absorbs energy that may be dissipated as a result of the slide returning beyond the reference position or failure of the motor to stop the slide before it reaches a mechanical limit. The ball screw is encapsulated in a cylindrical sleeve 43 whose outer end is supported on a stop block 40, which is keyed at 42 to the slide table 22. A telescoping sleeve assembly 39 has one end fixed to ball nut 34 and the opposite end connected to adaptor plate 8. As the nut moves axially, sleeve assembly 39 extends and retracts accordingly.
The worm gear speed reducer produces a speed reduction of 6 to 1 so that the ball screw turns with the maximum velocity of 600 rpm. As the screw rotates, the ball nut fixed to the slide moves axially on the screw whereby slide 22 is advanced and retracted at a velocity corresponding to the rotational speed of the motor and in a direction corresponding to the direction of rotation of the motor, as determined by the polarity of the voltage applied to the motor windings.
FIG. 2 shows the typical velocity-position relationship for a slide unit along its path for one full cycle of slide motion. The cycle begins with the slide at rest at the reference position 23. A step velocity output signal is transmitted to the motor indicating that full rotor speed is desired. Consequently, the slide accelerates along a ramp 24 to the maximum slide velocity 25, 300 inches per minute, which corresponds to the full rotor speed, 3600 rpm. The maximum speed condition can be obtained in approximately 230 mS. The slide attains the constant rapid forward speed 25 and may continue at this speed for approximately one second whereupon the control system decelerates along a ramp 26 to a feed speed 27. While the slide moves at the feed rate, the cutting tool is performing a machining operation on the workpiece. Typically, the cycle includes a dwell period 28 during which the slide pauses for a short time, perhaps for 0.5 seconds, at the conclusion of the feed cycle. The dwell period is followed by the return portion of the cycle during which the slide accelerates along a ramp 29 to the maximum slide velocity 30, which speed it may maintain for perhaps one second. The slide is decelerated along a ramp 31 to the reference position 23 at which point the system is initialized and the next cycle begun following a pause at the reference position that may last for about 5 seconds. During this dwell period and during the return portion of the cycle, the completed workpiece is removed from the work station and the next workpiece is moved into position for the subsequent machining operation.
The deceleration from rapid speed to feed speed along the ramp 26 must be controlled with particular accuracy so that the position of the slide when the feed speed condition begins is perhaps within 0.010 inches of the face of the workpiece to be machined. In conventional drives of this kind the starting point of the feed speed rate is not accurately reproducible; hence the target position must be set substantially ahead of the point where the cutting tool contacts the workpiece. This is done in order to prevent a high speed collision of the cutting tool with the workpiece that may result from slower than normal braking action. Assuming collision is averted, the feed speed rate, which is approximately one-tenth of the rapid speed rate, extends over a greater distance than required; the increased length accounts for the greater tolerance required to avoid the collision. During a portion of the feed speed portion of the cycle, therefore, the cutting tool, although turning, is not contacting the workpiece. The control system of our invention begins the feed speed motion as close as 0.002 inches from the work surface. Furthermore, if the actual location of the work surface varies within a significantly large tolerance, adaptive control permits the feed speed portion of the motion cycle to be adjusted accordingly.
The position control system is shown in FIG. 3 in combination with an electronic microprocessor 44, an optical incremental encoder 46, a motor 12 and a tachometer 48. The slide position encoder 46 is a non-contacting rotational transducer that generates a pulse train, which after being decoded provides one thousand pulses for each rotor revolution and one index or marker pulse per revolution of the motor shaft. The signals required by the position controller, which are received from encoder 46 through the line 52, are two pulse trains in quadrature having 250 cycles per revolution. When interpreted by the position logic, the required one-thousand pulses are derived from the rising and falling edges of the two quadrature waveforms. The maximum pulse rate therefore is 60,000 pulses per second.
During operation, a reference position for the slide is established at the beginning of each cycle. To accomplish this, the slide actuates a proximity switch 47 comprising a nonmagnetic, inductive circuit that senses the location of metallic vane 49, which is mounted on slide table 22. The circuit is closed when vane 49 moves under the switch 47. The reference position is accurately established by the index or marker pulse of the encoder. The data processor counts the encoder pulses occuring after the reference position is established as the slide advances and returns along its path. The encoder pulses are converted to a signal indicating the relative position of the slide measured from the reference position.
The reference position is defined as the position of the slide at the first occurence of a marker pulse following closure of the proximity switch 47 as the slide is moving backwardly. Therefore, the proximity switch is only required to locate the slide within one motor revolution of the true reference position. The reference position is derived from the marker pulse. Until the reference position is established, which action resets all counters, hardware and software to zero, the slide 22 is not permitted to move forward if proximity switch 47 is open.
The most retracted position is usually not the rest or reference position 23 at which the automatic cycle begins. To minimize production cycle time, the slide should move rearward only as far as necessary for tools to clear the workpiece and to permit workpiece transfer. It is necessary to set the reference position at some point forward of the most retracted position according to the requirement of each work application. This is done by mechanically setting the location at which the proximity switch produces its signal. The slide is moved to its most retracted position only by manual control during set-up or maintenance, usually during a tool change. The fully retracted position is therefore referred to as the "tool-change position". The automatic cycle does not begin there, but at the rest or reference position 23 that is jointly controlled by the proximity switch and by the shaft revolution count signal or marker pulse of encoder 46 that occurs once per revolution.
The variable speed motor 12 is brushless and has the characteristics of a d.c. servo motor. The rotor of the motor incorporates rare earth permanent magnets and the stator has power windings energized by three power leads, which during rotation are sequentially energized two at a time. Transistorized power devices are used for ON-OFF switching or commutation of the leads and for controlling the magnitude of the motor current. The incremental encoder 46 and tachometer 48 may be integrally formed with the motor to facilitate production of pulses synchronized to motor shaft revolution and to sense its speed. The power supplied to the motor 12 is controlled by three phase, pulse width modulated transistor switching amplifier having complete servo control and current limiting circuitry.
The binary counter 50 is connected through line 56 to a digital comparator 58 whose output is carried through line 60 to the microprocessor 44. The microprocessor has access to a non-volatile erasable programmable read only memory (EPROM) that has paired values of slide velocity and slide position defining any portion of the slide cycle shown in FIG. 2 but most particularly of interest would be the deceleration ramp 26. The target slide position recalled from memory is delivered through line 61 to a target position count register 62. The output from this register is delivered to one input of the comparator 58 through line 64. When the binary numbers from the target register and the binary counter are compared in the comparator 58 its output is carried on a line 60 to the microprocessor. When these values match, an interrupt signal to the microprocessor 44 suspends other activities of the microprocessor while a new target position and an updated velocity command are issued to the motor servo control 54.
The control of motor speed is exercised by the microprocessor by output signals issued to the motor servo control 54 on the line 63. The output signals are first latched and converted to a variable analog voltage whose magnitude varies in the range of 9 volts. The 9 volt signal corresponds to the maximum motor speed and the polarity of the voltage indicates the need for clockwise or counter clockwise rotation of the motor shaft.
A transfer line controller 66 issues advance and return slide signals on lines 67, 68 respectively. The microprocessor 44 provides five status signals to the transfer line controller 66 on line 70: slide advancing, full depth, slide returning, reference position proximity switch energized, and system inoperative.
Control of the microprocessor operation by computer programs stored in read only memory (ROM) is illustrated with the aid of FIG. 4. A cycle monitor 72 interprets the state of the externally developed input signals and the internal flags of the computer program to direct flow to the advance or retract subroutines 74, 75, respectively. Once the system is initialized upon actuation of the reference position proximity switch, the program flow always returns through the cycle monitor 72 unless a system fault is detected, in which case shut down is executed. The loop through the monitor is repeated as long as the system is operative. The cycle monitor is responsible for the selection of the appropriate directional processing routine but does not participate directly in the control algorithms. Cycle control is exercised by stepping through the look-up table of paired slide velocity-slide position values stored in EPROM. The data table is divided into six byte units called task control blocks (TCB) 76. Two types of TCBs control the choice between constant velocity segments and variable velocity segments of the slide motion cycle shown in FIG. 2.
The slide cycle begins when the various count registers and software instructions are initialized following determination of the referenced position. When this occurs, the first TCB is called from memory and is used to control slide velocity over that portion of the slide path to which the first TCB is dedicated. Referring to FIG. 2, ramp 24 indicates a rapid acceleration to the maximum motor speed. The signal that produces this result is +9 volts transmitted on line 63 to the motor servo control 54. An output signal from the servo control is transmitted to the motor 12 on line 78; this signal energizes the motor windings to produce the maximum speed. Successive TCB's are called from memory to control slide operation during decelerations 26, constant slide velocity at the feed rate 27 and during the dwell period 28. When the final TCB is completed, the stored value of the target slide position is compared to the final position recorded during the forward movements and final corrections are made if required. The position of the slide is held momentarily and a full depth signal is issued to the transfer line controller until the advance signal on line 67 is removed and the retract signal issues. The microprocessor uses the position information compiled during forward movement of the slide to calculate a set of temporary TCB entries of velocity and position that control execution of the return movement of the slide to the reference position.
Acceleration and deceleration of the slide are directed from different task control blocks whose incremental positions and corresponding velocities are spaced differently to provide the fastest possible overall cycle. Acceleration is programmed simply as a full velocity command allowing the motor and slide to accelerate to full speed at the maximum possible rate. Deceleration segments of the slide cycle, however, must control the arrival of a slide at a precise target position. Accordingly, the slide velocity-position combinations are stored in the table in paired sets corresponding to increments of the length of the deceleration ramp. Of course, the stored tables can be supplied with different deceleration profiles recalled from memory as required when the slide is, for example, operated to perform different machining functions. The acceleration ramp 24 could also be controlled by a table of stored velocity-position profiles where this is required.
Two options are available in the storage and processing of the slide motion cycle in memory. For example, the velocity-position pairs corresponding to the transition points of the slide cycle where the rate of change of velocity with respect to position changes rapidly may be coded into the look-up tables that control the slide motion. In this case, when only the transition points have velocity-position pairs to define the slide cycle, the microprocessor computes new values of the pairs at incremental positions between the transition points in real time as required to update the velocity commands. This option allows minimal use of computer memory to define the cycle, however, the operating computer program and computer instructions that are stored in RAM are increased correspondingly.
A second option, one to which reference has been made in the system description, has each velocity position pair precomputed and stored in EPROM during operation. The microprocessor simply reads the values from these tables to update the velocity commands by way of the target count that is transmitted through line 64 to the comparator 58. Computational execution time and operating computer memory requirements are reduced when this option is chosen.
If the first option is elected, the position control system 45 interacts with microprocessor 44, which has access to an algorithm stored in read only memory. The algorithm partitions the velocity-position profile of FIG. 2 and calculates paired values of velocity and position that define the desired slide operation at an appropriate number of velocity increments. The position of the slide relative to the reference position associated with a velocity increment is stored in programmable read only memory.
In operation the comparator 58 sequentially receives the binary numbers representing the slide position that has accrued since the occurence of system initialization. The other input to the comparator 58 is the byte comprising the least significant bits of the target count representing the target position of the slide corresponding to the next velocity increment. When motion of the slide causes the binary counter to register a slide position equal to the target count position, the updated velocity value corresponding to the target position is transmitted on line 80 to the digital-to-analog converter 82. Successive target positions are recalled from memory or computed before they are required; consequently, few real time computational delays are incurred between the occurence of the comparator match and the execution of the velocity signal. This permits minimum response time. A coded velocity value transmitted to the D/A converter 82 is used to produce an analog voltage signal on line 63 that is transmitted to the motor servo-control.
The signal from the tachometer 48 is transmitted through line 84 to the motor servo-control 54. The servo-control compares the voltage signal from the D/A converter 82 with a velocity signal received from the tachometer. Servo-control 54 produces a control signal for the motor drive amplifiers that will minimize the difference between the velocity measured by the tachometer and the command velocity voltage signal transmitted on line 63.
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A motion control system includes a single stage gear reducer and power screw, a brushless variable-speed electric motor with position and velocity sensing instrumentation, a solid state power amplifier, and a programmable controller. During operation an absolute positional reference is established when the slide actuates a non-contacting limit switch to signal that the slide is within less than one motor revolution of the correct starting point. A memory accessible by a microprocessor has paired values of velocity and position stored in a table representing ideal such values for deceleration portions of the motion cycle. Alternatively, the microprocessor computes each new value of position and velocity in real time as required to update the velocity commands sent to a comparator. The comparator compares the predetermined slide position to the actual slide position and signals the microprocessor that a change in output to the motor power supply is required. A digital to analog converter converts the motor velocity signal that issues from the microprocessor to a variable d.c. voltage whose magnitude varies over a range that determines the sense of direction and speed of the drive motor.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for mounting of an elongated member inside an elongated, elastic, flexible tubing, initially having an inside cross sectional dimension being about the same size as or smaller than the outside cross sectional dimension of the elongated member.
The invention also relates to a device for performing the mounting.
2. Description of the Prior Art
In different contexts it is desirable to provide an elongated member of some kind, with a shielding layer of an elastic material. This can sometimes be carried out by forming the shielding layer directly onto the elongated member, by for example extrusion. However, in certain cases this kind of operation is not possible to perform for different reasons. Instead the only available option is to insert the elongated member into a flexible tubing of the desired material.
In the field of for example medical implantable leads, it is known to insert or mount an elongated member in form of a metallic coil into a flexible tubing of e.g. silicone. Such leads may preferably be used for pacemaker applications to monitor and pace the activity of a human or animal heart. However, they could also be used for other medical applications, such as for example monitoring, diagnosing or pacing other arbitrary organs inside a body, or for nerve stimulation. The length of such medical implantable leads my vary, but is normally in the range of 40 to 100 cm.
The demands on this kind of medical implantable leads are high. The diameter should be as small as possible, down to about 1 mm in diameter, and they should be highly flexible to be able to be inserted into the body through e.g. narrow blood vessels. When mounting the lead into the body, the lead has to be steerable by means of a steering wire inserted through a bore inside the lead. Moreover, the bore is also utilized when fastening the lead to the desired organ by means of for example a helix in the distal end of the lead, wherein a second, permanently mounted elongated member inside the lead, or a supplementary, temporarily inserted torque transmitting wire is inserted into the bore for performing screw rotation of the helix for screwing it into the tissue and fasten the distal end of the lead to the organ. The coil of the lead should also serve as an electrical conductor for transmitting electrical signals to and from the organ.
The small dimensions as well as the highly flexible characteristics of the coil and the tubing, makes the introducing of the coil into the tubing very difficult. Accordingly, in prior art techniques for performing the assembling, it is known to use different chemical substances, such as for example isopropanol or heptane, serving as a lubricant agent when inserting the coil into the tubing. However, there are some disadvantages associated with this technique. The chemical substances may for instance be unhealthy for the personnel performing the assembling, and they might adversely effect other procedures during the manufacturing, such as gluing. Also, despite the use of lubricating chemical substances, it is still difficult and time consuming to properly insert the coil into the tubing and it is often necessary to use a tubing having an inner cross sectional dimension being larger than desirable to be able to insert the coil into the tubing. This could necessitate the use of an adhesive substance between the coil and the tubing to prevent movement of them in relation to each other during use. It also commonly occurs that the coil will be stretched out or compressed in relation to the tubing during assembling, in which case the assembled coil and tubing has to be relaxed by manually rolling them between hands and a plane surface after assembling.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate disadvantages associated with prior art methods for inserting of an elongated member into a flexible tubing. More precisely it is an object of the invention to provide a time-saving method, which simplifies the process to mount an elongated member into a flexible tubing.
The invention also relates to a device for mounting of an elongated member into a flexible tubing having essentially the same object as above.
Accordingly, the present invention is based on the use of fluid under pressure to expand or widen the cross sectional dimension of the tubing during insertion of the elongated member into the tubing.
The invention may be implemented in various ways. In a preferred embodiment, the pressurized fluid is air. However, other gases as well as liquids could be used, e.g. water. One advantage with using air, is that it is inexpensive and the assembled tubing and elongated member does not have to be dried after assembling as it normally would when using water or other liquids.
The expansion of the flexible tubing could be performed by a static pressure, if the distal end of the flexible tubing is sealed by any suitable means, such that the flexible tubing is “blown up” similar to a balloon. However, in a preferred embodiment, the expansion is performed by a continuous fluid flow with the distal end of the flexible tubing open. In this way the fluid flow may be used to draw the elongated member into the flexible tubing.
Moreover, the inventive method and device is in a preferred embodiment used for mounting of a metallic coil into a flexible tubing, of for example silicone, for application in a medical implantable lead as mentioned before. However, the method and device could be utilized for other types of applications whenever it is desirable to position an elongated member inside a tight, flexible tubing of an elastic material, when it for some reason is not suitably to form the elastic material directly onto the elongated member by e.g. extrusion.
In a first embodiment of a device for performing the mounting, the device has a nozzle body including an outlet passage and at least one separate, first inlet passage for the fluid and one separate, second inlet passage for the elongated member, with the second inlet passage disposed in alignment with the outlet passage. The outlet is formed as a pipe, on the outside of which the tubing may be threaded with one end. Preferably, the cross sectional dimension of the second inlet passage corresponds closely to the cross sectional dimension of the elongated member, whereas the outlet passage has a somewhat larger cross sectional dimension than the elongated member. In this way the elongated member may be inserted through the second inlet passage and into the outlet passage and when the pressurized fluid flow is turned on, the fluid flow can flow past the elongated member in the outlet passage and into the tubing, which due to the fluid pressure will expand such that the elongated member can be introduced into the tubing without any significant friction between the elongate member and the tubing. Only a small amount of the pressurized fluid will flow out from the second inlet passage since the elongated member has a cross sectional dimension which closely corresponds to the cross sectional dimension of the second inlet passage. Furthermore, since the pressurized fluid is flowing outside of the elongated member in the outlet passage, the fluid flow will help to draw the elongated member into the tubing.
In a second embodiment of the invention, the device also has an elongated pressure chamber in alignment with the outlet passage which is in form of a rigid tube having an inner dimension which is large enough to accommodate the elongated member. The pressure chamber has also an inlet for pressurized air. When mounting an elongated member into a flexible tubing by means of this device, the elongated member is first inserted into the pressure chamber through the outlet passage, thereafter the flexible tubing is threaded onto the pipe of the outlet and finally the pressurized air is turned on. One advantage with this second embodiment in comparison to the first, is that due to the closed pressure chamber, no pressurized fluid will leak in the wrong direction but all of it will pass close to the elongated member into the flexible tubing, such that the elongated member will firmly be drawn into the tubing.
The invention will hereinafter be described specifically in relation to manufacturing of a medical implantable lead for use in pacemaker applications, wherein the elongated member is in form of a coil of a helically formed wire, which is highly flexible and defining an inner bore and which has an outer diameter substantially corresponding to an inner diameter of an elastic, flexible tubing into which the coil will be mounted. However, it should be understood that the inventive method and device, defined by the claims, could be utilized to mount also other types of elongated members into elastic, flexible tubing, e.g. rigid elongated members and/or solid elongated members without any inner bore. It is also possible to utilize the inventive method and device for mounting elongated members having an outer cross sectional dimension being larger than the inner cross sectional dimension of the flexible tubing into which it is to be mounted in.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section through a schematically illustrated device according to a first embodiment of the invention in a stage before application of pressurized airflow.
FIG. 2 is a longitudinal section according to FIG. 1 during pressurized airflow, with the coil partly inserted into the flexible tubing.
FIG. 3 is a longitudinal section according to FIGS. 1 and 2 , with the coil completely inserted into the flexible tubing and the pressurized airflow turned off.
FIG. 4 is a perspective view of a second embodiment of a device according to the invention, with an elongated member in the form of a coil and a reinforcing wire shown separately.
FIG. 5 is a cut longitudinal section, in an enlarged scale, showing different portion in the area around the nozzle body of the device of FIG. 4 , before the application of pressurized airflow.
FIG. 6 is a cut longitudinal section according to FIGS. 4 and 5 , during pressurized airflow.
FIG. 7 is a cut longitudinal section according to FIGS. 4 through 6 , during pressurized airflow, when the coil has reached the stop rod.
FIG. 8 is a longitudinal section according to FIGS. 4 through 7 , after mounting the coil in the flexible housing when the pressurized airflow is turned off.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is first made to FIG. 1 to 3 illustrating, in longitudinal sections, a first embodiment of a device for mounting of an elongated member in form of a coil 1 into an elastic, flexible tubing 2 . The device comprises a nozzle body generally denoted 3 , having an outlet passage 4 forming a pipe 5 in one end of the nozzle body. The outlet passage 4 has a diameter which is slightly larger than the outer diameter of the coil 1 . The flexible tubing 2 is with one end threaded onto the pipe 5 and has in an initial, relaxed state an inner diameter which essentially corresponds to the outer diameter of the coil 1 . The nozzle body also comprises an inlet passage 6 for the coil 1 which is in alignment with the outlet passage 4 . The inner diameter of the inlet passage 6 corresponds closely to the outer diameter of the coil 1 . On either side of the nozzle body are formed inlet passages 7 for pressurized air, which are directed in acute angles towards the inlet passage 6 for the coil and converge towards a point where the inlet passage 6 changes into the outlet passage 4 . The inlet passages 7 for pressurized air are adapted to be connected to a not shown air pressure source by means of suitably pipes, tubing or the like.
FIG. 1 illustrates a situation where no air pressure is turned on and the coil is outside of the inlet passage 6 . In FIG. 2 is illustrated the situation when the pressurized air flow is turned on and the coil 1 is in part inserted through the inlet passage 6 , the outlet passage 4 and into the flexible tubing 2 . As is shown, the flexible tubing 2 is expanded by the pressurized air, which is flowing between the coil 1 and the inner circumference of the outlet passage 4 due to the larger cross sectional dimension of the latter. The expansion of the tubing enables the coil to slide into the tubing without any significant resistance due to friction against the inner walls of the tubing. The flow rate of the air flow in the direction of the tubing, also helps to draw the coil into the tubing. FIG. 3 illustrates the situation when the coil 1 is completely inserted into the flexible tubing 2 and the pressurized air flow is turned off, such that the flexible tubing is contracted and is pressed toward the coil.
Now reference is made to FIG. 4 of the drawings. Here is shown, in a perspective view, a second embodiment of the invention. As in the previous embodiment, the device comprises a nozzle body 3 , having an outlet passage 4 forming a pipe 5 in one end of the nozzle body, as is best seen in FIGS. 5 to 8 , which are cut longitudinal sections in an enlarged scale of different portions of the device in the area around the nozzle body. However, instead of separate inlet passages for the coil 1 and the pressurized air, as in the previous embodiment, the device is provided with a pressure chamber 8 in form of a tube, which is in alignment with the outlet passage 4 and which is large enough to accommodate the entire coil 1 . In the proximal or forward end of the pressure chamber 8 , a conduit 9 for pressurized air is connected. Beyond the nozzle body 3 , an elongated box 10 is positioned having a straight groove or slot 11 , being in alignment with the outlet passage 4 , and a lid 12 which can be closed over the slot 11 . In the distal end, the box 10 is provided with a stop rod 13 , which with one end extends into the slot 11 , having the other end disposed outside of the box and being adjustable in desired positions by means of a set screw.
In FIG. 4 is also shown, separated from the device, a coil 1 and a flexible tubing 2 . To reinforce and prevent length deformation of the coil during insertion into the tubing as well as sealing the inner bore of the coil to prevent air flow through the coil during mounting, this embodiment also utilizes a reinforcing wire 15 provided with a stop element 16 in each end of which at least one is detachable.
The procedure to mount the coil 1 into the flexible tubing 2 , by means of this second embodiment of the device, is as follows. Firstly the reinforcing wire 15 is inserted into the inner bore of the coil 1 and the stop elements 16 are attached at both ends. The length of the reinforcing wire 15 is adapted to the length of the coil in question, such that the stop elements 16 will be positioned adjacent the ends of the coil. Subsequently the coil 1 , including the reinforcing wire 15 , is inserted into the pressure chamber 8 through the outlet passage 4 and one end of the flexible tubing 2 is threaded onto the pipe 5 . The remaining of the flexible tubing 2 is placed in the slot 11 and the lid 12 is closed. This situation is illustrated in FIG. 8 . The coil 1 is now ready for mounting into the flexible tubing and, accordingly, the air pressure is turned on. This will in turn widen the flexible tubing 2 due to the air pressure and the pressurized air flow will draw the coil including the reinforcing wire 15 into the flexible tubing 2 , as is illustrated in FIG. 6 . The coil will be moved as far into the flexible tubing until the distal stop element 16 of the reinforcing wire 15 hits the end of the stop rod 13 , as is shown in FIG. 7 . Now the air pressure can be turned off such that the flexible tubing is contracted and is pressed toward the coil, as is illustrated in FIG. 8 . Subsequently the lid 12 can be opened and the flexible tubing 2 with the mounted coil 1 be taken away from the device. Finally, the reinforcing wire 15 may be removed from the assembled coil and flexible tubing by detaching at least one of the stop elements 16 .
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted heron all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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In a method and device for mounting an elongated member inside an elongated, elastic, flexible tubing, initially having an inside cross-sectional dimension that is approximately equal to or less than the outside cross-sectional dimension of the elongated member, the inner cross-sectional dimension of the flexible tubing is expanded by applying a pressurized fluid to the inner bore of the tubing, and inserting the elongated member into the tubing while the pressurized fluid is being applied.
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The invention described herein was made in the course of, or under, a grant from the National Institutes of Health.
TECHNICAL FIELD
This invention relates generally to the isolation of cell protein of microorganisms which exhibit antigenic properties and more particularly to the isolation of the principal outer membrane protein of Chlamydia trachomatis, which protein exhibits antigenic properties common to all the Chlamydia trachomatis serotypes.
BACKGROUND OF THE INVENTION
Chlamydia trachomatis is one of the two microorganism species of the genus Chlamydiaceae, order Chlamydiales. The other species is Chlamydia psittaci. Chlamydia trachomatis in its some 15 various strains, are the etiologic agents for a number of human ocular and genital diseases including trachoma, inclusion, conjunctivitis, lymphogranuloma venereum, "nonspecific" or non-gonococcal urethritis and proctitis. C. trachomatis infection is pervasive throughout the general population. It has been estimated, for instance, that C. trachomatis is accountable for several million cases per year of nongonococcal urethritis.
Since C. trachomatis mediated disease is widespread, a reliable, simple and inexpensive test for the organism's presence is highly desirable and of great importance so that proper treatment may be undertaken. The only serological test in current use is the microimmunofluoresence test. This test however requires that the strains of C. trachomatis be used as serological test antigen. In addition, the facilities for conducting this test are available in only a limited number of laboratories throughout the world. The test is very laborious, time consuming and difficult to perform.
Recently, U.S. Pat. No. 4,118,469, noted the preparation of an antigen of C. trachomatis useful in serological testing for lymphogranuloma venereum and nongonoccocal urethritis. Such antigen was purified from C. trachomatis organisms by immunoadsorption chromatography using the monospecific antiserum as a specific ligand covalently bound in an agarose gel column. This antigen had a molecular weight of about 160,000 daltons, and in counter-immunoelectrophoresis testing was capable of detecting antibodies from the sera of lymphogranuloma venereum patients. However, when utilized in a similar test with sera of non-gonoccocal urethritis patients, this antigen failed to detect antibodies. It was successful, however, in detecting antibodies in two dimensional immunoelectrophoresis testing.
In any event, however, there is still great medical interest in the isolation of species specific antigens of C. trachomatis which are capable of the detection of C. trachomatis infection, preferably by commonly practiced antigen-antibody assay methods.
BRIEF SUMMARY OF THE INVENTION
The present invention presents a species specific antigen which comprises the principal outer membrane protein of Chlamydia trachomatis. Such protein comprise about 60% of the total associated outer membrane protein of C. trachomatis, and have a size or subunit molecular weight of between 38,000 and 44,000 daltons, with a mean molecular weight of 39,500 daltons. Hereinafter for ease in reference, this principal outer membrane protein group will be referred to as MP 39.5 signifying "major outer membrane protein having a mean subunit molecular weight of 39,500 daltons".
When tested against C. trachomatis antibodies derived from all the serotypes thereof, MP 39.5 reacts with species specificity. Thus MP 39.5 is a C. trachomatis species specific antigen. MP 39.5 is a unique protein common to all C. trachomatis serotypes, and as an antigen provides a basis for the identification of all the C. trachomatis serotypes.
MP 39.5 is isolated from C. trachomatis elementary bodies, i.e., the intact microorganism cells, by first growing suitable strains of the organism and collecting the elementary bodies free from the growth medium. The purified elementary bodies are treated by means hereinafter described to isolate the outer cell membranes. These outer cell membranes are selectively separated from the cell cytoplasm membrane and protoplasm. The isolated outer cell membranes are then further treated by a method hereinafter described to yield essentially pure MP 39.5.
The MP39.5 recovered from the outer membranes is then available for either (1) direct reaction with C. trachomatis antibodies generated in the serum of C. trachomatis infected hosts; or (2) to be injected into laboratory animals to produce antiserum against MP39.5. Thus the recovered MP39.5 may be utilized in immunodiagnostic assay procedures for C. trachomatis.
It is therefore an object of the invention to provide the principal outer membrane protein (MP39.5) of Chlamydia trachomatis.
It is another object of the invention to provide a C. trachomatis species specific antigen.
It is yet another object of the invention to provide a method for isolating C. trachomatis principal outer membrane protein.
It is still another object of the invention to provide an antigen suitable for assaying chlamydial infection.
Other objects and advantages of the invention will be apparent from a review of the following description and the claims appended hereto.
DETAILED DESCRIPTION OF THE INVENTION
MP39.5 is the principal outer membrane protein of C. trachomatis and it is species specific antigen to all C. trachomatis serotypes.
isolation of MP39.5 from C. trachomatis elementary bodies is accomplished by an essentially two step extraction procedure. In the first step, purified elementary bodies are contacted with an aqueous solution of a mild anionic sarcosine detergent, preferably sodium N-lauroyl sarcosine (commonly referred to as sarcosyl). The sarcosyl selectively dissolves out the elementary body cytoplasm including the protein, nucleic acids and other molecular structures associated therewith, leaving the elementary body outer membrane as an insoluble residue.
Electron microscopic studies indicate that the sarcosyl treatment leaves an insoluble residue which consists of uniform particles of single intact double-track unit membranes of a size and morphology characteristic of native chlamydial elementary body outer membrane.
In the second process step, the residual elementary body membranes are lysed with a strong anionic detergent, preferably sodium dodecyl sulfate, which solubilizes the principal outer membrane protein, MP39.5. The MP39.5 is then recovered from the detergent solution, and purified to yield the MP39.5 antigen.
The purified MP39.5 protein, when tested against antibody derived from known C. trachomatis serotypes demonstrates that MP39.5 is a species specific antigen of C. trachomatis organisms.
The entire and detailed isolation procedure and characterization of MP39.5 as a C. trachomatis antigen may be best understood from a review of the following detailed procedures and tests:
Growth and purification of C. trachomatis organisms.--The following C. trachomatis strains were used: L2/434/Bu(L2), E/UW-5/Cx(E) and C/TW-3/OT(C). Chlamydiae were grown in HeLa 229 cells as described previously in the publication in October of 1975 in the Journal of Immunology v. 15, pgs 963-968 by Caldwell et.al., entitled "Antigenic Analysis of Chlamydiae by Two-Dimensional Immunoelectrophoresis." Such disclosure is incorporated herein by reference. The L2 strain was also grown in suspension cultures of L-929 cells. L-cell-propagated L2 organisms were used for the isolation and purification of the 39,500 dalton protein.
Chlamydiae were harvested from HeLa cell monolayers grown in 150 cm 2 polystyrene culture flasks (Corning Glass Works, Corning, N.Y.) with 90% of the cells containing inclusions at 48 hours postinoculation. Medium was poured off and cells were removed with 4 mm glass beads and 10 ml of cold Hanks' balanced salt solution. These cell suspensions were pooled and the cells ruptured by sonication (Braunsonic Model 1510). This suspension was centrifuged at 500×g for 15 min at 4° C. The supernatants were layered over 8 ml of a 35% Renographin solution (v/v) (diatrizoate meglumine and diatrizate sodium, 76% for injection, Squibb and Sons, N.Y.) in 0.01 M N-2-hydroxyethylpiperazine-N'-2-ethanesulfonic acid containing 0.15 M NaCl. They were then centrifuged at 43,000×g for 1 hour at 4° C. in an SW 27 rotor (Beckman Instruments Inc., Fullerton, Ca). The pellets were resuspended in 0.01 M sodium phosphate (pH 7.2) containing 0.25 M sucrose and 5 mM L-glutamic acid (SPG). pooled and layered over discontinuous Renographin gradients (13 ml of 40%, 8 ml of 44% and 5 ml of 52% Renographin, v/v). These gradients were centrifuged at 43,000×g for 1 hour at 4° C. in an SW 27 rotor.
The Chlamydiae elementary body bands, located at the 44/52% Renographin interface, were collected, diluted with three volumes of SPG and then centrifuged at 30,000×g for 30 min. The elementary body pellets were washed in SPG to remove residual Renographin. The purified elementary bodies were resuspended in SPG and stored at -80° C. The purity of the elementary body preparations was determined by electron microscopy and Macchiavello stained smears.
Isolation of chlamydial outer membrane complexes (COMC) by sarcosyl extraction of intact elementary bodies.--C. trachomatis L2 elementary bodies as collected above were suspended (approximately 5 mg protein/ml) in 5 ml of phosphate buffer solution (PSB) comprising 0.01 M sodium phosphate, and 0.15 M Nacl, pH 8.0, also containing 2% sarcosyl and 1.5 mM ethylenediaminetetracetic acid (EDTA). This suspension was incubated at 37° C. for 1 hour and then centrifuged at 100,000×g for 1 hour. The insoluble pellet was resuspended in the same sarcosyl buffer and centrifuged as before. The pellet was washed twice in PBS to remove excess detergent and then resuspended in 0.02 M sodium phosphate, pH 8.0, containing 19 mM MgCl 2 and 25 g/ml deoxyribonuclease (Worthinton Biochemical Corp., Freehold, N.J.) and ribonuclease (Millipore Corp., Freehold, N.J.). This suspension was then incubated for 2 hours at 37° C., centrifuged and the insoluble pellet washed twice with PBS to remove any remaining nucleases. This sarcosyl insoluble material consisted of chlamydial outer membrane complexes (COMC).
Purification of the 39,500 dalton outer membrane protein.--Isolated COMC prepared from 25-30 mg L2 EB protein in the procedures as noted above, was suspended in 5 ml of 2% sodium dodecyl sulfate buffer and incubated at 37° C. for 1 hour. This suspension was centrifuged at 100,000×g for 1 hour and the soluble supernatant fraction collected.
This sodium dodecyl sulfate extract, enriched in the 39.500 dalton protein, was then dialyzed against 200 volumes of 0.01 M sodium phosphate, pH 6.4, containing 1 mM dithiothreitol (DTT) and 0.1% sodium dodecyl sulfate (column equilibration buffer) for 24 hours with several changes of dialysate. This extract was fractionated by hydroxylapatite chromatograpy in the presence of sodium dodecyl sulfate using the technique disclosed by Moss and Rosenblum in J. Bio. Chem., 1972, V. 247, pgs. 5194-5198.
Briefly, the dialyzed extract (8-10 ml) was supplied to a pre-equilibrated hydroxylapatite column (0.9×30 cm). The column was washed with 100 ml of equilibration buffer and eluted with a 150 ml linear gradient of 0.1 M to 0.6 M sodium phosphate, pH 6.4, containing 1 mM DTT and 0.1% sodium dodecyl sulfate. The column eluate was collected in 40 drop fractions at a flow rate of 5-6 ml per hour and spectrophotometrically monitored at 280 nm absorbence. Those fractions showing positive absorbence were analyzed by sodium dodecyl sulfate-polyacrylamide gel electrophoresis.
The polyacrylamide gels were stained with Coomassie blue for protein and Stains-All to detect nucleic acid and glycolipid moieties. The phosphate molarity of every tenth column fraction was determined by measuring total phosphorous and converting to phosphate molarity by using a standard curve prepared wiht known sodium phosphate standards. Those fractions that contained only the MP39.5 were pooled and concentrated to a 1-2 ml volume by vacuum dialysis against 0.05 mM Tris-HCl, pH 8.5, containing 0.15 M NaCl and 0.1% sodium dodecyl sulfate. These concentrated preparations were used for performing analytical assays to test for protein purity and as a source of immunogen for the preparation of antisera in laboratory animals.
It will be understood that the detergent extraction temperatures and times noted in the procedures above may be varied from those as stated. It is perfectly feasible to extract at higher temperatures e.g., 45° C., 60° C., 80° C., or even 100° C. Higher extraction temperatures may be accompanied by shorter extraction times. For instance, extraction at 100° C. for 10 minutes, is sufficient to solubilize essentially all the elementary body components which are soluble in the particular detergent. Generally speaking, however, if time is not a problem, it is desirable to extract at the lower temperatures, e.g., 37° C., in order to avoid any chance of denaturing the desired proteins.
The molecular weights of the purified COMC proteins were determined by polyacrylamide gel electrophoresis. Specifically, the Chlamydial proteins were electrophoresed on 12.5% acrylamide slab gels in the discontinuous Tris (hydroxymethyl) aminomethane-glycine (Trisglycine) system described by Laemmli in Nature (London) v. 227, pgs. 680-685 (1970). The ratio of acrylamide to N, N'-methylenebisacrylamide was 30:0.8 in both the 12.5% separating gel and 5% stacking gel. Before electrophoresis samples were mixed with an equal volume of solubilizing solution (0.1 M Tris HCl, pH 6.8), containing 2.5% sodium dodecyl sulfate (BDH Chemicals Ltd.), 5% 2-mercaptoethanol, 20% glycerol and 0.0001% bromophenol blue and boiled for 10 min. Electrophoresis in Tris-glycine buffer (ph 8.6) containing 0.1% sodium dodecyl sulfate was carried out at a constant current of 25 mA. Gels were stained in 0.25% Coomassie brilliant blue R-250 in 7% acetic acid and 30% methanol. The protein standards used for estimating chlamydial protein molecular weights were: phosphorylase b (94,000), bovine serum albumin (67,000), ovalbumin (43,000), carbonic anhydrase (30,000), soy bean trypsin inhibitor (20,100) and α-lactalbumin (14,400) (Pharmacia, Inc., Piscataway, N.J.).
In one experimental study approximately 1.4 mg of purified MP39.5 protein was recovered after concentration, after following the procedures set forth above. Although the amount recovered was small compared to the recovery of outer membrane proteins from more readily cultivatable microorganisms, the yield was quite exceptional considering that only 25-30 mg. of elementary body protein was used as the starting material.
Preparation of Antisera--Swiss Webster mice strain 1CR (Charles River Co. Baltimore, MD) were immunized subcutaneously on day 0 with 30 μg of purified Mp39.5 emulsified with Freund's incomplete adjuvant. Immunizations were repeated with the same amount of purified protein administered subcutaneously without adjuvant on days 16 and 27. Mice were bled by cardiac puncture 5 days after each immunization (days 21 and 32, respectively). The reactivity and specificity of the pooled sera collected from each bleeding was evaluated by indirect immunofluorescence.
Table 1, below, presents the results of tests against elementary bodies of the various Chlamydiae serotypes (both trachomatis and psittaci) with the mouse generated antisera.
TABLE I______________________________________Indirect immunofluorescence of Chlamydia with mouse antiserumprepared against purified MP39.5 Reciprocal antibody titer of mouse* anti-MP39.5 Titer after 2nd Titer after 3rd Serotype or immunization immunizationOrganism strain (day 21) (day 32)______________________________________C. trachomatis A -- -- B -- -- Ba 8 128 C -- -- D 8 128 E 8 64 F -- -- G -- -- H -- -- I -- -- J -- -- K 8 128 L1 8 128 L2 64 512 L3 8 128 Mouse -- -- pneumonitisC. psittaci 6BC -- -- Feline -- -- pneumonitis Guinea pig -- -- inclusion conjunctivitis______________________________________ *Highest dilution of antiserum (starting at 1:8) showing fluorescence. Serum antibody titers are lgG only, no fluorescence was observed with antilgM specific conjugate.
In a procedure similar to that noted for the production of antiserum in mice, rabbits were inoculated with 300 μg each of purified MP39.5 protein. The protein was injected intramuscularly, and the rabbits were then bled after a suitable time was allowed for induction of the MP39.5 antibodies. The pooled rabbit sera was then utilized for evaluation for reaction against all the various Chlamydeae elementary body serotypes. The results of these tests are set forth in Table 2, below.
TABLE II______________________________________Indirect fluorescent antibody staining ofintact Chlamydeae with rabbit antiserumraised against the major outer membraneprotein MP39.5 of the L2 C. trachomatis strain. Reciprocal Fluor- escent AntibodyOrganism Serotype Titer______________________________________C. trachomatis A 64 B 4096 Ba 8192 C 64 D 512 E 4096 F 2048 G 4096 H 256 I 64 J 256 K 4096 L1 128 L2 8092 L3 4096C. psittaci 6BC <8 Mn <8 Feline pneumonitis <8 Guinea pig inclusion <8 conjunctivitis______________________________________
Fluorescence was determined by reacting elementary bodies of each Chamydia serotype with serial 2-fold dilutions of rabbit anti-MP39.5 (L2 antiserum). Note that anti-MP39.5 reacts with every C trachomatis serotype but not with the C. psittaci strains. These results show that MP39.5 is a C. trachomatis species specific antigen.
When MP39.5 protein prepared from other C. trachomatis serotypes, e.g. H, was utilized to generate antisera in laboratory animals, and the resultant antisera was reacted with elementary bodies of all the C. trachomatis serotypes, positive results similar to those set forth in Table II above were obtained.
In any event, however, it is clear that the MP39.5 antigen has species specificity against all the C. trachomatis serotypes.
As noted above monospecific antibodies against MP39.5 antigen can be generated by suitable inoculation procedures with laboratory animals such as mice and/or rabbits. The animal generated antibodies may be utilized in assays for Chlamydial infection in other mammals. These assays may be conducted in well known procedures for assaying the presence of bacterial antigen in the infected subject. Once a supply of monospecific antibodies has been secured from MP39.5 antigen inoculated laboratory animals, either direct or indirect assay procedures can be undertaken with specimens secured from mammals suspected of harboring Chlamydial infections.
Assay techniques such as enzyme linked immunoabsorbent assays (ELISA) or radioimmune assays (RIA) are suitable for these purposes.
In a direct assay procedure monospecific antibody against the MP39.5 protein may be covalently or non-covalently attached to a solid phase support system. As is customary in these techniques the support system may be glass, plastics and the like. The solid phase support with attached monospecific antibody against MP39.5 may be incubated with a specimen previously secured from the individual suspected with having Chlamydial infection. Prior to incubation, the specimen is treated with a detergent such as sodium dodecyl sulfate or other anionic, nonionic or cationic detergent to extract the MP39.5 outer membrane antigen from any Chlamydial organisms which may be present therein. It is the extracted specimen which is incubated with the solid phase support.
Monospecific antibody against MP39.5 antigen, which has been previously radiolabeled or conjugated with enzyme by known techniques, is then equilibrated against the support system. Any MP39.5 antigen present in the specimen and which had been bound to the antibody on the support system will in turn bind to the radiolabeled or enzyme conjugated antibody.
If radiolabeled antibody is used, the amount of residual radioactivity in the sample may then determined. This value is compared to specimens that have been determined to be free of Chlamydial MP39.5 antigen. In the event enzyme conjugated antibody is used, a substitute specific for the enzyme is added to the solid support reaction mixture and the resultant color change is recorded spectrophotometrically. This color change is compared to samples known to be free of Chlamydial MP39.5 antigen.
Thus the presence of MP39.5 antigen is mammalian specimens can be assayed directly.
Alternatively, indirect assay procedures can be used. specifically, the Chlamydial (MP39.5) antigen secured as in the procedures set forth above, may be covalently or non-covalently bound to a suitable solid phase support system. A specimen from the individual suspected of having Chalmydial infection is treated with detergent, e.g., sodium dodecyl sulfate to extract the major outer membrane protein antigen from any C. trachomatis cells which may be present.
The extract from the specimen may then be mixed with a known quantity of radiolabeled or enzyme conjugated antibody against the MP39.5 antigen, previously secured from a laboratory animal source. The specimen extract--antibody mixture may then be incubated with the solid support system and its bound MP39.5 antigen.
The radioactivity of the solid support system is measured; or color development in the enzyme conjugated system is measured; and compared to specimens similarly treated as standards and which do not contain any Chlamydial antigen.
The ability of the clinical sample suspected of containing C. trachomatis to inhibit the ability of the radiolabeled or enzyme conjugated antibodies to the MP39.5 antigen bound to the solid support thus reveals the presence, or absence, of the MP39.5 antigen in the clinical specimen. Any demonstrated inhibition indicates the presence of C. trachomatis infection.
Other suitable assay method and variations will be apparent to those skilled in such assay techniques.
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Procedures are presented for isolating the major outer membrane protein of Chlamydia trachomatis. The isolated protein is a species specific antigen which comprises about 60% of the C. trachomatis cell outer membrane structure. The protein has a molecular weight ranging from about 38,000 to 44,000 daltons, with a mean molecular weight of about 39,500 daltons. The protein antigen is purified from C. trachomatis cells by first extracting the cell contents with a mild anionic detergent, preferably sarcosyl, to leave a residue of intact outer cell membranes. These outer cell membranes are then extracted with a strong anionic detergent, preferably sodium dodecyl sulfate, which solubilizes the 39,500 dalton antigen. The antigen is then purified by hydroxlapatite chromatography. The antigen is species specific for Chlamydia trachomatis and may be utilized in assaying Chlamydial infection in mammals.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The invention concerns a container for a pasty or liquid cosmetic product, comprising a retractable application member, provided with an applicator which, outside of periods when the product is being applied, is engaged in a tubular reservoir containing the product to be applied. It applies particularly well to containers for mascara or gloss, that is to say fluid products, that is to say products that are liquid or viscous.
[0003] 2. Background Information
[0004] Conventionally, containers for liquid or viscous products have an application member. The application member in practice comprises a cap that the user grasps with the fingers of one hand to apply the product to her eyelashes or lips for example. The fact that the product is fluid means that efficient sealing must be provided outside of periods when the product is applied, when the cap is engaged on the neck of the container; in practice this sealing is obtained by a closure by screwing or by clip action of the cap onto the neck of the container. It follows that the cap is a member that forms a substantial part of the outside surface of a mascara or gloss container in a closed configuration, and that combined movements or significant forces may be necessary to open the container before an action to apply product.
[0005] A variant has been described in document EP-1 721 543 which, among various containers for cosmetic product, describes a container for mascara (or even for gloss) comprising:
a body that is elongate in a longitudinal direction and provided with a bottom and a free edge; a reservoir contained in that body and movable in translation between a low stable position and a high stable position, the reservoir comprising a neck; an elastically compressible device with two stable withdrawal positions that is disposed between the body and the reservoir and of which the two stable axial withdrawal positions define the two stable positions, low and high, of the reservoir; an application member comprising a shaft terminated by an applicator adapted to be loaded with mascara, this application member having a resting configuration in which a part of the shaft and the applicator are contained in the reservoir so as to enable the applicator to be loaded with mascara, and being able to leave that resting configuration until it is completely out of the reservoir and of the container; a cap joined to the shaft of the application member and adapted to engage within the body, the stable axial withdrawal configurations of the elastically compressible device being such that when the application member is in its resting configuration in the reservoir, the cap is either retracted into the body flush with the free edge of the body, or it projects at least partially from the body; a wiper provided at the exit of the reservoir so as to be traversed by the applicator when it enters the reservoir or when it is extracted out of it; and complementary sealing members respectively carried by the shaft and the neck of the reservoir constituted by a protuberance carried by the shaft and anchoring claws provided on the neck of the reservoir; in the high position of the reservoir, the claws spread outside the inside volume of the body in which the reservoir slides, whereas in the low position, the claws are maintained in a brought-together configuration by the inside wall of that body so as to remain engaged on the protuberance.
[0013] Such a configuration is simple and reliable in use without significant risk of inadvertent opening (the movable part fully retracts telescopically in a resting configuration), while making it possible to have very sleek aesthetics, and without leading to prohibitive voluminosity.
[0014] It should be noted that, in such a container, the reservoir is movable between two main positions that are essentially defined by the elastically compressible device, the complementary sealing members remaining engaged on each other so long as the reservoir has not reached its high position and having to come axially out of the body to be able to separate. This means that the travel of the elastically compressible device must be at least equal to the axial dimension of the cap.
[0015] Thus, not only is the use of such a container simple and reliable, but such a container furthermore has good sealing characteristics, without however requiring complex movements by the user, but at the cost of a certain complexity of structure and dimensional constraints.
[0016] Document FR-2 936 939 (or EP-2 346 370) then provided a container for a liquid or pasty cosmetic product having better sealing without all the same dimensional constraints.
[0017] This container has various differences relative to the teachings of document EP-1 721 543.
[0018] In particular, as regards the sealing members, the shaft comprises a protuberance comprising, towards the applicator, a sealing portion and, towards the cap, a transverse contact surface, and the reservoir comprises, before reaching its neck, a constriction adapted to receive the sealing portion in axial abutment and, beyond its neck, a collar formed, along its circumference, by a plurality of rigid sectors and elastic sectors, that collar having a relaxed configuration in which it is of larger transverse size than the inside cross section of the body and a restricted configuration in which it is confined inside the body, the rigid sectors comprising, along the inside edge of the collar, rims adapted to come into axial abutment against the transverse contact surface of the protuberance so as to maintain the sealing portion against the constriction when the application member is in its resting configuration. In a particular embodiment, at least the rigid sectors of the collar further comprise outside rims bearing against the inside wall of the body for maintaining the collar in its restricted configuration inside the body. Advantageously, the collar is linked by a skirt also formed by rigid or flexible portions, capping the constriction of the reservoir. In a particular embodiment, the constriction forms part of an added-on part of the reservoir which, towards the inside of the reservoir, comprises a wiper lip.
[0019] Furthermore, this document provides that, as soon as the elastically compressible device brings the cap into a configuration in which it gives a sufficient hold for the fingers of a user to be able to pull on it, it is no longer required for that elastically compressible device to be capable of causing the reservoir to rise to attain its high working position, a pulling force on the cap making it possible to complete the rising movement of the reservoir to attain that high position, in which the reservoir can then be held by the presence of a point of increased resistance braking descent from that high position.
[0020] It can be understood that the aforementioned cooperation between the protuberance of the shaft and sealing members provided by the neck of the reservoir have, in relation to the teachings of document EP-1 721 543, the advantage of no longer employing claws that are radially movable in relation to the axis of the shaft while being separated by slots liable to become clogged with the product brought by the applicator, which may adversely affect the cleanliness of the neck of the reservoir and the durability of the applicator. As a matter of fact, this document provides to dispose, between the rigid sectors of the collar, elastic sectors that ensure circumferential continuity for the collar.
[0021] However, the collar, like the claws of the prior art, can only spread radially and release the protuberance when the reservoir has been sufficiently raised in the body for that collar (or those claws) to be outside the body. In other words, the release of the protuberance is determined by passing the edge of the body into which the application member retracts. Furthermore, the sealing results from the existence of an axial component resulting from the effect of the collar on the protuberance, which amounts to saying that the function of axial linking between the application member and the reservoir and the sealing function are coupled.
SUMMARY
[0022] There are however configurations in which it would be advantageous to be able to dissociate the functions of axial linking by locking and sealing, so as in particular to be able to dissociate the aforementioned axial linking at an intermediate level within the body while maintaining the sealing.
[0023] To that end, the invention provides a container for a pasty or liquid cosmetic product, comprising:
an elongate body, extending in a longitudinal direction (Z-Z), provided with a bottom zone and a free edge; a reservoir containing the product and that is movable in translation in the body between a position of maximum pushing-in and a position of minimum pushing-in referred to as a high working position, the reservoir comprising a bottom and an edge remote from the bottom; an elastically compressible device situated between the body and the reservoir and having two stable axial configurations of withdrawal in relation to a configuration of maximum axial retraction determining the position of maximum pushing-in of the reservoir into the body, that is to say a configuration of maximum extension determining the high working position of the reservoir, and a stable retracted configuration determining for that reservoir a low resting position that is intermediate between the position of maximum pushing-in and the high working position, the passage of the device from one to the other of these stable configurations being made by retraction into the configuration of maximum axial retraction, against an axial spring interposed between that body and that reservoir; an application member joined to a cap, and comprising a shaft joined to the cap and terminated by an applicator configured to be loaded with product when it is plunged into the reservoir in a closing configuration in relation to the reservoir in which the shaft traverses the edge of the reservoir, the cap being configured, in the closing configuration, to be retracted at least approximately within the body and, when the reservoir is in its high working position, to project at least partly out from the body by a distance sufficient to enable the extraction of the application member out from the reservoir and from the body by grasping between the fingers of a user and mere axial pulling; complementary members distributed on the shaft of the application member and on the reservoir near its free edge to axially link the shaft to the reservoir while ensuring sealing obturation of the reservoir at its edge when the reservoir is in its configuration of maximum pushing-in,
wherein the complementary members include at least the following:
a peripheral part of which an upper portion caps the edge of the reservoir while extending laterally to the inside surface of the body and of which a lower portion is sealingly engaged in the reservoir near its edge; an inside part of a more flexible material than that constituting the peripheral part and which is fastened to that peripheral part, the inside part comprising an inside skirt comprising an upper portion having an inside surface which is flared towards the outside of the reservoir; a finger that is movable transversely in the peripheral part so as to move closer or farther away from the longitudinal direction, and comprising a head situated transversely outside the reservoir, but always inside the body; a cam-forming surface provided on the inside surface of the body, configured to push the head towards the longitudinal direction at the time of a descending movement of the reservoir into the body; and a widened portion provided on the shaft at a location such that, when the application member is in its closing configuration in the reservoir, the widened portion is engaged by friction in the upper portion of the inside skirt and, in relation to the longitudinal direction, being at a lower level than that of the finger.
[0034] According to the invention, the unlocking of the axial linking between the application member and the reservoir may be made at any location chosen by the designer of the container within the body, without it being necessary for the reservoir, or for the peripheral or inside parts, to leave that body. This contributes to preserving the aesthetics of the container including in configuration of use. Moreover, the engagement by friction of the widened portion of the shaft in the upper portion of the inside skirt, enables satisfactory sealing to be provided independently of the locking in an axial direction provided by the movable finger.
[0035] The invention does not involve a number of single parts greater than that provided in the known solutions.
[0036] Advantageously, the cam-forming surface is situated so as to cooperate with the head of the finger over the end of the travel of the reservoir towards its position of maximum pushing-in. This amounts to saying that the locking of the application member on the reservoir only occurs over a small part of the range of movement of the reservoir. If the raising of the reservoir to attain its high working position (position of minimum pushing-in) is provided by the elastically compressible device, pulling of the application member by the fingers of a user only occurs in practice at times in which that application member can be separated from the reservoir without it being necessary to preserve the sealing with the reservoir; the engagement by friction of the widened portion in the upper portion of the inside skirt thus does not need to be made with much force.
[0037] According to another advantageous feature, the cam-forming surface is situated so as to cooperate with the head of the finger over a longitudinal distance at most equal to one third of the range of movement of the reservoir within the body starting from the low resting configuration.
[0038] According to still another advantageous feature, the flared surface of the upper portion of the inside skirt of the inside part is connected to a formation in relief, which is advantageously annular, adapted to cooperate with the widened portion of the shaft, in which is advantageously formed a hollow, which may be annular, adapted to receive that formation in relief. As a variant, the flared surface of that inside skirt is connected to a hollow, which is advantageously annular, adapted to cooperate with the widened portion of the shaft, which is advantageously provided with a formation in relief that is advantageously annular.
[0039] According to another advantageous feature, the inside skirt further comprises a lower portion—the inside skirt thus forming a double skirt—and the lower portion converges towards the bottom of the reservoir and towards the longitudinal direction.
[0040] The lower portion is for example more flexible than the upper portion.
[0041] According to still another advantageous feature, the shaft comprises a constricted zone situated longitudinally at a level such that, when the application member is in its closing configuration in the reservoir, a free edge of the lower portion of the inside skirt of the inside part is situated around that constricted zone. This contributes to enabling a balance of the air pressure within the reservoir and to minimizing the forces to which the lower portion is subjected in the low configuration of the reservoir in the body. To be precise, the deformation of the upper portion on account of the engagement of the widened portion of the shaft may induce an inclination of the lower portion towards the longitudinal direction. There is then no advantage in the lower portion being pressed against the shaft. On the contrary, in a particular embodiment, the lower portion is not elastically acted upon during the periods in which the container is not used.
[0042] According to another advantageous feature, the lower portion of the inside skirt of the inside part extends, in the longitudinal direction, over a distance at most equal to half the distance over which extends the upper portion of the inside skirt.
[0043] According to another advantageous feature, the lower portion of the inside skirt of the inside part has a thickness that reduces towards the bottom of the reservoir. This makes it possible to confer a large degree of flexibility to the lower portion at its free edge, which facilitates its role as a wiper lip.
[0044] According to another advantageous feature, the widened portion of the shaft of the application member comprises a convergent portion extending from an upper edge of a flared surface of the widened portion towards the shaft, for example towards an apex of the shaft, so as to force spreading of the finger in relation to the shaft during a longitudinal movement of taking out the application member from the reservoir. This contributes to ensuring withdrawal of the finger away from the shaft when the head is no longer applied against the cam-forming surface.
[0045] According to another advantageous feature, the peripheral part and the inside part are of moldable plastic materials. This enables great simplicity of manufacture.
[0046] Furthermore, the peripheral part and the inside part may be formed as a single part or as two separate parts which would then, for example, be fitted elastically together by insertion of one into the other.
[0047] According to another advantageous feature, the body comprises an outside part and an inside part in which is provided the cam-forming surface. This enables a material to be chosen for the outside part that provides the desired aesthetics and a different material for the inside part that is compatible with the desired geometry.
[0048] According to another advantageous feature, the inside surface of the body and the outside surface of the reservoir comprise complementary members constituting a point of increased resistance inducing resistance to the movements of the reservoir in the body from its high working position, in particular for example the descent of the reservoir into the body from its high working position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] Aims, features, and advantages of the invention will appear from the following description, given by way of non-limiting illustration, with reference to the accompanying drawings in which:
[0050] FIG. 1 is an axial cross section view of a container according to a first embodiment of the invention, in a retracted configuration;
[0051] FIG. 2 is a similar view, but in an extension configuration;
[0052] FIG. 3 is an enlarged view of the upper portion of the container in its extension configuration;
[0053] FIG. 4 is an axial cross section view of another container in accordance with the invention, in a second embodiment;
[0054] FIG. 5 is a perspective view of the container of FIGS. 1 to 3 , in the retracted configuration;
[0055] FIG. 6 is a perspective view in the extension configuration;
[0056] FIG. 7 is a view in elevation of the container in the retracted configuration;
[0057] FIG. 8 is a cross section view of the sub-assembly constituted by the body and the reservoir;
[0058] FIG. 9 shows an exploded view of an inside cage of the body, a spring, a finger and a reservoir of the sub-assembly of FIG. 8 ; and
[0059] FIG. 10 presents a perspective view of the cage of FIG. 9 .
DETAILED DESCRIPTION
[0060] FIGS. 1 to 3 represent a container denoted 1 overall. It principally comprises a body 10 , a tubular reservoir 20 movable within the body 10 , an elastically compressible assembly 30 interposed between the body and the reservoir, an application member 40 configured to cooperate with the reservoir 20 and a cap 50 which bears the application member 40 and which is adapted to obturate the body 10 when the application member 40 is engaged in the reservoir 20 .
[0061] The body 10 is elongated, extending in a longitudinal direction Z-Z, which is vertical here, provided with a bottom zone 11 and a free edge 12 , The longitudinal direction here is an axis of symmetry, the cross section of the body having a square shape (see FIGS. 5 and 6 ) in the example considered, or more specifically the shape of a rounded square, that is to say that the lateral faces of the body are bowed outwards. As a variant not shown, the cross section may have a rectangular shape, or a simpler geometric shape, for example that of a circle (symmetry of revolution), or even a more complex shape, for example polygonal with a number of corners greater than four, or oval, etc. In a particular embodiment, this longitudinal direction is such that, in any plane passing through it, it is an axis of symmetry for the intersection of the body and that plane.
[0062] The body 10 may be formed from one part, or be formed from several parts mounted onto each other (for example a tube to which is mounted a bottom part). In the example represented here, the body is formed by an outside metal sleeve 10 A (defining the lateral wall and the bottom), of which the material and the texture are mainly chosen according to the appearance it is desired to give to the container and an inside cage 10 B, for example formed from plastic material.
[0063] The cage 10 B, also represented in FIGS. 9 and 10 , here comprises a bottom 10 C and three uprights 10 D, 10 E, 10 F which are disposed in three of the four dihedrons of the lateral wall of the sleeve. The outside contour defined by the three uprights of the cage has dimensions substantially equal to the inside dimensions of the sleeve, in order for the cage to be accommodated in the bottom of the sleeve. Moreover, the outside contour defined by the three uprights of the cage has a circular envelope to enable the guiding of a reservoir 20 that is described below. Two of the three uprights have a height that is in the neighborhood of half the height of the sleeve, this height not being critical, and the third upright 10 F is extended by a height-increasing portion that ends with an inclined surface 16 and a contact surface for lateral bearing 15 . These parts are described below. The assembly has a height that is defined by the height of the sleeve and the range of movement of the reservoir inside the body. This is described in more detail below. The three uprights may be linked together by cross-members distributed over the height of the cage 10 B. The opening of the cage, which is located in the dihedron without any upright, enables the part to be demolded at the time of injection molding and also enables the assembly of the reservoir and of the elastically compressible assembly inside the cage.
[0064] The cage 10 B is accommodated in the bottom of the sleeve 10 A and these members are assembled by any appropriate means, in particular by bonding using a thermoplastic adhesive. Other means may also be appropriate. As has already been stated, the sleeve 10 A and the cage 10 B may form a single part.
[0065] The reservoir 20 contains a product that is fluid, which is to say liquid or viscous, to apply using the application member 40 . The product is represented by the reference 100 in FIG. 8 . Here it is gloss but may, as a variant, be mascara for example. The reservoir 20 comprises a bottom 21 and an edge 22 ; its cross section is formed so as to be able to slide (simply by movement in translation) between the uprights of the cage between two longitudinally offset configurations of which one corresponds to a maximum pushing-in into the body towards the bottom of the body and the other corresponds to a minimum pushing-in into that body. The reservoir is designed so as to be entirely contained in the body over the entirety of the range of movement between the two pushing-in configurations. The height of the reservoir is thus less than the height of the body reduced by the amplitude of movement of the reservoir between its two pushing-in configurations.
[0066] In the illustrated embodiment, the reservoir has a generally circular cross section, as represented in FIG. 9 . It is possible for the wall to have a shoulder locally marked by a change in diameter of the reservoir, as for the shoulder 23 which is described below. Internally, the reservoir also has a circular cross section. This cross-sectional shape, however, is not limiting; it is preferred since it enables better output of the product.
[0067] The elastically compressible assembly 30 interposed between the cage and the reservoir is designed, in a way known per se, to confer upon the reservoir two stable withdrawal positions in relation to the configuration of maximum pushing-in. In FIG. 1 , the reservoir is, in relation to the body, in one of these stable positions, which is qualified as a “stable low position of withdrawal”, that is to say in a stable position close to the maximum pushing-in configuration. In FIG. 2 , the reservoir is, in relation to the body, in the other stable position of withdrawal, which is a “stable high position of withdrawal” and which corresponds to the minimum pushing-in configuration of the aforementioned reservoir. The assembly 30 in practice comprises a spring 31 compressed longitudinally between the bottom 11 of the body and the reservoir (here between the bottom 10 C of the cage and the shoulder 23 formed externally in the wall of the reservoir), combined with a follower finger 33 carried by the reservoir along a track 34 , represented in particular in FIG. 9 , hollowed out of the upright of the middle of the cage, the upright 10 E and of which at least one portion is in the shape of an inverted heart. For more detail, reference may be made in particular to the document EP-1 721 543, or to the document EP-2 346 370. In operation, when the reservoir 20 is in one of its stable positions of withdrawal in relation to the bottom 11 of the body, pressing applied to it until the maximum pushing-in configuration (not shown) is reached enables it, under the effect of the spring 31 , to come to its other pushing-in configuration.
[0068] Other ways of constructing the elastically compressible assembly may also be suitable, such as those described in the patent application EP 1 721 543 or for instance EP 2 346 370.
[0069] The low stable position of withdrawal of the reservoir is defined by the positioning of the follower finger 33 at the “dead center” 34 A of the track. The high stable position of withdrawal is defined by the passage of two diametrically opposite skids (only the skid 10 G is visible in FIG. 9 ) that pass in two diametrically opposite grooves hollowed into the outside surface of the reservoir 20 (only groove 24 is visible in FIG. 9 ). In the high stable position, the skids are in abutment against the lower end of the grooves and the spring 31 is not fully relaxed; it applies a thrust between the cage and the reservoir. Other forms of construction are also suitable for limiting the travel of the reservoir towards the free edge 12 of the body.
[0070] The application member 40 comprises a shaft 41 terminating by an applicator 42 configured to be loaded with product when it is plunged into the reservoir in a configuration referred to as a “closing configuration” in relation to the reservoir. At the other end is located the cap 50 by which a user holds the application member when it is used. The applicator 42 is of a known type and is not described in further detail. It may be of the spatula, brush or other appropriate type. It is mounted at the end of the shaft, or else may be formed as a single part with the shaft.
[0071] The cap 50 has a cross section shaped so as to be able to slide with a small degree of lateral play in the top portion of the body until it is retracted therein.
[0072] The cap 50 is joined to the application member 40 , but is generally formed as a part separate from that member. In the example represented, the shaft 41 is surmounted by a head that is mounted with a force fit inside the cap but, as a variant, it may be one and the same part, if the production technique enables this.
[0073] The reservoir 20 is provided, on its free edge 22 , with a peripheral added-on part 25 , in which is mounted an inside added-on part. On account of the respective functions of these two parts, the inside part 26 is of a material having lower rigidity than that of the peripheral part.
[0074] As shown in FIG. 3 , the peripheral part 25 comprises a lower portion 25 A (with reference to the direction Z-Z), of cylindrical general shape and which is engaged by a force fit in the top portion of the reservoir near the free edge 22 , and an upper portion 25 B that protrudes laterally out of the reservoir to the inside wall of the body, thus obturating the space situated laterally between the outside wall of the reservoir and the inside wall of the body while being able to slide along the inside wall during the movements of the reservoir inside the body. A protruding part 25 E of the upper portion 25 B, of which the shape and the dimensions substantially correspond to those of the body at the location of its free end 12 , may be assimilated to a circumferential lip for sliding able to pass along the inside wall of the body. In this manner, the reservoir is guided in the body, in its bottom portion, by the uprights of the cage and in its top portion by the protruding part 25 E that slides along the inside portion of the sleeve.
[0075] The upper portion 25 B comprises, below the protruding part, a bore directed towards the longitudinal direction Z-Z and in which is mounted a finger 25 C configured to slide therein. This bore is perpendicular here to the longitudinal direction Z-Z but may as a variant have a slight inclination in relation to a plane perpendicular to the longitudinal direction Z-Z.
[0076] The finger 25 C comprises an inside end configured to project, in some of its positions in the bore, towards the longitudinal direction Z-Z, and a widened head situated outside the upper portion 25 B and being configured to cooperate with various surfaces disposed outside the reservoir, as is described below.
[0077] For this, the finger may be situated, vertically, above the free edge of the reservoir. However, to ensure optimum mechanical strength properties of the upper portion 25 B in the reservoir, and thus optimum holding of the finger in that the upper portion, in a particular embodiment, the finger is situated across the wall of the reservoir, by virtue of a longitudinal cut-out (or even a simple opening) formed locally in the wall of the reservoir, which enables that finger to be situated, longitudinally, at a position in which the upper portion 25 B is held in the reservoir.
[0078] The bottom edge of the cut-out, denoted 27 in FIG. 3 or visible in FIG. 9 , is formed so as to be able to serve as an abutment for the head when the finger 25 C comes near the longitudinal direction Z-Z.
[0079] When the reservoir is in position in the body, the finger 25 C is in alignment with the third upright 10 F of the cage and its widened head is induced to come into contact with the inclined surface 16 of the upright.
[0080] The inclined surface 16 is provided to bring the finger 25 C from its position that is away from the longitudinal direction Z-Z (position of FIG. 2 ) to its position brought near to the longitudinal direction Z-Z (position of FIG. 1 ) on pushing-in of the cap 50 and the applicator inside the body. The contact surface for lateral bearing 15 retains the finger in its brought-near position when the reservoir is located in its stable low position of withdrawal.
[0081] As illustrated in FIG. 3 , the inside part 26 here comprises, starting from a transverse portion 26 A, an outside skirt 26 B and a dual inside skirt 26 C+ 26 D. The inside skirt is said to be dual here on account of it comprising an upper portion 26 C and a lower portion 26 D.
[0082] This lower portion is only optional, since the functions of the device of the invention are provided even in the absence of such a lower portion.
[0083] The outside skirt 26 B is formed so as to have an elastic insertion fit around a bottom portion, 25 D, of the lower portion 25 A of the peripheral part 25 . More specifically, this outside skirt, oriented upwardly in the Figures, here comprises a bead 26 F along its top edge, projecting towards the longitudinal direction Z-Z from the outside skirt 26 B, while the bottom portion 25 D of the peripheral part 25 comprises, along its bottom edge, a bead 25 F projecting oppositely to the longitudinal direction Z-Z. It is to be understood that the combination of the two beads 25 F and 26 F provides a good mutual connection between the parts 25 and 26 , although the presence of these beads is merely optional. In a particular embodiment, the transverse part 26 A defines the bottom of an annular channel defined by the outside skirt 26 B and an upper portion 26 C of the dual inside skirt 26 C+ 26 D.
[0084] The upper portion 26 C, oriented upwardly in the Figures from the transverse part 26 A, has a wall of which the general orientation is parallel to the longitudinal direction while having an inside surface 26 E (facing the longitudinal direction) which is flared upwardly, and an outside surface (facing the bottom portion 25 D of the peripheral part 25 ) which is approximately parallel to the inside surface of this bottom portion of the peripheral part 25 . It can thus be said that the upper portion 26 C here delimits a volume of substantially cylindrical shape in the mathematical sense of the term (for example of polygonal cross section, or oval, for example), or in the usual sense of the term (cross section of a disk), according to the function of the geometry of the shaft of the application member (see above). An annular space is provided between the upper portion of the dual skirt and the bottom portion of the peripheral part, configured to enable deformation of the upper portion away from the longitudinal direction.
[0085] A lower portion 26 D of the inside dual skirt, which extends the upper portion 26 C downwardly from the transverse part 26 A, converges slightly downwardly and towards the longitudinal direction. As described below, this lower portion is configured to perform wiping of the applicator. Furthermore, this lower portion may have a downwardly tapered cross section, giving it flexibility that increases from the transverse portion, enabling it to act as a wiping lip on the shaft. The lower portion of the skirt is however optional.
[0086] An intermediate portion 26 G links the upper portion 26 C and the lower portion 26 D. This intermediate portion is cylindrical. The intermediate portion is situated at the location of the transverse part 26 A of the inside part.
[0087] The outside skirt 26 B, which has a function of fastening the inside part 26 to the part 25 , and the upper portion 26 C of the dual skirt, which, as explained below, has a sealing function, are thicker than the lower portion 26 D of the dual skirt that, to be able to properly perform wiping, is more flexible than the other portions.
[0088] This form of construction of the peripheral part 25 of the inside part 26 gives good results, but other forms of construction are also possible. In particular, the peripheral part 25 and the inside part 26 could be formed as a single part, by injection molding or according to requirement by bi-injection molding.
[0089] The behavior of the finger 25 C according to the position of the reservoir in relation to the body enables temporary locking of the application member in the reservoir when the reservoir is in its stable low configuration of withdrawal and the shaft cooperates with the inside part 26 to provide air-tight obturation the reservoir.
[0090] As a matter of fact, this finger and the inside part cooperate with a widened portion 44 provided on the shaft 41 of the application member.
[0091] In a first phase, when the reservoir descends towards its maximum withdrawal position, the finger comes into contact with the cam-forming surface 16 , and is pushed away towards the axis Z-Z, whereas the widened portion 44 is situated below the level of the finger.
[0092] Thus, the shaft comprises the widened portion 44 in the vicinity of the cap. The widened portion is configured to cooperate with the inside part 26 when the application member is engaged to the maximum in the reservoir, in the closing configuration, and is thus situated on the shaft in a zone that comes inside the part 26 at the time of this closing configuration.
[0093] More particularly, the widened portion 44 has a flared bottom portion 45 that has a geometry and dimensions that are advantageously close to the inside dimensions and geometry of the upper portion of the dual skirt of the inside part 26 . In the example represented, the flared inside surface of the upper portion of the dual skirt has an inclination which, in relation to the longitudinal direction, is substantially equal to the inclination of the flared portion 45 . As a variant, the inclination of the inside surface may be less by a few degrees than that of the flared portion, to take into account the fact that the dual skirt can tip through a few degrees in relation to the transverse part 26 A. These inclinations here result from these surfaces being frusto-conical.
[0094] By way of example, the flared surface of the upper portion 26 C of the dual skirt and that of the flared portion 45 of the shaft have inclinations equal to at least 3°, for example in a range from 5 to 20°.
[0095] In the example represented here, the widened portion 44 further comprises an annular rib 46 , in relief, configured to be thrust into the wall of the intermediate portion 26 G of the dual skirt 26 by locally deforming that wall. The annular rib 46 is formed here around the flared portion 45 . The wall of the intermediate portion can comprise a recessed zone such as a channel configured to receive the annular rib 46 at least partly. As a variant, the flared portion may be connected to a recessed zone configured to cooperate with a zone in relief formed on the wall of the intermediate portion.
[0096] By respectively cooperating with the upper portion 26 C and the intermediate portion 26 G, the flared portion 45 of the shaft and the annular rib 46 produce a sealing closure of the reservoir when the applicator is in the closing position ( FIG. 1 ). In addition to its sealing function, the flared portion 45 also acts on the finger 25 C on closing the container if the finger has come towards the axis Z-Z; this is described in more detail below.
[0097] The flared portion 45 joins to a top convergent portion 47 of the widened portion 44 which converges towards an upper portion of the shaft.
[0098] The convergent portion 47 , which is situated below the level of the finger 25 C in the closing configuration ( FIG. 1 ), is provided to move the finger away from the axis Z-Z to reach its position of FIG. 2 when the reservoir rises after having left its position of maximum pushing-in.
[0099] In the exemplary illustrated embodiment, when the widened portion 44 is engaged in the upper portion 26 C of the dual skirt 26 , the free end of the lower portion of the dual skirt transversely faces a portion 25 C of the shaft that locally has a reduced cross section.
[0100] In the closing configuration of FIG. 1 , the application member 40 is engaged to the maximum in the reservoir, that is to say that the applicator 42 is in its lowest position in the reservoir. In this closing configuration, the widened portion 44 of the shaft is engaged against the flared inside surface of the upper portion of the dual skirt of part 26 , which is able to widen by virtue of the play situated between the outside surface of the upper portion and the inside surface of the bottom portion of the part 25 .
[0101] The finger 25 C, which is located above the level of the widened portion 44 , is retained in its position brought near to the axis Z-Z by the contact surface for lateral bearing 15 . It retains the applicator by opposing the passage of the widened portion 44 . Furthermore, the sealing is provided by the cooperation of the outside surface of the widened portion 44 and the inside surface of the upper portion 26 C of the dual skirt of part 26 . These two functions are however independent.
[0102] In the represented example, the closing configuration is a configuration in which the inside portion of the cap 50 bears longitudinally against the upper portion 25 B of the peripheral part 25 . However, the existence of such longitudinal bearing could be provided at another location, or even not exist, without this being detrimental to the effects of locking and sealing described above.
[0103] The height h of the cap 50 is substantially equal to the travel of the reservoir between its stable configuration of maximum pushing-in and its minimum pushing-in configuration such that in the first position the cap is flush with the level of the free edge 12 of the body, and such that in the second position, the cap provides a sufficient hold to be grasped between the fingers of one hand and extracted from the reservoir.
[0104] The contact surface for lateral bearing 15 extends from the cam-forming surface 16 to a depth in the reservoir that is greater than the travel of the reservoir between its upper stable position and its maximum pushing-in configuration, so that, at least in the lower portion of the travel of the reservoir, the applicator and the reservoir are linked to each other. The position of the cam-forming surface 16 is not critical. This position determines at what moment in the travel of the reservoir the applicator and the reservoir are linked to each other or at what moment in the travel of the reservoir that linking unlinks. In the configuration of FIG. 1 , the application member is in its closing configuration in the reservoir, while the reservoir is in its stable low configuration of withdrawal in the body. The cap is then retracted into the body and therefore offers no hold to the fingers of a user wishing to pull outwardly on it. It can be understood that the same comment would apply if the cap were to project by only a short distance out of the body.
[0105] When the user wishes to use the applicator to apply the product contained in the container, she pushes on the cap, so as to make the reservoir descend into its maximum pushing-in configuration, and to enable the spring to raise the reservoir to its minimum pushing-in configuration of FIG. 2 . The contact surface for lateral bearing 15 extends downwardly over a distance such that the descent of the reservoir from its configuration of FIG. 1 to its maximum pushing-in configuration is possible without deterioration of the finger 25 C.
[0106] At the time of the rising movement of the reservoir in the body under the effect of the spring 31 , the locking of the finger 25 C by the contact surface for lateral bearing 15 is eliminated as soon as the head clears the cam-forming surface 16 upwardly. However, the finger remains in position brought near to the axis Z-Z until the application member 40 has been extracted from the reservoir. Until that time, the sealing between the flared surface of the widened portion of the shaft 41 and of the flared inside surface of the upper portion of the dual skirt of the part 26 is preserved merely by the contact and the natural adherence that exists between the surfaces providing that sealing.
[0107] The fact that the locking can take place by withdrawal of the finger inside the body has the advantage that the reservoir can remain completely inside the body in its stable configuration of minimum withdrawal. It has been seen that, in the example represented, part 25 provides obturation of the lateral space between the reservoir and the body. This obturation is advantageously provided, in the minimum pushing-in configuration of the reservoir of FIG. 2 (or of FIG. 3 ), at the location of the free edge 12 of the body, that is to say that the widest part of part 25 is then advantageously at the same level as that free edge. It is to be understood that the level at which is situated the cam-forming surface 16 may be freely chosen by the designer of the container, but preferably, that level is located rather towards the maximum pushing-in position than towards the minimum pushing-in position, and for example the cam-forming surface is situated so as to cooperate with the head of the finger at a distance at most equal to one third of the range of movement of the reservoir inside the body from the low resting configuration.
[0108] In this configuration of FIG. 2 in which the reservoir 20 is in its minimum pushing-in configuration, the application member 40 is still engaged by friction in the reservoir. Since the cap 50 projects out from the body 10 by a distance enabling the grasping of the cap by the fingers of a user, the extraction of the application member out from the reservoir may be carried out merely by pulling on that cap. That pulling on the application member only induces moderate pulling on the reservoir, and the friction forces between the reservoir and the body may be sufficient to retain the reservoir in the body while the application member frees itself from the reservoir merely by spreading of the widened portion 44 in relation to part 26 .
[0109] On the extraction of the application member 40 , the convergent surface 47 pushes the finger 25 C away. And if by any chance the finger moves close to the axis Z-Z when the application member is taken out from the reservoir, it is then the flared bottom portion 45 that repositions the finger in the right position at the time at which the applicator is inserted again into the reservoir.
[0110] When it is provided for the peripheral part 25 to come flush with the free edge 12 of the body 10 in the minimum pushing-in configuration (that is to say the stable high configuration of withdrawal), the distance by which the cap 50 projects out from the body is substantially its height h (see FIG. 2 ). However, it may be provided for the peripheral part not to rise as far as the level of the free edge of the body without the operation described above being substantially modified (see FIG. 4 ).
[0111] Progressively as the pulling on the cap continues, the application member 40 separates from and spreads longitudinally in relation to the reservoir 20 . In a first phase, the lower portion of the dual skirt of the part 26 is slightly acted upon elastically due to the diameter of the shaft being advantageously chosen at a value slightly greater than the diameter of the cross section delimited by the free edge of that lower portion when it is not urged towards the wall of the reservoir. Slight scraping of the product that may have become attached to the shaft thus occurs. In a second phase, the lower portion is elastically acted upon by the applicator 42 . Since the latter in practice has a cross section greater than that of the shaft, it can be understood that the free edge of the lower portion of the dual skirt provides scraping (or wiping) of the applicator to detach therefrom the excess of product which has been attached thereto. The user may then apply the product as she pleases, where she wishes.
[0112] When the user wishes to load the applicator with product again, she plunges the applicator into the reservoir as is done with a usual container. The reservoir is now held in a high stable position by the pushing of the spring and does not move significantly in relation to the body.
[0113] When the user has finished applying product and wishes to bring the container into a resting configuration, she pushes the application member into the reservoir and continues to press on the cap, which results in the reservoir beginning to descend into the body. When the reservoir has descended to the level of the cam-forming surface 16 , this forces the head of the finger 25 C to move closer to the shaft, which results in the finger engaging towards the shaft, above the convergent portion 47 . The application member is then locked onto the reservoir. The assembly of these two parts then descends to attain the maximum pushing-in configuration of the reservoir. When the user releases her pushing force, the spring then brings the reservoir back into its stable low configuration of withdrawal in which the cap of the application member is retracted into the body. The application member is then locked in position in the reservoir while the combination of the flared surfaces of the widened portion 44 and of the upper portion of the dual skirt of the part 26 ensures good sealing.
[0114] In such a configuration, the locking function is dissociated from the sealing function and these functions are activated by very moderate forces, independently of the longitudinal position of the reservoir in the body, without any part of the reservoir having to come out of the body, longitudinally or laterally in any of the positions of the reservoir. Furthermore, the wiping effect provided by the lower portion of the dual skirt is obtained even though the lower portion extends over a short longitudinal distance. The inside part 26 has a simple form and is easy to manufacture. Similarly, the peripheral part has a simple form and is easy to manufacture. As regards the geometry of the widened portion of the shaft, this is also simple. The number of simple parts is only just three, i.e. the peripheral part 25 , the associated finger 25 C that is mounted to it, and the inside part 26 .
[0115] FIG. 4 represents a variant embodiment of a container in accordance with the invention. The reference numerals of the illustrated container, which is denoted 101 overall, are analogous to those of FIGS. 1 to 3 and are designated by reference numerals that are derived from the reference numerals appearing in FIGS. 1 to 3 increased by 100.
[0116] The container 101 thus comprises, like the container 1 , a body 110 , a reservoir 120 , an elastically compressible device with two stable positions of withdrawal 130 , an application member 140 and a cap 150 .
[0117] The cap 150 differs slightly from the cap 50 by the geometry of the inside structure, in particular as regards the fact that is by the peripheral part that the inside part comes to bear against the top surface of part 125 , without this affecting the operation described above. Moreover, the space situated between the outside surface of the upper portion 126 C of the dual skirt of the part 126 and the inside surface of part 125 is greater than in the container 1 , which results in enabling greater lateral deformation of that upper portion while facilitating the mounting of the inside part 126 on the peripheral part 125 .
[0118] In contrast to the case of FIGS. 1 to 3 , the reservoir 120 of the container 101 does not rise until the periphery of part 125 is flush with the free edge 112 of the body, but remains below that edge by a distance denoted d. Therefore, when the reservoir is in its minimum pushing-in configuration, the cap does not come fully out from the body, but it is sufficiently raised in relation to the body to enable it to be gripped.
[0119] Furthermore, the reservoir and the body have surfaces facing each other that are formed so as to provide retention of the reservoir in the upper position in the body. More specifically, the cage 110 B comprised by the body 110 comprises, in at least one zone, here a top zone situated approximately at the location of the contact surface for lateral bearing 115 under the cam-forming surface 116 , but being circumferentially offset from it (here to the right in FIG. 4 ), a projection 117 towards the shaft, whereas the outside surface of the reservoir comprises a projection 118 configured to come just above the projection 117 when the reservoir is in its minimum pushing-in configuration. At least one of these projections, here projection 118 , is joined to an inclined surface 119 forming a contact surface for the other projection at the time of a relative rising movement of the reservoir in relation to the body. Thus, when the reservoir passes from the low stable position to the high stable position, the projection 117 slides over the inclined surface which provides a braking effect. The raising of the reservoir under the thrust of the spring is slowed in this way. Other forms of construction may also be appropriate. When the reservoir has attained its high stable position, the projection 118 clears the bump formed by the other projection. This thus provides the effect of a point of increased resistance. This point of increased resistance effect is also experienced on closing the container, when the user presses on the cap 150 to retract it into the body.
[0120] The projection 117 is located above a zone in which guide members may be provided to ensure proper guiding of the reservoir in the body without the risk of rotation.
[0121] The added-on parts are obtained here by molding of plastic materials, for example a thermoplastics material (polyamide, PVC or low-density polyethylene, in particular) or a high-rigidity elastomer material as regards the peripheral part and an elastomer material for the inside added-on part. As a variant they could form only a single part formed by mono- or bi-injection molding.
[0122] FIGS. 5 and 6 represent the container 1 in perspective in the retracted configuration of FIG. 1 , or in the extension configuration of FIG. 2 , respectively. It will be understood that the cross section of the cap is square with the edges slightly bowed. Since the movement of the application member may be engaged by mere translation in the reservoir, it is in fact possible to give the body any desired cross section (polygonal, oval, or the shape of a clover leaf, etc.). It is possible to give the reservoir a similar form (for example slightly smaller than that of the body) or on the contrary a different form, for example a circular cross section, so leaving a space, laterally between the inside surface of the body and the outside surface of the reservoir, which has a maximum width facing the sides of the body, which enables guide members to be accommodated, or part of the elastically compressible device having two stable positions of withdrawal.
[0123] FIG. 7 illustrates that the fact of stating that the cap is retracted into the body does not imply that any part of the cap does not protrude from the volume of the body. In fact, what is important is for the cap to give, outside (to the fingers of a user or to an object that may come into contact with the container, for example in a bag), an insufficient hold to extract the application member from the body, or to push on the cap until the reservoir is made to pass into its maximum pushing-in configuration. In the example represented here, the face of the cap that is accessible at the outside is domed, giving rise to projecting slightly by a distance e.
[0124] Examination of FIG. 8 enables it to be understood that, on account of the small longitudinal bulk of the assembly of parts 25 and 26 , the reservoir can be filled with product 100 up to a level close to its free edge.
[0125] Lastly, as mentioned earlier, FIGS. 9 and 10 , showing perspective views, enable the constitution of the cage 10 B, the spring 31 , the follower finger 33 , and the reservoir 20 to be better understood. It is in particular easier to observe that the cage 10 B comprises three uprights positioned here at three of its four corners, with the middle upright, upright 10 E that has no upright situated opposite, comprising the track 34 , and the upright 10 F being extended by the height-increasing portion that terminates with the inclined surface 16 and the contact surface for lateral bearing 15 .
[0126] The invention is not limited to forms of construction that have been described. It applies generally to any dispenser of cosmetic product in which the liquid or pasty product is applied using an applicator.
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A container for a liquid or pasty cosmetic product has an elongate body, a reservoir that contains the product and is able to move in translation in the body between a top working position and a maximum depressed position under the action of an elastically compressible device, and an application element secured to a cap that is retractable into the body and including a shaft that is secured to the cap and is terminated by an applicator suitable for being loaded with product when it is dipped into the reservoir; a peripheral part provided with a locking finger that is able to move transversely and a more flexible internal part are attached to the reservoir close to its edge in order to engage in terms of sealing with a widened portion of the shaft and to lock the latter to the reservoir over only a part of the travel of the reservoir in the body.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 318,620, filed Nov. 5, 1981, now abandoned.
BACKGROUND OF THE INVENTION
Wagons for carrying earth, ore, rubble, and other excavated material are well-known. It is also known to connect such a wagon to a tractor by means of a gooseneck affixed to the wagon and pivotally mounted on the tractor for pivoting about a vertical axis, with the gooseneck affording clearance above the rear wheels of the tractor. Various external means may be used for loading the wagon, and the wagon generally includes some means for moving the load from the wagon. The bodies of some wagons are arranged to be tipped up simply to dump the load carried thereby, whereas other wagons have positive ejecting means.
Such ejecting means may include a wall or plate of generally vertical disposition which is movable horizontally to eject the load from the wagon. Tremendous amounts of power are needed to move an ejector of this nature, as the load must be moved bodily across the floor of the wagon for dumping. It is known to use hydraulic cylinders for this purpose, but the ejector must be moved many feet, and this leads to extended cylinder-piston arrangements which are many feet long, and which in the past have been susceptible to damage, such as by a front end loader when loading the wagon. Such cylinder arrangements also are quite vulnerable to damage when the tractor-wagon unit must be maneuvered close to rock walls.
Problems also have been encountered with bending movements produced by the cylinders and the reaction of the load tending to pivot the ejector plate or wall about the movable mounts or guides therefore.
It is necessary to provide a movable closure opposite to the ejector wall so that materials can be retained for transport and then can be ejected from the wagon. Prior art closures for such ejection openings have therefore not been entirely satisfactory.
Relevant patent art on prior ejector wagons of the type heretofore discussed includes T. L. R. Hardwick U.S. Pat. Nos. 3,352,439 and 3,941,260.
OBJECTS AND SUMMARY OF THE INVENTION
The principal object of the present invention is to provide an improved ejector wagon.
It is a further object of the present invention to provide an ejector wagon in which the ejector cylinders are disposed in a protected area.
It is yet a further object of the present invention to provide an ejector wagon in which the ejector wall is configured and has ejection cylinder means attached thereto in such manner as to minimize bending forces on the travelling guide or mount for the ejector.
A further object of the present invention is to provide an improved back closure for the wagon opposite to the ejector wall.
In achieving the foregoing and other objects and advantages an ejector wagon is provided with hydraulic pistoncylinder means mounted in or on the gooseneck and connected to a pusher or ejector front wall of the wagon with the piston-hydraulic cylinder means thus being in a relatively non-vulnerable position.
The sidewalls of the wagon diverge upwardly and outwardly, providing a favorable carrying capacity to overall size and strength, and permitting heaping of material above the top of the wagon. Accordingly, the front pusher wall is larger at the top than at the bottom, and extends above the top of the sidewalls. The hydraulic piston-cylinder means is connected to the front pusher wall in such position as to minimize or eliminate turning force about the track and rollers mounting the pusher wall.
At the rear of the wagon there is a two-piece closure opening. An upper mud gate is pivoted at its upper edge for upward pivoting about a horizontal axis transverse of the wagon. At the lower edge a tailgate is pivoted about a transverse horizontal axis, and is hydraulically operated between open and closed position, and is provided with a hook at its upper edge for holding the mud gate closed.
THE DRAWINGS
The invention will thus be understood with reference to the following detailed description when taken in connection with the accompanying drawings wherein:
FIG. 1 is a side view of a wagon constructed in accordance with the principals of the present invention;
FIG. 2 is an enlarged fragmentary cross-sectional view taken substantially along the line 2--2 in FIG. 1;
FIG. 3 is a front view of the wagon taken partly in section along the line 3--3 in FIG. 1;
FIG. 4 is a fragmentary top view as taken along the line 4--4 in FIG. 1;
FIG. 4a is a view similar to FIG. 4 showing a modification of the invention;
FIG. 5 is a fragmentary enlarged view of the rear portion of the wagon, taken partially in longitudinal section; and
FIG. 6 is a fragmentary rear view of the wagon on an enlarged scale.
DETAILED DESCRIPTION
Reference first should be made to FIGS. 1 and 3 wherein there is shown a wagon 10 constructed in accordance with the principals of the present invention. The wagon includes a body 12 having at the rear thereof a pair of wheels 14 having pneumatic tires 16 thereon. The wagon includes a pair of sidewalls 18 diverging upwardly from their lower edges 20. A fixed floor 22 extends between the sidewalls 18 from somewhat above their lower edges 20, there being cross-beams or channels 24 secured to the sidewalls as by welding and supporting the floor 22. The floor preferably is welded to the cross-beams 24 for enchanced rigidity.
A tubular cross-beam 26 extends between the sidewalls 18 at the front end thereof and slightly below the horizontal midline, and is secured thereto by suitable means such as welding. A gooseneck 28 is fixed to the tubular cross-beam, again as by welding, and extends forwardly of the wagon for attachment to a tractor by means well-known in the art, and not shown herein.
The sidewalls are provided along their upper edges with rails or box-like channels 30 running from front to back thereof. Reinforcing beams 32 of box-like configuration are welded to the sidewalls and lean slightly forwardly from bottom to top from a vertical position. The beams at their upper ends are welded to the undersides of the channels 30.
Each channel as best may be seen in FIG. 2 includes a relatively fixed top plate or wall 34, a thinner bottom plate or wall 36 parallel thereto, and an outer vertical plate 38, all welded or otherwise suitably secured in fixed position along the upper edges of the walls 18.
A front end wall 40 serves as a pusher plate or ejector and conforms to the cross-sectional shape of the wagon body, and extends somewhat thereabove. The front end walls leans somewhat forwardly from the vertical, at a slightly greater angle than the reinforcements 32. This affords greater carrying capacity than a vertical wall, and tends to lift sticky material from the floor. As may be seen in FIG. 3 the front end wall 40 does not quite contact the inner surfaces of the floor 22 and of the sidewalls 18, although the gap is very small. The wall is mounted from the side rails or channels 30 by means best seen in FIGS. 1 and 2. Side plates 42 are mounted at the upper ends of the front wall 40 on upwardly and laterally extending portions 44. Bracing is provided by angularly disposed plates 46 having vertical depending lower margins 48, with intermediate horizontal plates 50. A roller 52 is disposed between the plate 42 and the depending flange or plate extension 48 and rides on top of the plate or wall 34. A roller 52 (FIG. 1) is at the forward end of the plate 42, and a similar roller 54 is disposed at the rear end of the plate on a horizontal level with the roller 52, and also rollable on the plate or wall 34.
Similar rollers 56 and 58 are disposed at the lower corners at the plate 42 and bear against the undersurface of the wall or plate 36. Intermediate the top and bottom of the plates 42 and of the rails or channels 30 there are apertures 58 (FIG. 2) in the plates 42 with laterally extending pairs of lugs or ears 60 and 62 respectively mounting rollers 64 and 66 which extend through the aperture 58 into proximity with the vertical plates 38. Whether or not the rollers 64 actually engage the plates 38 is not of the utmost importance, since the rollers 64 and 68 are provided for positioning only, with the major support of the plates 42, and hence of the end wall 40 being provided by the rollers 52, 54, 56 and 58. Only one of these plates 42 and pertinent structures has been specifically shown and described, but it will be understood that there are two such plates and pertinent structures in mirror image relationship carrying the front wall 40 from the opposite tracks or channels 30.
Means is provided for moving the front or ejection wall 40 from the solid line position shown at the front of the wagon in FIG. 1 to the broken line position shown at the rear of the wagon for dumping material therefrom. Such means comprises a pair of hydraulic cylinders 68 (FIGS. 1 and 4) mounted on the front of the wall 40 by suitable means such as pairs of ears and pins 70. The cylinders are provided with a plurality of telescoping pistons 72 suitably mounted on opposite sides of the gooseneck 28 by suitable mounts 74. As will be seen the cylinders 68 and pistons 72 lie on immediately opposite sides of the gooseneck and are thus in a relatively inaccessible position where they are protected against accidental damage. Suitable hydraulic lines are connected to the cylinders (not shown) from a source of hydraulic fluid under pressure on the tractor (not shown) and controlled by suitable controls on the tractor (not shown).
An alternative construction is shown in FIG. 4a in which similar parts are identified by similar numerals with addition of the suffix a. This structure includes a single cylinder 68a mounted partially inside of the gooseneck and extending therefrom through a suitable aperture 76. The connection to the wall 40 by the structure 70a is along the vertical midline of the wall. The cylinder construction is thus even better protected against accidental damage.
It will be seen that the force exerted by the cylinder or cylinders 68 on the front wall or ejector plate 40 is symmetrical about the vertical center line of this wall. Thus, assuming a generally equal distribution of material in the wagon, there will be little or no tendency to rotate the ejector plate wall about its vertical axis.
As may be seen in FIGS. 1 and 3 the force exerted by the cylinders 68 is somewhat above the horizontal line of the wall 40. However, the wall is of lesser transverse dimension below the cylinders 68 than it is above. Furthermore, material is generally piled up above the top of the wall 40, and force necessary to eject the overlying material is exerted by the upper portion of the wall. Thus, forces encountered and exerted by the wall are approximately the same above and below the cylinders. As a result the force exerted by the cylinders is applied near the center of area or load and tends to move the wall straight back in its normal inclined position. This avoids any significant turning force about the plate 42 that would press the rollers more tightly against the rail 38, thus tending to cause some binding on the rail and a further pivot moment about the plate and rail, bearing in mind that in actual field conditions the rollers may not roll with their normal design efficiency.
The wagon is closed at the back by a mud gate 78 and a tail gate 80 (FIGS. 1, 5 and 6). The mud gate is pivoted at its upper edge on a pair of ears 82 at the top corner of the wagon, and gravitationally closes against the upper edge portion 84 of the rear end of the wagon, which portion extends downwardly at an angle slightly from the vertical and rearwardly of the wagon. The mud gate is pushed up to the horizontal position shown in broken lines in FIG. 5 by the force of material ejected from the wagon during ejection.
The mud gate 78 comprises a steel plate 86 having an upper reinforcing frame member 88 along the upper edge, and a lower reinforcing frame member 90 along the lower edge, interconnected by angled side frame members 92. Vertical reinforcing bars 94 extend between the upper and lower frame members 88 and 90 for further strengthening of the mud gate.
The tail gate 80 comprises in part a flat steel plate 96 which presses against the edges 98 at the rear of the wagon. The tail gate is pivoted at the lower edge as will be set forth shortly hereinafter, and extends diagonally upward and to the rear from the floor 22 of the wagon. The tail gate is provided along the upper edge thereof with a rather large transverse box beam 100 which carries a pair of hooks 102 thereon. With the tail gate in the solid line closed position of FIGS. 5 and 6 the upper ends of the hooks 102 overlie the reinforcement 90 of the mud gate to hold the mud gate in closed position. The tail gate further is provided with a triangular reinforcing channel 104 along the lower edge, and with a pair of diagonal side supports 106 and intermediate vertical supports 108 extending from the triangular channel 104 to the box beam 100 to reinforce the steel plate 96.
The tail gate is hinged at its lower edge to the floor of the wagon as indicated at 110. A deep box beam 112 extends across the underside of the floor for mounting the axles 114 for the wheels 14. Pairs of spaced ears 116 are welded to the box beam 112, and have welded to them spaced sections of tubing 118. Similarly, there are pairs of spaced ears 120 welded to the triangular channel 104 and having spaced tubes 122 welded thereto. The tubes 118 and 122 alternate, and a hinge rod 124 extends through them, thus hingedly to support the tail gate from the box beam 112.
A mounting member 126 depends from the floor 22 and one of the cross beams 24 to which it is welded (FIG. 5) and has pivoted thereto the mount 128 at the end of the hydraulic cylinder 130 having a piston rod 132 extending therefrom. The cylinder and piston rod extend through an opening 134 in the box beam along the center line of the wagon. The far end of the piston rod is pivoted at 136 to a depending lever 138 welded to the central reinforcing member 108 of the tail gate.
With no material in the wagon the mud gate 78 readily drops to a closed position, and actuation of the hydraulic piston arrangement 130, 132 by controls in the tractor from a pressure source in the tractor causes the tail gate to close tightly and to clamp the mud gate closed. The wall 40 is moved to its forward position by means of the piston and cylinder arrangement 68. Material is then heaped into the wagon as indicated at 140 by means of a front end loader or the like, and can readily be piled up above the top of the wagon as shown. When it is desired to dump the material from the wagon, which usually is done with the wagon moving slowly forwardly, the tail gate is dropped to the broken line position shown in FIG. 5 by the hydraulic piston-cylinder arrangement 130. The front wall or ejector plate 40 is then pushed to the rear by the hydraulic cylinder-piston arrangement 68 to push the material from the wall down the tail gate on to the ground. Much of the material may readily be passed beneath the mud gate in closed position, but any that is obstructed by the mud gate simply causes the mud gate to swing open up to the horizontal position shown in broken lines in FIG. 5. After all or part of the material has been dumped, as may be desired, the wagon is returned to its original condition with the tail gate or mud gate closed, and with the front wall in its forward position.
The specific example of the invention as herein shown and described is for illustrative purposes only. Various changes in structure will no doubt occur to those skilled in the art and will be understood as forming a part of the present invention insofar as they fall within the spirit and scope of the appended claims.
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A wagon for hauling earth, ore, and like materials is connected to a tractor by a gooseneck. The front wall of the wagon comprises an ejector and hydraulic cylinder-piston devices are secured substantially centrally of the wall and to the gooseneck for effecting ejection. A power-operated tail gate at the rear of the wagon secures an overlying mud gate in closed position for travel.
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FIELD OF THE INVENTION
The present disclosure generally relates to an apparatus and method for removing road markings. More particularly, the present disclosure relates to a road marking removal system which propels a solid media in either dry or slurry format towards a road marking to abrade and remove the marking, while in parallel, collecting the residue via a vacuum system
BACKGROUND OF THE INVENTION
The purpose of the present invention is to provide an apparatus and method for removal of road markings.
Road surface markings are used on paved roadways to provide guidance and information to drivers and pedestrians. Uniformity of the markings is an important factor in minimizing confusion and uncertainty about their meaning. Road markings can identify lanes, direction of traffic flow, turning guidance, speed limits, school zones, and the like. Road markings are applied with a material that is capable of continuous, harsh conditions, including weather, vehicular traffic, debris, and other abrasive conditions.
Road markings are applied using a variety of materials, including paint, thermoplastic, plastic, epoxy, and the like. Additives such as reflective glass beads are mixed into the material to aid the driver.
The road markings are applied using materials designed to withstand abrasion from traffic, weather, and the like. Contrarily, there are scenarios where traffic control groups desire to remove the road markings.
Several inventors have disclosed road marking removal systems. Each of these utilises ultra high pressure water jet technology. Water jet technology requires a significant amount of energy to pressurize, accelerate and blast the water towards the road marking. The equipment required for the water jet technology is bulky and expensive. The use of water introduces the potential for corrosion as well as high maintenance.
A second process utilizes mechanical abrading or grinding. Contact removal is generally slow and creates a large mess. The debris is spewed about as a result of the rotational grinding process, directing a second cleanup process. The system can damage the road if the operator is not careful.
What is desired is a road marking removal system that is effective and also environmentally friendly. The system should be capable of operation with only a minimal impact to traffic. The preferred system would also be capable of for use in small, precision jobs.
SUMMARY OF THE INVENTION
The present invention provides a system, which blasts media through a marking removal head assembly. The removal head assembly utilizes a housing for controlling the media disbursement, then provides a collection nozzle for retrieving the residual material via a vacuum system.
A first aspect of the present invention provides a road marking removal system comprising:
a marking removal head housing having a media inlet port in fluid communication with a blasting nozzle and a vacuum particle retrieval port for extracting residual particles;
an air compression unit;
a solid media hopper for injecting solid media into a media delivery conduit, the media conduit providing fluid communication between the air compressor unit and the media inlet port;
a vacuum unit; and
a vacuum conduit providing fluid communication between the vacuum particle retrieval port and the vacuum unit.
A second aspect of the present invention is an inclusion of a residue collection container in communication with the vacuum unit.
In yet another aspect, is an inclusion of a filtration system within the vacuum assembly, wherein the filtration system returns particles of a desired size to the solid media hopper.
While in another aspect, the blasting nozzle accelerates the blast media mixture towards the road marking. In one embodiment, the acceleration of the media is accomplished by reducing the diameter of the nozzle passageway along the flow path of the media.
And in another aspect, the road marking removal system is integrated onto a road marking removal vehicle.
In another aspect, the road marking removal head is operably mounted to a road marking removal frame.
While in another aspect, the road marking removal frame includes an articulating arm.
In yet another aspect, the road marking removal frame comprises at least one generally horizontally configured slide rail member.
While in another aspect, the marking removal head is mounted to a road marking removal arm, the arm having a frame mount disposed at the assembly end of the arm. The frame mount is slideably assembled to the slide rail member.
In yet another aspect, the road marking removal head can be removably attached to the road marking removal arm, allowing installation of the removal head onto a manually operated removal cart assembly. It is recognized the cart assembly can further comprise an auxiliary motor or other drive mechanism.
A method aspect of the present invention provides method of removal of road markings the method comprising the steps of:
providing compressed air;
combining particulate matter with flowing compressed air forming a blasting mixture;
transferring the blasting mixture to a road marking removal head, the head comprising a blasting nozzle;
passing the blasting mixture through the blasting nozzle, directing the blasting mixture towards a road marking;
applying a vacuum suction to the road marking removal head;
collecting the residual material via the vacuum; and
depositing the collected residual material in a residue collection container.
In yet another aspect, the method further comprising a steps of filtering the collected residual material and returning residual material of a predetermined size to the solid media hopper.
In yet another aspect, the method further comprising the steps of aligning the road marking removal head with a roadway marking via an operable mounting configuration.
In yet another aspect, the mounting configuration provides an articulating movement.
In yet another aspect, the mounting configuration provides a slideable motion sliding transverse to the vehicle. The mounting configuration further provides a height control by a pivotal assembly of the removal arm.
In yet another aspect, the method further comprising the steps of aligning the road marking removal head with a roadway marking via a manual operation, whereby the road marking removal head is assembled to a manually operated removal cart assembly. An auxiliary drive system can provide power assistance to the manually operated cart assembly.
These and other aspects of the present invention are best understood as described in the detailed description and respective figures presented herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, where like numerals denote like elements and in which:
FIG. 1 presents an exemplary block diagram illustrating the general components and flow of a road marking removal system;
FIG. 2 presents an isometric view of an exemplary road marking removal system as defined in FIG. 1 , the removal system being integrated into a road marking removal vehicle, the road marking removal head being shown in a stored configuration;
FIG. 3 presents an isometric view of the road marking removal vehicle of FIG. 2 , the road marking removal head being shown in a first in use position;
FIG. 4 presents an isometric view of the road marking removal vehicle of FIG. 2 , the road marking removal head being shown in a second in use position;
FIG. 5 presents an isometric view of the road marking removal vehicle of FIG. 2 detailing the operation of the road marking removal head;
FIG. 6 presents a side elevation view of the road marking removal vehicle of FIG. 2 ;
FIG. 7 presents a front elevation view of the road marking removal vehicle of FIG. 2 ;
FIG. 8 presents a sectioned view of a first exemplary road marking removal head, detailing a blasting nozzle and a vacuum assist sweeper assembly;
FIG. 9 presents a sectioned view of a second exemplary road marking removal head, detailing an articulating blasting nozzle;
FIG. 10 an isometric view of the road marking removal vehicle of FIG. 2 , introducing a manually operated removal cart assembly; and
FIG. 11 presents an alternate exemplary block diagram illustrating the general components and flow of a road marking removal system incorporating a recycling subsystem.
Like reference numerals refer to like parts throughout the various views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 2 . Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
Under certain circumstances, traffic management organizations need to alter road markings. The present invention provides an apparatus and method for removing road markings, referred to as a road marking removal system 100 , which is initially represented in the exemplary block diagram of FIG. 1 . The road marking removal system 100 comprises an air compressor assembly 120 , which provides compressed air into the system. The air compressor assembly 120 includes an air compressor 122 which can be of any form factor and reasonable power to provide continuous air pressure as needed for removal of the road markings. The air compressor assembly 120 can additionally include an air pressure tank (not shown, but well understood), which provides a reservoir ensuring continuous flow of pressurized air. A media hopper assembly 130 introduces particulate matter into the flow of compressed air forming a blasting mixture. The particulate matter can include any of the following: sand, aluminum oxide, black beauty, steel grit, soda-bicarbonate, abrasive sponge, and the like. The media hopper assembly 130 includes a media hopper 132 . The media hopper 132 stores and feeds particulate matter into the airflow generated by the air compressor 122 . The blasting mixture is transferred to a marking removal head assembly 110 and discharged, being directed towards the road marking via a nozzle ( 170 of FIG. 8 or 180 of FIG. 9 ). A vacuum assembly 140 provides a vacuum to collect residue. The marking removal head assembly 110 includes a marking removal head housing 112 , which creates a micro removal working environment. The created micro removal working environment aids the vacuum force in collection of the residual material. Fluid communication is provided between each of the individual components via a series of conduits represented by flow arrows in the block diagram.
The road marking removal system 100 can be integrated into any of a variety of support apparatus. A first exemplary apparatus is a road marking removal vehicle 200 , wherein the road marking removal system 100 is integrated onto a donor truck 210 , as illustrated in FIGS. 2 through 7 . The donor truck 210 comprises the general components of a vehicle, including a truck frame 220 . The donor vehicle is preferably arranged such to expose an upper section of the truck frame 220 in a manner conducive for mounting the vacuum assembly 140 and media hopper assembly 130 thereon. The marking removal head assembly 110 can be operably integrated to the donor truck 210 via a road marking removal mounting frame 250 . The exemplary embodiment of the road marking removal mounting frame 250 is assembled to a front end of the donor truck 210 . This provides the driver with an optimal view of the marking removal head assembly 110 during use. The road marking removal mounting frame 250 is configured having a mounting frame slide rail 254 span between a pair of mounting frame end members 252 . The illustration presents a pair of round, tubular members being used for the mounting frame slide rail 254 . It is understood that any beam having a continuous cross sectional shape can be used for the mounting frame slide rail 254 , including an “I” beam, “C” channel, and the like. It is understood that although a slide configuration is presented as an exemplary embodiment, there are many other well-known assemblies providing mechanical movement. Any configuration providing movement in a plurality of directions to register the marking removal head assembly 110 to the road marking can be utilized.
The marking removal head assembly 110 is assembled to an extended end of a road marking removal pivotal arm 262 . A road marking removal frame mount 260 is assembled to a proximate end of the road marking removal pivotal arm 262 . The road marking removal frame mount 260 is slideably assembled to the mounting frame slide rail 254 . A slide bearing can be provided between the road marking removal frame mount 260 and the mounting frame slide rail 254 to aid in the sliding motion. The road marking removal frame mount 260 is slideably positioned along the mounting frame slide rail 254 as illustrated in FIGS. 3 and 4 . Any form of motion controlling device can be integrated into the assembly to position the road marking removal frame mount 260 across the mounting frame slide rail 254 . This can include motors, a hydraulic actuator, a pneumatic actuator, a cable drive, and the like. The road marking removal pivotal arm 262 is pivotally assembled to the road marking removal frame mount 260 , whereby the road marking removal pivotal arm 262 rotates, positioning the marking removal head assembly 110 between a stored configuration ( FIG. 2 ) and an in use configuration ( FIG. 3 ). The road marking removal pivotal arm 262 can include additional motions to optimally position the marking removal head assembly 110 respective to the roadway and respective road marking 199 as illustrated in FIG. 5 . Blasting mixture 115 is thrust through the removal media inlet port 114 of the marking removal head assembly 110 towards the road marking 199 . The blast mixture 115 abrades the road marking 199 , removing the road marking 199 from the roadway. The marking removal head assembly 110 includes a marking removal head housing 112 , which can optionally comprise a skirt or other peripheral seal to optimize a vacuum force provided by the vacuum 142 . The vacuum force generates a residue collection vacuum 117 , which removes the residual material entrapped within the interior of the marking removal head assembly 110 through the vacuum particle retrieval port 116 . It is noted that the vacuum particle retrieval port 116 be oriented rearward of the removal media inlet port 114 . The residual material is collected and stored within the residue collection container 144 . The residue collection container 144 is then emptied via any reasonable process.
The marking removal head assembly 110 can be configured with a variety of nozzle configurations, with two exemplary embodiments being presented in FIGS. 8 and 9 . The blasting nozzle can be any off the shelf nozzle, or a custom configuration. A fixed direction blasting nozzle 170 is illustrated in FIG. 8 . The blast mixture 115 enters through the removal media inlet port 114 and flows towards the blasting nozzle 170 . The blasting nozzle 170 is configured with at least one nozzle port 172 having a nozzle inlet orifice 174 at an entrance end of the nozzle port 172 and a nozzle discharge orifice 176 at the discharge end of the nozzle inlet orifice 174 . The diameter of the nozzle inlet orifice 174 is greater than the diameter of the nozzle discharge orifice 176 causing the passing blast mixture 115 to accelerate. Where a plurality of nozzle ports 172 are utilised, the nozzle discharge orifice 176 may be arranged in fanning pattern as illustrated. Alternately, the nozzle discharge orifice 176 can be directed inward for a more focused pattern. A sweeper assembly 160 can be optionally integrated into the marking removal head assembly 110 . The exemplary sweeper assembly 160 includes a series of sweeper brushes 164 extending outward from a periphery of a sweeper roller 162 . The sweeper roller 162 is rotationally assembled to the marking removal head housing 112 . The sweeper assembly 160 can be rotationally driven via a motor, the residue collection vacuum 117 , and the like. The series of sweeper brushes 164 aid in mechanically collecting residual matter from within the interior of the marking removal head housing 112 and directing the residual matter towards the vacuum particle retrieval port 116 . A sealing skirt 190 can be assembled about a peripheral lower edge of the marking removal head housing 112 . The sealing skirt 190 can be of any conforming form factor, such as fringe, plastic or rubber sheeting, and the like. The lower edges of the sealing skirt 190 can be weighted if needed to ensure the material remains substantially vertically. The marking removal head assembly 110 can be pivotally assembled to the road marking removal pivotal arm 262 allowing the marking removal head assembly 110 to follow the contour of the road surface. Wheels (not shown, but well understood) can be assembled to the lower region of the marking removal head housing 112 , wherein the wheels contact the road surface. The marking removal head assembly 110 can be biased (such as via a spring or shock absorber) such to ensure the marking removal head assembly 110 follows the contour of the road surface. A camera 150 can be provided, such as being mounted onto the marking removal head housing 112 , to aid the operator in setting and maintaining proper registration between the marking removal head housing 112 and the road marking 199 .
An articulating nozzle assembly 180 is illustrated in FIG. 9 . The articulating nozzle assembly 180 utilizes a ball joint interface allowing an articulating nozzle 186 to move in a spherical coordinate arrangement. The articulating nozzle 186 includes a nozzle port 188 provide therethrough and a ball joint 184 formed at a connecting end thereof. The ball joint 184 is assembled within a ball joint socket 182 , providing the spherical motion. The nozzle port 188 includes a bend, wherein the passing airflow causes the articulating nozzle 186 to continuously reposition as illustrated in dashed lines. The articulating motion directs the focused blasting mixture 115 about a larger area. It is noted that the diameter of the inlet portion of the nozzle port 188 is larger than the diameter of the discharge portion of the nozzle port 188 , thus accelerating the blast mixture 115 .
An expanded exemplary embodiment introduces a manually operated removal cart assembly 300 , as illustrated in FIG. 10 . The marking removal head assembly 110 is assembled to the manually operated removal cart assembly 300 , allowing for a manual operation of the road marking removal system 100 . The exemplary manually operated removal cart assembly 300 comprises a cart frame 310 having a plurality of cart wheel 314 for portability and a cart handle 312 for operable control by the worker. The cart frame 310 can be of any reasonable material, shape, and the like. The marking removal head assembly 110 is connected to the media blast assembly 150 and vacuum assembly 140 via a blast delivery conduit 320 and a residue collection conduit 322 respectively. The operator would remove the marking removal head assembly 110 from the road marking removal pivotal arm 262 and fastened to the cart frame 310 . The operator then attaches the blast delivery conduit 320 and residue collection conduit 322 to the respective couplers. The operator then initiates operation of the road marking removal system 100 and directs the manually operated removal cart assembly 300 to align the marking removal head assembly 110 over the road marking. Operational controls can be attached proximate the cart handle 312 providing the user with easy, quick and direct access to system controls. An auxiliary power drive system can be integrated to aid the user in moving the manually operated removal cart assembly 300 .
Although the manually operated removal cart assembly 300 is presented as a manually propelled and directed cart, the concept can be equated to a separation of the road marking removal system 100 into two portions. A first portion can be placed onto a large transporting vehicle, wherein the first portion preferably comprises the air compressor assembly 120 , the media hopper assembly 130 , and the respective conduits. A second portion can be placed into the manually operated removal cart assembly 300 , wherein the second portion preferably comprises the marking removal head assembly 110 . The separation provides the user with a smaller and more manageable vehicle for aligning the marking removal head assembly 110 with the road marking 199 . The smaller vehicle can be the manually operated removal cart assembly 300 , a tractor, a golf cart, a lawn mower like vehicle, and the like.
An enhanced system is referenced as a recycling road marking removal system 101 , being illustrated in FIG. 11 . The recycling road marking removal system 101 introduces a media reclamation assembly 146 providing the ability of reusing the particulate matter. The media reclamation assembly 146 includes a vacuum system as well as a filtration or separation system integrated into a media reclamation vacuum and filter 148 . The system collects the residual material from the marking removal head assembly 110 , separates the collected material into a reusable size and a non-reusable size. The reusable material is then returned to the media hopper 132 . The non-reusable material is collected in a non-reclaimed media collection container 149 .
Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
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A road marking removal system creating a blasting mixture by injecting particulate matter from a media hopper into flowing compressed air. The blasting mixture is directed at a road marking via a blasting nozzle. The nozzle discharges the blasting mixture from within a marking removal head housing. A vacuum is applied to an interior of the marking removal head housing for collecting the residual material created by the removal process. The residual material consists of particulate matter, road marking debris, and the like. The collected material can optionally be sorted with material of an acceptable size being reclaimed and forwarded to the media hopper for reuse. The road marking removal system can be manually operated being integrated into a cart, or remotely operated when integrated into a vehicle.
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BACKGROUND
[0001] The present invention relates generally to semiconductor device structures, and, more particularly, to on-chip inductor's shielding structures.
[0002] Modern analog circuits increasingly embed inductors on the chip. FIG. 1A illustrates an on-chip spiral inductor 100 , which is formed by a spiral metal line 106 . A first terminal 102 of the inductor 100 is on the same metal layer of the spiral metal line 106 . A second terminal 104 is connected to an end of the spiral metal line 106 through vias 120 and a metal line 110 on another metal layer. FIG. 1B is a cross-sectional view of the on-chip spiral inductor 100 at a location A-A′. The inductor 100 is formed inside a dielectric material 130 on top of a semiconductor substrate 140 .
[0003] Performance of these analog circuits depends heavily on the quality of the inductor, where poor inductor quality factor (Q) of silicon processes leads to degradation in circuit efficacy, especially at radio frequency (RF) and microwave frequencies. The inductor quality factor (Q) is defined as:
[0000]
Q
=
2
π
·
energy
-
stored
energy
-
loss
-
in
-
one
-
oscillation
-
circle
(
1
)
[0000] The inductor Q degrades at high frequencies due to energy dissipation in the semiconductor substrate. Noise coupling via the substrate at gigahertz frequencies has also been reported. As inductors occupy substantial chip area, they can potentially be the source and receptor of detrimental noise coupling. Therefore, decoupling the inductor from the surrounding materials, including the substrate, can enhance the overall performance of the inductor: increase Q, improve isolation, and simplify modeling.
[0004] FIG. 2 is a cross-sectional view of a patterned-ground-shielding (PGS) 203 traditionally used to provide the decoupling of the inductor 100 from the semiconductor substrate 140 . The PGS 203 is commonly inserted between the inductor 100 and the substrate 140 , and formed by either a polysilicon layer or a metal layer. However, it is often difficult to find optimized widths and spacings for the PGS 203 to achieve maximum Q improvement. The fact that the PGS 203 is formed inside the dielectric layer 130 also limits its effectiveness in improving the Q of the inductor 100 .
[0005] As such, what is desired are alternative shielding structures for on-chip inductors that may benefit from new semiconductor processes, and these alternative shielding structures are often augmentative to traditional shielding structures.
SUMMARY
[0006] In view of the foregoing, the present invention provides a semiconductor structure for providing isolations for on-chip inductors. According to one aspect of the present invention, the semiconductor structure comprises a semiconductor substrate, one or more on-chip inductors formed above the first semiconductor substrate, a plurality of through-silicon-vias formed through the first semiconductor substrate in a vicinity of the one or more on-chip inductors, and one or more conductors coupling at least one of the plurality of through-silicon-vias to a ground, wherein the plurality of through-silicon-vias provide isolations for the one or more on-chip inductors.
[0007] According to another aspect of the present invention, the one or more conductors that couple at least one through-silicon-via of the plurality of through-silicon-vias to a ground are formed by a metallized backside of the semiconductor substrate.
[0008] Additionally, traditional patterned-ground-shielding structure can be combined with the semiconductor structure of the present invention by extending the plurality of through-silicon-vias into making contact with the patterned-ground-shielding conductors. Besides, in stacked chip application, both top and bottom chips may have through-silicon-vias in the vicinity of the on-chip inductors.
[0009] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A and 1B illustrate an on-chip spiral inductor.
[0011] FIG. 2 illustrates a traditional patterned-ground-shielding for the on-chip spiral inductor.
[0012] FIGS. 3A and 3B illustrate a first inductor shielding structure formed by through-silicon-vias and a metallized backside according to a first embodiment of the present invention.
[0013] FIGS. 4A and 4B illustrates a second inductor shielding structure combining the through-silicon-vias with the traditional patterned-ground-shielding according to a second embodiment of the present invention.
[0014] FIG. 5 illustrates the through-silicon-vias shielding structure is applied in a face-to-face stacked chip according to a third embodiment of the present invention.
[0015] FIG. 6 illustrates the combination of through-silicon-via and traditional patterned-ground-shielding being applied to the face-to-face stacked chip according to a fourth embodiment of the present invention.
[0016] FIG. 7 illustrates a face-to-back stacked chip employing the through-silicon-vias according to a fifth embodiment of the present invention.
[0017] FIG. 8 illustrates a face-to-back stacked chip employing a combination of the through-silicon-vias and the traditional patterned-ground-shielding according to a sixth embodiment of the present invention.
[0018] FIGS. 9A and 9B illustrate an inductor shielding structure formed by patterned metallized backside and the through-silicon-vias according to a seventh embodiment of the present invention.
[0019] The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer conception of the invention, and of the components and operation of systems provided with the invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings, wherein like reference numbers (if they occur in more than one view) designate the same elements. The invention may be better understood by reference to one or more of these drawings in combination with the description presented herein. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale.
DESCRIPTION
[0020] The following will provide a detailed description of a through-silicon-via (TSV) based shielding structure for improving the quality factor (Q) of on-chip inductors.
[0021] The TSV is a technology of forming via holes through a semiconductor substrate, which may be made of silicon or other materials. Therefore, the term, through-silicon, may also be called “through-wafer”. The TSV technology is developed to shorten interconnect lengths and to achieve 3 dimensional structure. Operations in the 3-D integration process include through-wafer via formation, deep via etching, laser-drilled vias, deep trench capacitor technology, via filling, deposition of diffusion barrier and adhesion layers, metallization, and wafer thinning, dicing, alignment and bonding. There are currently three process sequences available for the formation of through-wafer vias for wafer-level 3-D devices. In a front-end process sequence, vias can be fabricated using deep trench capacitor technology at any fab capable of embedded DRAM technology, before transistors and interconnect are processed on the chips. Such chips would subsequently go to semiconductor packaging houses where backside thinning would expose the bottom of the vias and allow backside interconnect formation. This sequence places the burden of via formation in the hands of the fab and eliminates the need to leave room within or between cells for post-fab via creation.
[0022] The second process sequence also requires chips to be specifically designed for 3-D stacking. Specific areas on the silicon, in the interconnect layers, and on the top pad surface are set aside as exclusion zones. Through-wafer connection is subsequently created in the completed chips by etching vias through these exclusion zones and filling them with insulators and conductive metals.
[0023] The third process sequence is used when chips not specifically designed for 3-D integration are stacked. In this sequence, the connecting vias are formed by redistributing pads into the area between the peripheral pads and via streets. Vias are then etched and filled in these natural exclusion zones.
[0024] FIGS. 3A and 3B illustrate a first inductor shielding structure formed by a plurality of TSVs 302 and a metallized backside (MB) 310 according to a first embodiment of the present invention. FIGS. 3A and 3B are a cross-sectional view and a layout view, respectively, of the first inductor shielding structure. Referring to FIG. 3A , the TSVs 302 is formed through the substrate 140 . The MB 310 has contacts with the TSVs 302 to provide a ground connection to the TSVs 302 . Referring to FIG. 3B , a plurality of TSVs 302 is placed around the on-chip inductor 100 , forming a grounded shielding fence for isolating the inductor 100 . With the shielding fence formed by the TSVs 302 surrounding and under the inductor 100 , Eddy current distributions in the substrate 140 will be stopped. Therefore, the Q factor of the inductor 100 will be improved. Besides, with better grounding of the MB 310 and better isolation of the TSVs 302 , the unwanted or high-order mode will also be suppressed.
[0025] Minimum cross-sectional widths and lengths of the TSVs 302 and minimum spacings between adjacent TSVs are determined by a process technology being employed to form the TSVs 302 . But other width, length and spacing may also be used to achieve an optimized Q improvement.
[0026] Although a rectangularly arranged TSV fence is illustrated in FIG. 3B . A skilled artisan may realize that it is the enclosing nature of the TSV fence provides the isolation to the on-chip inductor 100 , therefore, other shapes of TSV arrangements, such as a U-shape, a circle or even a double circle, may provide equally well Q improvement to the inductor 100 .
[0027] Although only the TSVs 302 surrounding the on-chip inductor 100 is illustrated in FIG. 3A , a skilled artisan will realize that TSVs under the on-chip inductor 100 can also provide isolation and Q improvement to the on-chip inductor 100 . An on-chip inductor may have guard-ring of its own, and such guard-ring may be connected to the TSV fence.
[0028] FIGS. 4A and 4B illustrates a second inductor shielding structure combining the TSVs 402 with the traditional patterned-ground-shielding (PGS) 420 according to a second embodiment of the present invention. FIG. 4A is a cross-sectional view, while FIG. 4B is a layout view of the second inductor shielding structure. The PGS 420 is formed in a metal or polysilicon layer in the dielectric material 130 . In forming the TSVs 420 , an etching process, via holes are etched not only through the semiconductor substrate 140 , but also through part of the dielectric material 130 and stopped by the PGS layer 420 . Grounding to both the TVSs 402 and the PGS 420 are provided by the MB 310 . Both the TSVs 402 and PGS 420 provide isolation to the on-chip inductor 100 , and better Q improvement thereof.
[0029] FIG. 5 illustrates the TSV shielding structure is applied in a face-to-face stacked chip according to a third embodiment of the present invention. A top chip is identical to the inductor structure shown in FIG. 3A , which includes the semiconductor substrate 140 and the dielectric layer 130 . The on-chip inductor 100 is formed in the dielectric layer 130 . The TSVs 302 are formed through the substrate 140 . The MB 310 provides the ground connection to the TSVs 302 . A second chip is stacked face-to-face on the first chip. The so called face-to-face refers to dielectric layers 130 and 530 of the first and second chip, respectively, come into contact with each other. The second chip includes a second semiconductor substrate 540 and a second dielectric layer 530 . Another plurality of TSVs 502 is formed through the second substrate 540 . Another MB 510 provides the ground connection to the plurality of TSVs 502 . Both the TSVs 302 and the pluralities of TSVs 502 are placed around the on-chip inductor 100 and provide isolations thereto.
[0030] FIG. 6 illustrates the combination of TSV and traditional PGS being applied to the face-to-face stacked chip according to a fourth embodiment of the present invention. The chip on top is the combination of TSV and traditional PGS structure shown in FIG. 4A . The chip on bottom is the same as the second chip shown in FIG. 5 . The traditional PGS adds another layer of isolation to the on-chip inductor 100 of the face-to-face stacked chip.
[0031] FIG. 7 illustrates a face-to-back stacked chip employing the TSVs according to a fifth embodiment of the present invention. A top chip here is the same as the top chip shown in FIG. 5 , which is stacked on a bottom chip in a face-to-back fashion, i.e., the dielectric layer 130 of the top chip comes into contact with a substrate 540 of the bottom chip. The bottom chip includes a dielectric layer 530 . As shown in FIG. 7 , TSVs 702 of the bottom chip make contacts to a metal layer 710 inside the dielectric layer 530 . The metal layer 710 provides the ground connection to the TSVs 702 . A skilled artisan may realize that other conduction layer, such as polysilicon, may be used in place of the metal layer 710 .
[0032] FIG. 8 illustrates a face-to-back stacked chip employing a combination of the TSVs and the traditional PSG according to a sixth embodiment of the present invention. Here a top chip is the same as the top chip shown in FIG. 6 , and a bottom chip is the same as the bottom chip shown in FIG. 7 . The top and bottom chip are stacked in a face-to-back fashion, i.e., the dielectric layer 130 of the top chip comes into contact with the substrate 540 of the bottom layer.
[0033] Referring to FIGS. 5 through 8 , the way two chips are stacked, either face-to-face or face-to-back, is determined by various design needs of the stacked chip. The examples shown here in FIGS. 5 through 8 , illustrate that TSV technologies can equally applied to both face-to-face and face-to-back cases for providing isolations to the on-chip inductor 100 . Variations available to the non-stacked chips shown in FIGS. 3A and 4A are also applicable to the stacked chips shown in FIGS. 5 through 8 .
[0034] FIGS. 9A and 9B illustrate an inductor shielding structure formed by patterned metallized backside (MB) and the TSVs according to a seventh embodiment of the present invention. FIG. 9A is a cross-section made at location B-B′ shown in FIG. 9B . The inductor shielding structure shown in FIGS. 9A and 9B is the same as the one shown in FIGS. 3A and 3B , except that the MB 910 shown in FIGS. 9A and 9B is patterned. Referring to FIG. 9A , the MB 910 still makes contacts to the TSVs 402 . FIG. 9B shows an exemplary mesh pattern etched on the MB 910 . Apparently the patterned MB can also be applied to the stacked chips shown in FIGS. 5 through 8 .
[0035] The above illustration provides many different embodiments or embodiments for implementing different features of the invention. Specific embodiments of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims.
[0036] Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims.
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A semiconductor structure for providing isolations for on-chip inductors comprises a semiconductor substrate, one or more on-chip inductors formed above the first semiconductor substrate, a plurality of through-silicon-vias formed through the first semiconductor substrate in a vicinity of the one or more on-chip inductors, and one or more conductors coupling at least one of the plurality of through-silicon-vias to a ground, wherein the plurality of through-silicon-vias provide isolations for the one or more on-chip inductors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a paper magazine which delivers a photosensitive material from an opening to a processing device while guiding the photosensitive material. The present invention is applicable to paper magazines which can be loaded into a photographic processing device such as a printer processor or the like in which a processor section is formed integrally with a printer for photographs or a printer section.
2. Description of the Related Art
Photographic printing paper, which is a photosensitive material, is wound in a roll shape in advance and accommodated within a paper magazine. The paper magazine is loaded in a printing device (printer section) for printing images from a negative film onto photographic printing paper. The photographic printing paper is pulled out from the interior of tile paper magazine and is conveyed to a printing position at which images are printed. Thereafter, the photographic printing paper is sent to a developing device (processor section) which follows the printing device, and developing processing is effected.
In conventional printing devices, after being developed, the photographic printing paper is cut per image. In such a system, when the paper magazine is to be replaced, a drawback arises in that there is a large amount of photographic printing paper to be rewound into the paper magazine. As a result, a structure has been proposed in which the photographic printing paper is conveyed to the printing position after having been cut in advance to the size of the image to be printed.
However, in such a printing device, because the photographic printing paper is first cut and then conveyed, although it is necessary to correctly position the photographic printing paper in a vicinity of the printing position, it is difficult to correct the inclination of the photographic printing paper within the printing device, the deviation of the photographic printing paper from the conveying path and the like.
Accordingly, for paper magazines which are used in such a printing device, it is necessary to regulate the position of the photographic printing paper within the paper magazine and to effect advance correction of the inclination of the photographic printing paper by providing guides within the paper magazine.
Such guides disposed within the paper magazine must improve the accuracy of regulating the position of the photographic printing paper within the paper magazine. Therefore, the guide usually has a groove which is formed so as to be long in the conveying direction of the photographic printing paper and which guides the photographic printing paper. An end portion of the photographic printing paper is placed into the groove so that the photographic printing paper is guided.
However, in accordance with the above-described structure, load due to friction or the like between the photographic printing paper and the guide during conveying becomes large, and a large conveying force is needed to convey the photographic printing paper. As a result, the photographic printing paper may be damaged.
Further, when the groove guiding the photographic printing paper is long, drawbacks arise in that work is required to insert the end portion of the photographic printing paper into the groove, and loading of the photographic printing paper is difficult.
SUMMARY OF THE INVENTION
In view of the aforementioned, an object of the present invention is to provide a paper magazine in which the loadability of the photographic printing paper is improved, load applied to the photographic printing paper during the conveying thereof is reduced, and the position of the photographic printing paper within the paper magazine can be regulated reliably.
In accordance with a first aspect of the present invention, there is provided a paper magazine including a magazine main body in which an elongated photosensitive material is accommodated from an open portion of the magazine main body; a guide member attached to the magazine main body and guiding the photosensitive material to a magazine opening through which the photosensitive material is delivered out to an exterior of the paper magazine; at least one guide roller attached to the guide member so as to be freely rotatable, the guide roller contacting a transverse direction end portion of the photosensitive material and guiding the photosensitive material when the photosensitive material is delivered out to the exterior of the paper magazine; and a cover supported at the magazine main body so as to be able to open and close the open portion of the magazine main body, and when the cover is closed, the cover is positioned so as to oppose the guide member with the photosensitive material being disposed between the guide member and the cover.
The following operations are carried out at the above-described paper magazine.
An elongated photosensitive material is loaded into a paper magazine from an open portion of the magazine main body. A guide member attached to the magazine main body guides the photosensitive material to a magazine opening. At this time, the at least one guide roller, which is attached to the guide member so as to be freely rotatable, contacts the transverse direction end portion of the photosensitive material and guides the photosensitive material so that the photosensitive material does not deviate in the transverse direction.
Further, the cover is supported so as to be able to open and close the open portion of the magazine main body. When the open portion is closed, the cover is positioned so as to oppose the guide member with the photosensitive material being disposed between the guide member and the cover.
Accordingly, when the photosensitive material is delivered out to the exterior of the paper magazine, not only is the photosensitive surface (or the reverse surface) of the photosensitive material guided by the guide member and the reverse surface (or the photosensitive surface) guided by the cover, but also, the transverse direction end portion of the photosensitive material is guided by the guide roller. As a result, the position of the photosensitive material within the paper magazine is reliably regulated.
Because the transverse direction end portion of the photosensitive material is guided by the freely rotatable guide roller at this time, the load applied to the photosensitive material during the conveying thereof is reduced. Further, when the open portion is closed by the cover, the cover is positioned so as to oppose the guide member. Therefore, when the photosensitive material is loaded into the paper magazine from the open portion of the magazine main body, the cover does not hinder the loading operation, and the loadability of the photosensitive material improves. Further, when the open portion is closed, the photosensitive material is interposed between the cover and the guide member, and the photosensitive material can be prevented from separating from the guide rollers.
In a specific example of the present embodiment, it is preferable that freely rotatable rollers are disposed at the guide member and the cover, and that protrusions which extend in the transverse direction of the photosensitive material are formed at the guide member. In accordance with such a paper magazine, friction between the photosensitive material and the guide member can be reduced even more, and the load applied to the photosensitive material during the conveying thereoff is reduced.
In accordance with another aspect off the present invention, there is provided a paper magazine including a magazine main body in which an elongated photosensitive material is accommodated from an open portion of the magazine main body; a guide member attached to the magazine main body so as to be rotatable, and guiding the photosensitive material to a magazine opening through which the photosensitive material is delivered out to an exterior of the paper magazine; at least one guide roller attached so as to be freely rotatable to a surface which is formed to be a step lower than a flat surface formed by the guide member, the guide roller contacting a transverse direction end portion of the photosensitive material and guiding the photosensitive material when the photosensitive material is delivered out to the exterior of the paper magazine; a cover supported at the magazine main body so as to be able to open and close the open portion of the magazine main body, and when the cover is closed, the cover is positioned so as to oppose the guide member with the photosensitive material being disposed between the guide member and the cover; and a positioning member attached to the cover so as to be elastically deformable, the positioning member contacting the guide member and positioning the guide member when the cover is closed.
The following operations are carried out at the above-described paper magazine.
Although the operations of the present aspect are the same as those of the previously-described aspect, in the present aspect, the at least one guide roller is attached so as to be freely rotatable to a surface which is formed to be a step lower than the flat surface formed by the guide member which is rotatably attached to the magazine main body. Further, the positioning member, which is attached to the cover so as to be elastically deformable, contacts the guide member and positions the guide member when the cover is closed.
Accordingly, in addition to the operations of the first aspect of the present invention, in the present aspect, the transverse direction end portion of the photosensitive material guided by the guide roller does not contact the corner portion of the guide roller, and consequently is not damaged by contacting the corner portion. Further, the guide member is reliably fixed by the positioning member.
In a specific example of the present invention, it is preferable that the surface, which is formed a step lower than the flat surface formed by the guide member, is formed so as to be long in the transverse direction of the photosensitive material, and that this surface has a plurality of screw holes aligned along the transverse direction of the photosensitive material. In accordance with such a structure, the paper magazine can be made to correspond to photosensitive materials of different widths, and the load applied to the photosensitive material can be reduced. Further, damage to the transverse direction end portions of the photosensitive material can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic structural view of a photographic printing device in which an embodiment of a paper magazine relating to the present invention is loaded.
FIG. 2 is a side view of the embodiment of the paper magazine relating to the present invention, illustrating an open state of the paper magazine.
FIG. 3 is a side view of the embodiment of the paper magazine relating to the present invention, illustrating a closed state of the paper magazine.
FIG. 4 is a partially broken front view of the embodiment of the paper magazine relating to the present invention, illustrating the closed state of the paper magazine.
FIG. 5 is a perspective view illustrating a guide plate of the embodiment of the paper magazine relating to the present invention.
FIG. 6 is a view taken along arrow 6--6 of FIG. 2.
FIG. 7 is an enlarged broken view of portion A of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, a detailed description of an embodiment of a paper magazine relating to the present invention will be described with reference to FIGS. 1 through 7 in which the paper magazine and a photographic printing device, in which the paper magazine is loaded, are illustrated.
A photographic printing device 10 in which the paper magazine of the embodiment of the present invention is loaded is illustrated in FIG. 1.
The photographic printing device 10, which forms a printer section of a photographic processing device, is structured such that a paper magazine 12, in which a photographic printing paper P is accommodated, can be loaded therein. When an opening/closing door 14 is closed after the paper magazine 12 is inserted into the photographic printing device 10, the loading of the paper magazine 12 is completed.
As illustrated in FIGS. 2 and 3, a main portion of the paper magazine 12 is structured by a box-shaped magazine main body 112 in which a reel 110, around which the photographic printing paper P is wound, can be accommodated from an open portion 112B. A plate-shaped guide plate 116, which is a guide member which guides the photographic printing paper P, is attached to one end portion of the magazine main body 112 via a hinge 114. The guide plate 114 can be pivoted around the hinge 114 between the open state illustrated in FIG. 2 and the closed state illustrated in FIG. 3.
As illustrated in FIGS. 5 and 6, a pair of collars 120 is screwed to the distal end side of the guide plate 116 by bolts 118. A cylindrical tube-shaped guide roller 122 is fit with each of the collars 120 so as to be freely rotatable. Further, in the same way as the above-described guide rollers 122, a pair of the guide rollers 122 are fit so as to be freely rotatable at the proximal end side of the guide plate 116 as well. Accordingly, as illustrated in FIGS. 4 and 5, transverse direction end portions of the photographic printing paper P are guided by the four guide rollers 122, so that the photographic printing paper P is conveyed correctly along the conveying direction, which is the direction of delivering the photographic printing paper P.
Attachment surfaces 117 are formed at portions at which the guide rollers 122 are disposed. The attachment surfaces 117 are formed so as to be long along the transverse direction of the photographic printing paper P, and so as to be a step lower than the surrounding regions. The attachment surfaces 117 are formed so that the photographic printing paper P does not abut a lower end corner portion 122A of the guide roller 122 and consequently is not damaged. A plurality of screw holes 123 are formed along the transverse direction of the photographic printing paper P in the attachment surfaces 117, which are formed so as to be a step lower than the surrounding regions, so that the respective positions of the guide rollers 122 can be changed to correspond to the width of the photographic printing paper P. Further, three protruding portions 124, which extend in a direction orthogonal to the conveying direction are provided on the top surface of the guide plate 116. Accordingly, when the photographic printing paper P is being conveyed, the photographic printing paper P is supported at the top edges of the protruding portions 124, and friction between the guide plate 116 and the photographic printing paper P is reduced.
Second rollers 126 which guide the photographic printing paper P are disposed at the distal end portion of the guide plate 116 so as to be freely rotatable so that friction between the guide plate 116 and the photographic printing paper P is reduced.
A cover 132 is attached to the other end portion of the magazine main body 112 via a hinge 134. The cover 132 is pivoted around the hinge 134 between the open state illustrated in FIG. 2 and the closed state illustrated in FIG. 3 so that the open portion 112B can be closed off.
As illustrated in FIG. 7, a pusher plate 138 is supported at the proximal end side of the cover 132 by a pair of screws 140 so as to be slidable. The pusher plate 138 is a positioning member, and an abutment member 136 is adhered thereto. Coil springs 142, which are elastic bodies wound around the screws 140, push the pusher plate 138 toward the guide plate 116. A supporting plate 144 is fixed to a portion of the magazine main body 112 which opposes the pusher plate 138.
Accordingly, in the closed state illustrated in FIG. 3, because the abutment member 136 contacts the guide plate 116, the guide plate 116 is pushed toward the supporting plate 144 of the magazine main body 112, and the guide plate 116 is fixed within the paper magazine 12.
A guide surface 133 is provided at the cover 132. The guide surface 133 forms an inner wall of the paper magazine 12 and is positioned so as to oppose the guide plate 116 with the photographic printing paper P disposed between the guide plate 116 and the guide surface 133. The guide surface 133 guides the photographic printing paper P. Recesses 133A are formed in portions of the guide surface 133 which oppose the guide rollers 122 such that the guide surface 133 does not contact the guide rollers 122.
A third roller, which is a driving roller 16 around which a vicinity of the leading end portion of the photographic printing paper P is trained, is supported so as to be freely rotatable at the upper left portion of the magazine main body 112 as seen in FIGS. 1 and 3. Via a driving belt 18 provided within the photographic printing device 10, the driving roller 16 receives the driving force of a motor 20 disposed within the photographic printing device 10, and is rotated thereby. Further, rollers 146, which guide the photographic printing paper P, as well as a pair of nip rollers 80, 82 are disposed at positions of the cover 132 which oppose the driving roller 16. As a result, the driving roller 16 nips the photographic printing paper P between the nip roller 80, 82 and delivers the leading end of the photographic printing paper P into the photographic printing device 10.
Accordingly, in the closed state illustrated in FIG. 3, the photographic printing paper P is interposed between the guide surface 133 of the cover 132 and the guide plate 116, and is guided toward the driving roller 16, the nip rollers 80, 82, and a magazine opening 112A. The driving roller 16 and the nip rollers 80, 82 nip and convey the photographic printing paper P.
A cutter 22, which is formed from a pair of upper and lower blades, is disposed within the photographic printing device 10. The cutter 22 cuts the photographic printing paper P which has been discharged from the paper magazine 12.
As shown in FIG. 1, a support stand 46, whose upper surface is formed along the horizontal direction (in left and right directions in FIG. 1), is disposed downstream of the cutter 22 in the conveying direction of the photographic printing paper P, i.e., at the right side of the cutter 22 in FIG. 1. A training roller 52, around which an endless belt 42 is trained, is disposed horizontally (in a direction orthogonal to the paper surface of FIG. 1) between the supporting stand 46 and the cutter 22. A rising/falling roller 54 is disposed above the training roller 52 and parallel thereto, such that the endless belt 42 is nipped between the training roller 52 and the rising/falling roller 54.
Axial direction end portions of the rising/falling roller 54 are axially supported by arms 56. The arms $6 are connected to a self-holding-type solenoid 66 via links 64. Accordingly, when an energizing pulse voltage is input to the solenoid 66 such that the solenoid 66 is operated, the arms 56 rise and the rising/falling roller 54 moves apart from the endless belt 42.
When a reverse operation pulse voltage is inputted to the solenoid 66, the rising/falling roller 54 contacts the endless belt 42 on the training roller 52 due to the urging force of unillustrated springs so that the photographic printing paper P can be nipped between the rising/falling roller 54 and the endless belt 42.
A guide roller 68, around which the endless belt 42 is trained, is located downstream of the supporting stand 46 in the conveying direction of the photographic printing paper P. A guide roller 69 is disposed at a position adjacent to the guide roller 68 such that the bottom surface of the guide roller 69 is at substantially the same height as the upper surface of the training roller 52. The guide roller 69 is pushed toward the outer periphery of the endless belt 42.
Namely, as illustrated in FIG. 1, the endless belt 42 is trained around approximately 1/4 of the outer circumference of the guide roller 69, and thereafter, is trained around about 2/3 of the outer circumference of the guide roller 68, such that this portion of the endless belt 42 is S-shaped. Further, the endless belt 42 is trained around a tension roller 76 beneath the guide roller 68 such that a triangular locus of movement is formed.
The guide roller 68 receives the driving force of a motor 72 via a timing belt 74 so as to be driven and rotated, and the endless belt 42 is driven and rotated in a clockwise direction in FIG. 1.
Accordingly, after the photographic printing paper P which has been delivered out from the paper magazine 12 is cut to a desired length at the cutter 22, the photographic printing paper P is set on the endless belt 42 and is conveyed to an exposure/printing position G which is a position on an optical axis S of the printing light. The printing light from a light source 26 reaches the photographic printing paper P via an optical means 28 and a shutter 32, so that an image recorded on a negative film N is printed onto the photographic printing paper P. The portion at which the image is printed is a printed image.
The photographic printing paper P, for which printing of an image has been completed, is nipped between the guide roller 68 and the guide roller 69. The conveying direction thereof is changed from horizontal to vertical, and the photographic printing paper P is conveyed in a vertical direction. Thereafter, the photographic printing paper P is sent via a conveying path 34 to a developing device 36 where the printed image is developed.
A plurality of small holes (unillustrated) are formed in the entire endless belt 42. Further, a plurality of small holes (unillustrated) are formed in the upper surface of the supporting stand 46 on which a portion of the endless belt 42 rests. At this portion of the endless belt 42, the photographic printing paper P should be disposed in a horizontal state at the image printing position G.
The interior portion of the supporting stand 46 is hollow. A pair of communicating ducts 84 (only one is illustrated in the drawings), which are formed so as to correspond to the transverse direction ends of the endless belt 42, are connected to the supporting stand 46. The communicating ducts 84 bypass the return portion of the endless belt 42 disposed under the supporting stand 46 and extend below the endless belt 42. The communicating ducts 84 extend further downward and are connected to a fan box 86 provided with a suction fan 85.
In this way, the air within the supporting stand 46 is drawn out from within the loop of the endless belt 42 to the transverse direction ends thereof via the communicating ducts 84, is sucked by the suction fan 85, and is blown out to the exterior. Therefore, the interior of the supporting stand 46 is at negative pressure. The negative pressure is transmitted to the photographic printing paper P on the endless belt 42 via the hole portions in the supporting stand 46 and the small holes in the endless belt 42, so that the photographic printing paper P is sucked to the endless belt 42 as illustrated by arrows A.
As a result, because the photographic printing paper P is not merely set on the endless belt 42 but is sucked thereto, the photographic printing paper P is reliably conveyed by the endless belt 42.
As illustrated in FIG. 1, an easel device 78 is provided above the portion off the endless belt 42 which moves on the supporting stand 46. When a bordered image is printed on the photographic printing paper P, the periphery of the photographic printing paper P is covered by the easel device 78.
Operation of the present embodiment will be described hereinafter.
In the open state illustrated in FIG. 2, an operator loads the reel 110, around which the photographic printing paper P is wound, from the open portion 112B of the magazine main body 112 into the paper magazine 12. Next, the guide plate 116 and the cover 132 are pivoted such that the paper magazine 12 is set in the closed state illustrated in FIG. 3. At this time, as illustrated in FIGS. 4 and 5, the leading end of the photographic printing paper P is delivered to the magazine opening portion 112A while the photographic printing paper P passes along the surface of the guide plate 116 between the guide rollers 122.
Thereafter, when the paper magazine 12 is loaded in the photographic printing device 10, the motor 20 is rotated, and the rotation is transmitted to the driving roller 16 via the driving belt 18. As a result, the driving roller 16 is rotated in the clockwise direction, and the photographic printing paper P is delivered out from the magazine 12 by a predetermined amount.
Accordingly, when the photographic printing paper P is delivered out to the exterior of the paper magazine 12, not only is the reverse surface of the photographic printing paper P is guided by the guide plate 116 and the photosensitive surface guided by the guide surface 133 of the cover 132, but also, the transverse direction end portions of the photographic printing paper P are guided by the guide rollers 122. As a result, when the photographic printing paper P is delivered out to the exterior of the paper magazine 12, the position of the photographic printing paper P within the paper magazine 12 is reliably regulated.
At this time, because the transverse direction end portions of the photographic printing paper P are guided by the freely rotatable guide rollers 122, the load applied to the photographic printing paper P while it is being conveyed is reduced so that the photographic printing paper P is not damaged. Further, in the state in which the open portion 112B is closed by the cover 132, the cover 132 is positioned so as to oppose the guide plate 116. Therefore, when the photographic printing paper P is loaded into the paper magazine 12 from the open portion 112B of the magazine main body 112, the cover 132 does not hinder the loading operation, and the loadability of the photographic printing paper P is improved. Moreover, in the closed state, the photographic printing paper P is interposed between the cover 132 and the guide plate 116, so that the photographic printing paper P can be prevented from separating from the guide rollers 122.
Further, the guide rollers 122 are attached so as to be freely rotatable to the attachment surfaces 117 which are formed so as to be a step lower than the flat surface formed by the guide plate 116. Therefore, the transverse direction end portions of the photographic printing paper P guided by the guide rollers 122 do not contact the corner portions 122A of the guide rollers 122. As a result, the transverse direction end portions of the photographic printing paper P are not damaged due to contact with the corner portions 122A. Moreover, in the closed state illustrated in FIG. 3, the guide plate 116 is reliably fixed by the abutment member 136 and the pusher plate 138 which contact and position the guide plate 116.
The photographic printing paper P which has been delivered out to the photographic printing device 10 is cut to a predetermined length by the cutter 22. The cut photographic printing paper P moves on the supporting stand 46 due to the endless belt 42. An image is printed on the photographic printing paper P which is then sent to the developing device 36 via the conveying path 34, and the printed image is developed. Accordingly, when the image is printed, the photographic printing paper P is not inclined and does not deviate from the conveying path, so that the image is printed correctly.
In the present embodiment, the reverse surface of the photographic printing paper P is guided by the guide plate 116, and the photosensitive surface is guided by the guide surface 133 of the cover 132. However, an opposite structure may be used, i.e., the photosensitive surface of the photographic printing paper P may be guided by the guide plate 116, and the reverse surface may be guided by the guide surface 133. Further, although the guide plate 116 pivots around the hinge 114 in the present embodiment, a fixed guide may be used provided that it does not deteriorate the loadability of the photographic printing paper P.
In the present embodiment, although the photosensitive material is photographic printing paper, a photosensitive material other than photographic printing paper, such as film or the like, may be used.
As described above, the paper magazine of the present invention provides a superior effect in that the loadability of the photographic printing paper is improved, load applied to the photographic printing paper during the conveying thereof is reduced, and the position of the photographic printing paper within the paper magazine can be regulated reliably.
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A paper magazine including a magazine main body in which a photosensitive material is accommodated; a guide member for guiding the photosensitive material to a magazine opening through which the photosensitive material is delivered out to an exterior; at least one guide roller which is attached to the guide member so as to be freely rotatable, and which contacts a transverse direction end portion of the photosensitive material and guides the photosensitive material when the photosensitive material is delivered out to the exterior; and a cover which is supported at the magazine main body so as to be able to open and close an open portion of the magazine main body, and when the cover is closed, the cover is positioned so as to oppose the guide member with the photosensitive material being disposed between the guide member and the cover. As a result, load caused by friction or the like between the photosensitive material and the guide member when the photosensitive material is being conveyed does not become large. There is no need for a large conveying force to convey the photosensitive material, and the photosensitive material is not damaged.
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