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[0001] The present application is related to U.S. patent application Ser. No. 12/260,046, filed Oct. 28, 2008, entitled “A Building Management Configuration System”. U.S. patent application Ser. No. 12/260,046, filed Oct. 28, 2008, is hereby incorporated by reference. The present application is also related to U.S. patent application Ser. No. 12/703,476, filed Feb. 10, 2010, entitled “A Multi-Site Controller Batch Update System”; and U.S. patent application Ser. No. 12/643,865, filed Dec. 21, 2009, entitled “Approaches for Shifting a Schedule”; all of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention pertains to software and controllers and particularly to controller configurations. More particularly, the invention pertains to configuration designing.
SUMMARY
[0003] The invention is an approach for creating a station with a configuration and making it active within a supervisor application without a need of actual site controller hardware. The configuration may be changed. The new station may be downloaded to a site controller. The approach may automate multiple steps into one or more sequences of operations.
BRIEF DESCRIPTION OF THE DRAWING
[0004] FIG. 1 is a flow diagram for an offline configuration and download approach;
[0005] FIG. 2 is a flow diagram of a jar transfer which is one of the features in an offline configuration and download;
[0006] FIG. 3 is a diagram of interaction among a user, a supervisor, and a controller;
[0007] FIG. 4 is a flow diagram of a user's case for a manual backup/restore;
[0008] FIG. 5 is a flow diagram of a restore for a redownload; and
[0009] FIGS. 6-25 are diagrams of screen shots showing significant portions of a process of the present application or approach.
DESCRIPTION
[0010] The Tridium™ (Tridium) NiagaraAX™ (NiagaraAX, Niagara) Framework™ (framework) may particularly be a base software application or approach for developing a site offline configuration and download feature. The feature may capture improvements made to an existing Niagara Workbench™ (workbench) user interface application to provide the customer a desired user experience in creating controller configurations and deploying them to site controllers.
[0011] The Novar™ (Novar) Opus™ (Opus) Supervisor™ (supervisor) may provide a basis of the present application or approach. The framework may generally be a software platform for integrating diverse systems and devices regardless of manufacturers, or communication protocols into a unified platform which can be managed and controlled in real time over an internet using a standard web browser. The supervisor may be a software platform built on the framework. The supervisor may communicate with site controllers via an intranet or internet. A site controller may be referred to as an XCM (executive control module) controller (XCM).
[0012] The supervisor may serve real-time graphical information displays to standard web-browser clients and provide server-level functions such as centralized data logging, archiving, alarming, real-time graphical displays, master scheduling, system-wide database management, and integration with Novar Enterprise™ (enterprise) software. The enterprise software family may be used for energy analysis and business-critical requirements such as alarm handling, systems configuration, data collection and performance monitoring.
[0013] A definition of “creating a site configuration offline” may indicate that a site controller configuration is created and made active within a supervisor application without a need of actual site controller hardware. A customer of a Novar retail business may wish to create a site configuration offline and, when complete, initiate a download of this configuration to a site controller. Upon completion of the download, the customer may want to have a copy of the downloaded site configuration safely backed up within the supervisor. The customer may want these operations to require minimal user interaction with the supervisor application.
[0014] The NiagaraAX workbench may be capable of approaches for creating an offline site controller configuration and then deploying it to a remote site controller. However, there are numerous user interactions that may be required to accomplish this task. The present approach may minimize these user interactions by automating multiple steps into sequences of operations.
[0015] The following items are individual user manual steps which may be required when using Niagara workbench technology. One may note that the term “supervisor” may be used to refer to the workbench application. The steps may incorporate the following: 1) Use a toolbar option to create a new site controller station baseline configuration within the supervisor; 2) Provide a unique station name based on guidelines using best practices; 3) Provide a unique port number for running within the supervisor; 4) Navigate to an application director view within the supervisor; 5) Select the newly created station and invoke a start command; 6) Connect the workbench to the running station within the supervisor; 7) Perform site specific configuration additions and changes; 8) Change the station to correct a port number for deployment; 9) Stop the station running within the supervisor; 10) Connect the workbench to a site controller platform service; 11) Navigate to the software manager view; 12) Ensure that required jar (Java archive) files are installed and up to date; 13) Navigate to the station copier view; 14) Select the new station to download and initiate a download; 15) Connect the workbench to the newly deployed site controller; and 16) Initiate a backup operation to create a safe archive of the site configuration. This set of steps may be simplified with some of the steps being automatically performed by the present application or approach.
[0016] The present application may provide the user an ability to create a logical, hierarchal structure representing the user's business and site deployment structure. A solution for the issue noted herein may be to provide a user friendly, streamlined experience to create and deploy the user's site configurations. Here, the user may perform the following steps: 1) Select a site node and use a right click menu option to create a new site controller station baseline configuration—This user action 1) may accomplish steps 1 through 6 specified for the related application or approach noted herein, by automatically performing the following four sub-steps: a) A unique station name may be constructed from hierarchal component branch names; b) The application may assign a unique temporary port number used while running in a supervisor; c) The station may be started within the supervisor environment; and d) The workbench application may be connected to the running station; step 2) Perform site specific configuration changes which may include additions and deletions—This may be the same user action as step 7 specified for the related application or approach noted herein; 3) Set a site controller IP address into an executive property sheet; 4) Select a new site controller node and use the right click menu option for a download, and to initiate the download—This user action may accomplish steps 8 through 16, specified for the related application or approach noted herein, by automatically performing the following six sub-steps: a) The present application or approach may stop the running station within the supervisor and release the temporary port number; b) The application may connect to the site controller platform service; c) The application may confirm that required jar files are installed; d) The application may perform a station download; e) The application may connect to the newly deployed site controller; and f) The application may perform a backup operation.
[0017] The present application or approach may be implemented as part of a “profiled” Niagara workbench. This means that the base workbench may be used as a basis and then extended to provide the desired user features which are needed. The Niagara framework may provide a public application programming interface to allow many of the manual operations to be initiated programmatically. To implement the present application, the application may consolidate the calls to the application program interfaces (API's) into sequences and may be initiated by simple and intuitive menu options.
[0018] In the flow diagrams in the present description, various instances of actions may be referred to as steps, blocks, actions, and the like. However, for illustrative purposes, the instances may be referred to as occurring at the symbols in the respective diagrams.
[0019] FIG. 1 is a diagram which indicates an overall flow of the present approach. The approach may go from a start place 121 to a symbol 122 where a new group, site and XCM may be created. At symbol 123 , a station may be constructed with a unique station name. Additionally, a unique temporary port number may be assigned at symbol 124 . The station may be started within a supervisor (i.e., begin a run mode) at symbol 125 to be running. A user may perform site specific configuration additions and changes at symbol 126 . Changes may incorporate additions and deletions. At symbol 127 , a download may be initiated. A question arises at symbol 128 as to whether an XCM address is available for a download. If the answer is no, then an XCM IP address may be accepted to download at symbol 129 and then go to symbol 130 , or if an address is already had then go to symbol 130 where the simulated station is stopped from running (i.e., end the run mode or put into a non-run mode) at the supervisor. Then a question of whether the JACE station is running may be asked at symbol 131 . If the answer is yes, then the station may be stopped at the XCM (JACE) as indicated at symbol 132 . If the answer is no, then the station may be deleted at the XCM (JACE) at symbol 133 . A question at symbol 134 concerns whether the XCM has all of the required JAR files to initiate a download. If not, the all of the required JAR files may be copied from the Opus client to the XCM (JACE) at symbol 135 . If the question is yes, then at symbol 136 , the offline station may be copied from the supervisor to the XCM. The XCM may be rebooted and the station started at symbol 137 . An enterprise hierarchy may be created at the JACE level (i.e., Group->Site->XCM) according to symbol 138 . An initial backup may be initiated from the XCM to the supervisor at symbol 139 . At symbol 140 , the approach may be stopped.
[0020] FIG. 2 is a flow diagram of a jar transfer approach as it may relate to an offline configuration and download to a site controller. From a start 11 , there may be a module dependency list generated from config.Bog, platform.bog and px files at symbol 12 . Opus™ (Opus) and Niagara related jars may be added to a generated list at symbol 13 . At symbol 14 , client and XCM (executive control module) Niagara versions may be compared. If the result of a comparison reveals the versions to be the same, then an inter-dependent module list may be generated from a client at symbol 15 . If the result of the comparison reveals the versions to be different, then an inter-dependent module list may be generated from the XCM at symbol 16 and the download may be continued at symbol 18 .
[0021] After generating an inter-dependent module list from the client at symbol 15 , the availability of all of the dependent modules in the XCM may be checked for at symbol 17 . If all of the dependent modules are available in the XCM at symbol 17 , then the download may be continued at symbol 18 . If all of the dependent modules are not available in the XCM at symbol 17 , then all the missing modules may be transferred at symbol 19 and on to continue download at symbol 18 .
[0022] After generating an inter-dependent module list from the XCM at symbol 16 , the availability of all of the dependent modules in the XCM may be checked for at symbol 21 . If all of the dependent modules are available in the XCM at symbol 21 , then the download may be continued at symbol 18 . If all of the dependent modules are not available in the XCM at symbol 21 , then a question of whether a missing module list contains only Opus jars may be asked at symbol 22 . If the answer at symbol 22 is no, then the download may be stopped and the missing modules be shown at symbol 24 . If the answer at symbol 22 is yes, then the Opus modules may be transferred at symbol 23 and the download continued at symbol 18 .
[0023] FIG. 3 is a diagram of interaction activity of the user 41 , Opus supervisor 42 and the XCM 43 . User 41 may enter the XCM IP address and credentials at a line 44 and initiate download( ) at a line 45 going from the user 41 to supervisor 42 . There may be a stop offline station( ) at line 46 going from user 41 to supervisor 42 . From Opus supervisor 42 to XCM 43 , the items may include a stop running XCM station( ) at a line 47 , a check( ) for dependency jars at line 49 , a transfer dependent jars to XCM( ) at line 38 , a delete existing XCM station( ) at line 48 , a create new station at XCM( ) at line 52 , a reboot XCM( ) at line 51 , a start station in XCM( ) at line 39 , a create enterprise hierarchy at XCM( ) at line 50 , and an initial backup( ) at line 53 . The Opus supervisor 42 may indicate to user 41 the XCM download as successful( ) at line 54 .
[0024] FIG. 4 is a flow diagram of a user's case for a manual backup/restore. A user 56 may go to an Opus workbench 57 and then to an Opus supervisor 58 to initiate a backup in an XCM node at symbol 59 . Then a backup dist (distribution) file may be generated at symbol 61 .
[0025] FIG. 5 is a flow diagram of a restore for a redownload. A user 81 may go to an Opus workbench at symbol 82 and connect to an Opus supervisor at symbol 83 . At symbol 84 , the user 81 may initiate a restore for a redownload at a dist file under a backup folder. The dist filed may be restored at the supervisor for an offline simulation at symbol 85 . A download flag set to false at symbol 86 may be included in the action at symbol 85 .
[0026] FIGS. 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 and 25 are diagrams of screen shots 101 , 102 , 103 , 104 , 105 , 106 , 107 , 108 , 109 , 110 , 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , and 119 , respectively, which show portions of a process of the present application. The screen shots are from a demonstration provided by a WebEx™ player with a label 91 , as shown in screen shot 101 of FIG. 6 , revealing the time of each screen shot taken during the process.
[0027] In the present specification, some of the matter may be of a hypothetical or prophetic nature although stated in another manner or tense.
[0028] Although the present system has been described with respect to at least one illustrative example, many variations and modifications will become apparent to those skilled in the art upon reading the specification. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
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A system for creating a station having a configuration and making the station active within a supervisor application without a need of actual site controller hardware. The configuration may be changed. The new station may be downloaded with the changed configuration to a site controller. Multiple steps for effecting the present configuration design and station download may automatically be accomplished by fewer steps.
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FEDERAL INTEREST STATEMENT
The inventions described herein may be manufactured, used, and licensed by, or for the U.S. Government for U.S. Government purposes.
FIELD OF THE INVENTION
The present invention generally relates to optical systems used in semi-active laser guided cannon launched projectiles. These projectiles typically use a seeker head which employs a folded optical system that includes a gimbaled platform supporting a flat mirror, a lens cluster, a photo detector, and a focusing shim. The gimbaled platform is usually the rotor of a gyro, but can be servo actuated instead. More specifically, the present invention relates to an optical bench that substitutes for the projectile seeker head, enables easy comparison of optical piece parts, provides a view of the focused image, but most importantly, will predict the performance of a costly projectile at a very early stage in its manufacture. In addition to that, precise instrumentation of the seeker optics will provide data for computerized six-degree-of-freedom flight simulations, which will lead to a more accurate assessment of battlefield defense systems.
BACKGROUND OF THE INVENTION
Two kinds of semi-active laser guided air-frames have been commonly used by the military, one type is the rocket propelled missile and the other type is the howitzer projectile. Each uses a seeker head on the nose of the air-frame to collect laser radiation emitted by the target, and enable guidance. The dish reflector is well suited for the missile seeker while the lens and mirror combination is best for the projectile seeker.
The missile uses a parabolic dish reflector to track the radiation emanating from the target. The dish reflector is thin, light in weight, has a wide aperture, good focusing throughout its field-of-view and allows a compact seeker head antenna. Along with the low weight antenna comes a lighter servo or gyro to point it for tracking. A lighter missile results in greater range.
The cannon launched projectile is subject to high acceleration inside the tube, a much more severe environment than the missile. The thin reflector is not compatible with the high shock resistance required during cannon launch and so it must be stiffened. Nose-heavy means flight stability for a projectile; but the heavier reflector, together with the additional weight of the accompanying servo, translates either into a significant penalty in range, or a significant loss in tracking response needed to follow the radiation.
One of the proposed solutions for the cannon launched projectile has been folded optics. Folded optics affords wide aperture throughout its field-of-view, the shock resistance of a strap-down optical cluster, and a light weight gyro agile enough to track easily. Its reflecting system only works with a flat mirror which is usually polished on the face of the gyro rotor. This is acceptable from a fabrication point of view because making the flat micro surface is an old technology. That said, the folded system is notorious for two troublesome characteristics. One is that the focused image morphs or changes shape as the gyro tracks in pitch or yaw. Focusing this system requires checking its focus throughout its gimbal range. This leads to the second quirk. The image is not plainly visible. These two peculiarities add uncertainty to guidance parameters like gain and feedback and this uncertainty is generally considered a drawback to folded optics. The unpredictability in optical feedback discredits computer flight simulations. The only way to be sure of the projectile's value is the costly way; to build a few and fire them. However, control over optical feedback will make this trait an asset instead of a liability, will bring a substantial improvement to performance and uniformity from one projectile to the next, and will reduce an expensive risk.
Guidance systems that track with a gimbaled antenna in the nose and try to keep a bead on the target have historically been known as using proportional navigation. The mirror is always facing the radiation, even when the missile body turns away from it, and that is the orientation of most concern. The focused spot of light must be centered on a screen in order to indicate when the antenna is on track. Missile body motion can disturb that setting. Optical feedback appears as a second order term in a folded system's transfer function, but this peculiarity is not necessarily bad. It can either enhance or degrade flight stability in a cross-wind or sudden jump in the direction of laser radiation; conditions that typically occur on the battlefield. If feedback has a positive value, then the path of the projectile will spiral away from the target; and that's bad. If it is negative then the projectile will recover from the perturbation and continue to pursue the target; and that's good. This is the reason why precise focusing of the optics is so critical.
Plastic lenses made of polycarbonate are both compact and shock resistant when incorporated into a folded optical system. However the optical characteristics of the plastic lens is sensitive to process variations of molding and annealing, resulting in significant variations in optical characteristics from one lens to another. The lens of most concern is the large plastic objective lens behind the transparent windshield where laser radiation enters. Adjustments must be made for focus for each individual seeker head, because focus, flare and other characteristics are unique to each lens. Quality cannot be held to rigid dimensions or process certification. Each seeker must be focused individually, as the lenses are not interchangeable. This leads to a serious problem.
The focused image in a folded optical seeker head is not plainly visible because it is hidden behind the mirror. This is worth repeating and cannot be over emphasized. The image of the target inside a folded seeker cannot be viewed directly. It cannot be focused by viewing an image and turning a knob, as is the case of a microscope or pair of binoculars. A folded optical seeker is so compact that there is just no way to see inside of it without extraordinary modifications to the system.
Prior to the advent of the present invention, there was no other alternative to focusing each seeker except by indirect means. Focusing done electronically through the output from the photo detector was a long and tedious process requiring skilled technicians, sophisticated equipment, hours of time, and cool precise concentration. The manufacturing record of these systems is speckled with unanticipated delays, loss of schedule and uncontrollable costs. At this writing there is still a need for a measurement system and a method to aid the focusing of seeker heads used in cannon launched projectiles. To date this need has not been satisfied.
SUMMARY OF THE INVENTION
The present invention satisfies this need, and overcomes the primary manufacturing obstacle for cannon launched laser guided projectiles that use folded optics with a flat mirror. The apparatus or mechanism comprising the present invention is referred to herein as the Shim Dialer. The original seeker head for which it was designed to control is referred to as the “folded seeker” or the “tactical seeker”. Dimensions taken from the tactical seeker assembly configuration are referred to as the “nominal.” The present invention provides a measurement instrument to view a focused image inside a projectile seeker equipped with a lens cluster, a photo detector, a gimbaled flat mirror, and a focusing shim. The present invention is not flyable but is well suited for a table top or assembly line.
The Shim Dialer will replicate an optical tracking system and indicate a focusing shim offset by viewing an image and turning a dial.
An object of this invention is to disclose an optical bench design which is optically equivalent to the folded seeker that employs a flat mirror, and can substitute for, mimic, imitate or simulate the folded seeker in a research, developmental or production environment.
An object of this invention is to disclose an optical bench design which makes plainly visible the image of the target on the photodetector of a folded seeker head, and enables taking measurements and photographs of it.
An object of this invention is to disclose an optical bench design which can view, measure and photograph the focused image of a folded seeker while easily swapping into the apparatus the individual optical component piece-parts, thus quickly isolating the effects of each component on tactical seeker head performance.
Another object of this invention is to disclose a method to select and match components for tactical seeker heads in mass production.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
FIG. 1 represents an optical apparatus or optical bench herein called the Shim Dialer with a light source, collimator, a micrometer shim dial, a primary lens cluster, a mask, a secondary lens cluster, a dovetail way that breaks into two segments, a universal slip joint (not shown), two rollers or clevises, a micrometer yaw barrel and a microscope stage with its own focusing barrel;
FIG. 2 represents a different perspective of the optical bench called the Shim Dialer of FIG. 1 , further showing a universal joint with slip joints, and a knob to drive the dovetail way;
FIG. 3 represents an isometric view of a pair of devises that forms part of the present system;
FIG. 4 represents an internally threaded block with four aligned bosses and a screw in support of the pair of devises in FIG. 3 ;
FIG. 5 represents a transmission that functions as a reversing linkage and uses a nut that trolleys on a threaded shaft, a pair of devises constrained by bosses on the nut and planar rack faces, all to replicate yaw action;
FIG. 6 represents the reversing linkage with the pair of devises rotated 10 degrees away from the zero yaw angle position of FIG. 5 ;
FIG. 7 represents the reversing linkage with a primary optical cluster mounted on a first clevis, and a secondary optical cluster mounted on a second clevis of the system in FIG. 5 ;
FIG. 8 represents the same rotation of the reversing linkage as shown in FIG. 6 ;
FIG. 9 represents the ray trace of a common laser tracking seeker head with a lens cluster, a gimbaled gyro rotor polished like a mirror, and a focusing shim;
FIG. 10 represents the ray trace of the seeker when tracking radiation that is incident 10 degrees in yaw angle;
FIG. 11 represents a ray trace of a mirrorless system that is optically equivalent to the system shown in FIG. 10 , as well as the mounted clusters of FIG. 8 ; and
FIG. 12 represents the optical path of the collimated beam traveling through the primary lens cluster, the mask, the secondary lens cluster; the objective of the microscope, the diagonal mirror, and finally the reticule viewed by the eyepiece of a microscope.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The Apparatus
For the purpose of illustration of the present invention, the seeker from a type-classified tactically deployed semi-active laser guided howitzer projectile is used; but in general the present invention can also be used to view and adjust the focal image of any folded optical seeker that uses a flat mirror.
FIG. 1 represents the complete assembly of the present invention, the Shim Dialer, together with its accompanying collimator. Specifically, the optical system 100 is called a Shim Dialer and Collimator and consists of a rigid mounting base 101 with the collimator and dialer components mounted on it. The accompanying collimator includes, a collimator base attached to mounting base 101 , a light source 102 , and a collimator lens 105 adjacent to the light source. On the other side of FIG. 1 is the mounting base 101 itself, which supports the individual dialer components. The complete Shim Dialer consists of its base 101 , a primary optical cluster 110 , a mask 115 , a secondary optical cluster 120 , a reversing linkage transmission 500 showing splines 325 , a pair of roller devises 125 a and 125 b showing splines, a shim dial 130 , a yaw barrel 135 , a primary dovetail way 140 a driven by the shim dial 130 , a secondary dovetail way 140 b driven by a universal joint 132 which has a slip joint 133 at each end shown in FIG. 2 , a microscope diagonal mirror housed inside slab 150 , a housing for the reticule 155 , a diopter adjusting microscope eyepiece 160 , and a microscope focusing barrel 145 . As shown in FIGS. 1 and 2 , the dovetail ways are canted at about ten degrees yaw relative to the incoming beam.
The yaw barrel 135 has been cut away in FIG. 1 and FIG. 2 to make the roller splines on the devises 125 visible. Both figures show one of two knob screws 103 by base 101 that rigidly attaches the collimator section to the dialer section, allowing the option of separating them. The two sections should reassemble to a unique relative position as they index through pins and shoulders. The mask 115 is an opaque screen which has a circular aperture cut through it that coincides with the finite boundaries of the gyro mirror in the tactical seeker. The two halves of the dovetail way 140 are each mounted on one of two devises of the reversing linkage 500 . The devises are constrained to rotate in opposite directions, in the same sense as the reflection of a rotating object would turn as seen in a mirror. The lead screw in the primary way is right-handed, while the screw in the secondary way is left-handed. Both screws have the same lead, an integer number of threads per unit division just like a micrometer. The two screws are connected by a combination universal and slip joint. Turning the shim dial 130 moves the two way platforms in opposite directions, again in the same sense as the reflection of a translating object would move as seen in a mirror. Specifically, clockwise rotation of the dial causes the way platforms to recede from each other, each moving away from the other by equal distances. A knob on the screw of the secondary way 131 drives the secondary way slide and also becomes an optional way of turning the dial 130 when the entire Shim Dialer is fully assembled.
The shim dial barrel 130 is engraved with numbered divisions to indicate the position of the way slide platforms on the dovetail way. The barrel includes a vernier scale. A small zero set knob on the end of the barrel, opposite the crank handle visible in FIG. 1 , locks the barrel scale to allow any arbitrary way slide position to coincide with any dial reading; that is, any position of the ways can be initialized to zero or any other value.
The optical bench 100 is set up in such a way that light initially travels horizontally through the optical clusters, through the microscope objective, and then is deflected vertically upward by a diagonal mirror to have its image focused on the reticule which is viewed by the eyepiece. The splitting of folded optics into two optical clusters 110 and 120 speeds shim selection by enabling accessibility and rapid changing of the two lenses 915 and 920 .
In addition to the moving parts on the Shim Dialer, there are also cross-plates visible in FIG. 1 and FIG. 2 . They are grooved with interlocking rectangular slots and rail protrusions to enable independent translation of the clusters in three directions to fixed positions relative to the dovetail way sliding platforms. Specifically, the dovetail way slides are milled to interlock with the cross plates. A stack of cross plates over each way fixes the cluster mounts on three translational axes. In each case of independent translation, set screws lock the cluster mounts to fixed positions. These elongated slots and protrusions on the cross plates also function as gauging surfaces indicating perpendicularity and parallelism to the dovetail ways. In contrast however, each way itself cannot be shifted on its clevis but is rigidly indexed to the clevis in a unique position through grooves and pins on surface 330 .
Each optical cluster 110 and 120 is fitted into a cluster mount shown in FIG. 1 and FIG. 2 . The cluster mounts themselves have circular cavities to receive the lens clusters, as well as shoulders to seat the large lens 915 . These shoulders coincide with the same shoulders on the tactical seeker. If the large lens is molded with threads, as it typically is, then the cluster mounts should be threaded as well. That will ensure easy swapping of lens samples and consistent shouldering to the nominal configuration.
Gauging fixtures must be provided which complement the Shim Dialer apparatus. The lens shoulder is a significant datum target in the assembly of the tactical seeker. A pair of gage plugs are cut to become otherwise replicas of the molded lens 915 , except they include some additional features which become surfaces of contact for instruments. The plugs are threaded and shouldered just like the molded lenses and slide or screw snugly inside the cluster mounts, just as the molded parts do. These plugs lack the optical curvatures of the lenses but have flat faces instead. The flats extend a little beyond the faces of the mounts and are parallel to the lens shoulders. The plugs also have pins or probes that protrude out an equal distance beyond the planes of the lens shoulders along center lines. Thus the gage plugs align themselves to a critical feature, the lens shoulder.
Each cluster mount can also be tilted up and down independently on horizontal axes that are at right angles to the ways. The cluster mounts are pivoted on collinear bosses in their yolks so that set screws clamp them at fixed angles of elevation relative to the dovetail ways.
The collimator 105 can also be tilted to fixed positions along horizontal and vertical axes, and can translate to fixed positions vertically and horizontally at right angles relative to the path of the light 902 .
The shim dialer is first assembled with crude alignment. The universal joint 132 is inserted on the lead screws of the way platforms and indexed on each keyway with a slip joint 133 such that the clusters are equally distant from the trolley nut 450 or mask 115 , at least within one or two threads. A constant velocity universal joint with two journals is preferred over a simple single journal because the midshaft provides smooth turning of the shim dial and insures more accurate dial indications. The splines 325 in the reversing linkage are also meshed so that zero degree yaw barrel 135 will center the devises 125 evenly within the rack 510 , as implied by FIG. 5 .
FIG. 3 shows the two rotating components 125 of the reversing transmission 500 . Both are identical; really sector gears which might have been cut with involute teeth but milled with splines 325 instead. Unlike gear teeth, the splines allow smooth rolling without gear tooth ripple or backlash, but like gears are constrained by their meshing. The rollers are hollow like ordinary split clevises, and each eyelet 310 is bored on the same collinear axis as the cylindrically splined face 325 or pitch circle. The faces 330 are parallel to each other and are normal to the cylindrical face. The parts shown are perfectly functional but there might be difficulty in hogging out the cavity 320 . It is probably more practical to assemble the devises 125 out of separate interconnecting pieces.
FIG. 4 shows the next two components of the reversing transmission 500 . The screw 440 with thrust bearing ends is threaded with an integer number of threads per unit division just like a micrometer and occupies the mid-section recesses 320 of the clevises. The nut 450 has a threaded hole which has a sliding fit with the screw. Two parallel shafts which may be integral to the nut appear as four bosses 410 that stick out of it. Each pair of collinear bosses 410 protruding on both sides of the block 450 function as a pivotal or rotational center of each clevis 125 . The screw hole 430 is exactly mid way between the axes of the two bosses or pins. A line connects the pins, shown in the figure, and is also referred to as 520 in FIG. 5 . This line, and the thread axis, and the collinear bosses are all mutually perpendicular. Finally, the distance between the axes of the pins is exactly double the distance from the gimbal center to the surface of the mirror of the tactical seeker; that is, twice the distance between the mirror surface 925 and the intersection of trunnion axes 940 in FIG. 9 or FIG. 10 . The pins 410 are mirror images of each other, but with one refinement. In this case, the object is behind the mirror and the image is in front of the mirror. The gimbal center is behind the polished surface, not in front of it. This explains the peculiar “C” shape of the devises and why they must wrap around each other as shown in FIG. 5 .
FIG. 5 shows the four components of the reversing transmission 500 listed in FIG. 3 and FIG. 4 assembled into a rack frame 510 . One pair of collinear bosses 410 fit through the holes 310 on a first clevis 125 a , and a second pair of collinear bosses 410 are pinned through the holes 310 on a second clevis 125 b . The frame 510 constrains the threaded screw 440 on its thrust and pivotal bearings. The screw bearings have a snug but sliding fit, though FIG. 5 shows a space at the end of the threaded section, only to distinguish the screw from the frame. The screw 440 constrains the threaded nut 450 . The threaded nut 450 constrains the clevises 125 on their eyelets. The clevis splines constrain or are constrained by the frame 510 by meshing with its piano rack splines 325 . The line 520 joining the two eyelets on the devises is always at a right angle to the slide-fit screw threads and block 450 cannot rotate on an axis normal to the plane of the drawing.
Clearly visible in FIG. 1 and FIG. 2 and just underneath transmission 500 is a base plate supporting the entire frame which further constrains the clevis surfaces 330 and prevents them from moving out of the plane of the drawing or rotating on an axis in the plane of the drawing. The bosses on the nut protrude slightly above the surface 330 of the devises and a horizontal plate or trolley is bolted on them. Visible as an inverted “T” in FIG. 1 and FIG. 2 is one end of the horizontal trolley plate with a vertical plate on top of it. It is just above screw 440 emanating from the yaw barrel 135 in FIG. 1 . The two trolley bolts, not shown, go through two holes in the trolley plate, through the two holes along the centers of both bosses of the reversing linkage nut, through two slotted holes in the base plate of the rack frame, and both are secured below through two holes in a single washer plate, two Belleville washers, and two nuts. The slotted holes in the base plate follow the path of the bosses 410 , allow the nut 450 to travel along the screw 440 , but keep the devises confined to a plane. The assembly can only move with one degree of freedom, and simulates the reversing action of a reflection. The plane of reflection, or mirror plane, is normal to the figure and includes the axis of the threaded screw 440 .
A line is scribed on the trolley plate joining the two bolt holes, and is parallel to and directly above line 520 . It is used to center the mask 115 . Specifically, a block, referred to herein as a “mask block” or “bridge”, is bolted on top of the trolley into a rigid indexed position. One vertical face of the mask block indexes directly over internal thread axis 430 in the transmission nut, and dissects line 520 . The mask block has two horizontally threaded holes in its vertical face to affix the mask plate. The corresponding holes in the mask are a little oversized for the accompanying screws. The plane of the mask will automatically include the axis of the threaded shaft 440 and the center axis of the mask aperture will automatically be parallel to line 520 . Screws and washers allow the mask axis to be adjusted directly above line 520 , and elevated to the optical axes of the cluster mounts. One more thing; interference occurs because the mask block on the trolley occupies the same space as the universal joint 132 . To allow passage of the joint through the mask block, a cavity is cut away from the bottom of it so that it resembles a bridge. Visible as an inverted “T” in FIG. 1 and FIG. 2 is one side of the trolley and bridge assembly.
Two micrometer barrels 135 each, indicating yaw angle, are keyed to each end of the threaded screw 440 , and provide one degree of yaw per turn. The screw has a single thread. If R is the pitch circle radius of face 325 on the clevis roller 125 , then the thread lead equals (2×PI×R)/360. As a rule of thumb, make R twice the focal length of the large lens 915 . Then round off the lead to a standard thread size. As an example for the apparatus shown, the focal length was 1.25 inch, making R about 2.5 inch and making the lead 0.0436. That seems to be close to twenty threads per inch, as is a common ½×20 UNF or SAE bolt. Solving for R using this standard thread size, calculate (0.05×360)/(2×PI), or R=2.866 inch. The splines 325 constrain angle to displacement and so making the spline spacing the same as the thread spacing allows the splines to become an angular indicator, though this refinement is not essential.
FIG. 6 represents the transmission rack 500 with the pair of devises 125 rotated from the zero yaw angle position of FIG. 5 . The clevis connection line 520 , shown in dotted line, is translated to the right along the axis of the threaded shaft 440 . The splines 325 on the pair of devises and on the planar surfaces of the rack 510 remain in contact. Thread pitching contact and spline meshing contact constrain clevis yaw angle to clevis displacement. In summary, the rack 510 is constructed with a line of symmetry along the axis of the assembled threaded shaft, resulting in symmetrical angular and linear movements of each of the pair of clevis 125 in the transmission rack system 500 . The devises can roll plus or minus fifteen degrees; which has been found to be an adequate range for tactical folded seekers. Cutting more slender “C” shaped devises may be necessary to reach a wider angular field-of-view range for a particular tactical seeker of interest.
FIG. 7 represents the transmission rack system 700 with a primary optical cluster 110 mounted on a first clevis 125 a , and a secondary optical cluster 120 mounted on a second clevis 125 b of the transmission rack system 500 of FIG. 5 . The primary optical cluster 110 is shown to be fitted with a windshield 905 from a projectile through which an incoming beam would pass. In addition, a mask 115 with aperture 710 is mounted midway between the opposing primary and secondary optical clusters 110 and 120 . The optical axes of both clusters are in the same vertical plane of the drawing as the axes of the clevis pins 520 . The clusters and mask are cut away or sectioned and the mask 115 is shown in three pieces. The mask is an opaque screen which has an aperture cut through it that coincides with the finite boundaries of the gyro mirror in the tactical seeker. A button is supported in the middle of the aperture by fine wires. It coincides with an opaque spot on the polished rotor surface for a fastener.
The mask is not attached to any clevis but rides with the nut bosses 410 , as described above for FIG. 5 . Specifically, a bracket in the shape of a bridge or an inverted “U”, is bolted onto the trolley plate and supports the mask 115 at exactly midway between the bosses. The clearance under the bridge allows the universal joint to pass through. The segment of the mask at the center of the assembly is referred to as the button, and represents an opaque spot face at the center of the polished rotor of the tactical seeker. The button travels with the nut, is always directly over line 520 , and is always midway between the reflections of the gimbal center at the ends of line 520 .
FIG. 8 represents a rotation of the optical transmission rack system 700 shown in FIG. 7 . As the yaw barrel 135 turns the threaded shaft 440 to induce the block 450 to translate, the pair of clevis 125 are also induced to rotate and translate under the constraint of the reversing transmission rack system 500 . The primary optical cluster 110 mounted on the first clevis and the secondary optical cluster 120 mounted on the second clevis also rotate and translate, following the motion of the pair of clevises. The yaw position FIG. 8 shows how the button has moved out of alignment with the optical cluster axes. It also shows that the two cluster are now slightly closer together, which explains the need for two slip joints 133 on both ends of the universal joint 132 . Notice that the clusters do not wander very far from the center of the collimator beam, a desirable feature as the lamp's parallelism degrades near the edges. The discussion of FIG. 11 will explain why the large piano convex lens is not shown in the secondary clusters of FIG. 7 and FIG. 8 . However, a complete pair of clusters and a rigid mask surface, or button, is useful to align the apparatus prior to using it, as will be discussed later in the procedure for using the Shim Dialer.
FIG. 9 and FIG. 10 are ray-traces showing the normal operation of the tactical seeker at zero and ten degrees yaw, respectively. Guidance systems that try to keep a bead on the target with a gimbaled antenna in the nose have historically been known as proportional navigation. The mirror is always facing the radiation, even when the missile body turns away from it; and it is this off-axis orientation which is of most concern. Light 902 either from a target that is far away or from a collimator that is on the inspection table passes through the single optical cluster assembly 912 . The first time it enters it passes sequentially through the windshield 905 , around the detector housing 935 , through the clear filter glass 910 , through the large piano convex lens 915 and is then reflected back by the gimbaled reflector 925 of gyro system 945 . The second time the same light enters the cluster is through the small piano convex lens 920 where it is focused on the detector 930 . These figures can explain why a substitute optical bench is necessary to focus the tactical seeker.
The image on the photo detector is inaccessible by any measurement equipment, as proven by the following thought exercise. The detector only has four quadrants designed to output pitch and yaw signals and cannot provide a clear video image of the focused spot. Any attempt to view the face of the detector through the gyro shaft would require an eyepiece small enough to fit through the rotor spot face and pivot inside the gimbal center, and would not provide an adequate view throughout the gimbaling range. Any attempt at temporarily replacing the detector with a translucent screen and viewing the spot image from inside the detector housing would require a diagonal mirror through the side of the housing or a hole in the collimator, and that would require blocking some of the incoming light. Possibly, either a miniature television camera, or pixeled silicon screen, or fiber-optic borescope can be temporarily fastened inside the detector housing with wires or optical filament bundles laced to the housing supporting tubes. That might be feasible, but manufacturing prefers that the detector be bonded into the housing well before the mirror and gimbaling are added to insure hardening from gun launch. We must reluctantly conclude that no independent means to directly view the image inside the tactical seeker for the purpose of optical alignment has been found at this writing.
One other drawback can be mentioned about shimming the deliverable tactical seeker head directly without reference to a parallel equivalent optical system. The assembly level to do the focusing operation occurs late in manufacture. At the very least, the large lens and detector housing assembly 915 and 935 is essential, as it is not possible to use the as-molded lens 915 as a separate interchangeable part. The small lens and detector housing do not fit inside the large lens as it came out of the injector blocks.
FIG. 11 is a through-optical system equivalent to that in the tactical seeker. In fact, FIG. 8 , FIG. 10 , and FIG. 11 are all optically equivalent. The flat mirror of the original seeker is what enables the use of existing components to substitute for the reflection. The mirrorless system shows two clusters back-to-back or eye-ball-to-eye-ball. It is clear now which components are not in the optical path and may be omitted from the Shim Dialer. The lens cluster 912 should be replicated twice in the Shim Dialer; but it has been determined through experimentation that each of the system's two clusters may often be compromised. They need not have a full complement of components in order to replicate the original seeker optics. Generally, those components that are not in the direct path of the radiation can be omitted, unless required for initial alignment, or support of other active parts, or needed for easy swapping of pieces for sampling.
Direct comparisons of guidance characteristics can be made between the tactical seeker and the Shim Dialer to confirm its fidelity. By virtue of the mirror image design of the Shim Dialer, the secondary optical cluster includes the small piano convex lens 920 with its immersed detector 930 . The presence of the detector allows the use of electronic instrumentation to check the focus of the dialer; that is, gain and feedback can be obtained in a manner similar to the formerly established laborious procedures using electronic pen plots.
For feedback, commonly known as optical-gimbal-coupling, a variable resistor or position encoder is attached to the yaw barrel. The collimator is replaced with one that uses a light emitting diode at the tactical wavelength and pulsed at the tactical frequency. The detector outputs go through log-amplifiers, are routed around conventional sample-and-hold circuitry, are summed accordingly, and converted into steady signals. Outputs from the resistor and detector then drive the X-ordinate and Y-abscissa pen plotter. By the time the technician is ready to examine his collection of plots, twenty or so curves have been generated. After sifting through all the sheets, his selections as to where feedback ramps the steepest is determined at last, though purely by eye and of necessity subjective. He then spends a long time manipulating a protractor and punching numbers into a calculator while drawing tangent lines to determine the maximum slopes. When done, feedback for only one focusing shim thickness is recorded. However, he enjoys a little relief albeit small. The technician does not need to keep removing the gyro every time he wants to change the shim as he would on the tactical seeker, but can shim it continuously by turning the shim barrel.
For gain, the technician can loosen the two knob screws 103 and separate the collimator from the dialer section. The collimator is fixed to his bench top. The dialer section is strapped to a rotary table and the yaw barrel set either to zero degrees or some angle of interest, usually less than one degree. Outputs from an encoder on the rotary table and the detector log-amps then drive the pen plotter, resulting in approximately four curves. The technician then spends a long time fussing with pencil and ruler drawing tangent lines to calculate the gain for just this one shim setting. This time, however, his work is slightly easier though small satisfaction. He does not need to remove the gyro over and over again to probe for the best shim, but can merely reset the shim dial instead. Thus, direct comparisons of guidance parameter characteristics can be made between the tactical seeker and the Shim Dialer.
Historically, the dome window 905 and the small piano convex lens 920 have not been a problem. One sample of each of these have been good representations of entire molded lots of thousands. These two items don't require sampling and can be made a permanent part of the dialer. However, the detector electronic device should be treated as follows.
The Shim Dialer becomes a through-optical system when the detector 930 b and detector housing cover are omitted, as can be concluded from FIG. 11 . However, the translucent fiber optic faceplate 922 b must be included. The translucent screen should be immersed on the piano side of lens 920 b ; that is, bonded there with transparent adhesive. The faceplate should be positioned according to the nominal tactical configuration; that is, the thicknesses of the adhesive and the faceplate should sum to the clearance between the piano surface of the small lens and the silicon face of the detector. The image will be visible on the exiting side of the face plate and be viewable by the microscope. In that way, the conversion of a folded-optical system into a through-optical system is complete.
For folded systems that have a face plate bonded to the detector, but lack the small lens to immerse the faceplate, the faceplate should be bonded to an optically pure glass plate which substitutes for the detector. A plug fixture which fits into the cluster mounts should be used to support the glass and faceplate assembly at the nominal tactical position.
For the secondary cluster, the large piano-convex lens 915 b would have no effect on the image. However, it is included anyway to support the small lens 920 b , faceplate 922 b and empty detector housing 935 . The empty cylindrical housing bonded inside the idle lens provides a tunnel to align the bezel for the microscope objective.
FIG. 12 shows the path of the Shim Dialer's through-optical system. Parallel rays 902 blanket a compromised primary cluster 110 . The primary cluster is reduced to a sawed-off dome windshield 905 attached to a sawed-off detector housing 935 attached to a blank glass filter 910 , all of which can be removed and installed into the dialer as a single assembly. The smaller lens has been omitted from primary cluster 110 , along with part of the detector housing normally bonded into the large lens. The large lens 915 a is inserted into the Shim Dialer as it was molded and annealed; injection stub, gate, parting lines, ejector pin marks and all. The sawed off cluster assembly attaches in front of the large lens to replicate its refraction and masking effects and enable rapid swapping of molded lenses. Characteristics of the large lens are examined without having undergone the costly secondary operations of boring and ultrasonic welding to form the housing assembly. The behavior of the seeker that employs this lens can be predicted long before that seeker is ever glued together. Such an assessment of end item performance at such an early stage in its manufacture is not possible with the tactical configuration.
The molded lens sample transmits light through mask 115 , and into the secondary cluster 120 . In this cluster the large lens 915 b and detector housing 935 are mounted as they are welded together, and are used for support of the small lens 920 b , as in FIG. 11 . The cover on the detector housing is removed to allow the microscope objective to penetrate into it. An image is focused on the translucent fiber optic screen 922 b immersed in the small lens. The microscope includes a diagonal mirror 150 to ease viewing, though this is not essential to function. The image is projected upward onto the reticule 155 which is printed or engraved with a scale or an outline of a gage marking on the detector surface, but at the correct magnification. The magnification implied by the figure is 10×, based on distance to object verses distance to image. The eyepiece 160 and reticule 155 of the microscope are mounted on the microscope tube with a camera lens bayonet fitting and can be broken away and replaced by a commercially available reflex camera. The emulsion focusing plane occupies the previous position of the reticule.
An internal red filter is stationed between light source 102 and collimator lens 105 which approaches the infrared wavelength received by the tactical seeker. The red color approximates the laser designator wavelength but allows the focused image to be visible on conventional black-and-white emulsions. However, optical characteristics like index of refraction, may not be exactly the same for the visible and the infra-red. In that instance, the red filter is removed to allow unfiltered light to pass through the optics, or the lamp replaced by a light-emitting-diode at the tactical wavelength. The clear glass filter 910 is replaced by the tactical filter, complete with blocking and bandpass layers, and the eyepiece is replaced by a video camera utilizing a silicon wafer screen sensitive to infrared. A real-time video of the focused image morphing with yaw is easily viewed on a monitor, and represents the tactical optics with even better fidelity than the simulation with visible light.
In summary, the Shim Dialer creates an optically equivalent apparatus to the original tactical seeker head. The yaw barrel provides angular rotations to simulate pitch and yaw angles induced on the projectile from either lift angle or cross wind. The shim barrel simulates the separation between the gimbaled mirror and the optical cluster controlled by the focusing shim. The image inside the tactical seeker can be viewed while its lens is still in the raw annealed state. Guidance parameters of gain and feedback can be measured electronically on the Shim Dialer and direct comparisons can be made with those values measured electronically on the tactical seeker. The gain and feedback determined by the focusing shim enables the projectile to navigate through the battlefield environment.
The Procedure
A method to operate the optical bench 100 to find a proper shim thickness for the objective lens 915 will be described herein.
Two identical plugs described under FIG. 1 and FIG. 2 above replace the large lens 915 inside the cluster mounts. These gage plugs have threads and shoulders identical to the molded lens. The plugs have flat faces and center probes that protrude out an equal distance from the lens shoulders in the mount cavities. Thus these centers and flats align themselves to the true position of the lens shoulder.
To summarize the procedure, it begins with determining the zero position of the yaw barrel. Then the mounts are set normal to the ways. Then the mask is centered along the trolley pins. Then the axes of the mounts and the center of the mask are made to coincide when the yaw barrel is zeroed. During this step, the mounts are set equally distant from the mask. Finally, the collimator is aligned to project symmetrical images when viewed through the eyepiece.
Align the cluster mounts so they are parallel as follows. Rotate the shim dial 130 clockwise and move the two way platform slides on 140 apart. Unfasten two right angle cross plates, one of which is clearly visible in FIG. 1 . Remove only the two lower screws on each of the two right-angled plates and remove both cluster mounts with their angle-irons still attached to them. Remove the bridge and mask assembly 115 . This will expose yet two more cross plates with ridge block protrusions where the angled cross plates were engaged. The exposed ridges are at right angles to the dove-tail ways. Place a rectangularly squared plate between the ridge protrusions. Bring the platforms against the gage plate by turning the dial counter clockwise, so that the squared ridges contact the plate and barely confine it. Slide the plate along the ridges to check their parallelism while adjusting the yaw barrel. When satisfied that the cross-plates are parallel, rock the yaw barrel about its end-play and pencil mark the mid-point of the play representing zero yaw. Remove the gage plate.
Set the mounts vertical with a square as follows. Install the primary cluster mount over its cross plate. Insert a gage plug into it. Loosen the set screw that tilts the mount on a horizontal axis which is at a right angle to the dovetail ways. Place a square on the secondary cross plate which is still exposed. It should square up with the face of the gage plug. Ideally, the target feature on the mount should be the shoulder for the large lens. Adjust and tighten the cluster mount to be vertical to the ways. Remove the primary mount and install the secondary over its cross plate. Insert the other gage plug into the secondary. Repeat to get the second mount vertical. Leave the secondary mount on and the primary off.
Align the bridge and mask. Each dovetail way is indexed to its clevis with grooves and pins, specifically surface 330 . Likewise, the bridge is also indexed to the trolley and always bolts onto it in a unique position. Back away the dovetail way slides as far as they will go by rotating the shim barrel clockwise. Remove the four screws that attach the primary way 140 a to its clevis. Slide the primary way away from the secondary way 140 b and out of its half of the keyway 133 while manually supporting the universal joint 132 . Place the primary way aside being careful not to disturb the dial setting. Slide the universal joint free of the remaining half of keyway 133 and place it aside. Screw the bridge and mask assembly onto the trolley plate. The center axis of the mask will go through the center of the button for the tactical seeker example given in the above discussions. The trolley should also be engraved with the mid line joining the two clevis pins, as described in the discussion of FIG. 5 above. A small hole in the center of the mask button should be directly above this mark as verified by a square. The thin mask plate has oversized holes where it attaches to the bridge. Place a square on the trolley and tighten the mask against the bridge so that its button is centered over the trolley; that is, it aligns directly above the engraved line joining the clevis pins. Adjust the height of the mask so that its center is about the same height as the center of the secondary mount. Tighten the screws which fasten the mask to the bridge to maintain that centered position.
Replace the primary dovetail way. Slide the universal joint under the bridge and back onto the keyway of the secondary dovetail way. Support the universal joint and slide the primary dovetail way toward the secondary and reconnect its keyway into its half of the slip joint. Replace the four screws in the clevis. With a plug still fixed inside the secondary cluster mount, crank the plug toward the mask with the shim dial 130 until it touches the mask. Loosen the cross plate position set screws on the secondary cluster mount. Adjust the cross-plates that fix the vertical and horizontal positions that are at right angles to the way direction. Tighten the vertical and horizontal positions to center the probe on the center of the mask. Back off the secondary cluster mount from the mask by one or two clockwise turns of the dial. Now install the primary cluster mount and insert its gage plug. Loosen the cross plates for fixing the horizontal position parallel to the way direction for both mounts. Fix them where they both contact the mask simultaneously when approached by slowly cranking the dial counter-clockwise. If cross plate latitude is insufficient to make them both reach the mask simultaneously, then one way must be indexed to a different thread position. In that event, remove the four screws going into the clevis from the primary dovetail way which index it to clevis surface 330 . Slide the way with its mount attached back while supporting the universal joint 132 , and disconnect the way assembly from the slip joint 133 . Rotate the secondary way screw using the knob 131 the appropriate number of complete turns, slide the primary way toward the other again, reconnect the universal joint keyway and replace the four screws. Keep repeating the removal and installation of the primary way until both probes contact the mask simultaneously. Once both probes are in contact with the mask, center the primary contacting probe to center on the mask. Remove the mask and bridge assembly by removing two screws on the trolley and check if the probe centers contact each other.
Check the zeroing of the yaw barrel by optical means. Remove both gage plugs and replace them with optical clusters shown in FIG. 12 . Assemble the microscope and collimator and adjust them until the reticule is illuminated. In order to do this, start with the shim dial set a little greater than the approximate nominal shim thickness where the tactical optics should be functional. Slowly bring the clusters together while tilting the collimator until some light is visible. The spot image at zero yaw should be centered on the reticule. If it is not, adjust the collimator position and angles. Bring the image to the sharpest possible focus. The surface of the screen or fiber optic faceplate should be in focus on the reticule. In the case of the tactical faceplate example given here, the hexagonal array of fiber optic filaments should be apparent. Back off the shim dial until a halo appears. It is permissible to remove the windshield to view a clearer image. The ring of light should be symmetrical. Determine if any asymmetry in the halo is due to the cluster or due to misalignment of the apparatus. Rotate the forward or primary cluster on its lens axis to observe if the asymmetry follows the cluster and is only a characteristic the seeker optics. If asymmetrical features of the halo remain fixed, it means that the apparatus must be realigned.
Attach the bridge and mask assembly, replace the windshield, and bring the image to the most concentrated spot possible with the shim dial. Crank the yaw barrels and observe the spot change shape into a comet. Adjust the dial to reveal distinguishing features of the image, such as sharp points or bright spots. These features will be most useful in determining shim thicknesses.
Following alignment of the dialer, it should be calibrated. Dimensions taken from the tactical seeker assembly configuration are used. These are referred to as the “nominal.” The piano faces of two clusters are first separated by the nominal expected for good guidance. Following that, the dial is set at the nominal shim thickness.
Remove the mask and bridge assembly and insert two complete lens clusters into each cluster mount. Set a telescoping gage to twice the nominal distance from the piano surface of lens 915 to the mirror 925 at zero yaw FIG. 9 . Close the two cluster piano surfaces against the gage using the shim dial. Loosen the zero knob on the dial and set it at the nominal shim thickness. Remove the clusters, install the gage plugs and mask. Check their alignment again as in step 4 . Remove the gage plugs. Reinstall the mask and bridge assembly.
This favorite lens is often considered to be the standard, associated with a “shop queen.” A reduced cluster should be inserted into the secondary mount which includes the a large lens 915 b welded to the detector housing 935 , a small lens 920 b shown in FIG. 11 , and the immersed fiber optic faceplate 922 b bonded into the small lens shown in FIG. 12 . Set the shim dial at the nominal and study the spot image morph over the entire yaw range. This is the image that forms inside the tactical seeker. The light patterns across the epitaxial boundaries of the detector comprise a critical transfer function of the guidance system loop.
At this point, gain and feedback can be measured electronically according to the description of FIG. 11 given above. Gain and feedback plots should agree with those sampled from lenses in seekers, as tested by the old laborious method of seeker head verification. Lenses may vary in focal characteristics, but all will project a similar spot image when each is assembled with its optimum shim. This fact has been verified through optical ray trace computation, as well as years of experience with thousands of lenses that were optically scanned and assembled into deliverable seekers. Lenses molded by a certified process and dimensionally correct, but do not form images close to that of a standard are not usable regardless of the shim setting. The Shim Dialer provides a method for isolating these defectives.
The Shim Dialer can now be used to determine the optimum shim thickness for a particular lens.
During operation of the optical bench 100 , the large objective lens 915 under test, as molded and annealed, is screwed or snapped into the primary optical cluster 110 mount. The reduced optical cluster, which includes a sawed off dome windshield 905 and filter glass 910 , is placed over the lens 915 to closely approximate the projectile nose optics. The technician zeros the yaw barrels and looks through the microscope while turning the shim dial. The spot is first brought to the sharpest and most concentrated focus. He or she then rotates the yaw barrel and observes the morphing or changing shape of the spot image. Through experience gathered from comparison of spot images with results from electronic instrumentation of the photo detector, the optimum shapes of the spot that give the best guidance characteristics are well known. He adjusts the shim dial until he judges that the optimum spot image for good guidance has been reached. That dimension is recorded and associated with the lens under test. In a parallel assembly line, the height of the gyro; that is, the distance from its shoulder to its mirror surface, is gauged. The depth of the gyro cavity in the seeker housing, as well as torquing allowances are also significant. The arithmetic sums of these parameters determines the selection of the best shim.
All the drawings are illustrative in nature and do not depict the actual size or scale of the objects shown. It is to be understood that the specific embodiments of the invention that have been described are merely illustrative of certain applications of the principle of the present invention. Numerous modifications may be made to a system and method to view the optical image of folded optics including a diagonal mirror or change in spline spacing or single journal universal joint as mentioned herein, without departing from the spirit and scope of the present invention.
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A through-optical bench is the optical equivalent of a folded-optical system. Folded optics is generally found in cannon launched guided projectiles and always includes a mirror mounted on a gimbal. Inside the projectile the optical image is hidden behind the mirror and is not easily accessible by measurement instrument. In the through-optical bench the image is repositioned to where it is easily viewed; hence enabling a much finer process to improve manufacturing accuracy and throughput. The through-optical bench uses a collimated beam of light which passes through the seeker nose optical cluster, then through a mask which mimics the mirror, then through an identical optical cluster which substitutes for the reflection, and finally onto a screen to form a focused image directly viewable by a microscope. The clusters and mask simultaneously step through various yaw angles made possible by a reversing linkage that moves them as mirror images. A micrometer dial simulates the focusing shim for the particular seeker nose cluster.
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This invention relates to an injector quill for distributing a treatment fluid into a confined fluid body. One prominent application is to inject pipeline petroleum products with an amine to scavenge hydrogen sulfide, H 2 S.
BACKGROUND OF THE INVENTION
It is current practice to employ an injector quill to inject pipeline petroleum with different chemicals: H 2 S scavengers, pH controls, anti-foulants and emulsion breakers, as examples. There are other applications as well.
The current quill employed commercially incorporates a nozzle outlet, centered in the pipeline or other conduit. As a consequence, treatment is concentrated in the area around the centerline of the moving stream. The primary object of the present invention is to construct a quill which will account for uniform treatment, even saturation, of the entire cross section of the body of liquid which is to be treated.
SUMMARY OF THE INVENTION
Instead of a quill having a working end terminating in a nozzle emitting a single stream of the treating agent, the quill stem of the present invention is of uniform diameter with staggered jet openings along the length, each opening serving to pass the treating agent into the body of fluid to be treated. Therefore, under the present invention, the cross section of the body of fluid is uniformly treated.
THE DRAWING
FIG. 1 is a diagram of the prior art practice;
FIG. 2 is a diagram of practice under the present invention;
FIG. 3 is an elevation of the quill member of the present invention;
FIG. 4 is a performance chart; and
FIG. 5 is a sectional view on the line 5--5 of FIG. 3.
GENERAL STATEMENT
FIG. 1 is a diagram of a typical quill installation associated with a pipeline or other transport pipe. The quill body 10 is coupled by flow communication to a pump P which feeds a treatment chemical to the quill. The quill is threaded to the receiving valve (not shown) of pipeline 12 and has a stem 14 terminating in an outlet end 16 which injects the stream of fluid ("FLOW") with the treating agent. The locale of the injected treating agent is denoted by dashed lines. It can be seen the treatment is confined generally to the center line of the moving stream of fluid.
Under the present invention, the quill assembly embodies a stem 20, FIG. 2, having several staggered rows of jet openings 22 by which the treating agent is spread mist-like and uniformly throughout the cross section of the body of fluid so treated, denoted by dots in FIG. 2.
DETAILED DESCRIPTION
A quill body or assembly is shown at 30 in FIG. 3. The construction is known except for the form of quill stem to be described. The quill assembly includes a nipple 32 having a threaded lower end 36 so the quill assembly can be threadedly connected to the valve (not shown) of the pipeline. Thus, the quill assembly is to be fixed to the pipeline.
The quill member or assembly 30 has a hollow, elongated stem 40 of reduced diameter compared to nipple 32. The stem 40 extends through nipple 32, through a collar 37 and through a packing gland 42 having a union 43.
The extended or projected length of the elongated stem 40 (below or beyond the nipple 32) is such as to extend through the aforementioned valve and into the cross section of the pipe with which it is to be used. The lower end of the quill stem is closed by a removable plug or cap, preferably a hex head set screw 44 which can be removed to clean the inside of the quill stem.
The projected, lower free end portion of the quill stem has (preferably) three staggered rows of drilled jet openings 46 uniformly spaced along its length and part way about its circumference for passing the treating agent into the pipeline in the form shown in FIG. 2.
The upper end of the quill stem 40 is coupled to a union 47 which in turn couples to a nipple 48. The nipple 48 communicates with the feed line of a pump as P, FIG. 1, by which the treating agent (TA, FIG. 3) is fed forcefully to the quill. Because of the numerous staggered openings 46 in the quill stem, the treating agent will be distributed substantially uniformly and equally across the diametrical cross section of the body of fluid to be treated; see FIG. 2.
Positioned above the union 47 and resting on it is a draw plate 54. The draw plate 54 has openings mated to a pair of threaded guide rods 56 parallel to and on opposite sides of the draw plate. The lower ends of the guide rods are inserted in openings in a stop plate 58 resting on lock nuts 60 threaded to the lower ends of the rods 56.
The draw plate is held against the union 47 by a pair of adjusting nuts 62 at the upper ends of the guides 56. By backing off union 43, and then by tightening the nuts 62, the draw plate 54 is forced downward against the union 47 and this action in turn extends the quill stem 40 to fit a transport pipe of large diameter. Conversely, the draw plate 54 can be retracted by retracting nuts 62, allowing the quill to be retracted by hand for a pipe of smaller diameter.
The pump to be employed is preferably a metering pump. The quill assembly is of such size and capacity as to feed to the pipeline as much as 100 gallons of treating agent per hour or as little as 5 gallons per hour.
Improved performance is shown by the chart, FIG. 4. The treatment was a chemical to combat H 2 S in a petroleum pipeline. The vertical bars show treatment costs during the 41/2 month term when a standard treating agent was added by the known quill, the one having an injector nozzle end as explained in connection with FIG. 1. The cost figures are cents per barrel (bb) of chemical treating agent (TA) based on the volume of hydrocarbon (HC) treated, expressed as cost TA/bb HC. In FIG. 4, the continuous solid line represents the H 2 S level in the hydrocarbon stream before any treatment.
An inventory of quills (all preferably 1/4" diameter) can be maintained, such as one group having openings 46 along an axis four inches in length (small transport pipe) and a second group having openings 46 along an axis eight inches in length for larger transport pipes.
The quill can be used in any application where a chemical can be or is applied to a liquid stream, whether a hydrocarbon based or water based stream, provided of course there is a sufficient flow rate to promote distribution of the treating agent.
It may be emphasized that orientation of the quill stem in the process stream to be treated is of considerable importance under and in accordance with the present invention. This explains why three rows of openings 46 are employed rather than four as might be expected.
Attention is now directed to FIG. 5 where the bold arrow ("PIPE FLOW") indicates the direction of flow of the process stream in which the quill stem 40 is immersed. The quill stem is shown in section. The quill stem is oriented so the jet openings face in the direction of flow inside the pipe 70, emitting the treating fluid in jet streams (smaller arrows) opposed to the pipe flow. Note the three rows of openings 46 are (preferably) 45° apart in terms of the circumference of the quill stem.
Using three rows of openings instead of four has to do with flow velocities of the treated stream, FIG. 5, and achieving maximum dispersion of the chemical being injected.
If four rows were used, with the fourth row located opposite the first row, no greater dispersion of chemical would be achieved. The two offset rows are not arranged perpendicular (not 90°) to the axis of the quill. This is because of the turbulence around the stationary quill. The quill is oriented so the rows of holes are facing into the flow of the treated stream, and FIG. 5 shows how the injected stream would look from an overhead view.
I have experimented with the angle of the two offset rows and have found that 45 to 60 degrees offset is optimal, depending on the flow velocity of the treated stream. The higher the velocity, the more the angle needs to approach the 45 degree angle. Again, it is possible to maintain an inventory of stems of different "offset."
Hence, while I have illustrated and described the preferred embodiment of the present invention, it is to be understood that this is capable of variation and modification.
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Injector for injecting a liquid treatment chemical into a moving body of liquid in a pipe and comprising an elongated hollow quill member having a stem portion of a length to span substantially the inside diameter of the pipe; and said stem being provided along substantially its entire length with a substantially uniform set of jet openings for injecting the cross-section of the body of liquid with a multiplicity of chemical treatment jet streams so that the cross section of the body of liquid will be treated equally across its diametrical cross section.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to toys, and more particularly to larger toy structures, such as kitchens and workbenches, that may be collapsed, such as for storage
[0003] 2. Description of the Prior Art
[0004] Life-size toy structures have become popular with children as they allow a child to re-create a real-life experience with a toy structure. Good examples include toy kitchens and toy workbenches that are now being made of a larger size so that a child can play with these structures as if the structure were a real kitchen or workbench.
[0005] Unfortunately, these larger toy structures consume significant space. Because of their size, many such toy structures cannot be stored as assembled in narrow or small areas, such as under beds or in some closets. Therefore, the toy structures may have to be partially disassembled into parts small enough to store in those areas. However, such disassembly (and subsequent assembly) may be time-consuming and parts of the toy kitchen may be lost during the storage process.
[0006] Therefore, there may be a need for toy structures, such as kitchens and workbenches, that may be quickly collapsed for storage in narrow or small areas without removal of numerous parts. There is also a need for toy structures that may likewise be quickly redeployed to its expanded position for use.
SUMMARY OF THE DISCLOSURE
[0007] In order to accomplish the objects of the present invention, there is provided a collapsible toy structure comprising a back support, a counter top pivotably connected to the back support, and a front wall that is pivotably connected to underside of the counter top. A locking mechanism has a block coupled to the back support and a locking bar rotatably connected to the block. The structure also has a left side wall having a left rear panel and a left front panel, the left rear panel having a rear edge that is secured is the left edge of the back support, and a front edge that is pivotably connected to the left front panel. The structure further includes a right side wall having a right rear panel and a right front panel, the right rear panel having a rear edge that is secured is the right edge of the back support, and a front edge that is pivotably connected to the right front panel. The toy structure assumes a collapsed position with the counter top pivoted to an upright position against the back support, the front wall pivoted to an upright position against the counter top, the left front panel and the right front panel pivoted against the front wall, and with the locking bar rotated to a position where its opposite ends are positioned against the left front panel and the right front panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a collapsible toy kitchen according to one embodiment of the present invention.
[0009] FIG. 2 is a left side view of the kitchen of FIG. 1 .
[0010] FIG. 3A shows the kitchen of FIG. 1 in the fully collapsed position.
[0011] FIG. 3B illustrates the same kitchen of FIG. 3A but with some of the components removed.
[0012] FIGS. 4, 5, 6A, 7 and 8 illustrate the steps for deploying the kitchen of FIG. 3 into a fully expanded position for use.
[0013] FIG. 6B illustrates the same kitchen of FIG. 6A but with a part of the side wall removed to illustrate the internal components.
[0014] FIG. 9 is a perspective view of a collapsible toy workbench according to another embodiment of the present invention.
[0015] FIG. 10 is a left side view of the workbench of FIG. 9 .
[0016] FIG. 11 shows the workbench of FIG. 9 in the fully collapsed position.
[0017] FIGS. 12A, 13, 14A and 15 illustrate the steps for deploying the workbench of FIG. 11 into a fully expanded position for use.
[0018] FIG. 12B illustrates the same workbench of FIG. 12A but with some of the components removed.
[0019] FIG. 14B illustrates the same kitchen of FIG. 14A but with a part of the side wall removed to illustrate the internal components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices and mechanisms are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0021] FIGS. 1 and 2 illustrate a collapsible toy kitchen 100 according to an embodiment of the present invention. The collapsible toy kitchen 100 is shown in FIG. 1 in the expanded position, for use. The collapsible toy kitchen 100 may include a back support 102 , a kitchen counter 104 , a front wall 106 and two side walls 108 and 110 .
[0022] The back support 102 may include a back wall 112 and a lower back support 130 . The back wall 112 and lower back support 130 can be provided in one piece, or they can be separated. The back wall 112 , two side walls 114 and 116 , a horizontal panel 120 and a top wall 122 together enclose and define an interior space that can be further divided up by shelving panels 124 and dividing walls 126 . All of these walls and panels 114 , 116 , 120 , 122 , 124 and 126 are attached to the back wall 112 . A faucet 118 can be connected to the horizontal panel 120 , and optional doors 128 can be hingedly connected (e.g., via hinges 198 as shown in FIG. 6B ) to certain dividing walls 126 or side walls 114 , 116 to enclose storage areas.
[0023] Each side wall 108 and 110 can be provided in two separate pieces that can be hingedly or pivotably connected to each other. Specifically, each side wall 108 , 110 has a rear panel 132 and a front panel 134 . The rear edge 136 of the rear panel 132 can be fixedly attached to a side edge of the lower back support 130 . The front edge 138 of the rear panel 132 and the rear edge 140 of the front panel 134 can be hingedly connected (e.g., via hinges 142 as shown in FIGS. 3-5 and 6B ) to each other. Legs 144 can be defined at the bottom of the panels 132 and 134 .
[0024] The kitchen counter 104 can include a countertop 150 and one or more kitchen components. The kitchen components may be positioned on and/or extend through the countertop 150 , and can include a range 152 connected to the countertop 150 , and a sink 154 extending through the countertop 150 . The faucet 118 , range 152 and sink 154 , as well as other elements of the toy kitchen may be considered toys and thus not be “operational” as their real counterparts, though in another embodiment one or more of those elements may actually be operational to a limited extent to simulate real play.
[0025] The kitchen counter 104 may be pivotably connected to the back wall 112 or other part of the back support 102 , as desired. In one such embodiment, a rear edge of the kitchen counter 104 is pivotably connected (e.g., via hinges 158 ) to the horizontal panel 120 .
[0026] The front wall 106 includes a wall portion with two doors 160 hingedly connected (e.g., via hinges) thereto. The upper edge 162 (see FIG. 3 ) of the front wall 106 is pivotably connected via hinges 178 (see FIG. 6B ) to the underside of the kitchen counter 104 at a location that is offset from the front edge 164 of the kitchen counter 104 . Legs 166 can be defined at the bottom of the front wall 106 .
[0027] Referring to FIGS. 3-5 and 6B , a lower horizontal panel 180 is hingedly connected at its rear edge via hinges 184 to another horizontal panel 182 that extends from the lower back support 130 . The front edge of the panel 180 is hingedly connected to the interior surface of the front wall 106 via hinges 190 . A locking mechanism is provided on the panel 180 . The locking mechanism includes a stationary mounting block 170 that is securely mounted to the panel 180 , and a pivoting bar 172 pivotably secured to the front of the block 170 . The depth of the block 170 is dimensioned so that it is slightly larger than the width of the rear panels 132 , so as to allow the bar 172 to snugly overlie the outsides of the front panels 134 after they have been folded towards each other in the collapsed position.
[0028] In addition, referring to FIG. 7 , the front panels 134 can be secured to the front wall 106 via threaded connections by the use of screws 176 .
[0029] FIGS. 3-8 illustrate how the kitchen 100 can be collapsed and deployed. Starting with FIGS. 1 and 8 , the kitchen 100 is shown in the fully deployed position. Trays B and cups C can be removed from the storage compartments in the back support 102 . In FIG. 7 , the screws 176 can be removed, and then the front panels 134 can be pivoted away from each other (see FIGS. 5 and 6A ), so as to allow the front wall 106 to be pushed upwardly about the pivoting connections (i) defined by the hinges 178 between the upper edge 162 of the front wall 106 and the underside of the kitchen counter 104 , (ii) defined by the hinges 158 between the kitchen counter 104 and the panel 120 , (iii) defined by the hinges 190 between the front edge of the panel 180 and the front wall 106 , and (iv) defined by the hinges 184 between the rear edge of the panel 180 and the front edge of the panel 182 . This allows the kitchen counter 104 to be pushed against the back board 102 (with the faucet 118 fitting inside the sink 154 ), and the front wall 106 to be pushed against the underside of the kitchen counter 104 , with the panel 180 sandwiched between the front wall 106 and the lower back support 130 , and positioned below the kitchen counter 104 . Referring to FIG. 4 , the front panels 134 can then be pivoted towards each other, and when the front panels 134 are resting against the front wall 106 , the bar 172 can be rotated by ninety degrees so that its opposite ends are resting against the front panels 134 to secure the entire assembly in a collapsed and secure arrangement as shown in FIG. 3 .
[0030] The kitchen 100 can be opened up and deployed by reversing the steps shown in FIGS. 3-8 , by following the sequence of steps shown in FIGS. 3-8 . First, the bar 172 is rotated by ninety degrees to free the front panels 134 ( FIG. 4 ), which are then pivoted away from each other ( FIG. 5 ). The front wall 106 is then pulled down ( FIG. 6 ) so that the kitchen counter 104 is deployed. The front panels 134 are then secured to the front wall 106 via the screws 176 ( FIG. 7 ) and then the components B and C are put into place and the kitchen 100 is ready for use.
[0031] FIGS. 9-15 illustrate a collapsible workbench 100 a according to the present invention. The workbench 100 a has a very similar construction as the kitchen 100 , so the same numerals will be used to designate corresponding elements in both embodiments except an “a” is added to the designations in FIGS. 9-15 .
[0032] The collapsible workbench 100 a is shown in FIG. 9 in the expanded position, for use. The collapsible workbench 100 a may include a back support 102 a , a counter top 104 a , a front wall 106 a and two side walls 108 a and 110 a.
[0033] The back support 102 a may include a back wall 112 a and a lower back support 130 a . The back wall 112 a and lower back support 130 a can be provided in one piece, or they can be separated. The back wall 112 a , two side walls 114 a and 116 a , a horizontal panel 120 a and a top wall 122 a together enclose and define an interior space that can be further divided up by shelving panels 124 a and dividing walls 126 a . All of these walls and panels 114 a , 116 a , 120 a , 122 a , 124 a and 126 a are attached to the back wall 112 a . Optional doors 128 a can be hingedly or otherwise connected to certain dividing walls 126 a or side walls 114 a , 116 a to enclose storage areas.
[0034] Each side wall 108 a and 110 a can be provided in two separate pieces that can be hingedly or pivotably connected to each other. Specifically, each side wall 108 a , 110 a has a rear panel 132 a and a front panel 134 a . The rear edge 136 a of the rear panel 132 a can be fixedly attached to a side edge of the lower back support 130 a . The front edge 138 a of the rear panel 132 a and the rear edge 140 a of the front panel 134 a can be hingedly connected (e.g., via hinges 142 a as shown in FIG. 13 and FIG. 14B ) to each other. Legs 144 a can be defined at the bottom of the panels 132 a and 134 a.
[0035] The counter top 104 a may be pivotably connected to the back wall 112 a or other part of the back support 102 a , as desired. In one such embodiment, a rear edge of the counter top 104 a is pivotably connected (e.g., via hinges 158 a ) to the horizontal panel 120 a.
[0036] The front wall 106 a includes a wall portion with two doors 160 a hingedly connected (e.g., via hinges) thereto. The upper edge 162 a (see FIG. 13 ) of the front wall 106 a is pivotably connected (e.g., via hinges 178 a ) to the underside of the counter top 104 a at a location that is offset from the front edge 164 a of the counter top 104 a . Legs 166 a can be defined at the bottom of the front wall 106 a.
[0037] Referring to FIGS. 11-13 and 14B , a lower horizontal panel 180 a is hingedly connected at its rear edge via hinges 184 a to another horizontal panel 182 a that extends from the lower back support 130 a . The front edge of the panel 180 a is hingedly connected to the interior surface of the front wall 106 a via hinges 190 a . A locking mechanism is provided on the panel 180 a . The locking mechanism includes a stationary mounting block 170 a that is securely mounted to the panel 180 a , and a pivoting bar 172 a pivotably secured to the front of the block 170 a . The depth of the block 170 a is dimensioned so that it is slightly larger than the width of the rear panels 132 a , so as to allow the bar 172 a to snugly overlie the outsides of the front panels 134 a after they have been folded towards each other in the collapsed position.
[0038] In addition, referring to FIG. 15 , the front panels 134 a can be secured to the front wall 106 a via threaded connections by the use of screws 176 a.
[0039] FIGS. 9-15 illustrate how the workbench 100 a can be collapsed and deployed. Starting with FIG. 9 , the workbench 100 a is shown in the fully deployed position. In FIG. 15 , the screws 176 a can be removed, and then the front panels 134 a can be pivoted away from each other, so as to allow the front wall 106 a to be pushed upwardly about the pivoting connections (i) defined by the hinges 178 a between the upper edge 162 a of the front wall 106 a and the underside of the counter top 104 a , (ii) defined by the hinges 158 a between the counter top 104 a and the panel 120 a , (iii) defined by the hinges 190 a between the front edge of the panel 180 a and the front wall 106 a , and (iv) defined by the hinges 184 a between the rear edge of the panel 180 a and the front edge of the panel 182 a . See FIGS. 13 and 14A-14B . This allows the counter top 104 a to be pushed against the back board 102 a , and the front wall 106 a to be pushed against the underside of the counter top 104 , with the panel 180 a sandwiched between the front wall 106 a and the lower back support 130 a , and positioned below the counter top 104 . Referring to FIG. 12 , the front panels 134 a can then be pivoted towards each other, and when the front panels 134 a are resting against the front wall 106 a , the bar 172 a can be rotated by ninety degrees so that its opposite ends are resting against the front panels 134 a to secure the entire assembly in a collapsed and secure arrangement as shown in FIG. 11 .
[0040] The workbench 100 a can be opened up and deployed by reversing the steps shown in FIGS. 11-15 , by following the sequence of steps shown in FIGS. 11-15 . First, the bar 172 a is rotated by ninety degrees to free the front panels 134 a ( FIG. 12 ), which are then pivoted away from each other ( FIG. 13 ). The front wall 106 a is then pulled down so that the counter top 104 a is deployed. The front panels 134 a are then secured to the front wall 106 a via the screws 176 a ( FIG. 15 ) and the workbench 100 a is ready for use.
[0041] The collapsible kitchen 100 and workbench 100 a may be made of various materials. For example, the back supports 102 , 102 a , the counter 104 , the counter top 104 a , the front walls 106 , 106 a , the panels 132 , 132 a , 134 , 134 a , 180 , 180 a and the various panels and walls 114 , 116 , 120 , 122 , 124 , 126 , 114 a , 116 a , 120 a , 122 a , 124 a and 126 a may be mostly made of medium density fiberboard or other wood. The faucet 113 , the sink 154 and the range 154 may be made of plastic. The doors 128 , 160 and 160 a can be made of fiberboard, wood, or plastic. Other materials may be alternatively or additionally be used for the aforementioned parts and other parts of any of the embodiments herein.
[0042] Thus, the present invention provides a collapsible toy workbench and kitchen which can provided in a “life-like” size for use by a child, yet can be quickly folded and collapsed for storage. The block 170 , 170 a and locking bar 172 , 172 a provide a simple and convenient locking mechanism for holding the collapsed workbench or kitchen together.
[0043] The above detailed description is for the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices, components, mechanisms and methods are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0044] For example, the design of the kitchen counter 104 and counter top 104 a can be varied by adding additional elements or making them simpler. The design and configuration of the storage spaces and doors in the back support 102 , 102 a can also be varied.
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A collapsible toy structure has a back support, a counter top pivotably connected to the back support, a front wall that is pivotably connected to underside of the counter top, a locking mechanism having a block secured to the back support and a locking bar rotatably connected to the block, a left side wall having a left front panel, and a right side wall having a right front panel. The toy structure assumes a collapsed position with the counter top pivoted to an upright position against the back support, the front wall pivoted to an upright position against the counter top, the left front panel and the right front panel pivoted against the front wall, and with the locking bar rotated to a position where its opposite ends are positioned against the left front panel and the right front panel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ceramic packages and ceramic packaging materials for large scale integrated electronic circuits, and more particularly to a composition of such ceramic packaging materials adapted to increasing the toughness (resistance to fracture) of such ceramic materials.
2. Description of Related Art
Zirconia particles toughen a ceramic by either impeding the motion of a propagating crack, or absorbing or dissipating its energy. H. Ruf and A. G. Evans, "Toughening by Monoclinic Zirconia", J. Amer. Cer. Soc., 66(55) 328-332 (1983) and N. Claussen and M. Ruhle, "Design of Transformation-Toughened Ceramics", Advances in Ceramics, Amer. Cer. Soc., (3) 137 (1981). The former includes crack bowing and deflection effects. The latter, termed transformation toughening, results from a stress induced martensitic transformation of the zirconia from its tetragonal crystal structure to its monoclinic crystal structure. This transformation is accompanied by a 4% volume increase and a shear strain up to a maximum of 6%. The attainable toughening is dependent upon the volume fraction of transformable tetragonal phase, size and distribution of the zirconia particles, the elastic constraining properties of the matrix and the size of the transformed zone around the crack. Claussen et al. supra; F. F. Lange, "Transformation Toughening", J. Mater. Sci., (17), 235-239 (1982); and A. G. Evans and A. H. Heuer, "Transformation Toughening in Ceramics: Martensitic Transformation in Crack Tip Stress Fields", J. Amer. Cer. Soc., 63 (5-6) 241-248 (1980), and R. McMeeking and A. G. Evans, "Mechanics of Transformation Toughening In Brittle Materials", J. Amer. Cer. Soc., 65(5) 242-245 (1982).
Zirconia toughening has been demonstrated in a variety of crystalline ceramic materials in the last decade. The earliest example, dating back over ten years, was in a two-phase zirconia ceramic consisting of tetragonal zirconia in a matrix of cubic zirconia. This material, described by R. Garvie, R. H. Hannink and R. T. Pascoe, "Ceramic Steel?", Nature, 258(12) 703-704 (1975) was produced by a precipitation heat treatment. Since this original work, a number of workers have demonstrated that the fracture resistance of many crystalline ceramic materials can be increased by incorporating in them particles of tetragonal zirconia, which transform to the monoclinic form when the material is fractured.
Claussen et al. showed that the incorporation of zirconia into an alumina body increased its fracture toughness. Claussen et al. prepared their materials by the usual methods of ceramic forming in which powders of alumina and zirconia were mixed together and then fired to sufficiently high temperatures that the material sintered (densified) to form a monolithic body.
U.S. Pat. No. 4,316,964 of Lange et al. for "Al 2 O 3 /ZrO 2 " describes a zirconia toughened alumina ceramic prepared by using submicron powders of Al 2 O 3 ZrO 2 . "The composite powders were ball-milled with methanol and alumina balls in a plastic container and then dried. Densification was achieved by hot-pressing the powders for 2 hours at a temperature selected to obtain small grain size and therefore favor the retention of tetragonal ZrO 2 ." The pressing temperatures in TABLE 1 were from 1400° to 1600° C. At Col. 5, line 18 it is stated, "The average grain size of the end member compositions which were hot-pressed at 1400° C. was about 2 μm for the Al 2 O 3 and 0.5 μm for the ZrO 2 ." The ceramic is not a glass ceramic and the pressing temperatures employed are excessive from the point ot view of the packaging of integrated circuits.
Stevens and Evans, "Transformation Toughening by Dispersed Polycrystalline Zirconia", Br. Ceram. Trans. J. Vol. 83, 28-31 (1984) describes transformation toughening of alumina ceramics by volume expansion when tetragonal zirconia transforms to the monoclinic form. It states at page 28, "The phenomenon of transformation toughened ceramics relies on the volume expansion, 3-5% and shear strain ˜7% developed when tetragonal zirconia transforms to the monoclinic form. Toughening of a ceramic host material is attained by retention of the tetragonal zirconia in a metastable state, the phase change to the monoclinic form being initiated by the tensile stress field of an advancing crack. Within a fixed distance of the crack tip, determined by the elastic stress field in its vicinity, any metastable tetragonal zironia will transform and, as a result of the volume expansion and accommodating shear stains, exerts a back stress on the crack. . . . "
U.S. Pat. No. 4,358,516 of Lange, for "Sodium Ion Conductor, Solid Electrolyte Strengthening with Zirconia", describes how the incorporation of transformable tetragonal zirconia could be used to increase the resistance to fracture of a sodium ion conductor solid electrolyte ceramic, β-alumina. For example, the addition of solid grains of metastable tetragonal ZrO 2 with "a grain size less than about 2 μm and has dissolved it in a rare earth oxide such as Y 2 O 3 . . . " (See abstract). The materials are added to the alumina to provide improved fracture toughness.
As in U.S. Pat. No. 4,316,964 Lange, one can use additions of rare earth oxides, such as yttria, to control the formation of zirconia that is stable in the finished material in its tetragonal form.
For example, the addition of 15 vol. % zirconia to β"-Al 2 O 3 increases the fracture toughness, K c , from 3.0 to 3.8 MPam 1/2 and the strength from 147 to 414 MPa. See Stevens et al. supra. Alumina with 7.5 vol. % zirconia shows an increase in K c from 4.5 to 7 MPam 1/2 , and adding 17.5 vol. % zirconia to spinel increased the strength from 200 to 500 MPa. (See Claussen et al. supra.)
Originally used to toughen zirconia ceramics and alumina, the use of transformation toughening has rapidly been accepted as a way of increasing the fracture resistance (toughness) of all sorts of ceramics including oxides, nitrides and carbides. In all these materials, marked increases in toughening have been achieved when the processing conditions have enabled the tetragonal form of zirconia to be retained in the microstructure. However, there is one class of materials in which, despite the incorporation of tetragonal zirconia, true transformation toughening has not been reported, namely glasses and glass-ceramics.
Previous workers, who have attempted to toughen glasses and glass-ceramics by the use of zirconia, have done so by precipitating the zirconia from the glass phase. This is the manner in which zirconia, one of the traditional nucleating aids in the manufacture of glass-ceramics, is known to be formed in its tetragonal form.
For instance, U.S. Pat. No. 4,396,682 of Mohri et al. for "Glazed Ceramic Substrate" describes a ceramic print head with 50-60 wt. % of SiO 2 , 10-30 wt. % of CaO and MgO, and 2-6 wt. % of ZrO 2 plus optional materials including the addition of one of BaO, ZnO, PbO, P 2 O 5 , B 2 O 3 , Na 2 O and K 2 O. The resulting material is a glass which has excellent high temperature stability for use in thermal print heads. The process used involves the heating in air to 1400° C., which is far above an acceptable level of heating for air process since it would be far above the melting point of the metallization. At Col. 3, lines 6-21 it is explained that the ZrO 2 raises the transition point of the glass composition above 2 wt % of ZrO 2 in the material. Above 6 wt % the ZrO 2 becomes an obstacle to the surface smoothness of the material. No mention is made of the tetragonal phase of the zirconia. In view of the temperature of 1400° C. to which the material is heated in the Example, the zirconia is in a solid solution in the glass. Moreover, no mention is made therein of particles of zirconia in the glass.
See also U.S. Pat. No. 4,353,047 where zirconia is added as a nucleating agent.
U.S. Pat. No. 4,234,367 of Herron, Master and Tummala for "Method of Making Multilayered Glass Ceramic Structures Having an Internal Distribution of Copper-based Conductors" describes use of cordierite glass in conjunction with a thermoplastic binder in laminated green sheets. The glass comprises MgO, Al 2 O 3 , SiO 2 , B 2 O 3 , SnO 2 , Al 2 O 3 , P 2 O 5 and ZrO 2 glass particles in a glass ceramic. The laminate of green sheets is heated to a burnout temperature of 720° to 785° C. Then the laminate is later heated to a crystallization temperature of about 920° to 970° C. Here the composition of the glass particles is quite different from those employed here in view of the presence of P 2 O 5 , B 2 O 3 and in some cases SnO 2 and the absence of a stabilizing compound such as yttria plus the absence of teachings of particle size limitations claimed herein.
U.S. Pat. No. 4,301,324 of Kumar, McMillan and Tummala for "Glass Ceramic Structures of Gold, Silver or Copper" describes β-spodumene glass ceramic and cordierite glass ceramic materials. In connection with the cordierite glass. There is no CaO or Y 2 O 3 stabilizing material, but there is CaO with respect to the β-spodumene at Col. 7, lines 61 and 62 and in Table 1, Col. 4. The cordierite glass does contain from 0 to 2.5 wt % of ZrO 2 in Table 1. Glass No. 11 in Table III includes B 2 O 3 plus ZrO 2 but also includes P 2 O 5 and is sintered at 925° C. Glass No. 12 in Table III includes B 2 O 3 but also includes P 2 O 5 and is sintered at 950° C. There is no suggestion of using yttria as a stabilizing agent. There is also no mention of the tetragonal zirconia phase in connection with Glasses No. 11 and 12. The cordierite is of the μ form for glass No. 11 and of the α form for glass No. 12. See Col. 9, lines 17 to 45. It is stated that the ceramic has greater strength than other ceramics. It is stated that it was thought that the enhanced strength was attributable to inclusion of ZrO 2 , Col. 9, lines 25 to 28. There is no discussion of the particle sizes of the zirconia. A key distinction of the result of the process of the instant invention from the process of Kumar et al. is that the zirconia is in a solid solution in the glass ceramic. We find that there is no encapsulation of particles of zirconia in the tetragonal phase in the Kumar et al. product.
The objective of this invention is to provide a glass which is transformation toughened through the use of zirconia, which glass is crystallized to a cordierite (2MgO.2Al 2 O 3 .5SiO 2 ) glass-ceramic upon heat treatment. The method of manufacture, a "composite" route in which particles of the glass, having the desired glass-ceramic composition, and the zirconia are mixed together and fired as in a standard ceramic process. It avoids the conventional glass-ceramic manufacturing route which involves melting of the ingredients, and subsequent crystallization to produce the glass-ceramic body. Furthermore, the method enables the size of the tetragonal particles to be kept within a desirable range.
U.S. Pat. No. 4,421,861 of Claussen for "High-Strength and Temperature-Change Resistant Ceramic Formed Body, Especially of Mullite, its Production and Use" describes a zirconia toughened cordierite ceramic made by a reaction process, which involves deriving zirconia from a salt of zirconium. To obtain zirconia in that way the material is sintered at unacceptably high temperatures of from 1300° C., to 1600° C., preferably. Such a high temperature is far higher than an acceptable temperature for formation of VLSI packaging products since it is so high that the copper metallization of the circuits on the package would be destroyed by the heat. In short, the copper would turn to useless puddles on the package. Thus the Claussen et al. process is a very significantly different process from ours. It also produces a much different result.
Ruh et al. "Phase Relations in the System ZrO 2 -Y 2 O sub 3 Contents", Communications of American Ceramic Society, C-190 to C-192, (September 1984), describes use of yttria with zirconia to lower the monoclinic-tetragonal transformation temperature of zirconia, but it does not suggest the use of such material with cordierite.
B. Schwartz "Making High Strength Ceramics", IBM Technical Disclosure Bulletin, Vol. 11, No. 7,848 (December 1968), describes placing the surfaces of a ceramic material in compression relative to the central portions of the article by altering the composition of the outer layers of at least three layers of green ceramic material slightly prior to firing, by adding chromium to alumina. The ceramic materials are used as substrates for microelectronic devices. Obviously this disclosure does not contemplate use of zirconia or the equivalent as the material which provides hardening. In addition it does not suggest the temperature range that is taught here.
In D. J. Green and M. G. Metcalf, "Properties of Slip-Coat Transformation-Toughened β"-Al 2 O 3 / ZrO 2 Composites", Ceramic Bulletin, Vol. 63, No. 6 pp. 803-807, and 820 (1984), it is stated at page 805 first full paragraph that "The majority particles are less than 1 μm for both powders but there are some particles as large as 20 μm".
Porter, D. L., Evans, A. G., & Heuer, A. H. Acta MetalVol. 27, p. 1649 (1979) describes toughening of β" Alumina and of Zirconia, respectively. None of the prior art suggests the range of sizes of particles of zirconia or hafnia. The temperature range used in forming the hardened ceramic materials is suggested by none of the prior art for forming ceramic, but merely to the formation of ceramics and the Herron et al. U.S. Pat. No. 4,234,367 does not relate to hardening of ceramics, per se.
A number of test methods have been used to measure the fracture toughness of ceramics, and the effect of zirconia additions. One of these is the indentation test method, which is described in detail by Antis et al., "A Critical Evaluation of Indentation Techniques For Measuring Fracture Toughness: I. Direct Crack Measurements", Journal of the American Ceramic Society, 64(9) 533-538, (1981). In this method, a diamond pyramid is pressed, with a known load, into the surface of a material until cracks propagate from the corners of the indentation impression. The length of the cracks so formed for a given load are a measure of the resistance of the material to fracturing (its so-called fracture toughness).
The transformation of zirconia from its tetragonal form to its monoclinic form as a result of the passage of a crack (the basis of transformation toughening) has been shown to lead to an increase in fracture toughness by Garvie et al., "Ceramic Steel?", Nature, (258), pp. 703-704 (1975) and by Clarke and Adar, "Measurement Of The Crystallographically Transformed Zone Produced By Fracture In Ceramics Containing Tetragonal Zirconia", Journal Of The American Ceramic Society 65(6) pp. 284-288 (1982). Garvie et al. measured their materials before and after fracturing by techniques of X-ray diffraction, to show that some of the tetragonal zirconia had transformed to monoclinic zirconia. Clarke and Adar used Raman spectroscopy to show that some of zirconia particles around cracks had transformed from the original tetragonal form to the monoclinic form.
The degree of transformation of zirconia from the tetragonal form to the monoclinic form dictates the attainable toughening. Thus, if only 25% of the tetragonal zirconia in a body is transformed to monoclinic zirconai, the fracture toughness will not exceed 25% of the theoretically possible. Likewise, a material made in such a way that part of the zirconia is already in its monoclinic form, there will be less zirconia available in its tetragonal form for transformation to monoclinic.
SUMMARY OF THE INVENTION
In its broadest aspect this invention is a fracture toughened glass ceramic, the method of fabrication thereof and a toughened glass ceramic substrate containing conducting patterns embedded therein.
There is a need to improve the strength of glass-ceramics. The material needs to be toughened in order to withstand handling in the electronic circuit manufacturing process.
An object of this invention is to provide a process of manufacturing ceramic materials suitable for packaging of electronic circuits at a temperature compatible with the metallization used to provide electrical circuit conductors. Producing a ceramic laminate with conductor patterns therein is well known in the art. U.S. Pat. No. 4,234,367 to Herron et al. and U.S. Pat. No. 4,504,339 to Kamehara et al., the teachings of which are incorporated herein by reference, are primarily directed to producing such a laminate:
As taught in Herron et al.: In view of the high packaging densities attainable with multilevel ceramic circuit structure, they have achieved extensive acceptance in the electronics industry for packaging of semi-conductor integrated devices, and other elements, as for example see U.S. Pat. No. 3,379,943 granted Apr. 23, 1968 to J. G. Breedlove, U.S. Pat. No. 3,502,520, granted Mar. 24, 1970 to B. Schwartz and U.S. Pat. No. 4,080,414 granted Mar. 21, 1978 to L. C. Anderson et al. In general, such conventional ceramic structures are formed from ceramic green sheets which are prepared from ceramic "paints" by mixing a ceramic particulate, a thermoplastic polymer (e.g. polyvinylbutyral) and solvents. This "paint" is then cast or spread into ceramic sheets or slips from which the solvents are subsequently volatilized to provide a coherent and self-supporting flexible green sheet, which may be finally fired to drive off the resin and sinter the ceramic particulates together into a densified ceramic substrate. In the fabrication of multilevel structures, an electrical conductor forming composition is deposited (by spraying, dipping, screening, etc.) in patterns on required green sheets, which form component layers of the desired multilevel structure. The component sheets may have via or feedthrough holes punched in them, as required for level interconnection in the ultimate structure. The required number of component green sheets are stacked or superimposed to register on each other in the required order. The stack of green sheets is then compressed or compacted at necessary temperatures and pressures to effect a bond between adjacent layers note separated by the electrical conductor forming pattern. Thereafter, the green sheet laminate is fired to drive off the binders and to sinter the ceramic and metal particulates together into a ceramic dielectric structure having the desired pattern of electrical conductors extending internally therein.
We have found it is critically important that the process be performed at a temperature below the melting or sintering temperature of the metallization, such as copper, formed on or within the ceramic material. The melting point of copper is about 1083° C. If the metallization is heated excessively, it melts, disperses, or acts as a flux to the glass or melts to form a puddle on the ceramic material. If the metallization is damaged, the electrical circuits in the integrated circuit structure are destroyed, thereby destroying the value of the package. Previous work in ceramics did not involve such metallization and accordingly process temperatures which were far too high have been employed. It is a prerequisite in the art of electronic circuit packaging that the ceramic materials be processed at lower temperatures compatible with preserving the metallization structures on the packages. Metals for use in packages include but is not limited to Ag, Au, Al and Cu.
Ceramic materials suitable for practicing the present invention include but are not limited to cordierite, spodumene, eucryptite, borosilicate glass, lead glass, enstatite, celsian, wollastonite, willemite, anorthite, lithium disilicate, lithium metasilicate, mullite, combinations thereof and combinations thereof with alumina. This list is exemplary only and not limiting.
U.S. Pat. Nos. 4,301 and 4,413,061 both to Kumar et al., the teachings of which is incorporated herein by reference, describe spodumene and cordierite compositions. The following is a list of the general formula for the predominant components of the materials mentioned above:
celsian, BaO.Al 2 O 3 .2SiO 2
anorthite, CaO.Al 2 O 3 ,2SiO 2
lithium disilcate, Li 2 O 6 .2SiO 2
lithium metasilicate, Li 2 O.SiO 2
wollastinite, CaO.SiO 2
willemite, 2ZnO.S i O 2
eucriptite, Li 2 O.Al 2 O 3 .2SiO 2
mullite, 3Al 2 O 3 .2SiO 2
enstatite, MgO.SiO 2
The term glass ceramic means an aggregate of randomly oriented crystallites, for example, the material listed above, wherein the intersticies between crystallites may contain uncrystallized material such as glass, for example the precursor of the above listed materials.
For convenience the invention will be described with reference to a cordierite glass ceramic which is the most preferred glass ceramic.
In accordance with this invention, a ceramic material suitable for electronic large scale integrated circuit packaging comprises a cordierite or other glass ceramic material mixed with particles consisting essentially of a powdered, tetragonal phase of a material selected from the group consisting of one or more zirconia or hafnia powder containing a stabilizing oxide compound. The cordierite or other glass ceramic crystalline material encapsulates the particles and the stabilizing oxide compound. The stabilizing oxide compound is selected from the group consisting of MgO, CaO, Y 2 O 3 and titania, and selected rare earth oxides. The stabilizing oxide compound comprises from 0.1 mole percent to 8 mole percent of said zirconia or hafnia. The stabilizing oxide compound plus said zirconia of hafnia comprises at least about 5 volume percent of the total volume percent of the ceramic material. The glass ceramic material comprises at least about 75 volume percent of the total volume of the ceramic material. The particles have a size within the range from about 0.5 to about 8.0 μm.
A ceramic material in accordance with this invention, which is suitable for packaging, is produced by the process of forming a mixture of a powdered glass ceramic material which is a glassy precursor to cordierite or other ceramic materials, formed by the steps which are as follows:
a. Mix tetragonal phase material selected from the group consisting of zirconia or hafnia powder containing a stabilizing oxide compound selected from the group consisting of MgO, CaO and Y 2 O 3 and a glass frit powder or frit of a glassy precursor of cordierite or other glass ceramics to yield a suspension of solids. Preferably, a binder is included.
b. Disperse the suspended solids to yield a dispersion of the zirconia or hafnia containing the stabilizing oxide compound and the glassy precursor.
c. Densify the dispersion of zirconia or hafnia containing the stabilizing oxide compound and the glassy precursor by a sintering heat treatment at a temperature above the glass transition temperature to melt the glassy precursor into a viscous fluid at a temperature below the melting point of the zirconia or hafnia powder particles to yield a densified intermediate material with the zirconia of hafnia particles encapsulated in the molten glassy precursor. The preferred temperature is about 840° C.
d. Crystallize the densified intermediate material into a polycrystaline composite by heating up to about 1100° C., preferably from about 840° C. to about 950° C., most preferably, from 900° C. to 950° C. The crystallization time decreases with the temperature being for a cordierite glass ceramic about 1 hour at 840° C. and about a minute at 950° C.
The process yields a ceramic material consisting of the tetragonal phase material encapsulated in crystalline cordierite or other glass ceramic materials.
A ceramic material suitable for packaging is produced by the process of forming a mixture of a powdered glass ceramic material which is a glassy precursor to the cordierite or other crystalline glass ceramic materials, formed by the steps which are as follows:
a. Mix zirconia or hafnia powder containing a stabilizing oxide compound selected from the group consisting of MgO, CaO and Y 2 O 3 and a glass frit powder or frit of the glassy precursor yielding a suspension of solids. Preferably, prior to mixing, perform the step of milling of the zirconia or hafnia powder in a fluid in a ball mill for one hour to produce ball milled zirconia or hafnia powder. Preferably, the fluid used to facilitate mixing is methanol. Preferably, the step of ball mixing of the glassy precursor and the zirconia or hafnia mixture is performed for a time duration of on the order of from about two minutes to about 13 hours, preferably 13 hours. The mixture is preferably mixed during the dispersion step with an ultrasonic probe. Then it is preferable that the product of mixing with an ultrasonic probe be dried while stirring magnetically or the equivalent.
b. Disperse the suspended solids to yield a dispersion of the zirconia or hafnia with the and the glassy precursor.
c. Densify the dispersion of zirconia or hafnia and glassy precursor by heat treatment at a temperature of about 840° C. to yield a densified intermediate material.
d. Crystallize the densified intermediate material into a polycrystalline composite material by heating up to about 1100° preferably from about 840° C. to 950° C.
e. The process yields a ceramic material consisting of the tetragonal phase material encapsulated in crystalline cordierite or other glass ceramic materials.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows the X-ray diffraction pattern of 2.2 mol % Y 2 O 3 --ZrO 2 as received from supplier.
FIG. 2 shows the X-ray diffraction pattern of 10 vol % 2.5 mol % Y 2 O 3 --ZrO 2 incorporated into the cordierite glass ceramic of TABLE I.
FIG. 3 shows the Fracture Toughness K c vs Vol % ZrO 2 indicating the variation of fracture toughness with the addition of pre-calcined 2.2 mol % Y 2 O 3 --ZrO 2 .
FIG. 4 is a graph of the fracture toughness of the glass-ceramic for different values of yttria additions and for different volume additions of zirconia.
FIG. 5 is a sketch based upon a photograph of a Vickers indentation from a 88.236N load in a Table I composition of cordierite glass-ceramic containing 10 vol % 2.5 mol % Y 2 O 3 --ZrO 2 .
In FIG. 6, are presented Raman Spectra recorded using an optical probe of a material shown in TABLE III.
The foregoing and other objects, features and advantages of the invention will be apparent from the more particular description of the preferred embodiments of the invention which follows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Disclosure of the Invention, Best Mode and Other Modes of Carrying Out the Invention
Transformation toughening requires a well dispersed phase of metastable tetragonal zirconia, that upon fracturing will transform to the monoclinic form. Zirconia exists as three phases, monoclinic, tetragonal and cubic. Monoclinic is the stable form below 950° C. The monoclinic to tetragonal transformation occurs between 950° C. and 1200° C. The cubic phase is formed at 2370° C. as explained by R. Stevens, Introduction to Zirconia, Magnesium Elecktron Inc., Flemington, N.J. (1983). Tetragonal zirconia is retained at room temperature through the use of stabilizing oxide compounds such as MgO, CaO and Y 2 O 3 , control of the particle size and the elastic properties of the host matrix. (See Lange, supra and Stevens et al., supra). Adding the stabilizing oxide compounds magnesia (MgO), calcia (CaO) and yttria (Y 2 O 3 ), reduces the tetragonal to monoclinic transformation temperature.
Zirconia or hafnia is added to the frit of a glass precursor of a cordierite glass-ceramic to toughen the fabricated glass ceramic. Zirconia or hafnia is added in the tetragonal phase. This phase is unstable at temperatures below about 950° C. The tetragonal phase transforms to the monoclinic form at temperatures above about 950° C. At temperatures below 950° C. crack formation in the ceramic initiates the transformation from tetragonal to monoclinic crystal structure. The transformation involves a volume expansion which causes the toughening. Toughening increases as the percentage of the tetragonal phase increases. When the ceramic material is used as a microelectronic packaging substrate, the use temperature is generally less than about 200° C. If the transformation temperature is closer to the use temperature, a larger percentage of the zirconia or hafnia will be in the tetragonal phase since it is more stable with a lower transformation temperature. The transformation temperature is lowered by adding to the zirconia or hafnia a stabilizing oxide material. A molecule of the stabilizing oxide takes the place of a zirconia or hafnia molecule at a lattice site of the tetragonal crystal structure. This substitution results in lowering the transformation temperature. To achieve effective stabilization, a fraction of the total lattice sites must be replaced by stabilizing oxide molecules. As used herein, stabilizing refers to lowering the tetragonal to monoclinic zirconia transformation temperature. This is achieved by adding stabilizing oxides to the tetragonal zirconia.
We have found that the yttria stabilized zirconia, employed in accordance with this invention, forms the transformable tetragonal phase in the compositional range of 0-5 mol %. Decreasing the particle size also increases the stability of the tetragonal phase. The maximum particle size at which pure zirconia will remain tetragonal is generally less than 1 μm, whereas for a 2 mol. % Y 2 O 3 stabilized zirconia it is larger. The volume constraining effects of the matrix also increases the stability of the constraining effects of the matrix also increases the stability of the tetragonal form, increasing the critical diameter. (See Lange, supra). Pure zirconia particles less than 0.5 μm in diameter remain tetragonal while constrained in an alumina matrix. The critical diameter in a matrix increases with the use of the partially stabilized zirconias of MgO, CaO and Y 2 O 3 .
Dispersion of zirconia powder in the host matrix is an important processing step of this invention. Agglomerates of zirconia particles contribute flaws to a fired microstructure. Techniques for dispersion included mechanically mixing the powders, attrition of zirconia grinding media, and sol-gel techniques. (Claussen et al., supra). Aside from mechanical mixing, the other processing techniques are expensive and difficult to control. For these reasons, in one aspect of this invention, the mechanical mixing approach is employed in accordance with this invention.
Examples of compositions of glass ceramic materials toughened according to the present invention, suitable for electronic large scale integrated circuit packaging, are shown in TABLE I.
TABLE I______________________________________WEIGHT PERCENTCORDIERITE+3% BETA- WILLE- ANOR-ENSTATITE SPODUMENE MITE THITE______________________________________Al.sub.2 O.sub.3 21.23 14.42 14.0 14.42MgO 20.00 -- -- --SiO.sub.2 55.00 71.5 31.0 55.0P.sub.2 O.sub.5 2.77 2.08 -- 2.08B.sub.2 O.sub.3 1.00 -- 10.0 --LiO.sub.2 -- 10.0 -- --K.sub.2 O -- 2.0 45.0 --ZnO -- -- -- --CaO -- -- -- 23.0ZrO.sub.2 -- -- -- 2.5______________________________________
The most preferred glass ceramic contains a cordierite glass ceramic, of the formula (2MgO--2Al 2 O 3 --5SiO 2 ) encapsulating particles of zirconia, hafnia or some combination of the two such as an alloy thereof. These particles increase in size when they transform from their initial crystal structure to a structure which requires more volume. This increase in volume produces forces which increase the fracture toughness of the material.
We have discovered that it is essential that the zirconia or hafnia particles have a size within the range from about 0.5 μm to about 8.0 μm and preferably about 3.0 μm. It is critically important to the invention, that the particles are so small. When materials are made with significantly larger sizes than the range from about 0.5 μm to about 8.0 μm, no transformation toughening has been obtained during our experiments with the process of this invention.
In addition, we have found it is critically important that the process be performed at a temperature below the melting or sintering temperature of the metallization such as copper formed in, i.e. on or within, the ceramic material. If the copper is heated excessively, it melts, disperses, or acts as a flux to the glass or melts to form a puddle on the ceramic material. If the copper is damaged, the electrical circuits in the integrated circuit structure are destroyed, thereby destroying the value of the package.
In this invention the known additive of a stabilizing oxide compound material, such as yttria, magnesia, calcia, titanium dioxide and oxides of rare earths, is employed to reduce the tetragonal to monoclinic transformation temperature so that the tetragonal state will be maintained at room temperature. Yttria is sometimes included within the class of rare earth oxides. However, yttria has atomic number 39, whereas the lathamide rare earth elements have atomic number 58 to 71 and the actinide rare earth elements have atomic number 90 to 101.
EXAMPLES
Five zirconia powders have been employed. One was a pure unstabilized zirconia with a mean particle diameter of 0.03 μm and a partially stabilized 2.5 mol. % yttria-zirconia with a mean size of 0.02 μm. The third, a 2.2 mol. % yttria-zirconia with a mean size of 25 μm was employed.
Two 3 mol. % MgO-zirconia powders were investigated, one of which was spray dried. These were prepared from the citrates.
X-ray diffraction studies revealed that the tetragonal content of the partially stabilized powders could be increased by calcining (heating a granular or particulate solid at a temperature sufficient to remove most of its chemically combined volatile matter) to 1180° C. Samples were prepared using both the original powders as received from the manufacturers and powders calcined, as above.
Ball-Milling
Ball-milling was used to disperse the zirconia powders with the glass powder of the glass ceramic material shown in TABLE I, above.
For compatibility with current techniques for substrate manufacture, methanol, used in the green sheet binder system for MLC structures, is employed as the milling suspension. Methanol produced a superior dispersion of zirconia powders when compared with methyl iso-butyl ketone.
The zirconia powders were milled for one hour prior to adding the powder of the composition shown in TABLE I. Then they were milled an additional 13 hours.
After milling, the powders were further dispersed with a 300 watt ultrasonic probe operated at maximum power for two minutes.
Evaporation of Solvent
After the ultrasonic mixing step, the methanol solvent was evaporated from the samples while mixing with a magnetic stirrer to prevent preferential particle settling of the denser zirconia particles.
Pressing
To reduce porosity to a minimum for accurate fracture toughness measurements, one gram green pellets were uniaxially pressed at 88 MPa (Megapascals, where 1 Megapascal=145 psi), without binder, and then isostatically pressed at 69 MPa.
Air Firing
All samples were subsequently air-fired at 960° C. for two hours.
The fracture toughness of the samples was measured using the indentation technique after the sample surfaces were ground and polished. See G. R. Anstis, P. Chantikul, B. R. Lawn and D. B. Marshall, "A Critical Evaluation of Indentation Techniques for Measuring Fracture Toughness: I, Direct Crack Measurements", J. Amer. Cer. Soc. 64(9) 533-538 (1981); B. H. Mussler and M. W. Shafer, "Preparation and Properties of Mullite-Cordierite Composites", Bull. Amer. Ceram. Soc., 63 (5) 705-710 (1984).
X-ray diffraction revealed that the polished and as fired surfaces were equivalent in tetragonal phase content, assuring test validity. At least three indentations per sample were made with a Zwick (Zwick Company Old Saybrook, Conn.) hardness tester, configured with a Vickers diamond pyramidal indenter. Indentations were done at loads of 29.412 and 88.236N.
The sonic resonance technique (Schreiber, Anderson and Soga, Elastic Constants and Their Measurements, McGraw-Hill, New York, p. 91 (1974)) was used to measure Young's modulus (required for fracture toughness calculations) for a bar of 10 vol % 2.5 mol % yttria-zirconia and the material of TABLE I, above, air fired to 960° C. This bar was made by the lamination at 31 MPa, of 15 layers of 0.29 mm cast green sheets. The green sheet slurry was prepared by using 130% of the binder system employed for casting the powder of TABLE I. Due to the high surface area of the 0.02 μm zirconia particles, more binder liquid was needed to lower the slurry viscosity in order to pour it from the ball mill. Dispersion was done in the binder system, first by milling the zirconia powder for one hour and then adding the powder of TABLE I and ball milling for an additional two hours. It should be noted that this method is not effective for complete dispersion and was used only for a Young's modulus specimen.
FIG. 1 shows the X-ray diffraction pattern of 2.2 mol % Y 2 O 3 --ZrO 2 as received from the supplier.
FIG. 2 shows the X-ray diffraction pattern of 10 vol % 2.5 mol % Y 2 O 3 --ZrO 2 incorporated into the cordierite glass ceramic of TABLE I.
X-ray analysis of the powders showed that calcining the commercially manufactured, partially stabilized zirconia to 1180° C. could significantly increase the tetragonal phase content. The results, shown in TABLE II below indicate an increase from 50% to 95% tetragonal phase for the 2.5 mol % yttria-zirconia of sample 1 in TABLE II and from 73% to 85% for the 2.2 mol % yttria-zirconia of sample 9 in TABLE II below. The pure zirconia remained monoclinic.
TABLE II______________________________________X-RAY DIFFRACTION DATAVOL % TETRAGONALSAMPLE POWDERS FIRED PELLETS______________________________________1) MgO--ZrO.sub.2 (Sp. dried) 74% 10%2) Calc. 1180° C. 0 .sup. NM*3) MgO--ZrO.sub.2 (Sp. dried) 42% 04) Calc. 1180° C. 0 .sup. NM*5) Pure ZrO.sub.2 0 06) Calc. 1180° C. 0 .sup. NM*7) 2.5 mol % Y.sub.2 O.sub.3 --ZrO.sub.2 50 588) Calc. 1180° C. 95 669) 2.2 mol % Y.sub.2 O.sub.3 --ZrO.sub.2 73 5810) Calc. 1180° C. 85 .sup. NM*______________________________________ *NM = Not Measured
Chemically prepared 3 mol % magnesia-zirconia showed a reversal in tetragonal content, becoming completely monoclinic upon calcination. The spray dried powder did show the highest tetragonal content, 74%, of the as-received powders. The magnesia-zirconia system does decompose at 1200° C. An analysis of a sample of this zirconia dispersed in the glass-ceramic and fired to only 960° C. shows that the tetragonal content is very low compared to other specimens containing partially stabilized zirconia (TABLE II). It is possible that various cationic impurities are present in these citrated derived powders that lend stability to the tetragonal phase. Upon firing, these impurities are evolved, decreasing the stability of the tetragonal phase. If the stabilizing oxide compounds along with the impurities could be controlled such that the tetragonal phase begins to lose stability at 960° C., one could incorporate a highly metastable tetragonal zirconia in the glass-ceramic matrix. One would have a zirconia powder that remains highly tetragonal during processing at room temperature, but becomes highly metastable upon heat treatment to 960° C., maximizing transformation toughening.
The zirconia powders partially transform upon processing. A precalcined powder that was 95% tetragonal changed to 74% tetragonal after attritor milling for 30 minutes. The formation of the green pellets by pressing, did not lead to transformation of the zirconia particles.
The fired samples of the commercially manufactured zirconias incorporated in the glass-ceramic do show considerable tetragonal content in an X-ray diffraction pattern, FIG. 2. The tetragonal content calculated for these samples are rough estimates and should not be directly compared with data obtained for zirconia powders.
Additional test firing the zirconia mixed with the glass of TABLE I revealed that no zircon (ZrSiO 4 ) was formed upon firing the zirconia mixed with the glass of TABLE I even up to temperatures of 1180° C., holding the temperature there for one hour.
Young's modulus for a composite of 10 vol % 2.5 mol % yttria-zirconia in the material of TABLE I, air fired to 960° C., as determined by sonic resonance was 137 GPa. This compares with a Young's modulus of 130 GPa for the material of TABLE I alone. The 137 GPa value coincides with the calculation of Young's modulus from equations for two phase systems. Young's modulus for 15% added zirconia was not measured, but calculated as 141 GPa.
The results of fracture toughness measurements are given in both TABLE III and in the graph of FIG. 3. FIG. 3 shows the Fracture Toughness K c vs Vol % ZrO 2 indicating the variation of fracture toughness with the addition of precalcined 2.2 mol % Y 2 O 3 --ZrO 2 . The maximum error in these measurements is 0,1 MPam 1/2 . The values for fracture toughness, K c , were all measured at the same load, of 88.236N (9 Kg). The graph of FIG. 4 plots the fracture toughness of the glass-ceramic for different values of yttria additions and for different volume additions of zirconia. It plots K c in MPam 1/2 vs the Zirconia type used for 15 and 20 percent zirconia with 3, 4 and 5 percent yttria. The variation in measured values of fracture toughness exhibited by the data of FIG. 4 was attributed to variations in dispersion of the zirconia particles and local densification resulting from the presence of agglomerates. The variation thus emphasizes the necessity of good dispersion of the zirconia particles during the material preparation. The increase in fracture toughness of the materials containing zirconia, could be shown to be due to transformation toughening by examining the materials after fracturing.
In FIG. 6, are presented Raman Spectra recorded using an optical probe of a material shown in TABLE III. The Raman Spectra were recorded from a region remote an indentation crack (top) and from an indentation crack (bottom). The lower ration of the tetragonal to monoclinic peaks in the bottom spectrum indicates that a fraction of the the tetragonal zirconia grains have been transformed by the fracturing process.
TABLE III______________________________________FRACTURE TOUGHNESS DATA K.sub.C (MPam.sup.1/2) ± %SAMPLE 0.1 Max CHANGE______________________________________1) TABLE 1 COMPOSITION 1.75 --2) 10 vol. % Pure ZrO.sub.2 2.00 +163) 10 vol. % 2.5 mol % 2.15 +23 Y.sub.2 O.sub.3 --ZrO.sub.24) same-precalcined ZrO.sub.2 2.15 +235) 10 vol. % 2.5 mol % 2.43 +39 Y.sub.2 O.sub.3 --ZrO.sub.26) same-precalcined ZrO.sub.2 2.30 +307) 15 vol. % 2.2 mol % -- -- Y.sub.2 O.sub.3 --ZrO.sub.28) same-precalcined ZrO.sub.2 2.68 +539) Beta-spodumene composition of 1.5 +20 TABLE I 15 Vol % ZrO.sub.2 stabilized with Y.sub.2 O.sub.3______________________________________
FIG. 5 is a sketch made from a photograph of a Vickers indentation from a 88.236N load in a TABLE I composition of cordierite glass-ceramic containing 10 vol % 2.5 mol % Y 2 O 3 -ZrO 2 .
It is important that the zirconia particles be uniformly distributed throughout the matrix. This powder did result in the highest value for fracture toughness, and should contribute the fewest flaws to the fired microstructure.
Adding 10 vol % of the 2.5 mol % yttria-zirconia to the glass-ceramic increased its dielectric constant from 5.0 to 5.8. The value of 5.8 compares with a calculated value of 5.5. The coefficient of thermal expansion increased from 1.8×10 -6 /°C. for the glass-ceramic alone to 2.5×10 -6 /°C. at 25° C. to 300° C.
Conclusions
1. Adding a second phase of zirconia particles to the glass-ceramic of TABLE I reduces its brittleness and increases its fracture toughness.
2. Dispersion is very important to the densification and thus the strength of this two phase system. The larger particles size, 25 μm powder disperses very well during comminution and mixing in the ball mill and showed the highest fired density of the zirconia plus glass-ceramic mixtures. This powder also resulted in the highest values for fracture toughness: adding 10 vol % increased K c by 30% to 40%, and adding 15 vol % increased K c by more than 50%.
3. The 0.02 μm and 0.03 μm powders were too fine to obtain a good dispersion using this process.
ALTERNATIVE DESIGNS
In one alternative design, the zirconia or hafina particles are found localized in a specific region, for example, only in the outer layer of the material to provide compressive forces there to form an outer compressive layer to resist crack propagation due to the transformation of the zirconia and/or hafina material to the monoclinic phase from the tetragonal phase, if possible. The incorporation of the zirconia only a localized region such as in the outer layer of the ceramic has the advantage of maintaining a low overall dielectric constant for the ceramic material. That is in spite of the fact that the dielectric constant of the zirconia and/or hafnia.
The ceramic material is produced by the process of forming a mixture of a powdered glass ceramic material (which is a glassy precursor of cordierite crystalline ceramic material), formed by the steps which are as follows:
1. Mix a powdered, tetragonal phase of a material selected from the group consisting of one or more of zirconia or hafnia powder containing a stabilizing oxide compound selected from the group consisting of MgO, CaO, Y 2 O 3 , titania, and selected rare earth oxides, and a glass frit powder or frit of a glassy precursor of a crystalline ceramic material, for example, cordierite, spodumene, eucriptite, borosilicate glass, lead glass, enstatite, celsian, wollastinite, willemite, anorthite, lithium disilicate, lithium metasilicate, mullite, combinations thereof and combinations thereof with alumina, most preferably of a cordierite containing composition yielding a suspension of solids.
2. Disperse the suspended solids to yield a dispersion of the zirconia or hafnia and the glassy precursor.
3. Densify the dispersion of zirconia or hafnia and glassy precursor by a sintering heat treatment at a temperature of about 840° C. to melt the glassy precursor composition into a viscous material at a temperature below the melting point of the zirconia or hafnia powder particles to yield a densified intermidediate material with the zirconia or hafnia particles encapsulated in the molten glassy precursor.
4. Crystallize the densified intermediate material by heating at 840° C. to 950° C.
A process is provided for making the new ceramic material suitable for packaging. It is produced by the process of forming a mixture of a powdered glass ceramic material which is a glassy precursor to the matrix material of the ceramic matrix, formed by the steps which are as follows:
1. Mix a powdered, tetragonal phase of a material selected from the group consisting of one or more of zirconia or hafnia powder, a stabilizing oxide compound selected from the group consisting of MgO, CaO, Y 2 O 3 , titania and selected rare earth oxides, and a glass frit powder or frit of a glassy precursor of a crystalline ceramic material most preferably of cordierite composition yielding a suspension of solids. The stabilizing oxide compound comprises from 0.1 mole percent to 8 mole percent of the zirconia or hafnia.
2. Disperse the suspended solids to yield a dispersion of the zirconia or hafnia containing a stabilizing oxide compound, and the cordierite.
3. Densify the dispersion of zirconia or hafnia and cordierite or other glass ceramics by heat treatment at a temperature of about 840° C. to yield a densified intermediate material.
4. Crystallize the densified intermediate material into a polycrystalline composite by heating at 900° C. to 950° C.
In one version of this invention, prior to the step of mixing, one mills the zirconia or hafnia powder in a fluid in a ball mill for one hour to produce ball milled zirconia or hafnia powder. The fluid used to facilitate mixing is methanol. Preferably, the step of ball mixing of the glassy precursor and zirconia or hafnia mixture lasts on the order of 13 hours, and the mixture is mixed during the dispersion step with an ultrasonic probe. Then one dries the product while stirring magnetically or the equivalent.
INDUSTRIAL APPLICABILITY
This invention is applicable in data processing such as personal computers, minicomputers, large scale computers and other data processing equipment. In addition, this system and process will be applicable to industrial and consumer electronic devices employing LSI chips. Electronic products such as transportation and control systems incorporating data processing systems for continuous monitoring and like functions can use the packaging methods and systems of this invention.
While the invention has been illustrated and described with respect to preferred embodiments, it is to be understood that the invention is not limited to the precise constructions herein disclosed, and the right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.
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A ceramic material suitable for packaging of large scale integrated circuits is produced by the process of forming a mixture of a powdered glass ceramic material which is a glassy precursor to cordierite ceramic material, formed by the steps which are as follows:
a. Mix tetragonal phase material selected from the group consisitng of zirconia or hafnia powder containing a stabilizing oxide compound selected from the group consisting of MgO, CaO and Y 2 O 3 and a glass frit powder or frit of a glassy precursor of cordierite glass ceramic to yield a suspension of solids. Preferably, a binder is included.
b. Disperse the suspended solids to yield a dispersion of the zirconia or hafnia with the stabilizing oxide compound and the glassy precursor.
c. Densify the dispersion of zirconia or hafnia with the stabilizing oxide compound and the glassy precursor by a sintering heat treatment at a temperature of about 840° C. to melt the glassy precursor into a viscous fluid at a temperature below the melting point of the zirconia or hafnia powder particles to yield a densified intermediate material with the zirconia or hafnia particles encapsulated in the molden glassy percursor.
d. Crystallize the densified intermediate material into a polycrystalline composite by heating at 900° C. to 950° C.
The process yields a ceramic material consisting of the tetragonal phase material encapsulated in crystalline cordierite glass ceramic material.
This invention is a continuation in part of application Ser. No. 07/146,455 filed on Jan. 21, 1988 now abandoned which was a continuation of Ser. No. 06/892,687 filed Aug. 1, 1986 now abandoned.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of controlling a building against an earthquake, comprising the steps of utilizing an earthquake observing network and a communication network when an earthquake happened to adjust positively the rigidity of a building itself by a control device or giving exciting force for cancelling a seismic oscillation input to the building in the opposite direction, thereby preventing the building from damages due to resonance phenomena.
2. Description of the Prior Art
Conventionally, in earthquake-proof designs of multistoried buildings, important structures or the like have been calculated the movement of foundation and the response of buildings when on earthquake happened to carry out the dynamic design for checking the safety.
For the earthquake-proof method are employed a quake avoiding or reducing method in which laminated rubber supports and dampers are interposed between the building and the foundation, a method of consuming the seismic energy through the breakage of non-main members of building contituents, a method of providing slits in walls, pillars or the like to adjust the building to the optimum rigidity.
Also, the present applicant has already developed the quake avoiding and resisting system which controls a trigger device interposed connectively or releasably between the building and the foundation side base by utilizing the earthquake observing network and communication network (see Japanese Patent Laid-Open No. Sho 62-63776).
Now, the safety of buildings designed by the current quake resisting design method in an earthquake is confirmed on the basis of the fundamental concept that the absorbing energy due to hysteresis characteristics accompanied by the plasticization of structure exceeds the seismic energy acting on the structure. However, the above case presents a problem of reliability on hysteresis loop characteristics.
Further, all conventional methods except for the method by said application give the quake resisting structures passive to the natural external forces such as earthquake, wind or the like so that the resonance phenomena to an uncertain input of earthquake cannot be avoided since a building has a specific natural frequency.
SUMMARY OF THE INVENTION
The present invention aims to give the safety of buildings and apparatus, residents, etc. in the building, not by said passive earthquake-proof methods, but by a method of varying the rigidity of a building itself under the judgement of response forecasting system based on the sensed seismic oscillation, i.e., varying the natural frequency of the building to provide the condition having no or few resonance regions or by another method of applying exciting force to the building in the opposite direction under the judgement of said response forecasting system to restrain the resonance.
With a method of controlling a building against an earthquake according to the present invention, connectors varying the connecting condition according to the command of a control device using a computer are placed between pillars, beams, braces, walls and all or a portion of these connections, or between the building and the base or adjacent building to control the buildings against the earthquake as follows;
(1) The occurrence of earthquake is sensed by quake sensors disposed in narrow and wide regions centering around the building to transmit observed data to the control device through wire and wireless communication networks. The quake sensors in the wide region are connected to seismographs placed at existing quake observing spots or ones installed exclusively through microcircuits, telephone circuit or the like. Also, the quake sensors in the narrow region consist of seismographs placed around the building or in the peripheral foundation and oscillation sensors installed in the building and on the base thereof. The effect of wind power or the like is sensed through the oscillation sensors in the building.
(2) The computer in the control device judges the magnitude of sensed earthquake, analyzes frequency characteristics and forecasts the responsive amount. Subsequently, it is judged whether or not the oscillation of the building should be controlled. Further, control amount in the case to be controlled is judged as what avoids the resonance to give an optimum rigidity (natural frequency) having small seismic responsive amount.
(3) The command of the control device is transmitted to the connectors placed at each section of the building to operate the connectors such that the rigidity of the building provides an optimum one based upon the forecast of the control device. The connecting condition is adjusted by adjusters proposed to adjust the fixed and connection releasing conditions by turning on and off a hydraulic mechanism, electromagnet, or the like and adjust the introduction of tensile force and the fixation at any position in addition to the fixed and connection releasing conditions by making use of the hydraulic mechanism or special alloys or the like.
Further, the responsive amount in each section of the building and the actual oscillation when effecting control operation can be detected by the oscillation sensors disposed in the building to be fed back for correction of control amounts or the like.
With another method according to the present invention, an exciter consisting of an additional mass oscillated with required frequency according to the command of the control device and a drive mechanism is installed in the building or the top thereof to control the building against the earthquake as follows:
(1) The occurrence of earthquake is detected by quake sensors disposed in narrow and wide regions centering around the building to transmit observed data to the control device through wire and wireless communication networks. The quake sensors in the wide region are connected to seismographs placed at existing quake observing spots or ones installed exclusively through micro circuits or telephone circuits or the like. Further, the quake sensors in the narrow region consist of seismographs placed around the building or in the peripheral foundation and oscillation sensors installed in the building and on the base thereof. The effect of wind power or the like is sensed through the oscillation sensors in the building.
(2) The computer in the control device judges the magnitude of sensed earthquake, analyzes frequency characteristics and forecasts responsive amount. Subsequently, it is judged whether or not the oscillation of the building should be controlled. With reference to the control amount in the case to be controlled, the frequency and direction are calculated to cancel the seismic oscillation input with exciting force applied to the building by the exciter and thus minimize the response to the building.
(3) The command of the control device is transmitted to the exciter to give the exciting force corresponding to the seismic oscillation input to the building. This exciting force will suffice to restrain the resonance of the building and give to the building the force having the same magnitude and opposite direction with the natural frequency producing the resonance, for example.
For the exciter are proposed one oscillated by an actuator supported by roller bearings, for example, and having an additional mass block connected to a portion of the building body through an elastic member like a spring to be controlled by the control device, one oscillated by changing the direction of electromagnetic force or the like.
Further, the present invention does not hinder the use of said method in combination with prior quake avoiding and attenuating methods, but permits said method to be used in combination with these methods for improving the safety and economy.
Also, the quake observing network and communication network can utilize the existing facilities and be held jointly at a plurality of buildings, thereby reducing the expenses of the facilities.
OBJECTS OF THE INVENTION
An object of the present invention is to judge data sensed by quake sensors disposed in narrow and wide regions instantly by a computer in a control device and vary the rigidity of a building itself at will on the basis of the responsive forecast to provide an optimum condition free from resonance according to individual earthquake characteristics.
Another object of the present invention is to cancel resonation components and minimize the effect of an earthquake to a building according to individual earthquake characteristics by judging instantlty data sensed by quake sensors disposed in narrow and wide regions with a computer in a control device and giving to the building oscillation in the opposite direction to seismic force on the basis of the responsive forecast.
A further object of the present invention is to ensure the safety of a building, apparatus and residents in the building and attend the business in the building under the tranquil condition according to said methods.
The above-mentioned and other objects and features of the invention will become apparent from the following detailed description taken in conjunction with the drawings which indicate embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the outline of an embodiment according to the present invention;
FIG. 2 is a block diagram showing the embodiment shown in FIG. 1;
FIGS. 3(a) to 3(g) are sectional views showing patterns of connector installing positions;
FIGS. 4(a) to 4(d) are a side view showing a connector using an electromagnet, a sectional view showing the connecting condition, a sectional view showing the released condition and a sectional view taken along the line A--A, respectively;
FIGS. 5(a) to 5(d) are a side view showing a connector using a hydraulic cylinder, a sectional view showing the connecting condition, a sectional view showing the released condition and a sectional view taken along the line B--B, respectively;
FIGS. 6(a) and 6(b) are sectional views showing the connecting and released conditions of the connector between brace members using hydraulic cylinders, respectively;
FIG. 7 is a sectional view showing the connector provided on an end of the brace;
FIG. 8 is a schematic view showing the outline of another embodiment according to the present invention;
FIG. 9 is a block diagram of the embodiment shown in FIG. 8;
FIG. 10 is a front view showing an exciter; and
FIG. 11 is a plan view showing said exciter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 showing the outline of an embodiment according to the present invention together with FIG. 2 showing the block diagram, seismic oscillation sensed by a seismograph 3a in a quake observing network disposed in a wide region and near a seismic center X, a seismograph 3b centering a building 1 and in the proximity thereof and further a quake sensor 4 or the like installed in the building 1 is sent to the input of a control device 2 (which is usually a computer installed in the building 1). When the scale of earthquake is judged to exceed a certain allowable value from the oscillatory acceleration or the like of the earthquake, the control device 2 measures the acceleration, analyzes the frequency characteristics, and calculatively forecasts the oscillatory property, displacement or the like of the building. When these values are also assumed to exceed a certain allowable value, an amount of change in rigidity due to changing the connected condition of a connector 5 is examined to determine an optimum rigidity for avoiding the resonance accompanying the quake oscillation within the range of maintaining the function as a structure. To this calculable forecast can be applied a quake response analyzing means utilizing the definite element method or the like which is employed generally. In this case, the computer judges instantly the situation and sends the commands to the respective connectors 5 to change the rigidity of the building 1.
Referring to the numerical example of the seismograph 3a disposed in the wide region, assuming that the earthquake center X, the seismograph 3a and the building 1 to be controlled are aligned on a straight line and spaced 50 Km from each other respectively, about 18.5 seconds are taken from the detection of P wave to the motion of S wave and about 12 seconds are taken from the detection of S wave to the motion of S wave. Therefore, the completion of control during such seconds will suffice for changing the rigidity. Also, referring to the seismograph 3b in the narrow region, when the distance between the earthquake center X and the seismograph 3b is 100 Km, about 12 seconds are taken from the detection of P wave to the motion of S wave and thus the completion of control during such seconds will suffice.
Also, the actual response after the rigidity has been changed is sensed by the quake sensor 4 in the building 1 to be fed back for correction.
FIGS. 3(a) to (g) show the patterns of positions in which the connectors 5 are installed and the following connectors are considered and combined with each other to cope with earthquakes;
(1) Connectors 5a between the building 1 and the base 6
(2) Connectors 5b interposed between the building 1 and adjacent buildings 1'
(3) Connectors 5c interposed between anchors of legs or pillar 7
(4) Connectors 5d,5d' in members of brace 9 or on ends of the braces 9
(5) Connectors 5e in quake resisting walls 10
(6) Connectors 5f in the connection between pillar 7 and beam 8
(7) Connectors 5g in the members of pillar 7.
FIGS. 4(a) to (d) show the connectors 5a between the building 1 and the base 6 utilizing an electromagnet 11 to operate the electromagnet 11 according to the command of the control device so that the fixed condition (FIG. 4(b)) and the connection releasing condition (FIG. 4(c)) can be provided. This construction is suitable for use in combination with the quake avoiding device using laminated rubber.
FIGS. 5(a) to (d) show the connectors between the building 1 and the base 6 utilizing a hydraulic cylinder 13 to provide the fixed condition (FIG. 5(B)) and the connection releasing condition (FIG. 5(c)). In the drawing, reference numeral 12 designates an electrohydraulic pump.
FIGS. 6(a) and (b) show an example of the connectors 5d interposed between members 9a,9b of the brace 9 and changed between the fixed condition (FIG. 6(a)) and the connection releasing condition (FIG. 6(b)) by the movement of a piston 16 in a hydraulic cylinder 15.
FIG. 7 shows an example of the connector 5d' on an end of the brace 9. The end of the brace 9 is moved in a cylinder 17 by oil pressure to provide not only the fixed and released conditions, but also the tensioned condition of the brace 9 or the like.
While the embodiments in case when changing the rigidity of a building itself have been heretofore described, next will be described embodiments in which the seismic oscillation input is cancelled by counter force due to exciter.
FIG. 8 shows the outline of a second embodiment. Referring to FIG. 8 together with a block diagram in FIG. 9, the earthquake oscillation sensed by a seismograph 23a near the earthquake center X in the earthquake observing network disposed in a wide region, a seismograph 23b centering the building 1 and in the proximity thereof, and further a quake sensor 24 or the like installed in the building 21 is sent to the input of a control device 22 (which is usually a computer installed in the building 21). When the scale of the earthquake is judged to exceed a certain allowable value from the oscillatory acceleration or the like of the earthquake, the computer 22 measures the acceleration, analyzes frequency characteristics and calculatively forecasts the oscillatory property, displacement or the like of the building. When these value are also assumed to exceed a ertain allowable value, the control device 22 sends the command to an exciter 25 which can set the building 21 to the natural frequency in the resonance point to be forecasted of the building 21 and give oscillation in the opposite direction to the seismic input to cancel the resonating components.
Referring to the numerical example of the seismograph 23a disposed in the wide region, assuming that the earthquake center X, the seismograph 23a and the building 21 to be controlled are aligned on a straight line and spaced 50 Km from each other, about 18.5 seconds are taken from the detection of P wave to the motion of S wave and about 12 seconds are taken from the detection of S wave to the motion of S wave so that the completion of control during such seconds will suffice for the control of the building. Also, referring to the seismograph 23b in the narrow region, when the distance between the earthquake center X and the seismograph 23b is 100 Km, about 12 seconds are taken from the detection of P wave to the motion of S wave so that the completion of control commanding within such seconds will suffice for the control.
Also, the actual response is sensed by the quake sensor 24 in the building 21 and fed back for correction.
FIGS. 10 and 11 show an embodiment of the exciter 25 installed on the roof of the building 21.
That is, an additional mass block 27 supported slidably by roller bearings 28 is adapted to be oscillated by a plurality of actuators 26 fixed to the building 21. The block 27 is connected to a riser 21' on the roof through springs 29 for maintaining the neutral position so that the building is oscillated through the riser 21' by operating the actuators. Further, in the drawing, reference numeral 30 designates a hydraulic pump, 31 a servo valve, 32 a stopper for preventing the displacement from being excessively large.
The earthquake observing network, control device using the computer, exciter or the like can be applied to the existing buildings since they can be added thereto later.
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A method of controlling a building against an earthquake according to the present invention comprises the steps of analyzing instantly the earthquake on the basis of data observed by earthquake sensors disposed in the building and narrow and wide regions, varying the connecting conditions in the building on the basis of obtained earthquake response forecast to vary the rigidity of the building or giving counter force to a building with an exciter to control oscillation according to individual earthquake characteristics.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application Serial No.60/157,680, filed Oct. 1, 1999.
ACKNOWLEDGMENT OF FEDERAL RESEARCH SUPPORT
This invention was made, at least in part, with funding from the United States Department of Agriculture (USDA 95-37302-1796), the Public Health Service and the National Institutes of Health (AI33586-01). Accordingly, the United States Government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
The field of this invention is the area of molecular genetics, in particular, in the area of mobile genetic elements, e.g., transposons, the transposase enzymes responsible for mobility and methods for isolating mutant transposase enzymes which mediate higher frequencies of transposition than do the naturally occurring enzymes, and uses thereof.
Transposable genetic elements are DNA sequences, found in a wide variety of prokaryotic and eukaryotic organisms, that can move or transpose from one position to another position in a genome. In vivo, intra-chromosomal transpositions as well as transpositions between chromosomal and non-chromosomal genetic material are well known. In several systems, transposition is known to be under the control of a transposase enzyme that is typically encoded by the transposable element. The genetic structures and transposition mechanisms of various transposable elements are summarized, for example, in “Transposable Genetic Elements” in “The Encyclopedia of Molecular Biology,” Kendrew and Lawrence, Eds., Blackwell Science, Ltd., Oxford (1994).
Mariner-family transposable elements are a diverse and taxonomically widespread group of transposons occurring throughout the animal kingdom [Robertson, (1993) Nature 362:241-245; Robertson and MacLeod, (1993) Insect Mol. Biol. 2:125-139; Robertson and Asplund, (1996) Insect Biochem. Mol. Biol. 26:945-954; Robertson, et al. (1998) Horizontal Gene Transfer, eds. Syvanen and Kado (Chapman & Hall, London)]. They encode transposases that belong to an extended superfamily of transposases and retroviral integrases distinguished by a conserved D,D35E (or variants thereof mariners=D,D34D) motif in the catalytic domain of the protein [Doak, et al. (1994) Proc. Natl. Acad. Sci. USA 91:842-946]. Transposition of these elements follows a conservative cut-and-paste mechanism [Craig, (1995) Science 270:253-254].
Most mariners are known only from their sequences obtained either through homology-based PCR screens or by the examination of sequenced genes or ESTs [Roberts (1993) supra; Robertson and Lampe, (1995) Mol. Biol. Eval. 12:850-862]. Hundreds of different mariners have been detected in this way. Of these, only two are known to be active. The first is the canonical mariner element from Drosophila mauritiana discovered by its activity in that fly [Jacobson, et al. (1986) Proc. Natl. Acad. Sci. USA. 83:8684-8688]. The most active copy of this particular element is known as MosI [Medhorn, et al. (1988) EMBO J. 7:2185-2189]. The second is the Himar1 element discovered by using homology-based PCR in the horn fly, Hacmatobia irritans, and reconstructed as a consensus sequence [Robertson, et al. (1986) supra; Lampe, et al. (1996) EMBO J. 15:5470-5479]. Both MosI and Himar1 require no host-specific factors for transposition and so have been advanced as generalized genetic tools [Loha and Hartl, (1996) Genetics 143:3265-374; Gueiros-Filho and Beverley, (1997) Science 276:1716-1719; Lampe, et al. (1998) Genetics 149:179-187]. Indeed, MosI has been used as a transformation vector for chicken [Sherman, et al. (1998) Nat. Biotechnol. 16:1050-1053], zebrafish [Fadool, et al. (1998) Proc. Natl. Acad. Sci. USA 95:5182-5186], the yellow fever mosquito, Aedes Aegypri [Coates, et al. (1998) Proc. Nation. Acad. Sci. USA 95:3748-3751], Drosophila melanogaster [ Lidholm, et al. (1993) Genetics 134:859-868], Drosophila virilis [Loha and Hartl (1996) supra], and Leishmanla major [ Guiros-Filho, (1997) supra], with varying degrees of success. Himar1 has been used as a prokaryotic genetic tool, via in vivo transposition and subsequent homologous recombination in Haemophilus influenzae and Streptococcus pneumoniae, and in vivo in Escherichia coli and Mycobacterial spp. [Akerley, et al. (1998) Proc. Natl. Acad. Sci. USA 95:8927-8932; Rubin, et al. (1999) Proc. Natl. Acad. Sci. USA 96:1645-1650]. It is also active in human cells [Zhang, et al. (1998) Nucleic Acids Res. 26:3687-3693].
Whereas mariner elements are becoming increasingly important tools for eukaryotic genetics, neither MosI nor Himar1 appear to be as active as would be desired to make them efficient tools, particularly for whole metazoa [Lampe, et al. (1998) supra; Fadool (1998) supra]. In fact, these transposases may have evolved to be less active in their hosts and, therefore, be less deleterious [Lampe, et al. (1998) supra; Lohe and Hartl, (1996) Mol. Biol. Eval. 13:549-555; Hartl, (1997) Genetics 100:177,184]. Such low transposition activity makes the use of these elements for genetic manipulations less practical. Identifying mutant transposases with higher activity might help to solve this problem but is difficult to carry out in metazoan systems [Lohe, et al. (1997) Proc. Natl. Acad. Sci. USA 94:1293-1297].
In order to identify mutant transposases with higher activity and a broad host range, the ability of Himar1 to transpose in prokaryotes was exploited to create a genetic system for isolation of transposase mutants with altered activity in vitro and in vivo. The present invention discloses three highly active mutants that significantly improve the efficiency of transposition of Himar1-derived elements as genetic tools. Analysis of these mutants shows the locations of functional domains and amino acids within the Himar1 transposase. The hyperactive mutants of Himar1 transposase described herein are useful in generating random mutations in vivo and in vitro or in introducing a heterologous DNA into a wide range of host cells.
SUMMARY OF THE INVENTION
The present invention provides mutant Himar1 mariner transposase proteins and coding sequences therefor. These mutant transposases are such that the frequency of transposition is significantly higher than the comparison transposase which occurs in nature. By significantly higher, it is meant at least about 2-fold higher, and desirably greater than about 5-fold, and including the ranges of about 3 to about 1000-fold, and all ranges therebetween. The mutant transposases of the present invention further exhibit the useful property of being active in a wide range of prokaryotic and eukaryotic cells, including but not limited to bacteria, insects, nematodes, flatworms, and vetebrates (e.g. humans). Thus, these mutant transposases can be used to improve the efficiency of a variety of genetic manipulations which require the step of transposition of a genetic element.
The mutant Himar1 tranposases of the invention were identified as having higher transposition efficiency by a combination of the trans-papillation screen and the mating assay. The mutant transposases of the invention represent the first example of the eukaryotic transposases isolated using these assays. Using the combination of these two assays, additional transposase mutants with a varying transposition frequency can be isolated from the Himar1 transposon or any related transposable elements.
The hyperactive mutant transposases of the present invention are useful in a variety of genetic manipulations which require a transposition event in vitro and in vivo. These include but are not limited to sequencing of unknown DNA, generating random mutations in vitro or in vivo such as gene knock-outs, introducing a gene of interest, or identification of essential genes in an organism.
The hyperactive Himar1 transposase mutant proteins can be expressed and purified for use in in vitro assays using the methods known in the art. The nucleic acid coding sequences for the mutant transposases provided herein can be cloned into a transposon such as Himar1 to be used for in vivo transposition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of Himar1 transposase showing notable landmarks, proposed functional domains, and the positions of the hyperactive mutations described herein. The putative DNA-binding domains are based on comparisons to the Tcl and Tc3 transposases of C. elegans and to computer predictions of Tcl/mariner transposase structures. “D” indicates the positions of the catalytic residues of the putative D,D34D catalytic domain. Specific amino acids noted are hyperactive mutations described in the invention. C9 and A7 refer to clones for those specific mutants as described in the Specification. NLS refers to the positions of two putative nuclear localization signals (beginning at positions 184 and 243, respectively) as predicted by the program PSORT [Nakai and Kanchisa (1992) Genomics 14:897-911].
FIG. 2A is a papillation assay used for detection of mutant Himar1 transposases. The papillation screen was used to examine a pool of mutant transposase sequences to isolate hyperactive transposases. FIG. 2B shows a mating-out assay used for measuring transposition frequency of mutant Himar1 transposases. This assay quantifies the relative frequency of individual transposase constructs.
FIG. 3 shows relative activity of wild-type and hyperactive Himar1 transposases as measured in the mating-out assay. The frequency of transposition is expressed relative to that of wild-type Himar1 transposase which has been normalized to a value of 1.0. A typical transposition frequency for wild-type transposase under the conditions described here is ˜ 4×10 −6 . Relative frequencies are calculated by dividing each of the absolute frequencies by the average absolute transposition frequency of wild-type Himar1 transposase. The errors are SEM. Relative errors are computed by dividing the absolute errors by the mean absolute frequency for the wild-type transposase.
FIG. 4A is an overview of in vitro transposition assay. Purified transposase is mixed with a short 32 P-end-labeled DNA fragment containing the 5′ ITR of Himar1 and cold supercoiled plasmid target DNA. Transposition using two labeled ITR fragments is equivalent to a normal transposition event by Himar1. The target DNA was linearized and labeled with 32 P, which is easily measured by autoradiography and phosphorimaging. The rate at which the product accumulates is a measure of the transposition frequency. FIG. 4B shows typical results of the in vitro assay. Autoradiograph showing the accumulation of the radiolabeled linear transposition product for wild-type, E1 (H267R), and C9 (Q131]R/E137K) transposases, respectively, over a period of 6 h. FIG. 4C is a graphical representation of the data in FIG. 4 B. The gel was analyzed by using a Molecular Dynamics PhosphorImager. The values on the y axis are density units based on the numbers of pixels per unit area as measured by IMAGEQUANT software.
FIG. 5 illustrates an overview of the method to create random insertions into purified DNA using a mutant Himar1 transposase of the invention in vitro. The details of this assay can be found in Example 9. Briefly, in vitro transposition assay is initiated by adding purified transposase to a mixture of donor and target plasmids. After incubating at room temperature for 2 hrs, the DNA is extracted and transformed into E. coli. The transformed bacterial cells are then plated on LB-ampicillin agar plates to test for DNA recovery and on LB-ampicillin/kanamycin agar-plates to detect transposition products. The transposition frequency is scored by dividing the number of colonies that are resistant to ampicillin and kanamycin with the number of colonies that are resistant to ampicillin alone. The transposition products can also be sequenced or subjected to restriction analysis to confirm their identity.
FIGS. 6A and 6B show the GAMBIT method to identify essential genes. A critical part of this methodology utilizes in vitro Himar1 transposition. FIG. 6A shows strategy for producing chromosomal mutations by using in vitro transposon mutagenesis. FIG. 6B shows genetic footprinting for detection of essential genes.
FIG. 7 illustrates a typical scheme for using the P-element to transform D. melanogaster. All other proposed methods of transforming D. melanogaster using transposons are derivatives of this scheme. The presence of red eyes in G1 progeny indicates transposition of the P-element from the injected plasmid into the germline chromosomes which can be inherited by the progeny of the injected fly.
FIG. 8 is the amino acid sequence alignment of the wild type Himar1 transposase protein (SEQ ID NO:2) and three hyperactive mutant proteins described in the Specification as A7, C5 and C9 (SEQ ID NOs. 4, 8, and 10 respectively). The amino acid residues that are identical in all four proteins are indicated as dots in the mutant proteins.
DETAILED DESCRIPTION OF THE INVENTION
The following definitions are provided to remove any ambiguities as to intent or scope of their usage in the specifications and claims.
A “wild type Himar1 transposase” is intended to mean a transposase which occurs in nature and contains the amino acid sequence as given in SEQ ID NO:2. This transposase is used as control to compare the transposition frequency of the mutant transposases of the invention. A “mutant” Himar1 transposase refers to a transposase which is different from the wild type transposase in one or more amino acid residues as exemplified herein. The mutant Himar1 transposases can be generated by point mutations, substition, deletion, or insertion mutations and identified as having a higher transposition frequency than the control transposase employing the assays disclosed herein. The present invention discloses six mutant Himar1 transposases which exhibit a transposition frequency at least about-two fold higher than the control transposase in the mating-out assay described herein. The transposition frequency of a mutant Himar1 transposase can also be measured in any art-recognized assay such as an in vitro transposition assay or a mating-out assay as described in the present invention along with a control transposase. Of the six mutants, the A7 (SEQ ID NOs:3 and 4) and C9 (SEQ ID NOs:9 and 10) mutants contain two amino acid changes as shown in FIG. 8 and four mutants named C5, E1, B1 and B2 contain single amino acid substitutions as follows: C5 (E66G, SEQ ID NOs:7 and 8), E1(H267R, SEQ ID NOs:5 and 6), B1(Q131R, SEQ ID NOs:11 ans 12) and B2(E137K, SEQ ID NOs:13 and 14). Synonymous codings are within the scope of the present invention, and are well within the grasp of the ordinary skilled artisan without the expense of undue experimenation, given the teachings of the present disclosure taken with what is well known in the art.
“A host” or “host cell” as used herein refers to an organism, cell or tissue which serves as target or recipient for transposable elements to insert themselves into. A host cell or host can also indicate a cell or host which expresses a recombinant protein of interest when the host cell is transformed with an expression vector containing a gene of interest.
The term “vector” refers to a nucleic acid molecule capable of transporting another nucleic acid molecule to which it has been linked. One type of vector is a plasmid vector which often contains a coding sequence for a selectable marker (e.g. antibiotic resistance gene). Certain vectors are capable of directing the expression of a gene to which they are operably linked. Such vectors are referred to herein as “expression vectors”.
The “expression vectors” of the invention comprise a nucleic acid encoding a mutated transposase of Himar1 operably linked for expression of the nucleic acid in a host cell, which means that the vectors include one or more regulatory sequences, selected on the basis of the host cells to be used in a manner suitable for expression. The term, “regulatory sequences” is intended to include promoters, enhancers, transcription termination signals, polyadenylation sequences, and other expression control elements.
The term, “transformation” or “transfection” refers to a method of introducing DNA into a host cell. Transformation or transfection can be carried out by various methods known in the art including electroporation, calcium-phosphate precipitation, protoplast fusion etc.
“Primer” refers to a single stranded deoxynucleic acid molecule of at least about 10 nucleotides in length up to generally about 25 nucleotides in length.
The present invention is based on the discovery that certain mutants of the Himar1 mariner transposases exhibit an increased frequency of transposition in vitro compared to that of wild type Himar1 transposase. Because of the wide host range of the Himar1 transposons and the fact that no host factors are required for transposition to occur, the mutants described herein are useful as genetic tools in a variety of methods which require a transposition event in vitro and in vivo.
To introduce a mutation in the coding region of the Himar1 transposase, error-prone PCR was employed to create a pool of transposase mutants as shown in FIG. 2A. A papillation screen was used to detect altered levels of transposition frequency. The Himar1 papillation screen is based on the ability of Himar1 to mobilize a nonautonomous Himar1 transposon carrying an in-frame fusion of a lazZ gene off an F plasmid and into the E. coli chromasome. If the transposon insertion fuses in frame with an expressed E. coli gene, a protein fusion can be produced that contains β-gal activity. The Lac(+) subpopularion of cells in an otherwise Lac(−) E. coli colony can metabolize lactose if plated on MacConkey agar. The Lac(+) cells grow faster than the surrounding Lac(−) cells and thus will produce bumps, or papillae, on the colony. Moreover, these paillae turn red on MacConkey lactose agar because of the production of lactic acid and its detection by the neutral red in the media. The greater the number of papillae produced after a given period of time, the greater is the frequency of transposition.
Transposition of Himar1 in E. coli was readily detected by using the papillation screen. Papillation only occurred when using Himar1 transposase constructs. The proportion of colonies showing any transpositional activity depended strongly on the concentration of MnCl 2 used in the error-prone PCR. Using 250 μM MnCl 2 , we recovered only one hypertransposer (A7) among 2,500 colonies screened, the vast majority of which were nulls or hypomorphs, presumably through introduction of multiple mutations. Using 100 μM MnCl 2 , the number of colonies showing papillation of some degree to ≈30% was increased and 10 potential hypertransposers were recovered from 2,300 colonies screened.
A mating-out assay was used to measure quantitatively the relative frequency of transposition produced by individual transposases [Huisman and Kleckner, (1987) supra;
Johnson and Reznikoff, (1984) J. Mol. Biol. 177:645-661]. This assay measures the frequency with which an F plasmid is used as a target by a nonautonomous Himar1 transposon mobilized by a given transposase source. After mating the target F plasmids to a recipient strain, the transposition frequency is determined by measuring the ratio of F plasmids carrying KanR (the marker in Himar1 ) to all exconjugates (FIG. 2 B).
Two mutants, named A7 and C9, were particularly active in the papillation screen and so were chosen for further analysis in the mating-out assay. The A7 mutant was ≈10-fold more active in E. coli than the wild type whereas the C9 mutant was ≈50-fold more active (FIG. 3 ). Sequencing showed that both mutants contained multiple amino acid changes (two each in A7 and C9). By substituting wild-type sequences for mutated ones and testing the isolated mutant amino acid changes again in the papillation assay, it was possible to determine which amino acid changes actually conferred the hyperactivity. Doing this, it was found that a H267R change in mutant A7 (this mutant is renamed as E1) and both the Q131R and E137K changes in mutant C9 conferred hyperactivity (FIG. 1 ). Testing the individual C9 mutations in the mating-out assay showed that the Q131R mutation alone (this mutant is named B1) was ≈4-fold more hyperactive whereas the E137K alone (this mutant is named B2) was ≈20-fold more hyperactive. The combination of these mutations is ≈50-fold more active, indicating that these mutations act synergistically, and not simply additively.
Most of the seemingly hyperactive mutants isolated in the papillation assay were not hyperactive in the mating-out assay. The reason for this is unclear, but false positive results have been reported in similar assays with both Tn10 and Tn5 [Huisman and Kleckner (1987) supra; Krebs and Raznikoff (1988) supra]. Wild-type Himar1 is most active at 30° C. [Lampe, et al. (1998) supra], so the fact that the mutants were isolated at 32° C. and their activity was measured at 37° C. indicates that A7 and C9 are more stable at the higher temperature used for the mating-out assay.
To examine whether the hyperactive mutations described above were attributable to some novel interaction with the E. coli host and not to some property in the transposase itself, purified E1 and C9 transposases were tested in an in vitro transposition assay. This assay measured the relative ability of purified transposase to process and insert two 32 P end-labeled ITR DNA fragments into an unlabeled supercoiled DNA target, thus producing a labeled linear transposition product that is easily quantified (FIG. 4 A). The rate at which this labeled product accumulates is a measure of transposition frequency. FIGS. 4B and 4C show that the E1 and C9 transposases were both hyperactive compared with the wild type. By measuring the slopes of the linear portions of the curves in FIG. 4C (between 1 and 5 h), one can compare the rate of product accumulation. By this analysis, the A7 transposase was 4.8-fold more active than the wild type whereas C9 was 7-fold more active. Thus, the purified transposases were less active in the in vitro assay than in the mating-out assay. These results, however, do confirm that hyperactivity is intrinsic to the transposase protein and not the result of some novel interaction with E. coli.
In vitro mutagenesis is rapidly becoming an important tool for studies of gene function. The Himar1 mariner system has been used to mutagenize targeted genomic regions of the chromosome of a human respiratory pathogen, Haemophilus influenzae [ Akerly, et al. (1998) supra]. Analysis of such regions is enhanced by using large pools of mutants, which requires high efficiency of transposition. This system was used to test whether the hyperactive transposases could improve mutagenesis frequencies. Wild-type, A7, and C9 transposases were tested for the ability to move the minimariner element Tn-magellan1 carrying the gene for kanamycin resistance into a PCR-amplified chromosomal segment of H. influenzae. After repair of single-strand gaps introduced into the target DNA by the transposition reaction, DNA was transformed into competent H. influenzae cultures as described [Akerly, et al. (1998) supra]. The number of Kan-resistant H. influenzae colonies obtained with the wild-type, A7, and C9 transposases were 217±122, 633±50, and 733±49, respectively. These results indicate that mutagenesis of H. influenzae with Himar1 is significantly improved by the use of hyperactive transposases of the present invention.
Mariner transposons are well known for their wide distribution in animals, which suggests that they do not rely on any host-specific factors for transposition. Indeed, members of the Tcl-mariner1 superfamily are active in a wide range of organisms, and both Tcl and Himar1 transposases are capable of catalyzing transposition in the absence of any host proteins [Lampe, et al. (1996) supra; Vos, et al. (1996) Genes Dev. 7:1244-1253. The recent finding that Himar1 is active in E. Coli [Rubin, et al. (1999) supra] has provided the opportunity to utilize bacterial genetic methods to create and study transposase mutants of this eukaryotic transposon in a manner that would be very difficult in a metazoan system. Mutants of MosI mariner have been isolated by ethane methyl-sulfonate (EMS) mutagenesis in Drosophila melanogaster, but this system is laborious, and only mutations that negatively affected transposition were detected [Lohe, et al. (1997) supra]. The combination of the papillation screen and mating-out assay in E. Coli described above is a simple method to produce mutants of mariners and any other related transposases and ascertain their level of activity.
Two hyperactive mutants (A7 and C9) disclosed herein are double mutants. The fact that both amino acid changes in C9 mutant contributed synergistically to the overall hyperactivity in a quantitative mating assay suggests that additional combinations of mutants constructed directly, or by shuffling during the mutagenesis, might be even more hyperactive.
Although there is no structural data available for the Himar1 transposase, analysis of the mutant sequence along with comparison to other known transposases suggests the locations of functional domains. The only structural information for any of the Tcl-mariner superfamily of transposons is that for the Caenorhabditis elegans transposase Tc3, and then only for the specific DNA binding domain, a region that does not include the Himar1 mutations [van Pouderoyen, et al. (1997) EMBO J. 16:6044-6054]. Functional studies have been performed for both Tcl and Tc3 transposases that demonstrated the existence of a separate, nonspecific DNA binding domain in each [Vos, et al. (1993) Genes Dev. 7:1244-1253; Colloms, et al. (1994) Nucleic Acids Res. 22:5548-5554]. By comparing Tcl and Tc3 transposases and computer models [Pietrokovski and Henikoff (1997) Mol. Gen. Gener. 254:689-695] with Himar1 transposase, specific DNA binding is likely to be encoded by the first approximately 113 amino acids of Himar1 , nonspecific DNA binding by approximately amino acids 114-173, and catalysis by at least amino acids 158-287, the first and last amino acids of the D, D34D catalytic triad (FIG. 1 ). The C-terminal-most region is of unknown function. Given the fact that the Q131R and E137K mutations occur in a region of the transposase implicated in nonspecific DNA binding, the enhanced activity in these mutants may be attributable to increased affinity for DNA in general (FIG. 1 ). Similarly, the H267R mutation, which occurs in the putative catalytic domain, may be attributable to increased or altered catalysis. In Tn5 transposase, these various regions are known to overlap extensively, so a mutation in one region may affect a completely different property of the transposase [Braam, et al. (1999) J. Biol. Chem. 274:86-92]. Indeed, the ways in which a transposase can be hyperactive are diverse. For example, at least three different classes of hyperactive mutations have been uncovered for Tn5. These affect the production of cotranslated inhibitor protein [Wiegand and Reznikoff (1992) J. Bacteriol. 174:1229-1239], an increase in the affinity of Tn5 transposase for ITR DNA [Zhou and Reznikoff (1997) J. Mol. Biol. 271:362-373], and a decrease in the self-inhibitory activity of intact Tn5 transposase [Weinreich, et al. (1994) Genes. Dev. 8:2363-2374]. The combination of these three classes of hyperactive mutants are synergistic, leading to an extraordinarily active transposase [Goryshin and Reznikoff, (1998) J. Biol. Chem. 273:7367-7374].
Abundant sequence information is available for members of the Tcl-mariner family of transposons. Alignment of the available transposase sequences [Robertson and Asplund (1996) supra] allowed us to determine whether any of the amino acid replacements identified in the Himar1 hyperactive mutants are present in related transposases. Interestingly, one of the amino acid changes is present in a homologous position in the highly active Mos1 mariner. This transposase contains an arginine residue at the position of the Q131R mutation. This is not a highly conserved position in mariner transposases generally, although Tcl-like elements are biased toward basic residues at this position. The E137R mutation is not present in most other mariner family elements because this region is a unique small insertion in the irritans subfamily of mariner transposases to which Himar1 belongs. Finally, the H267R replacement of A7 is shared with one other member of the irritans subfamily (Hsmar2) and two members of the mellifera subfamily (Gpmar1) and Demar1), but again, this is not a widely conserved position in mariner transposases.
Reznikoff and coworkers have stressed that the ability to isolate hyperactive transposases of Tn5 strongly suggests it has not evolved for maximal activity [Braam, et al. (1999) supra]. Tn5 transpsase mutants have been isolated that can increase the intrinsic activity of the transposase or eliminate regulatory mechanisms [Zhou and Reznikoff (1997) supra; Weinreich, et al. (1994) Annu. Rev. Genet. 241:166-177]. Low intrinsic activity and self-regulation appear to allow Tn5 to persist in E. Coli without producing serious levels of genetic damage. The fact that hyperactive mutants for Himar1 were isolated may be attributable to similar evolutionary forces at work on mariner-family transposons. Horizontal transfer is a major feature in the evolutionary history of these mobile genes [Robertson, et al. (1998) supra; Robertson and Lampe (1995) supra; Hartl, et al. (1997) Annu. Rev. Genet. 31:337-358; Lohe, et al. (1995) Mol. Biol. Evol. 12:62-72]. Clearly, the elements must be active enough to make copies of themselves when they transfer to a new host to persist. If not, they will be eliminated because of stochastic mechanisms [Lohe, et al. (1995) supra]. Their activity, however, cannot be so high as to significantly reduce the fitness of the host. Unregulated transposition can be highly deleterious to a host organism [Engels, et al. (1987) Genetics 117:745-757]. Thus, the mariners that persist in nature are not likely to be present in their most active forms. From the standpoint of copy number in the host organism, Himar1 is very successful, being present in 17,000 copies of the H. irritans genome [Robertson and Lampe (1995) supra]. It may be that this success is attributable to a fairly benign level of activity in that genome because of either a comparatively low intrinsic activity level, some self-regulatory mechanism [Lampe, et al. (1998) supra], or both. The fact that hyperactive forms of the Himar1 transposases were isolated as disclosed herein is consistent with this view.
The primary advantage of the Himar1 mutants disclosed herein is that they make Himar1 transposition more efficient both in vivo and in vitro. For applications such as in vitro mutagenesis for identifying essential genes in an organism as described in Akerley, et al. (1998) supra, one can complete the project with much less starting material and obtain higher total numbers of desired mutants while avoiding the inherent difficulty of scaling up existing procedures. In cases where one wishes to use the transposon to mark genes in vivo, many fewer events need to be screened and in some cases the increase in transposition efficiency will allow detection of mutations which were too infrequent to be detected using previously available technology. For applications such as DNA sequencing, use of a highly efficient transposon such as hyperactive Himar1 transposase should make creation of sequencing templates quicker and easier than using existing transposases.
Hyperactive Himar1 mutants of the invention are particularly useful in creating random insertions at high frequency into purified DNA in vitro. One application for doing this is to introduce “islands” of known sequence (e.g. transposase) into unknown DNA so that the unknown DNA can be sequenced using primers derived from the known sequence. Another application of the insertions made in vitro is to knock out a gene of interest in vivo by homologous recombination if the insertion introduced in vitro is directed in the region of a gene of interest. There are kits commercially available for generating random insertions based on the primer island concept (“Primer Island Transposition Kit”, Applied Biosystems, The Perkin-Elmer Corporation, Foster City, Calif. and “Genome Priming System”, New England Biolabs, Inc.). However, the Himar1 transposases of the present invention provide higher transposition efficiency and broader host range than any system currently available. In vitro gene knock-outs can also be generated using this method depending on the location of the random Himar1 insertion in a given target DNA. The details of the methodology for introducing random Himar1 insertions into a plasmid is described in Lampe, et al. (1996) supra.
The Himar1 tranposons containing hyperactive mutant transposase can be used to generate mutants in a living organism by in vivo transposition. This is analogous to the in vitro transposition method described above except the living organism is used under controlled conditions to mobilize the transposon into random location in the genome. For this, a specific phenotypic screen needs to be designed which will allow the detection of a particular class of mutants of a given gene. The principle behind this application is outlined in FIG. 7 .
All of the utilities of the hyperactive Himar1 transposases described above can be practiced in a wide variety of prokaryotic and eukaryotic cells including humans. This eliminates the need for having to isolate endogenous transposases from an experimental system as has been the case previously.
Another utility of the Himar1 transposases of the invention lies in generating transgenes in vivo by introducing exogenous DNA into the germline of a target organism in a controlled manner, generally in single copy. The principle of this can be illustrated using the P element transposon of Drosophila as shown in FIG. 7 . Two plasmids are injected into preblastoderm embryos in the area of the presumptive germ line. One plasmid carries the transposon construct having P element terminal sequences flanking the heterologous DNA to be inserted and the other is a transposase gene lacking the DNA sequences for mobility. Tranposase produced by transcription and translation off the transposase gene construct can mobilize the modified P element off its plasmid and integrate it into the chromosome. The Himar1 transposons containing the hyperactive mutants of the present invention can be used similarly in cell culture for both eukaryotic and prokaryotic cells.
Hyperactive transposase mutants such as those described here can be used and are well suited for both in vivo and in vitro work. For in vitro applications, purified mutant protein is needed. The nucleic acids encoding three hyperactive mutants of Himar1 transposase are provided in the present specification. Therefore, one skilled in the art can readily clone the nucleic acid for a given mutant transposase into an expression vector and produce recombinant Himar1 transposase using methods described herein in combination with the techniques well known in the art. For in vivo applications, the mutant protein can be expressed in vivo from a transposon such as Himar1 comprising the nucleic acid encoding a mutant transposase. The two mutants of the invention are somewhat tolerant of high temperatures, which would be particularly useful in E. Coli and human cells. Another application of the hyperactive mutants is in functional genomic analysis to identify essential genes in an organism. A method known as GAMBIT [Akerly, et al. (1998) supra] has been used for this purpose, however, using the hyperactive mutant transposases disclosed herein will make the method more efficient. Particularly labor-intensive methods such as germline transformation could be eased by more active transposases, such as those disclosed in the present invention.
TABLE 1
Bacterial strains and plasmids used in the present invention
Strains, plasmids
Description
Strains
β2155
thrB1004 pro thi strA hsdS lacZΔM15
(F′ lacZΔM15 lacI9 traD36 proA + proB +)
ΔdapA::erm (=EmR) pir:RP4 [::kan (KmR) from
SM10]
HB101
supE44 hsdS20 (r B -m B -) recA13 ara-14
proA2 acY1 galK2 rpsL20 xyl-5 mtl-1
HBfLac
HB101 F::minHimar1 LacTet from pMMLacTet
DH5α
Δ(lac)U169 endA1 gyrA96 hsdR17 recA1
relA1 supE44 thi-1 φ80lacZΔM15
DL1
DH5α F::miniHimar1LacTet from pMMLacTet
RZ212/pOX38-Gen
D(lac-pro), ara, str recA56, srl, thi,
RZ212MK
RZ212/ pACMarKan (mating-out strain)
RZ221
polA, Δ(lac-pro), ara, str nal
BL21(DE3)
F-, omp T, r B -m B - | DE3
Plasmids
pMMOrf
Like pMMar but with ORF througth 3′ ITR
pMMLacTet
pMMOrf containing lacZYA and Tet r gene
pBCMAR
Himar1 coding sequence under P lac control
pMarNco
Himar1 coding sequence with NcoI at start site
pRZ1495
Tn5 papillation factor
p27fH-5′
pK19 containing left (5′) ITR of Himar1
pACMarKan
pACYC184 carrying Kan r Himar1
pMarNde18
Himar1 lacking ITR sequences
pMinimariner
Himar1 of only the first and last 100 bp
pBAD24
Expression plasmid with ara BAD promoter
pBADMar1
Himar1 tpase under ara BAD promoter
pBADH267R
As pBADMar1 but with H267R mutation
pBADC9
As pBADMar1 but with Q131R and E137K
mutations in Himar1 tpase
pET29A7
pET29b+ carrying H267R mutation in Himar1 tpase
pET29C9
pET29b+ carrying Q131R and E137K mutations
in Himar1 tpase
pCDNAII
Target plasmid for in vitro reactions
Techniques and agents for introducing and selecting for the presence of heterologous DNA in animal cells, insect cells, yeast cells, bacterial cells, plant cells and/or tissue are well-known. Genetic markers allowing for the selection of heterologous DNA in plant and other eukaryotic cells are well-known, e.g., genes carrying resistance to an antibiotic such as kanamycin, hygromycin, gentamicin, or bleomycin. The marker allows for selection of successfully transformed cells growing in the medium containing the appropriate antibiotic because they will carry the corresponding resistance gene. Selective markers for bacterial cells are also well known, and include those resistant to kanamycin, ampicillin, tetracycline, chloramphenicol, mercuric ion, among others. The skilled artisan can readily select an appropriate selective marker for a particular cell or strain and a particular vector and/or resistance gene.
Techniques for genetically engineering animal, insect, yeast, plant or bacterial cells and/or tissue to contain and express a transposase of the present invention are well known to the art, and the choice of a method for introducing heterologous DNA depends on the cell to be so modified. Techniques include Agrobacterium-mediated transformation, electroporation, microinjection, particle bombardment, transformation, transfection or other techniques known to the art.
Many of the procedures useful for practicing the present invention, whether or not described herein detail, are well known to those skilled in the art of molecular biology. Standard techniques for cloning, DNA isolation, amplification and purification, for enzymatic reactions involving DNA ligase, DNA polymerase, restriction endonucleases and the like, and various separation techniques are those known and commonly employed by those skilled in the art. A number of standard techniques are described in Sambrook, et al. (1989) Molecular Cloning, Second Edition, Cold Spring Harbor Laboratory, Plainview, N.Y.; Maniatis, et al. (1982) Molecular Cloning, Cold Spring Harbor Laboratory, Plainview, N.Y.; Wu (ed.) (1993) Meth. Enzymol. 218: Part I; Wu (ed) (1979) Meth Enzymol 68; Wu, et al. (eds) (1983) Meth. Enzymol. 100 and 101; Grossman and Modave (eds.) Meth. Enzymol. 65: Miller (ed.) (1972) Experiments in Molecular Genetics, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.; Old and Primrose (1981) Principles of Gene Manipulation University of California Press, Berkeley; Schleif and Wensink (1982) Practical Methods in Molecular Biology; Glover (ed.) (1985) DA Cloning Vol. I and II, IRL Press, UK; Hames and Higgins (eds.) (1985) Nucleic Acid Hybridization, IRL Press, Oxford, UK; and Setldow and Hollaender (1979) Genetic Engineering: Principles and Methods, Vols. 1-4, Plenum Press, New York, Kaufman (1987) in Genetics Engineering Principles and Methods, J. K. Setlow, ed., Plenum Press, NY, pp. 155-198; Fitchen, et al. (1993) Annu. Rev. Microbiol. 47:739-764; Tolstoshev, et al. (1993) in Genomic Research in Molecular Medicine and Virology, Academic Press. Abbreviations and nomenclature, where employed, are deemed standard in the field and commonly used in professional journals such as those cited herein.
All references cited in the present application are incorporated by reference herein to the extent that they are not inconsistent with the present disclosure.
EXAMPLES
The following examples are provided for illustrative purposes, and are not intended to limit the scope of the invention as claimed herein. Any variations in the exemplified articles which occur to the skilled artisan are intended to fall within the scope of the present invention.
Example 1
Media and Antibiotics
Strains were grown at the temperatures indicated in LB broth or on agar plates prepared as described [Sambrook, et al. (1989) Molecular Cloning A Laboratory Manual (Cold Spring Harbor Lab. Press, Plainview, N.Y.)]. Papillation assays were performed on thick McConkey lactose agar plates. Antibiotics concentrations were ampicillin (Amp), 100 μg; gentamicin (Gen), 10 μg; kanamycin (Kan), 40 μg; tetracycline (Tet), 34 μg; naladixic acid (Nal), 20 μg; chloramphenicol (Cam), 34 μg, all per ml, respectively, except where otherwise noted.
Example 2
Plasmids and Bacterial Strains
pMarNco was constructed via PCR using the primers 5′-CCCCTCGAGCCATGGAAAAAAAGGAATTTCGTG-3′ (SEQ ID NO:15) and 5′-CCGCTCAGAATCATCAACACGTT-3′ (SEQ ID NO:16) and pMarNde18 [Lampe, et al. (1996) supra] as a template. The resulting PCR fragment and pMarNde18 were cut with XhoI and EcoRV and were ligated to created pMarNco, which contains the Himar1 transposase coding sequence with an NcoI site at the start codon. pBCMar was constructed by cleaving pMarNde18 with PstI, creating a blunt end using T4 DNA polymerase, then digesting with XhoI. The fragment that encodes the transposase was gel purified and cloned into pBCKS+ that had been digested with XhoI and Ecl1361.
A miniHimar1 transposon containing an ORF through the 3′ inverted terminal repeat (ITR) was constructed by PCR using a PCR-ligation-PCR method [Ali and Steinkasserer, (1995) BioTechniques 18:746-750]. The 5′ ITR was amplified with primers 5′ TACCCGGGAATCATTTGAAGGTTGGTAC (76rSma, SEQ ID NO:17) and 5′ TAATACGACTCACTATAGGG (T7, SEQ ID NO:18), and the 3′ ITR was amplified with the primers 5′AACGAATTTTAACAAAAAAATGTG (Mar3′r, SEQ ID NO:19) and 5′CGATTTAGGTGACACTATAG (SP6, SEQ ID NO:20), both using pMinimariner [Lampe, et al. (19989) supra] as a template and Pfu polymerase. The two separate PCR reactions were treated with T4 polynucleotide kinase and ATP. Five microliters of each kinase reaction were ligated with T4 DNA ligase for 15 min at room temperature. Another PCR reaction then was performed by using the SP6 and T7 primers and 1 μl of the ligation as a template, using Taq DNA polymerase. The resulting product was cloned as a t-tailed fragment into a pTAdv1 (CLONETECH, Palo Alto, Calif.), producing pTAdvMMOrf. This clone was cut with BamHI, and the fragment containing the minimariner was isolated and ligated to the BamHI site of pCDNAII (Invitrogen, Carlsbad, Calif.) to produced pMMOrf which contains a unique BglII site in the middle of the element.
A papillation construct was produced by cleaving pMMOrf with BglII and ligating it to the BamHI/BglII fragment of pRZ1495 [Makris, et al. (1998) Proc. Natl. Acad. Sci. USA 85:2224-2228] to produce pMMLacTet. The lacZ gene of this insert has no transcriptional or translational controls [Hediger, et al. (1985) Proc. Natl. Acad. Sci. USA 82:6414-6418].
An F-plasmid containing the papillation transposon from pMMLacTet was produced by transforming E. Coli β 2155 [Dehlo and Meyer (1997) J. Bacteriol. 179:538-540] by electroporation with pMCMar and pMMLacTet with selection on Amp, Cam (20 μg/ml), and diaminopimelic acid. Diaminopimelic acid is required for growth of β2155, which is a dapA mutant. Approximately 5,000 colonies were pooled and mixed with HB101 for a 6 h of mating on LB agar. Exconjugants in which the F′ from β2155 was mated out into HB101 were selected on Tet and Xgal (20 μg/ml) in the absence of diaminopimelic acid, resulting in colonies that were dark blue, light blue, white, or mosaic. White colonies were picked and colony purified on a second LB-Tet-Xgal plate. Resulting clones were patched to plates containing either Amp, Cam, Kan, or Tet, and clones confirmed to be Amp s , Cam s , Kan s , and Tet R were named HBFlac.
To verify that the HBFlac strains contain functional Himar1′lacZ elements, they were transformed with pBCMar and were selected on Cam and Xgal. The resulting colonies were dark blue, light blue, white and mixed (i.e., exhibited blue papillae on white colonies). The F′ from HBFlac3 (the lightest blue strain) was transferred to DH5α by conjugation with selection on Nal and Tet, yielding the strain DL1.
A Himar1 transposon for use in the mating-out assay was constructed by ligating the BamHI/EagI fragment of pMarKan [Lampe, et al. (1996) supra] containing a KanR-marked Himar1 transposon to the BamHI/EagI fragment of pACYC184, resulting in the plasmid pACMarKan.
E. Coli protein expression plasmids were made for each of the hyperactive transposase mutants by cutting the pBAD24 vectors containing the hyperactive inserts with NcoI, making this site blunt with Klenow, and cutting again with KpnI. The coding sequence fragments were purified from a 0.5% 1×TAE (40 mM Tris-acetate/1 mM EDTA) gel and were ligated to the NdeI (made blunt with Klenow as above)/KpnI sites of pET29b+ (Novagen, Madison, Wis.), yielding pET29A7 and pET29C9 for the pBADA7- and pBADC9-containing transposase mutants, respectively. A vector capable of expressing C5 mutant protein can be prepared similarly.
Example 3
Transposase Mutagenesis
Mutations were introduced into the coding region of Himar1 transposase by error-prone PCR using pMarNco as a template [Zhou and Reznikoff (1997) J. Mol. Biol. 271:362-373]. The reactions contained ≈2 ng of template DNA, 50 mM KCl, 10 mM Tris HCl (pH 9.0 at 25° C.), 0.1 % Triton X-100, 1.5 mM MgCl2, and either 200 or 100 μM MnCl 2 in a volume of 25 μl and were run for 30 cycles at 95° C. for 1 min, 52° C. for 1 min, and 75° C. for 1.5 min. PCR products were cut with NcoI and PstI at 37° C. for 45 min. The cleaved products were isolated from a 0.5% agarose gel in 1×TAE buffer by using a Qiagen (Chatsworth, Calif. ) gel purification kit. Purified products were ligated into the NcoI and PstI sites of pBAD24 [Guzman, et al. (1995) J. Bacteriol. 177:4121-4130]. These ligation reactions were used as the source of transposase mutants in the papillation assay.
Example 4
Papillation Assay
A papillation assay to detect mutants of Himar1 was performed by transforming 1 μl of a ligation of mutated Himar1 coding sequences in pBAD24 into electrocompetent DL1 cells (see FIG. 2 A). Screens of similar design have been used for bacterial transposons, including in Tn5 and Tn10 transposases [Huisman and Kleckner, (1987) Genetics 116:185-189; Krebs and Reznikoff, (1988) Gene 63:277-285; Reznikoff, et al. (1993) Methods Enzymol 217:312-322 ]. Cells also were transformed with pBAD-Marl as a wild-type control. Transformed cells were resuspended in 1 ml of cold LB medium and were shaken at 37° C. for 1 h. Dilutions of these cells were plated onto thick (50 ml in 100-×15-mm dishes) MacConkey lactose agar plates containing Amp and Tet so that there were ≈100-150 colonies per plate, and the plates were incubated at 32° C. for 2-3 days. Typically, papillae could be detected by using the wild-type transposase source at ≈50 h after plating. Potential hypertransposers were picked and grown overnight in LB with Amp, and the mutant transposase source DNA was purified. Putative hypertransposers were examined again by using the papillation assay to confirm hyperactivity.
Example 5
Mating-Out Assay
A mating-out assay, which measures the frequency of transposition of a KanR Himar1 minitransposon from a plasmid to an F factor, was carried out to quantify the activity of the putative hyperactive mutants (see FIG. 2 B). RZ212(MK) cells were transformed with individual mutant transpose sources isolated in the papillation assay, and the cells were grown as above. Cells were plated on LB agar containing Amp, Gen, and Cam and were grown overnight at 37° C. Five colonies were picked the following day and were grown for 16 h in LB containing Amp, Gen, and Kan at 37° C. These cells were mated to RZ221 cells by mixing 10 μl of recipient cells from overnight cultures in 1 ml of LB medium. The mating mixture was shaken gently at 37° C. for 6-10 h. Mating cultures were vortexed vigorously, and suitable dilutions were plated on LB agar plates containing Nal and Gen to detect total numbers of exconjugates and Nal and Kan to measure the number of exconjugates that contained a Himar1 insertion.
Example 6
Transposase Purification
Transposases were purified as described in Lampe, et al. (1996) supra. Protein purity was determined by Coomassie blue-stained 10-20% polyacrylamide gradient gels. Protein concentrations were determined spectrophotometrically as described in Lampe, et al. (1998) supra and were confirmed visually on Coomassie blue-stained 4-20% SDS/PAGE gels.
Example 7
In Vitro Transposition Assay
Comparative rates of transposition were determined by measuring the relative ability of the transposases to incorporate a radiolabeled DNA fragment containing the left ITR of Himar1 into an unlabeled supercoiled plasmid target in a reaction similar to that for Tn10 in vitro (FIG. 4) [Kennedy and Haniford, D. B. (1996) J. Mol. Biol. 256:533-547]. The fragment containing the ITR was labeled by cutting p27fH5′ [Lampe, et al. (1996) supra] with EcoRI and isolating the 111-bp fragment on a 1.5%, 1×TAE agarose gel. The DNA was purified from the agarose as described above and then was radiolabeled by filling the overhanging ends with 32 P-α-dATP using Klenow enzyme under standard conditions. The reaction was stopped by heating to 70° C. for 20 min, and the labeled DNA was purified by passing the reaction over a G50 spin column.
Transposition reactions contained 10% glycerol (vol/vol), 25 mM Hepes (pH 7.9 at room temperature), 250 μg acetylated BSA, 2 mM DTT, 100 mM NaCl, 5 mM MgCl 2 , 450 ng of target plasmid DNA, ≈10,000 cpm labeled ITR DNA, and a 10 nM concentration of one of the purified transposases. Reactions were performed at 28° C., the optimal temperature for wild-type Himar1 transposase [Lampe, et al. (1998) supra]. Ten-microliter aliquots were removed at 1-h intervals of 6 h, and the reaction was stopped by adding 2 μl of stop solution (60 mM EDTA/0.25% bromophenol blue/0.25% xylene cyanol/15% ficoll). Reaction products were separated on a 0.5 % 1×TE agarose gel. The gel was photographed, was placed on a piece of exposed x-ray film as a support, and then was dried until completely flat in a forced-air oven set at 55 ° C. for 5-6 h. Reaction products in dried gels were analyzed by using a Molecular Dynamics PhosphorImager (Molecular Dynamics, Sunnyvale, Calif.) and IMAGEQUANT software (Molecular Dynamics, Sunnyvale, Calif.).
Example 8
Mutagenesis of Haemophilus influenzae
In vitro reactions for H. influenzae mutagenesis were conducted as above except that 100 nM transposase was added to reactions containing 500 ng of target PCR product and 200 ng of transposon donor plasmid pENT3 carrying Tn-magellan1. Independent reactions and transformations were performed in triplicate. Repair of transposon junctions and transformation of H. influenzae was as described [Akerley, et al. (1998) Proc. Natl. Acad. Sci. USA. 95:8927-8932].
Example 9
Genetic Assay for in vitro Transposition
In vitro transposition assays were carried out in 10% glycerol (v/v), 25 mM HEPES (pH 7.9 at room temperature), 250 μg of acetylated bovine serum albumin (BSA). 2 mM DDT, 100 mM NaCl and 5 mM MgCl 2 , and contained ˜12.5 nM purified transposase in a final volume of 20 μl. The donor plasmid was pMarKan described in Lampe, et al. (1996) supra. The target plasmid was a naturally occurring tetramer of pBSKS+. Approximately 12 fmol (˜100 ng) of target DNA and 12 fmol of donor DNA (˜32 ng) were used per each 20 μl reaction. The reactions wee allowed to incubate for 2 h at room temperature. They were then stopped by the addition of 80 μl of stop solution (50 mM Tris-HCl, pH 7.6; 0.5 mg/ml proteinase K: 10 mM EDTA; 250 μg/ml yeast tRNA), and allowed to incubate at 37° C. for 30 min after which they were phenol/chloroform extracted and precipitated using standard techniques. The precipitated DNA was resuspended in 10 μl of TE and 1 μl was electrotransformed into TOP10F′ E. Coli cells (Invitrogen) using a BRL electroporation device following the manufacturer's instructions. One ml of SOC (0.5% yeast extract, 2% tryptone, 10 mM NaCl, 2.5 mM KCl, 10 mM MgCl 2 , 20 mM MgSO 4 , 20 mM glucose) was added to the transformed cells and the suspension incubated at 37° C. with vigorous shaking for 45 min. One μl of the cells was plated on LB-ampicillin (100 μg/ml) agar plates to test for DNA recovery and 500 μl were plated on LB-ampicillin (100 μg/ml)-kanamycin (30 μg/ml) agar plates to detect transposition products. DNA from potential transposition products was prepared by a boiling miniprep method (Sambrook, et al. 1989) and examined by restriction digestion and sequencing. Reactions containing Mn 2+ were performed identically except 5 mM MnCl 2 was substituted for MgCl 2 in the in vitro assay. Controls were performed by adding a mock transposase extract in place of purified transposase. This extract was made from uninduced E. Coli cells carrying the pET 13a/mariner construct in a manner identical to that of induced cells.
Example 10
Identification of Essential Genes Using the Himar1 Mutant Transposase
The details of this method is provided in Akerley, et al. (1998) Proc. Natl. Acad. Sci. USA 95:8927-8932 and Akerley, et al. WO 99/50402. As illustrated in FIG. 6, target DNA is mutagenized in vitro with the modified Himar1 transposon containing one of the mutant transposases disclosed herein and introduced into bacteria by transformation and homologous recombination. Recombinants were selected for drug resistance encoded by the transposon, and insertions in essential genes were lost from the pool during growth. PCR with primers that hybridize to the transposon and to specific chromosomal sites yields a product corresponding to each mutation in the pool. DNA regions containing no insertions yield a blank region on the electrophoresis gels.
20
1
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
1
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agt gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tca aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gca aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa caa cgt gtt gat gat tct gag cgg tgt ttg cag ctg tta act 432
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgt aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
aca gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cat gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
2
348
PRT
Haematobia irritans
2
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
3
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
3
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agc gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tcg aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gca aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa caa cgt gtt gat gat tct gag cgg tgt ttg cag ctg tta act 432
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgc aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
acg gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cgt gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile Arg Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac cga aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Arg Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
4
348
PRT
Haematobia irritans
4
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile Arg Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Arg Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
5
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
5
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agc gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tcg aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gca aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa caa cgt gtt gat gat tct gag cgg tgt ttg cag ctg tta act 432
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgc aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
acg gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cgt gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile Arg Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
6
348
PRT
Haematobia irritans
6
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile Arg Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
7
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
7
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tcc gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agt gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa ggg gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Gly Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tca aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gca aaa tgg gtg ccg cgc gag ctc aca ctt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Leu Asp Gln
115 120 125
aaa caa caa cgt gtt gat gat tct gag cgg tgt ttg cag ctg tta act 432
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgt aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
aca gcg acc ggt gaa ccg act ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Thr Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cat gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
8
348
PRT
Haematobia irritans
8
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Gly Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Leu Asp Gln
115 120 125
Lys Gln Gln Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Thr Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
9
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
9
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agt gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tca aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gcg aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa cga cgt gtt gat gat tct aag cgg tgt ttg cag ctg tta act 432
Lys Gln Arg Arg Val Asp Asp Ser Lys Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgt aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
aca gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cat gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
10
348
PRT
Haematobia irritans
10
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Arg Arg Val Asp Asp Ser Lys Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
11
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
11
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agt gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tca aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gcg aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa cga cgt gtt gat gat tct gag cgg tgt ttg cag ctg tta act 432
Lys Gln Arg Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgt aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
aca gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cat gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
12
348
PRT
Haematobia irritans
12
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Arg Arg Val Asp Asp Ser Glu Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
13
1047
DNA
Haematobia irritans
CDS
(1)..(1044)
13
atg gaa aaa aag gaa ttt cgt gtt ttg ata aaa tac tgt ttt ctg aag 48
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
gga aaa aat aca gtg gaa gca aaa act tgg ctt gat aat gag ttt ccg 96
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
gac tct gcc cca ggg aaa tca aca ata att gat tgg tat gca aaa ttc 144
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
aag cgt ggt gaa atg agc acg gag gac ggt gaa cgc agt gga cgc ccg 192
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
aaa gag gtg gtt acc gac gaa aac atc aaa aaa atc cac aaa atg att 240
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
ttg aat gac cgt aaa atg aag ttg atc gag ata gca gag gcc tta aag 288
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
ata tca aag gaa cgt gtt ggt cat atc att cat caa tat ttg gat atg 336
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
cgg aag ctc tgt gcg aaa tgg gtg ccg cgc gag ctc aca ttt gac caa 384
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
aaa caa caa cgt gtt gat gat tct aag cgg tgt ttg cag ctg tta act 432
Lys Gln Gln Arg Val Asp Asp Ser Lys Arg Cys Leu Gln Leu Leu Thr
130 135 140
cgt aat aca ccc gag ttt ttc cgt cga tat gtg aca atg gat gaa aca 480
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
tgg ctc cat cac tac act cct gag tcc aat cga cag tcg gct gag tgg 528
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
aca gcg acc ggt gaa ccg tct ccg aag cgt gga aag act caa aag tcc 576
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
gct ggc aaa gta atg gcc tct gtt ttt tgg gat gcg cat gga ata att 624
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
ttt atc gat tat ctt gag aag gga aaa acc atc aac agt gac tat tat 672
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
atg gcg tta ttg gag cgt ttg aag gtc gaa atc gcg gca aaa cgg ccc 720
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
cac atg aag aag aaa aaa gtg ttg ttc cac caa gac aac gca ccg tgc 768
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
cac aag tca ttg aga acg atg gca aaa att cat gaa ttg ggc ttc gaa 816
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
ttg ctt ccc cac ccg ccg tat tct cca gat ctg gcc ccc agc gac ttt 864
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
ttc ttg ttc tca gac ctc aaa agg atg ctc gca ggg aaa aaa ttt ggc 912
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
tgc aat gaa gag gtg atc gcc gaa act gag gcc tat ttt gag gca aaa 960
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
ccg aag gag tac tac caa aat ggt atc aaa aaa ttg gaa ggt cgt tat 1008
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
aat cgt tgt atc gct ctt gaa ggg aac tat gtt gaa taa 1047
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
14
348
PRT
Haematobia irritans
14
Met Glu Lys Lys Glu Phe Arg Val Leu Ile Lys Tyr Cys Phe Leu Lys
1 5 10 15
Gly Lys Asn Thr Val Glu Ala Lys Thr Trp Leu Asp Asn Glu Phe Pro
20 25 30
Asp Ser Ala Pro Gly Lys Ser Thr Ile Ile Asp Trp Tyr Ala Lys Phe
35 40 45
Lys Arg Gly Glu Met Ser Thr Glu Asp Gly Glu Arg Ser Gly Arg Pro
50 55 60
Lys Glu Val Val Thr Asp Glu Asn Ile Lys Lys Ile His Lys Met Ile
65 70 75 80
Leu Asn Asp Arg Lys Met Lys Leu Ile Glu Ile Ala Glu Ala Leu Lys
85 90 95
Ile Ser Lys Glu Arg Val Gly His Ile Ile His Gln Tyr Leu Asp Met
100 105 110
Arg Lys Leu Cys Ala Lys Trp Val Pro Arg Glu Leu Thr Phe Asp Gln
115 120 125
Lys Gln Gln Arg Val Asp Asp Ser Lys Arg Cys Leu Gln Leu Leu Thr
130 135 140
Arg Asn Thr Pro Glu Phe Phe Arg Arg Tyr Val Thr Met Asp Glu Thr
145 150 155 160
Trp Leu His His Tyr Thr Pro Glu Ser Asn Arg Gln Ser Ala Glu Trp
165 170 175
Thr Ala Thr Gly Glu Pro Ser Pro Lys Arg Gly Lys Thr Gln Lys Ser
180 185 190
Ala Gly Lys Val Met Ala Ser Val Phe Trp Asp Ala His Gly Ile Ile
195 200 205
Phe Ile Asp Tyr Leu Glu Lys Gly Lys Thr Ile Asn Ser Asp Tyr Tyr
210 215 220
Met Ala Leu Leu Glu Arg Leu Lys Val Glu Ile Ala Ala Lys Arg Pro
225 230 235 240
His Met Lys Lys Lys Lys Val Leu Phe His Gln Asp Asn Ala Pro Cys
245 250 255
His Lys Ser Leu Arg Thr Met Ala Lys Ile His Glu Leu Gly Phe Glu
260 265 270
Leu Leu Pro His Pro Pro Tyr Ser Pro Asp Leu Ala Pro Ser Asp Phe
275 280 285
Phe Leu Phe Ser Asp Leu Lys Arg Met Leu Ala Gly Lys Lys Phe Gly
290 295 300
Cys Asn Glu Glu Val Ile Ala Glu Thr Glu Ala Tyr Phe Glu Ala Lys
305 310 315 320
Pro Lys Glu Tyr Tyr Gln Asn Gly Ile Lys Lys Leu Glu Gly Arg Tyr
325 330 335
Asn Arg Cys Ile Ala Leu Glu Gly Asn Tyr Val Glu
340 345
15
33
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
15
cccctcgagc catggaaaaa aaggaatttc gtg 33
16
23
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
16
ccgctcagaa tcatcaacac gtt 23
17
28
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
17
tacccgggaa tcatttgaag gttggtac 28
18
20
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
18
taatacgact cactataggg 20
19
24
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
19
aacgaatttt aacaaaaaaa tgtg 24
20
20
DNA
Artificial Sequence
Description of Artificial Sequence
Oligonucleotide primer
20
cgatttaggt gacactatag 20
|
Mariner-family transposable elements are active in a wide variety of organisms and are becoming increasingly important genetic tools in species lacking sophisticated genetics. The Himar1 element, a member of the mariner family, isolated from the horn fly, Haematobia irritans, is active in Escherichia coli when expressed appropriately. Using this fact, a genetic screen was devised to isolate hyperactive mutants of Himar1 transposase that enhance overall transposition from 4 to 50-fold as measured in an E. coli assay. These hyperactive Himar1 mutant transposases should enable sophisticated analysis of the biochemistry of mariner transposition and should improve efficiency of a variety of genetic manipulations involving transposition in vivo and in vitro such as random mutagenesis or transgenesis in a wide range of host cells than the transposable elements previously available.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to beverage dispensing nozzles and more particularly, but not by way of limitation, to a beverage dispensing nozzle for use in dispensing medium to low flow applications. Further embodiments include dispensing flavor additives and dispensing multiple flavored drinks from a single nozzle without intermingling drink flavors.
2. Description of the Related Art
In the food and beverage service industry, counter space is at a premium. As such, it is desirable to minimize the space requirements of counter top dispensers through dispensing multiple flavors of drinks, including flavor additives, from a single nozzle. Problems associated with multiple flavor dispensing nozzles include syrup carryover, proper mixing, and excessive foaming problems. U.S. Pat. Nos. 6,098,842, 6,047,859 and 6,345,729 disclose multiple flavor nozzles that provide solutions to these problems. These multiple flavor nozzles are designed for use in high volume beverage dispensing accounts and thus produce higher than normal finished drink flowrates. While the designs of the referenced patents address the foregoing problems, they did not address problems associated with delivery of products at lower flowrates for medium to low volume beverage dispensing accounts. Furthermore, medium to low volume accounts may not require a multi-flavor beverage dispensing nozzle to satisfy the demand.
At lower flowrates, problems arise due to different system dynamics, wherein the product stream flows out of the nozzle in an irregular pattern and not the prescribed stream. Visually, the water segment of the product stream looks as if the water is exiting the nozzle on only one side. This training effect is present when the flow system energy does not overcome the surface tension properties of the mixing fluid in a lower flowrate system. This type of problem must be corrected to ensure proper mixing, as well as being aesthetically functional.
A second problem with the lower flowrate nozzles is the surface tension of the water as it leaves the underside of the nozzle. In a lower flowrate system, the water adhesion properties take over at the end of a dispense, wherein the mixing fluid then clings to the underside of the nozzle. Liquid clinging to the underside of the nozzle that contacts both the mixing fluid ports and the syrup ports can create avenues for intermingling of the different varieties of products, as well as discoloring and distaste of a dispensed drink. Accordingly, a beverage dispensing nozzle that operates at lower product flowrates would be beneficial for use in medium to low volume beverage dispensing accounts.
SUMMARY OF THE INVENTION
A method and apparatus for a beverage dispensing nozzle equipped with at least one flow director allow products to be dispensed at lower flowrates. In a first embodiment, a single flavor beverage dispensing nozzle equipped with the at least one flow director segment the flow to provide a reduced cross sectional area. As the nozzle cavity fills, the product is forced to move down a flow director channel. A method of using the beverage dispensing nozzle with the at least one flow director is also provided.
A second embodiment provides an improvement to an existing beverage dispensing nozzle, by adding at least one flow director in an annular channel of a multi-flavor beverage dispensing nozzle. The addition of the at least one flow director in the annular channel has provided the beverage dispensing nozzle with the ability to dispense product at lower flowrates by increasing the velocity component of the exiting product. The exiting product now has sufficient energy to separate from the beverage dispensing nozzle. A method of using the beverage dispensing nozzle with the at least one flow director is also presented.
It is therefore an object of this invention to provide a beverage dispensing nozzle suitable for use with lower flowrates.
It is further an object of this invention to provide an increased velocity component to the product exiting the beverage dispensing nozzle.
It is yet further an object of this invention to segment the flow of product within the beverage dispensing nozzle.
It is still yet further an object of this invention to provide a visually acceptable fluid stream exiting from the beverage dispensing nozzle.
Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following. Also, it should be understood that the scope of this invention is intended to be broad, and any combination of any subset of the features, elements, or steps described herein is part of the intended scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a section view of a single flavor beverage dispensing nozzle according to the preferred embodiment.
FIG. 2 provides a method flowchart for using flow directors in a single flavor nozzle according to the preferred embodiment.
FIG. 3 provides an exploded view of beverage dispensing nozzle as viewed from above according to the preferred embodiment.
FIG. 4 provides an exploded view of nozzle as viewed from below according to the preferred embodiment.
FIG. 5 is a cross section view of the nozzle as assembled according to the preferred embodiment.
FIG. 6 is a cross section view of the nozzle as assembled according to the preferred embodiment.
FIG. 7 is a cross section view of the nozzle as assembled according to the preferred embodiment.
FIG. 8 a is a top view of the outer housing after the addition of flow directors according to the preferred embodiment.
FIG. 8 b is a section view of the outer housing after addition of the flow directors according to the preferred embodiment.
FIG. 9 a provides a side view of the assembled beverage dispensing nozzle according to the preferred embodiment.
FIG. 9 b provides a section view of the beverage dispensing nozzle before the addition of flow directors according to the preferred embodiment.
FIG. 9 c provides a section view of the beverage dispensing nozzle after the addition of flow directors according to the preferred embodiment.
FIG. 10 provides a cross section of an embodiment of the beverage dispensing nozzle that inlcudes flavor additives according to the preferred embodiment.
FIG. 11 a provides a method flowchart for using flow directors in a beverage dispensing nozzle with a single beverage flavor according to the preferred embodiment.
FIG. 11 b provides a method flowchart for using flow directors in a beverage dispensing nozzle with two beverage flavors according to the preferred embodiment.
FIG. 11 c provides a method flowchart for using flow directors in a beverage dispensing nozzle with three beverage flavors according to the preferred embodiment.
FIG. 11 d provides a method flowchart for using flow directors in an embodiment that delivers flavor additives according to the preferred embodiment.
FIG. 12 a provides a method flowchart for using flow directors in a standard beverage dispensing nozzle dispensing a single beverage flavor according to the preferred embodiment.
FIG. 12 b provides a method flowchart for using flow directors in a standard beverage dispensing nozzle dispensing two beverage flavors according to the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. It is further to be understood that the figures are not necessarily to scale, and some features may be exaggerated to show details of particular components or steps.
U.S. Pat. Nos. 6,098,842, 6,047,859 and 6,345,729, the disclosures of which are herein incorporated by reference, disclose a nozzle designed to mix beverage concentrates with a mixing fluid at high flowrates, up to 5 oz./sec. An important feature of the previously disclosed beverage dispensing nozzle is the annular discharge of a beverage syrup, wherein the annularly discharged mixing fluid contacts the beverage syrup in mid-air below the dispensing nozzle. The annular discharge shape of the beverage syrup and the mixing fluid significantly increases the contact surface area between the two streams, resulting in more effective mixing. The embodiments of this invention improve over the previously disclosed nozzle by broadening the working range of the nozzle, therein making the beverage dispensing nozzle suitable for use in lower flowrate applications, as well as the higher flowrate applications. Further embodiments of this invention include a single flavor beverage dispensing nozzle and dispensing of product flavorings.
As shown in FIG. 1 , a first embodiment of a beverage dispensing nozzle 300 includes a body 301 having a single syrup flowpath 309 and a single mixing fluid flowpath 302 . The syrup flowpath 309 includes a syrup inlet port 303 , a syrup outlet port 304 and a beverage syrup channel 305 . The mixing fluid flowpath 302 includes a mixing fluid inlet port 306 , a mixing fluid outlet port 307 and a mixing fluid channel 308 disposed around the syrup flowpath 309 . The mixing fluid channel 308 further includes at least one flow director 310 to increase the velocity of the mixing fluid. Multiple flow directors 310 may be used for increased control of the mixing fluid flow dynamics. The flow director 310 segments a lower portion of the large mixing fluid channel 308 into at least one smaller channel known as a flow director channel 312 .
In operation, a beverage syrup is delivered to the beverage syrup inlet port 303 of the beverage dispensing nozzle 300 and a mixing fluid is delivered to the mixing fluid inlet port 306 . The beverage syrup is then delivered from the beverage syrup inlet port 303 to the beverage syrup outlet port 304 via a beverage syrup channel 305 disposed in the nozzle 300 . The beverage syrup is then discharged from the beverage syrup outlet port 304 . The mixing fluid is delivered from the mixing fluid inlet port 306 to the mixing fluid channel 308 surrounding the syrup flow path 309 . Once inside the mixing fluid channel 308 , the mixing fluid flows towards the mixing fluid outlet port 307 , therein passing the at least one flow director 310 . Upon reaching the at least one flow director 310 , the mixing fluid's downward velocity component is increased as the mixing fluid is forced through the reduced cross-sectional flow area and the hydraulic pressure of the incoming mixing fluid. The mixing fluid is then discharged from the mixing fluid outlet port 307 to contact exiting beverage syrup.
As shown in FIG. 2 , a method of using flow directors in a beverage dispensing nozzle 300 commences with step 80 , delivering a beverage syrup to a beverage syrup inlet port 303 of the beverage dispensing nozzle 300 . A mixing fluid is then delivered to a mixing fluid inlet port 306 of the beverage dispensing nozzle 300 , step 81 . In step 82 , the beverage syrup is delivered from the beverage syrup inlet port 303 to a beverage syrup discharge port 304 via a syrup flowpath 309 disposed inside of the beverage dispensing nozzle 300 . The method continues with step 83 , wherein the mixing fluid is delivered from the mixing fluid inlet port 306 to the mixing fluid channel 308 surrounding the beverage syrup flowpath 309 . Step 84 provides for the discharge of the beverage syrup from the beverage syrup discharge port 304 . The velocity of the mixing fluid is increased as it passes the flow director 310 in the flow director channel 312 as shown in step 85 . In step 86 , the mixing fluid is discharged from the beverage dispensing nozzle 300 to mix with exiting beverage syrup.
In a second embodiment, a beverage dispensing nozzle 10 characteristic of the nozzle disclosed in the referenced U.S. Patents is equipped with an at least one flow director 200 to permit the nozzle 10 to operate at lower flowrates. As shown in FIGS. 3–7 , the nozzle 10 includes a cap member 11 , an o-ring 12 , a plurality of gaskets 13 – 15 , an inner housing 16 , a first or outer annulus 17 , a second or intermediate annulus 18 , a third or inner annulus 19 and an outer housing 20 . The inner housing 16 defines a chamber 40 and includes an opening 44 into the chamber 40 . The inner housing 16 includes a plurality of cavities 41 – 43 that communicate with the chamber 40 through a plurality of conduits 45 – 47 , respectively. The conduits 45 – 47 are concentrically spaced apart; namely, conduit 47 is innermost, conduit 45 is intermediate, and conduit 46 is outermost (see FIGS. 3–7 ). The conduits 45 – 47 are concentrically spaced apart so that beverage syrup may enter the chamber 40 at three separate points. The interior wall of the inner housing 16 defining the chamber 40 includes a plurality of stair steps 48 – 51 .
The first or outer annulus 17 includes an upper member 52 and a discharge member 53 . The first or outer annulus 17 fits within the chamber 40 of the inner housing 16 such that a portion of the upper member 52 engages the stair-step 49 . That portion of the upper member 52 may press fit with the stair step 49 or an adhesive may be used to secure that portion of the upper member 52 with the stair step 49 . The first or outer annulus 17 and the interior wall of the inner housing 16 defining stair step 48 form a first beverage syrup channel 54 that connects with the conduit 46 of the inner housing 16 . The first beverage syrup channel 54 insures a large volume of beverage syrup flows uniformly about the first or outer annulus 17 during discharge. The discharge member 53 includes a plurality of discharge channels 55 to aid the first beverage syrup channel 54 in discharging the beverage syrup because the discharge member 53 is sized to substantially reside within the lower portion of the interior wall for the inner housing 16 . The discharge member 53 operates to discharge the beverage syrup in a restricted flow to insure uniform distribution of the beverage syrup as it exits from the beverage dispensing nozzle 10 , thereby providing a maximum surface area for contact with mixing fluid also exiting from the beverage dispensing nozzle 10 .
The second or intermediate annulus 18 includes an upper member 56 and a discharge member 57 . The second or intermediate annulus 18 fits within the first or outer annulus 17 such that a portion of the upper member 56 engages the stair step 50 . That portion of the upper member 56 may press fit with the stair step 50 or an adhesive may be used to secure that portion of the upper member 56 with the stair step 50 . The second or intermediate annulus 18 and the interior wall of the first or outer annulus 17 form a second beverage syrup channel 58 that connects with the conduit 45 of the inner housing 16 . The second beverage syrup channel 58 insures a large volume of beverage syrup flows uniformly about the second or intermediate annulus 18 during discharge. The discharge member 57 includes a plurality of discharge channels 59 to aid the second beverage syrup channel 58 in discharging the beverage syrup because the discharge member 57 is sized to substantially reside within the lower portion of the interior wall of the first or outer annulus 17 . The discharge member 57 operates to discharge the beverage syrup in a restricted flow to insure uniform distribution of the beverage syrup as it exits from the beverage dispensing nozzle 10 , thereby providing a maximum surface area for contact with mixing fluid also exiting from the beverage dispensing nozzle 10 .
The third or inner annulus 19 includes a securing member 60 , an intermediate member 61 and a discharge member 62 . The inner annulus 19 fits within the intermediate annulus 18 such that the securing member 60 protrudes through the opening 44 of the inner housing 16 and engages the interior wall of the inner housing 16 defining the opening 44 . The securing member 60 may be press fit with the interior wall of the inner housing 16 defining the opening 44 or an adhesive may be used to secure the securing member 60 with the interior wall of the inner housing 16 defining the opening 44 . The third or inner annulus 19 , the stair step 51 and the interior wall of the second or intermediate annulus 18 form a third beverage syrup channel 64 that connects with the conduit 47 of the inner housing 16 . The third beverage syrup channel 64 insures a large volume of beverage syrup flows uniformly about the third or interior annulus 19 during discharge. The discharge member 62 includes a plurality of discharge channels 63 to aid the third beverage syrup channel 64 in discharging the beverage syrup because the discharge member 62 is sized substantially reside within the lower portion of the interior wall for the second or intermediate annulus 18 . The discharge member 62 operates to discharge the beverage syrup in a restricted flow to insure uniform distribution of the beverage syrup as it exits from the beverage dispensing nozzle 10 , thereby providing a maximum surface area for contact with mixing fluid also exiting from the beverage dispensing nozzle 10 .
The cap member 11 includes a plurality of beverage syrup inlet ports 21 – 23 that communicate with a respective beverage syrup outlet port 24 – 26 via a respective connecting conduit 37 – 39 through the cap member 11 . The beverage syrup outlet ports 24 – 26 snap fit within a respective cavity 41 – 43 of the inner housing 16 to secure the inner housing 16 to the cap member 11 . The gaskets 13 – 15 fit around a respective beverage syrup outlet port 24 – 26 to provide a fluid seal and to assist in the securing of the inner housing 16 to the cap member 11 . With the inner housing 16 secured to the cap member 11 , a beverage syrup path involving the beverage syrup inlet port 21 ; the conduit 37 ; the beverage syrup outlet port 24 ; the cavity 41 ; the conduit 46 ; and the first beverage syrup channel 54 , which includes the discharge channels 59 is created. A beverage syrup path involving the beverage syrup inlet port 22 ; the conduit 38 ; the beverage syrup outlet port 25 ; the cavity 42 ; the conduit 45 ; the second beverage syrup channel 58 , which includes the discharge channels 55 , and one involving the beverage syrup inlet port 23 ; the conduit 39 ; the beverage syrup outlet port 26 ; the cavity 43 ; the conduit 47 ; the third beverage syrup channel 64 , which includes the discharge channels 63 are also created.
The cap member 11 includes a mixing fluid inlet port 27 that communicates with a plurality of mixing fluid outlet channels 66 – 71 via a connecting conduit 28 through the cap member 11 . The mixing fluid outlet channels 66 – 71 , in this preferred embodiment, are uniformly spaced within the cap member 11 and communicate with an annular cavity 36 defined by a portion of the cap member 11 to deliver mixing fluid along the entire circumference of the annular cavity 36 . Nevertheless, one of ordinary skill in the art will recognize that other mixing fluids, such as plain water may be used. Furthermore, although the preferred embodiment discloses the formation of a beverage from a beverage syrup and a mixing fluid, such as carbonated water or plain water, one of ordinary skill in the art will recognize that a mixing fluid, such as carbonated or plain water, may be dispensed individually from a beverage path as described above instead of a beverage syrup.
The outer housing 20 snap fits over the cap member 11 , including the o-ring 12 which provides a fluid seal and assists in the securing of the inner housing 16 to the cap member 11 . The outer housing 20 has an inwardly extending lip portion 73 at its exit end to direct exiting mixing fluid into the exiting beverage syrup. An inner surface 201 of the outer housing 20 in combination with the portion of the cap member 11 defining the annular cavity 36 and an exterior wall 202 of the inner housing 16 define a mixing fluid channel 72 . With the outer housing 20 secured to the cap member 11 , a mixing fluid path involving the mixing fluid inlet port 27 , the conduit 28 , the mixing fluid outlet channels 66 - 71 , the annular channel 36 and the mixing fluid channel 72 is created.
Similarly, upon mating the outer housing 20 and the cap member 11 , three different beverage flow paths are defined. Beverage syrup enters the beverage syrup inlet ports 21 , 22 , 23 , flows through the conduits 37 , 38 , 39 and the beverage system outlet ports 24 , 25 , 26 to the cavities 41 , 42 , 43 ; the beverage syrup then flows through the conduits 46 , 45 , 47 , the first, second and third beverage syrup channels 54 , 58 , 64 , the discharge channels 55 , 59 , 63 , and the discharge members 53 , 57 , 62 , respectively, prior to being discharged from the beverage dispensing nozzle 10 .
In operation, mixing fluid enters the beverage dispensing nozzle through the mixing fluid inlet port 27 and travels through the conduit 28 to the mixing fluid outlet channels 66 – 71 for delivery into the annular cavity 36 . Under high flow rates, the annular cavity 36 receives a large volume of mixing fluid to insure the mixing fluid channel 72 remains full for uniform flow as the mixing fluid moves downwardly through the mixing fluid channel 72 to the discharge end of the nozzle. The objective is to maintain a uniform distribution of mixing fluid exiting the entire circumference of the mixing fluid channel 72 . The inwardly extending lip portion 73 of the outer housing 20 directs the mixing fluid inwardly toward a beverage syrup stream exiting from one of the discharge members 53 , 57 , or 62 .
The beverage syrup inlet ports 21 – 23 each receive a different flavor of beverage syrup, which is delivered through a conduit by a beverage syrup source (not shown). Each beverage syrup travels through its particular flow path for discharge from the beverage dispensing nozzle 10 as previously described. Illustratively, a beverage syrup delivered to the beverage syrup inlet port 21 flows through the conduit 37 , the beverage syrup outlet port 24 , the cavity 41 , the conduit 46 , the first beverage syrup channel 54 , and the discharge channels 55 prior to discharge from the beverage dispensing nozzle 10 . The first, second ad third beverage syrup channels 54 , 58 , and 64 provide a large volume of beverage syrup around each of a respective first or outer, second or intermediate, and third or inner annulus 17 , 18 , and 19 for discharge through one of the discharge members 53 , 57 , and 62 . The discharge members 53 , 57 , and 62 restrict the flow of beverage syrup to insure uniform distribution of the beverage syrup as it exits from the beverage dispensing nozzle 10 , thus insuring a maximum surface area for contact with the mixing fluid exiting from the mixing fluid channel 72 . Although only one beverage syrup is typically dispensed at a time, it should be understood that more than one beverage syrup may be discharged from the beverage dispensing nozzle 10 at a time to provide a mix of flavors.
As a solution to the problems associated with dispensing at lower flowrates, the outer housing 20 of the nozzle 10 has been outfitted with a plurality of flow directors 200 , eight in this preferred embodiment, on an inner surface 201 of the outer housing 20 . The flow directors 200 extend upward from the inwardly extending lip portion 73 at its exit end to the edge of the inner surface 201 as shown in FIGS. 8 a and 8 b . The flow directors 200 do not run the full length of the mixing fluid channel 72 . Full-length flow directors 200 would prevent the filling of an upper section of the mixing fluid channel 72 around the beverage syrup flowpath. The addition of the flow directors 200 segments a lower section of the mixing fluid channel 72 into a plurality of smaller flow channels or flow director channels 210 . It should be noted that the quantity and length of flow director 200 features may vary depending on mixing requirements for different products and additives.
With the installation of flow directors 200 , assembly of the cap member 11 and the outer housing 20 now define a slightly different flow path for the mixing fluid. The inner surface 201 of the outer housing 20 in combination with the portion of the cap member 11 defining the annular cavity 36 and the exterior wall 202 of the inner housing 16 define the mixing fluid channel 72 which now encompasses flow director channels 210 . The flow director channels 210 are defined by the inner surface 201 of the outer housing 20 , the outer wall 202 of the inner housing 16 , and two adjacent flow directors 200 as shown in FIG. 9 c . FIGS. 9 b and 9 c provide section views of the beverage dispensing nozzle 10 before and after the addition of flow directors 200 . With the outer housing 20 secured to the cap member 11 , a mixing fluid path involving the mixing fluid inlet port 27 , the conduit 28 , the mixing fluid outlet channels 66 – 71 , the annular channel 36 , the mixing fluid channel 72 and the flow director channels 210 is created.
With the flow directors 200 in place, the upper section of the mixing fluid channel 72 fills with mixing fluid. Once filled, the hydraulic pressure of the incoming mixing fluid forces the mixing fluid in the upper section of the mixing fluid channel 72 into the series of flow director channels 210 defined by the flow directors 200 . The reduced cross sectional area of the flow director channels 210 provides an increased velocity component for the mixing fluid exiting the nozzle 10 since the velocity component of the mixing fluid is being directed downward through all of the flow director channels 210 . The increased velocity component provides the mixing fluid stream with enough energy to separate from the nozzle 10 at the end of the dispense. The increased velocity of the mixing fluid eliminates the problem of the mixing fluid clinging to the underside of the nozzle 10 , and crossing over into other discharge ports. The addition of flow directors 200 improves the distribution of mixing fluid by regaining the desired discharge velocity for a more effective mix.
In a dispense, the syrup and mixing fluid flow separately through the nozzle 10 to mix with beverage syrup discharged from the nozzle 10 . Illustratively, syrup enters the nozzle 10 through a syrup inlet port 21 , flows through the conduit 37 , moves into the beverage system outlet port 24 to the cavity 41 ; the syrup then flows through the conduit 46 , the beverage syrup channel 54 , the discharge channel 55 , and finally, the discharge member 53 . Concurrently, a mixing fluid enters the nozzle 10 through the mixing fluid inlet port 27 , moves through the conduit 28 , exits the mixing fluid outlet channels 66 – 71 , flows into the annular channel 36 , through the mixing fluid channel 72 , and flows through the flow director channels 210 to the end of the nozzle 10 . Once the mixing fluid exits the flow director channels 210 , it is redirected inward into the syrup stream exiting the nozzle 10 by the inwardly extending lip portion 73 . As both fluids are being dispensed in concentric annular rings, the opportunity for mixing is increased. While the preferred embodiment provides for annularly shaped discharging of the syrup and mixing fluid, it should be apparent to those of ordinary skill in the art, that the shape of the discharge streams is not limited to annular rings. Additionally, it should be further apparent to one skilled in the art that the beverage syrup and the mixing fluid flowpaths may be switched for products with fractional mixing ratios, wherein the mixing fluid could exit the center of the beverage dispensing nozzle.
As illustrated in FIG. 10 , an embodiment of the beverage dispensing nozzle 900 provides for delivery of flavor additives from the beverage dispensing nozzle 900 along with beverage syrup and mixing fluid. Examples of flavor additives in this embodiment include, but are not limited to, cherry or vanilla, which are utilized to form new drink combinations such as cherry cola. In this embodiment, the third or inner annulus 919 includes a securing member 960 , an intermediate member 961 , and a discharge member 962 . The third or inner annulus 919 mounts within the second or intermediate annulus 18 , protrudes through the opening of the inner housing 16 , and engages the interior wall of the inner housing 16 defining the opening identically as previously described with reference to the beverage dispensing nozzle 10 . The third or inner annulus 919 , however, includes a pair of passageways 907 and 908 therethrough, which are utilized to deliver flavor additives from the third or inner annulus 919 . The intermediate member 961 and the discharge member 962 are identical to the intermediate member 61 and the discharge member 62 of the third or inner annulus 19 , except the intermediate member 961 and the discharge member 962 define a portion of the passageways 907 and 908 . The securing member 960 is identical to the securing member 60 of the third annulus 919 , except the securing member 60 defines a cavity 909 as well as a portion of the passageways 907 and 908 .
The cap member 911 is configured and operates as the cap member 11 , except the cap member 911 further includes a plurality of flavor additive inlet ports 901 and 902 that communicate with a respective flavor additive outlet port 903 and 904 via a respective connecting passageway 905 and 906 through the cap member 911 . Identical to the cap member 11 , beverage syrup outlet ports of the cap member 911 snap fit within a respective cavity of the inner housing 16 to secure the inner housing 16 to the cap member 911 . Gaskets fit around a respective beverage syrup outlet port to provide a fluid seal and to assist in the securing of the inner housing 16 to the cap member 911 . In addition, the securing member 960 of the third or inner annulus 919 extending through the opening of the inner housing 16 snap fits around a protrusion 35 of the cap member 911 to aid in the securing of the inner housing 16 to the cap member 911 . With the inner housing 16 secured to the cap member 911 , a flavor additive conduit involving the flavor additive inlet port 901 ; the passageway 905 ; the flavor additive outlet port 903 ; and the passageway 907 is created. Similarly, a flavor additive conduit involving the flavor additive inlet port 902 ; the passageway 906 ; the flavor additive outlet port 904 ; and the passageway 908 is created.
The operation of the beverage dispensing nozzle 900 in delivering a mixing fluid for combination with a beverage syrup to produce a desired drink is identical to the operation of the beverage dispensing nozzle 10 . However, the beverage dispensing nozzle 900 provides a user the option of altering drink flavor through the addition of flavor additives, such as cherry or vanilla, delivered from flavor additive sources. When the user has selected a flavor additive, the flavor additive enters a respective passageway 907 or 908 via a respective passageway 905 or 906 and flavor additive outlet port 903 and 904 . The selected additive flavor traverses a respective passageway 907 or 908 and exits the third or inner annulus 919 , where the flavor additive combines with the flowing beverage syrup and mixing fluid to produce an alternatively flavored drink, such as cherry or vanilla cola.
A method flowchart for using flow directors 200 in a beverage dispensing nozzle 10 mixing a single beverage syrup and a mixing fluid is shown in FIG. 11 a . The process begins with step 98 , wherein a beverage syrup is delivered to a first beverage syrup inlet port 21 . In step 102 , a mixing fluid is delivered to a mixing fluid inlet port 27 . Step 103 provides for delivering the beverage syrup from the first beverage syrup inlet port 21 to the first beverage syrup channel 54 . Next, the mixing fluid is delivered from the mixing fluid inlet port 27 to the mixing fluid channel 72 , step 107 . The process continues with step 108 , wherein the beverage syrup is discharged from the first beverage syrup channel 54 . In step 112 , the velocity of the mixing fluid is increased as the mixing fluid passes the flow directors 200 . Step 113 provides for discharging the mixing fluid from the mixing fluid channel 72 to contact exiting beverage syrup to mix therewith outside of the beverage dispensing nozzle 10 .
In embodiments where a second beverage dispensing stream is also being dispensed from the nozzle 10 , the method of FIG. 11 a would further include steps 99 , 104 and 109 as shown in FIG. 11 b . Similarly, the process begins with step 98 , wherein a beverage syrup is delivered to a first beverage syrup inlet port 21 . A second beverage syrup is then delivered to a second beverage syrup inlet port 22 as shown in step 99 . Next, step 102 , a mixing fluid is delivered to a mixing fluid inlet port 27 . The process then moves to step 103 , wherein the first beverage syrup is delivered form the first beverage syrup inlet port 21 to a first beverage syrup channel 54 . In step 104 , the second beverage syrup is delivered to a second beverage syrup channel 58 . The mixing fluid is delivered from the mixing fluid inlet port 27 to a mixing fluid channel 72 in step 107 . Next, the first beverage syrup is discharged from the first beverage syrup channel 54 , step 108 . Likewise, the second beverage syrup is discharged from the second beverage syrup channel 58 , step 109 . In step 112 , the velocity of the mixing fluid is increased by passing it through the flow directors 200 . The mixing fluid is then discharged from the mixing fluid channel 72 to mix therewith outside of the beverage dispensing nozzle 10 with exiting beverage syrup.
In an embodiment wherein three syrups are desired, the method of FIG. 11 b further includes steps 100 , 105 and 110 , as shown in FIG. 11 c . Similarly, the process begins with step 98 , wherein a beverage syrup is delivered to a first beverage syrup inlet port 21 . A second beverage syrup is then delivered to a second beverage syrup inlet port 22 as shown in step 99 . In step 100 , a third beverage syrup is delivered to a third beverage syrup inlet port 23 . Next, step 102 , a mixing fluid is delivered to a mixing fluid inlet port 27 . The process then moves to step 103 , wherein the first beverage syrup is delivered form the first beverage syrup inlet port 21 to a first beverage syrup channel 54 . In step 104 , the second beverage syrup is delivered to a second beverage syrup channel 58 . The process then moves to step 105 , wherein the third beverage syrup is delivered to a third beverage syrup channel 63 . The mixing fluid is delivered from the mixing fluid inlet port 27 to a mixing fluid channel 72 in step 107 . Next, the first beverage syrup is discharged from the first beverage syrup channel 54 , step 108 . Likewise, the second beverage syrup is discharged from the second beverage syrup channel 58 , step 109 , and the third beverage syrup is discharged from the third beverage syrup channel 63 , step 110 . In step 112 , the velocity of the mixing fluid is increased by passing it through the flow directors 200 . The mixing fluid is then discharged from the mixing fluid channel 72 to mix therewith outside of the beverage dispensing nozzle 10 with exiting beverage syrup.
In an embodiment where a flavor additive is desired while using the beverage dispensing nozzle 900 , the method flowchart of FIG. 11 a further includes steps 101 , 106 and 111 as shown in FIG. 11 d . The process begins with step 98 , wherein a beverage syrup is delivered to a first beverage syrup inlet port 21 . The process then moves to step 101 , wherein a flavor additive is delivered to a flavor additive inlet port 901 . In step 102 , a mixing fluid is delivered to a mixing fluid inlet port 27 . Step 103 provides for delivering the beverage syrup from the first beverage syrup inlet port 21 to the first beverage syrup channel 54 . The process then moves to step 106 , wherein the flavor additive is then delivered from the flavor additive inlet port 901 to a flavor additive passageway 905 in the third annulus 919 . Next, the mixing fluid is delivered from the mixing fluid inlet port 27 to the mixing fluid channel 72 , step 107 . The process continues with step 108 , wherein the beverage syrup is discharged from the first beverage syrup channel 54 . The process moves to step 111 , wherein the flavor additive is discharged form the third annulus 919 . In step 112 , the velocity of the mixing fluid is increased as the mixing fluid passes the flow directors 200 . Step 113 provides for discharging the mixing fluid from the mixing fluid channel 72 to contact exiting beverage syrup to mix therewith outside of the beverage dispensing nozzle 900 .
In another embodiment, the beverage dispensing nozzle 10 may be a standard beverage dispensing nozzle, i.e. not an air-mix beverage dispensing nozzle, wherein the beverage syrup and the mixing fluid streams mix in a mixing chamber prior to exiting the nozzle. The method flowchart for this embodiment is shown in FIG. 12 a . The method process commences with step 115 , wherein a beverage syrup is delivered to a first beverage syrup inlet port 21 . In step 117 , a mixing fluid is delivered to a mixing fluid inlet port 27 . Step 118 provides for delivering the beverage syrup from the first beverage syrup inlet port 21 to the first beverage syrup channel 54 . Next, the mixing fluid is delivered from the mixing fluid inlet port 27 to the mixing fluid channel 72 , step 120 . The process continues with step 121 , wherein the beverage syrup is discharged from the first beverage syrup channel 54 . In step 123 , the velocity of the mixing fluid is increased as the mixing fluid passes the flow directors 200 . Step 124 provides for discharging the mixing fluid from the mixing fluid channel 72 to mix with exiting beverage syrup.
A method flowchart for one variation of using flow directors 200 in an application with two beverage syrups is shown in FIG. 12 b . Similar to the method shown in FIG. 12 a , the process commences with a delivery of a first beverage syrup to a first beverage syrup inlet port 21 , step 115 . A second beverage syrup is then delivered to a second beverage syrup inlet port 22 in step 116 . The process continues with the delivery of a mixing fluid to a mixing fluid inlet port 27 as shown in step 117 . Step 118 provides for delivering the first beverage syrup from the first beverage syrup inlet port 21 to a first beverage syrup channel 54 . Similarly, the second beverage syrup is delivered from the second beverage syrup inlet port 22 to a second beverage syrup channel 58 in step 119 . Delivery of the mixing fluid from the mixing fluid inlet port 27 to a mixing fluid channel 72 follows in step 120 . The first beverage syrup is then discharged from the first beverage syrup channel as shown in step 121 . Likewise, the second beverage syrup is discharged from the second beverage syrup channel 58 in step 122 . The velocity of the mixing fluid is increased in the mixing fluid channel 72 as it passes the flow directors 200 disposed therein in step 123 . In step 124 , the mixing fluid is discharged from the mixing fluid channel to mix with exiting beverage syrup.
Although the present invention has been described in terms of the foregoing preferred embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing detailed description; rather, it is defined only by the claims that follow.
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A method and apparatus for a beverage dispensing nozzle equipped with at least one flow director dispenses at lower flowrates. In a first embodiment, a single flavor beverage dispensing nozzle equipped with at least one flow director segments the flow and reduces the cross sectional area of the fluid stream, thereby forcing product to move downward. A second embodiment provides an improvement to an existing beverage dispensing nozzle, by adding at least one flow director in an annular channel of the beverage dispensing nozzle. The addition of the at least one flow director in the annular channel provides the beverage dispensing nozzle with the ability to dispense product at lower flowrates by increasing the velocity component of the exiting product. The exiting product now has sufficient energy to separate from the beverage dispensing nozzle. Methods for using the beverage dispensing nozzles with the at least one flow director are also presented.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119 from Japanese Patent Application No. 2008-245873 filed on Sep. 25, 2008. The entire subject matter of the application is incorporated herein by reference.
BACKGROUND
1. Technical Field
The following description relates to one or more image forming devices, more particularly to one or more techniques to protect the image forming devices from electrostatically-caused errors.
2. Related Art
A technique has been known which is adapted to reset an application specific integrated circuit (ASIC) to avoid electrostatically-caused malfunction when a cover is opened such that a user can access the inside of a printer (an image forming device).
SUMMARY
However, according to the aforementioned technique, the ASIC is reset even when the cover is opened in such a manner that the user can hardly touch the inside of the device, such as when the cover is opened just for a moment and then soon closed. Therefore, in such a case, an unnecessary time period might be required for restoring the ASIC from the reset state, and thus it result in lower printing efficiency.
Aspects of the present invention are advantageous to provide one or more improved image forming devices that make it possible to improve efficiency of image formation.
According to aspects of the present invention, an image forming device is provided, which includes a processor configured to process image data, an image forming unit configured to perform image formation based on the image data processed by the processor, a cover configured to, when being opened, allow an external access to the image forming unit therethrough, a detector configured to detect whether the cover is opened, and an interrupting unit configured to, when determining with the detector that the cover is kept opened for a first time period, interrupt the processing of the image data by the processor.
According to aspects of the present invention, further provided is an image forming device, which includes a processor configured to process image data, an image forming unit configured to perform image formation based on the image data processed by the processor, a cover configured to, when being opened, allow an external access to the image forming unit therethrough, a detector configured to detect whether the cover is opened, and a maintaining unit configured to, when determining with the detector that the cover is kept opened for less than a first time period, maintain the processing of the image data by the processor.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is a cross-sectional view schematically showing an overall configuration of a color printer in an embodiment according to one or more aspects of the present invention.
FIG. 2 is a block diagram schematically showing an electrical configuration for light emission control illumination, in which a main ASIC, a sub ASIC, and LED units are connected in the embodiment according to one or more aspects of the present invention.
FIG. 3 schematically shows positional states of the LED units when an upper cover is closed in the embodiment according to one or more aspects of the present invention.
FIG. 4 schematically shows positional states of the LED units when the upper cover is opened in the embodiment according to one or more aspects of the present invention.
FIG. 5 is a perspective view schematically showing an LED unit in the embodiment according to one or more aspects of the present invention.
FIG. 6 is a time chart showing a relationship between an open-close detection signal Sd issued in response to an operation of opening/closing the upper cover and a reset signal Reset in a ready state of the printer in the embodiment according to one or more aspects of the present invention.
FIG. 7 is a time chart showing a relationship between the open-close detection signal Sd and the reset signal Reset during a printing operation by the printer in the embodiment according to one or more aspects of the present invention.
FIG. 8 is a time chart showing a relationship between the open-close detection signal Sd and the reset signal Reset corresponding to each block in the ready state of the printer in the embodiment according to one or more aspects of the present invention.
FIG. 9 is another time chart showing a relationship between the open-close detection signal Sd and the reset signal Reset corresponding to each block in the ready state of the printer in the embodiment according to one or more aspects of the present invention.
DETAILED DESCRIPTION
It is noted that various connections are set forth between elements in the following description. It is noted that these connections in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect.
Embodiment
1. Overall Configuration of Printer
Hereinafter, an embodiment according to aspects of the present invention will be described with reference to FIGS. 1 to 9 . FIG. 1 is a cross-sectional view schematically showing an overall configuration of a color printer 1 as an image forming device in an embodiment according to aspects of the present invention. The image forming device of the embodiment is not limited to a color printer. For instance, the image forming device may be a Multi-Function Peripheral (MFP) provided with various functions such as a copy function and a facsimile function.
In FIG. 1 , the left side and the right side on the figure are defined as a front side and a rear side of the printer 1 , respectively. Further, the near side and the far side in the direction perpendicular to the figure are defined as a right side and a left side of the printer 1 , respectively. Moreover, the upside and the downside on the figure are defined as an upside and a downside of the printer 1 , respectively. Here, the color printer 1 is configured to form a color image with four colors (black K, yellow Y, magenta M, and cyan C) of developers.
As illustrated in FIG. 1 , the color printer 1 (hereinafter, simply referred to as a printer 1 ) includes, in a main body 10 , a feeding unit 20 configured to feed a sheet P, an image forming unit 30 configured to form an image on the sheet P fed, an ejecting unit 90 configured to eject the sheet P with the image formed thereon, and a main control board 100 configured to control each of the aforementioned units when forming the image.
At an upper side of the main body 10 , an upper cover 11 is attached rotatably in the vertical direction around a rotation shaft 12 which is provided at a rear end of the printer 1 . The upper cover 11 is provided with an LED control board 110 configured to control an LED unit ( 40 K, 40 Y, 40 M, or 40 C) corresponding to each color. It is noted that, in the following description, respective components corresponding to the colors that have the same configuration may be identified with only an element number. Specifically, for instance, each of the LED units ( 40 K, 40 Y, 40 M, and 40 C) may be identified as the LED unit 40 .
When a front end of the upper cover 11 is lifted and opened around the rotation shaft 12 , an opening 11 A is formed sequentially from the front side of the main body 10 . Through the opening 11 A, a user can access the image forming unit 30 .
Further, to a portion of the main body 10 that faces a front end of the upper cover 11 , a cover switch 13 is provided which is configured to detect an opened/closed state of the upper cover 11 with it being set ON/OFF depending on the opened/closed state of the upper cover 11 . The cover switch 13 generates an open-close detection signal Sd based on the ON/OFF state thereof.
The upper cover 11 is configured with an upper surface thereof onto which the sheet P is ejected from the main body 10 , and a lower surface thereof at which four holding members ( 14 K, 14 Y, 14 M, and 14 C) for holding the respective LED units ( 40 K, 40 Y, 40 M, and 40 C) is provided.
The feeding unit 20 , disposed at a lower side within the main body 10 , includes a feed tray 21 detachably attached to the main body 10 , and a sheet feeding mechanism 22 configured to feed the sheet P from the feed tray 21 to the image forming unit 30 . The sheets P stacked in the feed tray 21 are sequentially conveyed up by the sheet feeding mechanism 22 in a manner separated on a sheet-by-sheet basis. After that, the sheet P is fed to the image forming unit 30 via a registration roller 29 that performs positional correction for the sheet P.
The image forming unit 30 includes the four LED units ( 40 K, 40 Y, 40 M, and 40 C) respectively corresponding to the four colors and four process cartridges ( 50 K, 50 Y, 50 M, and 50 C) respectively corresponding to the four colors, a transfer unit 70 , and a fixing unit 80 . Each of the LED units 40 , placed above a corresponding one of photoconductive drums 53 , has an LED head 41 disposed to face the photoconductive drum 53 , and a back plate 42 .
The LED head 41 has a plurality of light-emitting diodes (LEDs) aligned in the right-to-left direction on a surface of the LED head 41 that faces the photoconductive drum 53 (see FIG. 5 ). Each of the LEDs emits light in accordance with a signal input thereinto from the below-mentioned LED control board 110 based on image data of an image to be formed, and exposes the surface of the photoconductive drum 53 with the emitted light. Namely, each of the LEDs is driven by a sub ASIC 114 of the LED control board 110 in accordance with a lighting pattern based on the image data (see FIG. 2 ).
The back plate 42 , which is a member supporting the LED head 41 , is attached swingably to the upper cover 11 via the holding member 14 . Thereby, when the upper cover 11 is turned up, each LED unit 40 (LED head 41 ) is moved from an exposure position where the LED unit 40 faces the photoconductive drum 53 to an upper evacuation position (see FIG. 4 ).
As illustrated in FIG. 1 , the process cartridges ( 50 K, 50 Y, 50 M, and 50 C) are aligned in the front-to-rear direction between the upper cover 11 and the feed unit 20 . Further, each process cartridge 50 has a drum unit 51 and a development unit 61 detachably attached to the drum unit 51 . The development unit 61 has a development roller 63 and a toner container 66 . It is noted that the process cartridges 50 have the same configuration with just difference among the colors of toners respectively stored in the toner containers 66 of the development units 61 .
The drum unit 51 is provided with the photoconductive drum 53 and a charger 54 . When the development unit 61 is attached to the drum unit 51 , the drum unit 51 has an exposure hole formed such that the photoconductive drum 53 is externally viewed therethrough. The LED unit 40 (LED head 41 ) is inserted into the exposure hole 55 to face an upper surface of the photoconductive drum 53 .
The transfer unit 70 , provided between the feed unit 20 and the process cartridges 50 , includes a driving roller 71 , a driven roller 72 , a feeding belt 73 , and a transfer roller 74 .
The feeding belt 73 is wound around the driving roller 71 and the driven roller 72 . Inside the feeding belt 73 , four transfer rollers 74 are disposed to face the respective photoconductive drums 53 across the feeding belt 73 . In other words, the feeding belt 73 is pinched between each transfer roller 74 and the photoconductive drum 53 facing the transfer roller 74 . The fixing unit 80 is disposed behind the process cartridges 50 and the transfer units 70 .
In the image forming unit 30 configured as above, first, the surface of each photoconductive drum 53 is evenly charged by the corresponding charger 54 , and then exposed with LED light emitted by the corresponding LED head 41 . Thereby, an electrical potential of the exposed portion drops, and an electrostatic latent image based on the image data is formed on the surface of each photoconductive drum 53 .
Subsequently, the toner stored in the toner container 66 is supplied to the development roller 63 . The toner held on the development roller 63 is supplied to the electrostatic latent image formed on the photoconductive drum 53 . Thereby, the toner is selectively held on the photoconductive drum 53 and the electrostatic latent image is developed into a visible image. Thus, a toner image is formed through inversion development.
Then, while the sheet P supplied onto the feeding belt 73 is passing between the photoconductive drums 53 and the transfer rollers 74 , the toner images respectively formed on the photoconductive drums 53 are sequentially transferred onto the sheet P. When the sheet P passes through the fixing unit 80 , the toner images transferred onto the sheet P are thermally fixed. Thereafter, the sheet P with the toner images thermally fixed thereon is ejected onto the upper cover 11 .
2. Electrical Configuration for Light Emission Control
Next, an electrical configuration for light emission control in the embodiment will be described with reference to FIGS. 2 to 5 . FIG. 2 is a block diagram schematically showing an electrical configuration for light emission control, in which the main control board 100 , the LED control board 110 , and the LED units 40 are electrically connected. FIG. 3 shows a positional state of each LED unit 40 when the upper cover 11 is closed. FIG. 4 shows a positional state of each LED unit 40 when the upper cover 11 is opened. FIG. 5 is a perspective view schematically showing the LED head 41 .
The main control board 100 includes a main application specific integrated circuit (ASIC) 102 , a memory unit 103 , and a timer unit 104 . The main ASIC 102 is configured to control each element included in the printer 1 when the printer 1 performs image formation. The memory unit 103 includes a ROM and a RAM. Further, the timer unit 104 includes one or more timers for measuring time periods taken for processes by the main ASIC 102 .
Specifically, the main ASIC 102 controls rotational speeds of the photoconductive drum 53 and the driving roller 71 , a speed at which the sheet P is fed at the feed unit 20 or the fixing unit 80 , and timing for exposure directly or indirectly via another control board such as the LED control board 110 . Especially, in control for illumination of the light emitted by each LED unit 40 , the main ASIC 102 supplies print data, reset signals (Reset), control signals (containing setting data and correction data), and a clock signal (clock) to the LED control board 110 .
In the meantime, the LED control board 110 provided to the upper cover 11 includes a sub ASIC 114 . The main ASIC 102 and the sub ASIC 114 are linked via a flat cable 140 . The sub ASIC 114 is configured to transmit control signals (CONT) and drive signals (DRIV) to the LED heads 41 based on the image data of the image to be formed and to control emission of each LED head 41 in accordance with the lighting pattern based on the image data.
More specifically, the sub ASIC 114 includes four blocks ( 115 K, 115 Y, 115 M, and 115 C) that correspond to the four LED units ( 40 K, 40 Y, 40 M, and 40 C), respectively. Each of the blocks 115 receives the print data, the control signals (containing setting data and correction data), and the reset signal Reset from the main ASIC 102 via the flat cable 140 . Each of the blocks 115 is individually brought into a reset state where an operation thereof is reset, by the reset signal Reset. In the reset state, a process performed by each block 115 for the image formation, such as generation and output of the control signal CONT and the drive signal DRIV, is stopped.
In addition, the LED units 40 (the LED heads 41 ) are electrically connected with the blocks 115 of the sub ASIC 114 via flat cables ( 130 K, 130 Y, 130 M, and 130 C), respectively. An earth cable 84 of each LED unit 40 is linked with a shield plate 81 . Further, as illustrated in FIGS. 3 and 4 , the shield plate 81 is linked, via an earth cable 83 , with a conductive chassis 10 A connected to ground. Namely, each earth cable 84 is connected to ground. It is noted that, as illustrated in FIG. 5 , the earth cables 84 is provided at both sides of each LED head 41 in the right-to-left direction.
In addition, each LED unit 40 has earth contact points 82 . As illustrated in FIG. 5 , the earth contact points 82 are respectively provided at both the sides of the LED head 41 in the right-to-left direction. Each of the earth contact points 82 establishes contact with the conductive chassis 10 A only when the upper cover 11 is closed (see FIG. 3 ). In other words, as shown in FIG. 4 , when the upper cover 11 is opened, each of the earth contact points 82 is away from the conductive chassis 10 A. Therefore, when the upper cover 11 is opened, the LED control board 110 is connected to the ground at the side of the LED control board 110 via the earth cable 83 .
Further, as illustrated in FIG. 2 , the printer 1 includes a low-voltage power source board 150 . The low-voltage power source board 150 generates, e.g., a low voltage of 3.3 V and supplies the low voltage to the main control board 100 via a power source cable 151 and to the LED control board 110 via a power source cable 152 .
3. Reset Control of Sub ASIC
Subsequently, referring to FIGS. 6 to 9 , reset control for the sub ASIC 114 to be taken along with operations of opening and closing the upper cover 11 will be set forth.
3-1. Reset Control in Ready State
Practical Example 1
Referring to FIG. 6 , reset control for the sub ASIC 114 will be described which is taken when the upper cover 11 is opened in a ready state where the printer 1 performs no printing operation. FIG. 6 is a time chart showing a relationship between the open-close detection signal Sd issued in response to an operation of opening/closing the upper cover 11 and the reset signal Reset, in the ready state of the printer 1 .
It is assumed that the user opens the upper cover 11 at a time t 1 shown in FIG. 6 , for an operation such as replacing a process cartridge 50 . At this time, the cover switch 13 generates an open-close detection signal Sd which drops from a logic high level (H) to a logic low level (L) in response to the upper cover 11 being opened, and supplies the open-close detection signal Sd to the main ASIC 102 .
Then, at a time t 2 after lapse of a predetermined time period K 1 since the time t 1 , the main ASIC 102 generates a reset signal Reset which drops from a logic high level (H) to a logic low level (L). The predetermined time period K 1 is, for instance, measured by a timer of the timer unit 104 . It is noted that the predetermined time period K 1 is, for instance, set to a time period until the user may touch the image forming unit 30 such as the process cartridge 50 after opening the upper cover 11 .
The reset signal Reset is supplied to the sub ASIC 114 . Specifically, for example, the reset signal Reset is concurrently supplied to each of the blocks ( 115 K, 115 Y, 115 M, and 115 C) of the sub ASIC 114 to concurrently set each of the blocks 115 to the reset state. The reason why each of the blocks 115 is set to the reset state here is to avoid malfunction of each block 115 electrostatically caused when the user touches an earth contact point 82 of an LED unit 40 during the operation.
Subsequently, it is assumed that the user completes the operation and closes the upper cover 11 at a time t 3 shown in FIG. 6 . At this time, the cover switch 13 generates an open-close detection signal Sd that rises from the logic low level (L) to the logic high level (H) in response to the upper cover 11 being closed, and supplies the open-close detection signal Sd to the main ASIC 102 .
Then, at a time t 4 after lapse of a predetermined time period K 2 since the time t 3 , the main AISC 102 changes the reset signal Reset from the logic low level (L) to the logic high level (H). The predetermined time period K 2 is, for example, measured by a timer of the timer unit 104 .
By the reset signal Reset of the logic high level (H), the reset state of each block 115 of the sub ASIC 114 is concurrently released, and an initialization process is carried out in each block 115 . After the initialization process is completed, each block 115 keeps waiting in a ready state.
The reason why the reset state of each block 115 is released after lapse of the predetermined time period K 2 since the upper cover 11 has been closed is as follows. For example, when the upper cover 11 is not completely closed, the open-close detection signal Sd may wiggle between the logic high level (H) and the logic low level (L). Even in such a situation, when the reset state of each block 115 is released, it is possible to prevent the operations of setting and releasing the reset state of each block 115 from being unnecessarily repeated by the open-close detection signal Sd wiggling. In other words, it is possible to render invalid fluctuation of the open-close detection signal Sd within the predetermined time period K 2 .
In addition, as shown in FIG. 6 , when the upper cover 11 is opened at a time t 5 and closed at a time t 6 , and a cover-opened time period Topen between the time t 5 and the time t 6 is shorter than the predetermined time period K 1 , the main ASIC 102 does not render valid the reset signal Reset (namely, does not set the reset signal Reset to the logic low level) or reset each block 115 .
In other words, when the user opens the upper cover 11 for a short while such that the user does not touch the inside of the main body 10 (e.g., for just taking a look at the inside of the main body 10 ) and soon closes the upper cover 11 , each block 115 is not reset. This is to reduce unnecessary stop operations for the sub ASIC 114 and improve efficiency of the image formation by the printer 1 .
3-2. Reset Control in Printing Operation
Practical Example 2
Next, referring to FIG. 7 , reset control for the sub ASIC 114 will be set forth which is taken when the upper cover 11 is opened during a printing operation by the printer 1 . FIG. 7 is a time chart showing a relationship between the open-close detection signal Sd and the reset signal Reset during the printing operation by the printer 1 . It is noted that the “printing operation” by the printer 1 includes operations until the printer 1 prints out a predetermined number of pages of sheets P after receiving a command to print the predetermined number of pages of sheets P.
For example, it is assumed that a sheet P becomes jammed at a time t 1 shown in FIG. 7 and the user opens the upper cover 11 to remove the jammed sheet P. At this time, in response to the upper cover 11 being opened, the cover switch 13 generates the open-close detection signal Sd which drops from the logic high level (H) to the logic low level (L) and supplies the open-close detection signal Sd to the main ASIC 102 .
At this time, the main ASIC 102 changes the reset signal Reset from the logic high level (H) to the logic low level (L) to set each block 115 of the sub ASIC 114 to the reset state. Namely, when the upper cover 11 is opened during the printing operation, each block 115 is reset at the same time when the upper cover 11 is opened, as illustrated in FIG. 7 . When the upper cover 11 is opened during the printing operation by the printer 1 , the user is, in general, likely to access the image forming unit 30 to perform paper jam settlement or cartridge replacement. In such a case, a long cover-opened time period Topen is required. Therefore, by stopping (resetting) the sub ASIC 114 promptly, it is possible to avoid malfunction of the sub ASIC 114 electrostatically caused when the user touches an earth contact point 82 of an LED head 41 in an operation.
It is noted that, in the same manner as the practical example 1, the reset state of each block 115 is not released at the same time when the upper cover 11 is closed. Hence, it is possible to reduce unnecessary stop operations for the sub ASIC 114 .
3-3. Reset Control for Each Block
Practical Example 3
Subsequently, referring to FIGS. 8 and 9 , reset control will be set forth which is taken to individually reset the blocks 115 of the sub ASIC 114 . FIGS. 8 and 9 are time charts showing relationships between the open-close detection signal Sd and a reset signal (Reset_K, Reset_Y, Reset_M, or Reset_C) corresponding to each of the blocks 115 . In the practical examples 1 and 2, each of the blocks 115 is concurrently reset by the reset signal Reset. Meanwhile, in the practical example 3, a predetermined time period K 1 after the upper cover 11 is opened is set for each of the blocks 115 , and the blocks 115 are reset at respective different moments.
Specifically, in the case where the upper cover 11 is opened at a time t 1 shown in FIG. 8 when the printer 1 is in the ready state, the main ASIC 102 first changes the reset signal Reset_K for the block 115 K from the logic high level (H) to the logic low level (L) at a time t 2 after lapse of a predetermined time period (K 1 - 1 ) since the time t 1 . Then, the main ASIC 102 supplies the reset signal Reset_K of the logic low level (L) to the block 115 K and sets the block 115 K to the reset state.
Subsequently, the main ASIC 102 changes the reset signal Reset_K for the block 115 Y from the logic high level (H) to the logic low level (L) at a time t 3 after lapse of a predetermined time period (K 1 - 2 ) since the time t 1 . Then, the main ASIC 102 supplies the reset signal Reset_Y of the logic low level (L) to the block 115 Y and sets the block 115 Y to the reset state.
In the same manner, at a time t 4 after lapse of a predetermined time period (K 1 - 3 ) since the time t 1 , the main ASIC 102 supplies the reset signal Reset_M of the logic low level (L) to the block 115 M and sets the block 115 M to the reset state. Further, at a time t 5 after lapse of a predetermined time period (K 1 - 4 ) since the time t 1 , the main ASIC 102 supplies the reset signal Reset_C of the logic low level (L) to the block 115 C and sets the block 115 C to the reset state. It is noted that, here, the predetermined time period (K 1 - 1 ), which corresponds to the LED unit 40 K provided the closest to an open end (a front end opposite to the rotation shaft 12 ) of the upper cover 11 , is set to be the shortest among the predetermined time periods K 1 (K 1 - 1 , K 1 - 2 , K 1 - 3 , and K 1 - 4 ).
The reason why the different predetermined time periods K 1 after the upper cover 11 is opened are respectively set for the blocks 115 , and the blocks 115 are reset at respective different moments is given as follow. For example, as illustrated in FIG. 9 , the cover-opened time period Topen during which the upper cover 11 is opened is longer than the predetermined time period (K 1 - 1 ) and shorter than the predetermined time period (K 1 - 2 ), the block 115 K is only reset. In other words, when the cover-opened time period Topen is short, the number of blocks 115 reset can be reduced. Therefore, an initialization time period for initializing the blocks 115 after the reset states of the blocks 115 are released can drastically be reduced in comparison with the case where all the blocks 115 are initialized (see FIGS. 8 and 9 ). Thus, it leads to improved efficiency of the image formation by the printer 1 to reduce unnecessary stop operations for the blocks 115 depending on the cover-opened time period Topen and shorten the initialization time period for the blocks 115 .
Further, the reason why the blocks 115 are reset depending on the cover-opened time period Topen sequentially in the order of block arrangement from the open end (the front end opposite to the rotation shaft 12 ) of the upper cover 11 to the rotation shaft 12 , i.e., from the front side to the rear side of the printer 1 is as follows. In general, in the case of the upper cover 11 turning around the rotation shaft 12 as a supporting axis, the LED unit 40 K provided at the open end of the upper cover 11 is likely to be first touched by the user (see FIG. 4 ). Therefore, by setting the predetermined time period (K 1 - 1 ) for the LED unit 40 K provided at the open end of the upper cover 11 to be the shortest and resetting the block 115 K first, it is possible to avoid electrostatically caused malfunction in a preferable manner.
4. Effects of Embodiment
When the cover-opened time period Topen is shorter than the predetermined time period K 1 , the main ASIC 102 does not render valid the reset signal Reset or reset the blocks 115 . Therefore, for instance, when the cover-opened time period Topen is too short for the user to touch the inside of the main body 10 , the blocks 115 are not reset. Thereby, it is possible to reduce unnecessary stop operations for the sub ASIC 114 and improve efficiency of the image formation by the printer 1 .
In addition, after lapse of the predetermined time period K 1 , each of the blocks 115 is set to the reset state. Therefore, it is possible to avoid malfunction of the blocks 115 electrostatically caused when the user touches an earth contact point 82 of an LED head 41 in an operation.
Further, the reset state of each of the blocks 115 is released after lapse of the predetermined time period K 2 since the upper cover 11 has been closed. Therefore, it is possible to prevent the operations of setting and releasing the reset states of the block 115 from being unnecessarily repeated by the main ASIC 102 .
Further, when the user opens the upper cover 11 during the printing operation by the printer 1 , the sub ASIC 114 is concurrently stopped (reset). Hence, even when the user touches an earth contact point 82 of an LED head 41 , for example, during an operation of settling a paper jam, it is possible to avoid electrostatically caused malfunction of the sub ASIC 114 .
Moreover, by setting the predetermined time period K 1 defined from the moment when the upper cover 11 is opened individually for each of the blocks 115 and resetting the blocks 115 at respective different moments, it is possible to reduce unnecessary stop operations for the blocks 115 depending on the cover-opened time period Topen during which the upper cover 11 is opened. Thereby, it is possible to shorten the initialization time period, and thus it leads to improved efficiency of the image formation by the printer 1 .
Further, when the predetermined time period K 1 is set individually for each of the blocks 115 , by first resetting the block 115 K which corresponds to the LED unit 40 K located the closest to the open end of the upper cover 11 , it is possible to avoid electrostatically caused malfunction in a preferable manner.
Hereinabove, the embodiment according to aspects of the present invention has been described. The present invention can be practiced by employing conventional materials, methodology and equipment. Accordingly, the details of such materials, equipment and methodology are not set forth herein in detail. In the previous descriptions, numerous specific details are set forth, such as specific materials, structures, chemicals, processes, etc., in order to provide a thorough understanding of the present invention. However, it should be recognized that the present invention can be practiced without reapportioning to the details specifically set forth. In other instances, well known processing structures have not been described in detail, in order not to unnecessarily obscure the present invention.
Only an exemplary embodiment of the present invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein. For example, the following modifications are possible.
[Modifications]
(1) In the aforementioned embodiment, a control system is configured with the sub ASIC 114 provided to the upper cover 11 and the main ASIC 102 provided to the main body 10 , and the main ASIC 102 is adapted to interrupt the operations of the sub ASIC 114 and to release the interrupted state. However, for example, a control circuit configured to process image data for forming an image, an interrupting unit configured to interrupt the image data processing of the control circuit when a time period during which the upper cover 11 is kept opened reaches a predetermined time period, and a releasing unit configured to release the interrupted state of the image data processing by the control unit may separately be provided.
(2) In the aforementioned embodiment, the main ASIC 102 interrupts the operations of the sub ASIC 114 by supplying the reset signals to the sub ASIC 114 . However, for example, a function for interrupting the operations of the sub ASIC 114 and a function for releasing the termination of the operations may be achieved by a power source supply unit. Specifically, the power source supply unit may be configured to, in response to the upper cover 11 being opened/closed, interrupt/resume the operations of the sub ASIC 114 through ON/OFF control of power supply to the sub ASIC 114 .
(3) The aforementioned practical example 3 of the embodiment has exemplified that the block 115 K is first reset. However, the block 115 C may first be reset. In other words, the main ASIC 102 may be configured to first reset a predetermined one of the plural blocks 115 . In such a configuration, even when an initialization process is required after the termination of the operations of the sub ASIC 114 is released, as the operations of all the blocks are not necessarily required to be terminated, the initialization process can promptly be achieved. Hence, it is possible to improve efficiency of the image formation by the printer 1 . Additionally, a block 115 , which is likely to be electrostatically influenced when the upper cover 11 is opened, may be selected appropriately depending on a situation as a block to be first reset.
(4) In the aforementioned embodiment, the LED head 41 using the LEDs is employed to expose the surface of the photoconductive drum 53 with light emitted thereby. However, as substitute for the LEDs, light emitting elements such as electroluminescence (EL) devices, fluorescent substances, and laser emitting devices may be employed. Further, as substitute for the LED head 41 , a unit may be employed which has multiple light shutters aligned (e.g., liquid crystal devices, PLZT devices, etc.) and selectively controls respective open/close time periods of the multiple light shutters based on the image data.
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An image forming device includes a processor configured to process image data, an image forming unit configured to perform image formation based on the image data processed by the processor, a cover configured to, when being opened, allow an external access to the image forming unit therethrough, a detector configured to detect whether the cover is opened, and an interrupting unit configured to, when determining with the detector that the cover is kept opened for a first time period, interrupt the processing of the image data by the processor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of Applicant's prior U.S. App. No. 07/664,772 filed Mar. 5, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This industrial invention relates to a steam generator for domestic and industrial use. More particularly, the present invention provides a steam generator which enables the user to obtain maximum steam efficiency and minimum wastage of electrical energy.
2. Brief Description of the Prior Art
Steam generator which can be used for distributing steam to a plurality of appliances, non-limiting examples of which are a smoothing iron, general cleaning appliances, saunas, humidifiers, etc., are well-known, examples being devices such as shown and described in U.S. Pat. Nos. 1,576,568; 4,480,173; and 4,878,458; and Italian Patent Application No. 2927/A87 which matured into Italian Patent No. 1,218,483 on Apr. 19, 1990. Italian Patent No. 1,218,483 is incorporated herein by reference. Such steam generators have given excellent industrial results but require the availability of an electrical system able to sustain sudden absorbed current increases to an extent not always possible in the case of normal users. These absorbed current increases are due to the fact that when the generator is used for feeding steam to appliances which themselves absorb electrical energy, such as a smoothing iron, switching on the appliance results in a current increase and, as stated, implies the need for a large installed power availability. A further limitation is that in order to ensure that the electromechanical pressure switch retains its reliability with time, it is not possible for constructional reasons to reduce the operating pressure hysteresis to a minimum. Finally, prior art steam generators for home or light industrial use have only two levels of steam output; full on or completely closed off. No selection in the amount of steam can be easily made by the user.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a steam generator which does not suffer from the aforesaid drawbacks.
Specifically, in the steam generator according to the invention: a) the maximum operating pressure is regulated by a hysteresis-free pressure switch, i.e. free from on-off hysteresis, with consequent constant operating pressure without surges due to hysteresis; b) the power of the resistance heater element of the generator is reduced when the heater element of another appliance connected to the generator is switched on, such as a smoothing iron or the like, thus resulting in constant mains energy consumption without sudden increases due to the switching on of the appliance; c) an indication is given by visual and/or acoustic or other means when the pressure is sufficient for use; d) a device can be provided for reducing the heating power of the generator (energy saving); e) means are provided for interrupting the electrical energy feed to the generator after a predetermined time of operation without water; and f) means are provided to give the user a selection of available steam output rates.
These and further objects of the invention will be apparent to the expert in the art upon reading the following description. The steam generator for domestic and industrial use is of the type comprising a boiler provided with a resistance heater element and a steam and energy take-off unit, and comprises at least a first and a second solenoid valve or equivalent connected between the boiler and the take-off unit, the generator comprising an electronic controller card for controlling the generator operation.
BRIEF DESCRIPTION OF THE DRAWING
The steam generator according to the present invention is illustrated by way of non-limiting example in the figures of the accompanying drawings, in which:
FIG. 1 is an overall perspective view of the generator;
FlG. 2 is a partial view of the generator with its cover open; and
FIG. 3 is a block diagram of the generator;
FIG. 4 is a side elevation view of a prior art steam generator showing a steam and power take-off unit device;
FIG. 5 is a cross-sectional view of the steam and power connections at the steam and power take-off unit of FIG. 4; and
FIG. 6 shows the connections and steam paths for the different operating modes of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the figures, the generator, indicated overall by 1, comprises essentially a base 2 provided with castors 3, and a cover 4.
In the base 2 there is mounted a boiler 5, of the type described in said Italian Patent No. 1,218,483, suitably covered with insulating material and provided with a filing cap 6 with a double-acting safety valve (not shown).
To assist in the understanding of the manner in which steam and power may be taken off a boiler unit, the following description refers to FIGS. 4 and 5 showing the steam and power take-off unit according to the aforementioned Italian Patent No. 1,218,483 which is prior art relative to the present invention.
A flexible rubber tube 140 is located at the exit of tap 137 and intended to convey steam to a further check valve 141, which will open when the coupling with a complementary male member 142 is effected, the member pertaining to a particular plug 144 integral with the end of a utilizing tube 143. Plug 155 is formed by a male member 142 bearing externally two sealing rings 145 ("O" Ring type) engaging with the cylindric recess of the valve intended to receive said male coupling member 142, the male member opening the aperture of the check valve 141 through the thrust exerted by its extremity 142E; in this way steam can flow from said valve 141 to the interior of a hole 146 axial with said male member 141 and from there pass to the interior of the flexible utilizing tube 143. The axial constraint between the two parts, which is necessary inasmuch as they convey a fluid under pressure, is representsd by a tooth 147 (FIG. 5). This tooth yieldably retracts in respect of the reference plane 148 when it is pressed against the inclined guiding surface 149 during the coupling operation and/or when it is raised by a first lever 150 fulcrumed at 151 and operated at a protruding portion 152. Said lever 150 causes the tooth 147 to be raised by its reactive end 153. This end is forked so as to house interiorly an extension of the tooth body provided with shoulders 154. The tooth body extension is provided with a recess to contain a spring 156 reacting on the body of the plug 144 to push the tooth body externally until the boundary imposed by the interposition of the end 153 between the shoulders 154 and the lower body of the plug 144. This plug 144, besides representing a means for connecting the steam tubes, is intended to bring about also the electric connection between the utilizing fitting and the body of the generating apparatus including the boiler. This electric connection is necessary when the user is provided with a pushbutton for controlling the electrovalve 138; e.g. a smoothing iron, a pavement-washing brush etc. When using a fitting requiring electric power for its intrinsic operation, other electric cables have to be connected by the plug; this is the case of steam smoothing irons, which require two conductors for the heating of its plate and two further conductors for controlling the electrovalve provided for the steam inflow, and, obviously, the conductor(s) for the grounding. This electric connection is provided by conventional electric male-female means, with the peculiarity that the female is formed by a "block" of a certain number of holes (e.g. six) supplied with voltage, and the male by pins whose number and position is such as to satisfy the needs. In fact, each user (smoothing iron, brush etc.) is provided with its own plug which differs from those of other user fittings only for the number and position of its own male pins 158 which draw the electric current.
In order to offer a sure guarantee against accidents and as machine protection, the plug 144 is provided with a bulkhead 157 separating the zone of the electric connections from the zone of the steam connection to avoid steam leakages causing short-circuits between the electric polarities. A further safety device is represented by a bipolar microswitch 159 which applies voltage to the female plug 160 of the machine only after a proper insertion of the plug 144 and the latter has established contemporarily the correct coupling between the steam tubes. If the user fitting is that of a smoothing iron, its connection with the steam generator is obtained exclusively through a flexible sheath 143 (FIG. 4) and controlled by a pushbutton operated microswitch controlling the aperture of the electrovalve 138 only by a specific maneuver.
Returning to FIGS. 2, 3, and 6, to the boiler 5 of the present invention there are connected a first solenoid valve 7 and a second solenoid valve 8, the two outlets of which, 7' and 8' respectively, are connected to a single pipe 9 with which there is associated a steam and energy take-off unit 10, to which the appliances and relative controls, such as a smoothing iron, are connected as required. There is also connected to the boiler 5 a hysteresis-free pressure switch or equivalent, 11, the output 12 of which is connected to an electronic control card 13, the functions of which are displayed by a plurality of LEDs 14 1 , 14 2 , . . . 14 9 , and which is powered by the mains 15.
The output 16 of the card 13 controls the resistance element 17, the output 18 controls the solenoid valve 7, the output 19 controls the solenoid valve 8 and the output 20 is associated with the take-off 10. The input 21 to the card 13 is associated with the thermostat 22 provided on the boiler 5, the inputs 23, 24, of low voltage and isolated from the mains, are associated with the take-off unit 10, and the inputs 25, 26 and 27 are associated with a steam selector switch 28.
In operation, having filled the boiler 5 with the scheduled quantity of water, the user operates a mains switch 29 and then selects the type of operation by setting the switch 28 (steam OFF, steam ON with 100% of energy, steam ON with 50% of energy, economizer operation and/or humidification).
In the described example of operation it will be assumed that 100% ON operation has been selected. In this case on operating the switch 28 the LED 14 9 lights to indicate this selection, and the resistance element 17 is fed with 100% of its power, to consequently commence steam production. During this initial stage the LED 14 8 also lights to indicate a steam pressure which is too low for use.
When the pressure in the boiler 5 reaches the working value the LED 14 8 is extinguished and the LED 14 7 lights to indicate that the working pressure has been reached. As heating continues, the maximum allowable working pressure is reached, as measured by the pressure switch 11, and the LED 14 6 light jointly with the LED 14 7 . The lighting of the LED 14 6 causes the resistance element 17 to be switched off.
The pressure in the boiler 5 is regulated by the hysteresis-free pressure switch 11, which measures it with maximum precision due to the lack of system hysteresis.
From the time the LED 14 7 lights, the generator is ready for use, and the user by operating the switches associated with the inputs 23 and 24 can select three different steam loads (four including "off") via the take-off unit 10, as follows: by operating the switch associated with the input 23 he activates the solenoid valve 7 and lights the LED 14 3 to indicate minimum steam withdrawal (e.g. 30%), by operating the switch associated with the input 24 he activates the solenoid valve 8 and lights the LEDs and 14 4 and 14 5 to indicate medium steam withdrawal (e.g. 70%), and by operating the switches associated with the inputs 23 and 24 simultaneously, he activates both the solenoid valves 7 and 8 and lights the LEDs 14 3 , 14 4 and 14 5 to indicate maximum steam withdrawal (e.g. 100%). The operating switch (not shown) for making these selections can be conveniently located at the user end of the flexible sheath 143 and the electrical connection through pins 158 to controller card 13.
FIG. 6 shows, in partial cross-section, the connections and inner workings of valves 7 and 8. The two valves operate substantially identically, except that valve 7 includes a self-cleaning device, while the output of valve 8 is large enough to not require one.
Using like numerals for like components in valves 7 and 8, each valve contains a housing 201 with a large inlet 209, and a small outlet 208 for valve 7, and a larger outlet 208' for valve 8. As previously indicated, the steam flow through the two valves are such that, when valve 7 is open, a small amount of steam is permitted to pass therethrough, and when valve 8 is open, a larger amount than that of valve 7 is permitted to flow therethrough. Both valves operate independently and are controlled by the electronic control card 13 which energizes or deenergizes a solenoid coil 215 which magnetically pulls the shank of plunger 203 against spring 217 lodged in the rear of the housing 201. Without electrical energy applied, the magnetic hold on plunger 203 is released, and compression spring 217 forces the plunger to close the outlet of the valve. For a complete seal of the valve outlet 208, a soft rubber or plastic washer 205 is provided at the end of plunger 203 and, when the valve is closed, presses against seat 211 which may be a raised annular rib around outlet 208, 208'.
Because valve 7 is designed to pass only a small amount of steam, the output opening 208 is very small and can be occluded by the calcareous deposits in the water used to produce the steam. Valve 7 thus includes a means to clean valve opening from such calcareous deposits so as to be self-cleaning. The cleaning means includes a small plunger or needle fixed to the plunger 203, the former passing through the valve opening when the valve plunger closes it, thus cleaning the opening against the accumulation of deposits. Valve 8, having an output opening with a larger size does not suffer this shortcoming, and no self-cleaning device is shown.
Connections to valves 7 and 8 are by standard means using, for example, high temperature plastic tubing which would include a source tube 243 from the steam generator, a tube 245 leading to the input valve connection 209 of valve 7, and a tube 247 leading to the inlet connection 209 of valve 8. A "T" connector 241 interconnects the three-mentioned tubes, and a seal at the points of connection of the tubes can be made by any appropriate clamp or strap 249. A second "T" 241' is shown to connect the outputs of the two valves together leading to the summed output conduit or tube 9.
With continued steam withdrawal, the water in the boiler 5 will ultimately be completely consumed, with consequent temperature rise as measured by the thermostat 22, which lights the flashing LED 14 2 and disconnects the resistance element 17. If this situation persists beyond a certain predetermined time, power is switched off to the system. Reactivation can only be done by switching off and switching on the switch 29.
If electrical energy is also withdrawn from the take-off unit via the output 20, for example for the smoothing iron, the card 13 automatically reduces the energy to the resistance element 17 proportionally, to maintain the electrical energy consumption of the generator constant. This means that the installed electrical system can present a power load which simulates normal use, i.e. there are no sudden excessive load changes.
If the 50% ON function is selected, for example for operating the system as a humidifier, the LED 14 9 lights with 50% brightness to indicate this selection, while the other functions remain unaltered. The 50% mode (i.e. the economizer operation functions independently of the steam rate selection made at the take-off unit 10. That is, the proportions of steam output determined by the operation of valves 7 and 8 are effective whether 100% energy is applied or 50% energy is applied to the boiler 5.
If the generator 1 is to be used without steam, the switch 28 is put in the steam OFF position. The LED 14 9 will therefore not light, so indicating this selection, and only electrical energy will be available at the take-off unit 10 via the output 20 of the card 13, for example to allow a smoothing iron to be used dry. The LED 14 1 associated with the switch 29 lights to indicate that the generator 1 is powered.
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A steam generator for domestic and industrial use, of the type which has a boiler (5) provided with a resistance heater element (17) and a steam and energy take-off unit (10) for supplying steam and electrical power to an external user item, such as a smoothing iron. At least a first solenoid valve (7) and a second solenoid valve (8) are connected between the boiler (5) and the take-off unit (10) to give rise to at least three separate levels of output steam rate. An electronic controller is coupled to the resistance heater element (17), steam and electrical power take-off unit (10), the power source and the solenoid valves (7,8) for automatically and proportionally exchanging electrical power applied to the resistance heater element (17) with electrical power applied to the external user item, thereby effectively exchanging the amount of steam available for use by, and the electrical power applied to, the external user item.
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FIELD OF INVENTION
The present invention relates to a process for producing syndiotactic 1,2-polybutadiene with a catalyst system which comprises a chromium-containing compound, an organoaluminum hydride, and a hydrogen phosphite. Syndiotactic 1,2-polybutadiene exhibits properties of both plastics and rubber. It can be blended into rubbers and due to its residual carbon-carbon unsaturation it can be cocured with unsaturated rubbers.
BACKGROUND OF THE INVENTION
Syndiotactic 1,2-polybutadiene can be made by solution, emulsion or suspension polymerization. The syndiotactic 1,2-polybutadiene from solution, emulsion, or suspension polymerization typically has a melting temperature which is within the range of about 195° C. to 215° C.
Various transition metal catalyst systems based on cobalt, titanium, vanadium, chromium, and molybdenum have been reported in the prior art for the preparation of syndiotactic 1,2-polybutadiene (see, e.g., L. Porri and A. Giarrusso, in Comprehensive Polymer Science, edited by G. C. Eastmond, A. Ledwith, S. Russo and P. Sigwalt, Pergamon Press: Oxford, 1989, Volume 4, Page 53). However, the majority of these catalyst systems have no practical utility because they have low catalytic activity or poor stereoselectivity and in some cases produce low molecular weight polymers or crosslinked polymers unsuitable for commercial use.
The following cobalt-based catalyst systems are well known for the preparation of syndiotactic 1,2-polybutadiene: (1) cobalt bis(acetylacetonate)/triethyl aluminum/water/triphenyl phosphine (U.S. Pat. Nos. 3,498,963 and 4,182,813; Jap. Kokoku 44-32426, assigned to Japan Synthetic Rubber Co. Ltd.), and (2) cobalt tris(acetylacetonate)/triethyl aluminum/carbon disulfide (U.S. Pat. No. 3,778,424; Jap. Kokoku 72-19,892, 81-18,127, 74-17,666, and 74-17,667; Jap. Kokai 81-88,408, 81-88,409, 81-88,410, 75-59,480, 75-121,380, and 75-121,379, assigned to Ube Industries Ltd.). These two catalyst systems also have serious disadvantages.
The cobalt bis(acetylacetonate)/triethyl aluminum/water/triphenyl phosphine system yields syndiotactic 1,2-polybutadiene having very low crystallinity. In addition, this catalyst system develops sufficient catalytic activity only in halogenated hydrocarbon solvents as the polymerization medium, and halogenated solvents present the problems of toxicity.
The cobalt tris(acetylacetonate)/triethyl aluminum/carbon disulfide system uses carbon disulfide as one of the catalyst components. Because of its high volatility, obnoxious smell, low flash point as well as toxicity, carbon disulfide is difficult and dangerous to use and requires expensive safety measures to prevent even minimal amounts escaping into the atmosphere. Furthermore, the syndiotactic 1,2-polybutadiene produced with this catalyst system has a very high melting temperature within the range of 200-210° C., which makes it difficult to process the polymer. Although the melting temperature of the syndiotactic 1,2-polybutadiene can be reduced by the use of a catalyst modifier as a fourth catalyst component, the presence of such a catalyst modifier also has an adverse effect on the catalyst activity and polymer yields. Accordingly, many restrictions are required for the industrial utilization of the two aforesaid cobalt-based catalyst systems of the prior art.
Coordination catalyst systems based on chromium-containing compounds such as chromium(III) acetylacetonate/triethylaluminum have been known for a long time, but they have low catalytic activity and poor stereoselectivity for the polymerization of 1,3-butadiene and give rise to oligomers, low molecular weight liquid polymers or crosslinked polymers. Therefore, these chromium-based catalyst systems of the prior art have no industrial utility.
Japanese patents JP-A-7306939 and JP-A-7364178, both assigned to Mitsubishi, disclose a process for polymerization of 1,3-butadiene to amorphous 1,2-polybutadiene by using a ternary catalyst system comprising: (a) a soluble chromium(III) compound, (b) a trialkyl aluminum compound, and (c) a dialkyl hydrogen phosphite. The product was reported to be a white rubbery polymer which contained a portion of gel and displayed no obvious melting point.
U.S. Pat. No. 4,751,275, assigned to Bayer, discloses a process for the preparation of syndiotactic 1,2-polybutadiene by solution polymerization of 1,3-butadiene in a hydrocarbon polymerization medium. The catalyst system used in this solution polymerization contains a hydrocarbon-soluble chromium(III) compound, a trialkylaluminum compound, and dineopentyl hydrogen phosphite or methyl neopentyl hydrogen phosphite. However, the polymerization product was not well characterized as neither the melting temperature nor the degree of syndiotacticity of the product is reported.
U.S. Pat. No. 4,168,357 and U.S. Pat. No. 4,168,374, both assigned to Goodyear, describe a similar chromium-based catalyst system for the preparation of high cis-1,4-polypentadiene. They disclose dialkylaluminum hydrides for preparing high cis-1,4-polypentadiene, e.g. in column 2, lines 44-52 of U.S. Pat. No. 4,168,357, but they do not claim dialkylaluminum hydrides as part of their catalyst system in the claims.
SUMMARY OF THE INVENTION
The present invention relates to an improved process for polymerization of 1,3-butadiene to syndiotactic 1,2-polybutadiene using a catalyst system comprising: (a) a chromium-containing compound, (b) an organoaluminum hydride compound, and (c) a hydrogen phosphite. While chromium-based catalyst systems are known, the use in combination with organoaluminum hydride and hydrogen phosphite to yield syndiotactic 1,2-polybutadiene was not known. The catalyst system of the present invention is operational under a variety of conditions (e.g. with or without solvents, over broad temperature range, and with a variety of molecular weight regulators). The use of the catalyst system avoids the use of environmentally detrimental components such as the carbon disulfide and halogenated solvents used in prior art catalysts. The use of the catalyst system of this disclosure also offers an alternative lower melting temperature syndiotactic 1,2-polybutadiene which can be mixed with rubber at lower temperatures than the 195-215° C. melting temperature typical of syndiotactic 1,2-polybutadiene made by prior art catalyst systems.
DETAILED DESCRIPTION OF THE INVENTION
This invention teaches a process for producing syndiotactic 1,2-polybutadiene by polymerizing 1,3-butadiene in the presence of a catalyst system comprising: (a) a chromium-containing compound, (b) an organoaluminum hydride compound, and (c) a hydrogen phosphite.
As the component (a) of the catalyst system of the present invention, various chromium-containing compounds can be utilized. It is generally advantageous to employ chromium-containing compounds that are soluble in a hydrocarbon solvent such as aromatic hydrocarbons, aliphatic hydrocarbons, or cycloaliphatic hydrocarbons. Nevertheless, insoluble chromium-containing compounds may merely be suspended in the polymerization medium to form the catalytically active species. Accordingly, no limitations should be placed on the chromium-containing compounds to insure solubility.
The chromium in the chromium-containing compounds employed in the catalyst system of the present invention can be in various oxidation states including, but not limited to, the 0, +2, +3, and +4 oxidation states. It is preferable to use divalent chromium compounds (also called chromous compounds), wherein the chromium is in the +2 oxidation state, and trivalent chromium compounds (also called chromic compounds), wherein the chromium is in the +3 oxidation state. Suitable types of chromium-containing compounds that can be utilized in the catalyst system of the present invention include, but are not limited to, chromium carboxylates, chromium β-diketonates, chromium alkoxides or aryloxides, chromium halides, chromium pseudo-halides, and organochromium compounds.
Some specific examples of suitable chromium carboxylates include chromium(II) formate, chromium(III) formate, chromium(II) acetate, chromium(III) acetate, chromium(II) acrylate, chromium(III) acrylate, chromium(II) methacrylate, chromium(III) methacrylate, chromium(II) valerate, chromium(III) valerate, chromium(II) gluconate, chromium(III) gluconate, chromium(II) citrate, chromium(III) citrate, chromium(II) fumarate, chromium(III) fumarate, chromium(II) lactate, chromium (III) lactate, chromium(II) maleate, chromium(III) maleate, chromium(II) oxalate, chromium(III) oxalate, chromium(II) 2-ethylhexanoate, chromium(III) 2-ethylhexanoate, chromium(II) neodecanoate, chromium(III) neodecanoate, chromium(II) naphthenate, chromium(III) naphthenate, chromium(II) stearate, chromium(III) stearate, chromium(II) oleate, chromium(III) oleate, chromium(II) benzoate, chromium(III) benzoate, chromium(II) picolinate, and chromium(III) picolinate.
Some specific examples of suitable chromium β-diketonates include chromium(II) acetylacetonate, chromium(III) acetylacetonate, chromium(II) trifluoroacetylacetonate, chromium(III) trifluoroacetylacetonate, chromium(II) hexafluoroacetylacetonate, chromium(III) hexafluoroacetylacetonate, chromium(II) benzoylacetonate, chromium(III) benzoylacetonate, chromium(II) 2,2,6,6-tetramethyl-3,5-heptanedionate, and chromium(III) 2,2,6,6-tetramethyl-3,5-heptanedionate.
Some specific examples of suitable chromium alkoxides or aryloxides include chromium(II) methoxide, chromium(III) methoxide, chromium(II) ethoxide, chromium(III) ethoxide, chromium(II) isopropoxide, chromium(III) isopropoxide, chromium(II) 2-ethylhexoxide, chromium(III) 2-ethylhexoxide, chromium(II) phenoxide, chromium(III) phenoxide, chromium(II) nonylphenoxide, chromium(III) nonylphenoxide, chromium(II) naphthoxide, and chromium(III) naphthoxide.
Some specific examples of suitable chromium halides include chromium(II) fluoride, chromium(III) fluoride, chromium(II) chloride, chromium(III) chloride, chromium(II) bromide, chromium(III) bromide, chromium(II) iodide, and chromium(III) iodide.
Some representative examples of suitable chromium pseudo-halides include chromium(II) cyanide, chromium(III) cyanide, chromium(II) cyanate, chromium(III) cyanate, chromium(II) thiocyanate, chromium(III) thiocyanate, chromium(II) azide, and chromium(III) azide.
As used herein, the term "organochromium compounds" refers to any chromium compound containing at least one covalent chromium-carbon bond. Some specific examples of suitable organochromium compounds include tris(allyl)chromium(III), tris(methallyl)chromium(III), tris(crotyl)chromium(III), bis(cyclopentadienyl)chromium(II) (also called chromocene), bis(pentamethylcyclopentadienyl)chromium(II) (also called decamethylchromocene), bis(benzene)chromium(O), bis(ethylbenzene)chromium(O), and bis(mesitylene)chromium(O).
The component (b) of the catalyst system of the present invention is an organoaluminum hydride compound. As used herein, the term "organoaluminum hydride compound" refers to any aluminum compound containing at least one covalent aluminum-carbon bond and at least one covalent aluminum-hydrogen bond. It is generally advantageous to employ organoaluminum hydride compounds that are soluble in the hydrocarbon polymerization medium. Thus suitable types of organoaluminum hydride compounds that can be utilized in the catalyst system of the present invention include, but are not limited to, dihydrocarbylaluminum hydride compounds and hydrocarbylaluminum dihydride compounds, which are represented by the formula AlH n R 3-n (n=1 or 2), wherein each R, which may be the same or different, is selected from the group consisting of alkyl, cycloalkyl, aryl, aralkyl, alkaryl, and allyl groups; each group preferably contains from 1, or the appropriate minimum number of carbon atoms to form such group, up to 20 carbon atoms. Dihydrocarbylaluminum hydride compounds are generally preferred.
Some specific examples of suitable organoaluminum hydride compounds that can be utilized in the catalyst system of the present invention are: diethylaluminum hydride, di-n-propylaluminum hydride, diisopropylaluminum hydride, di-n-butylaluminum hydride, diisobutylaluminum hydride, di-n-octylaluminum hydride, diphenylaluminum hydride, di-p-tolylaluminum hydride, dibenzylaluminum hydride, phenylethylaluminum hydride, phenyl-n-propylaluminum hydride, phenylisopropylaluminum hydride, phenyl-n-butylaluminum hydride, phenylisobutylaluminum hydride, phenyl-n-octylaluminum hydride, p-tolylethylaluminum hydride, p-tolyl-n-propylaluminum hydride, p-tolylisopropylaluminum hydride, p-tolyl-n-butylaluminum hydride, p-tolylisobutylaluminum hydride, p-tolyl-n-octylaluminum hydride, benzylethylaluminum hydride, benzyl-n-propylaluminum hydride, benzylisopropylaluminum hydride, benzyl-n-butylaluminum hydride, benzylisobutylaluminum hydride, and benzyl-n-octylaluminum hydride and other organoaluminum monohydrides. Also included are ethylaluminum dihydride, n-propylaluminum dihydride, isopropylaluminum dihydride, n-butylaluminum dihydride, isobutylaluminum dihydride, and n-octylaluminum dihydride and other organoaluminum dihydrides. Mixtures of the above organoaluminum hydride compounds may also be utilized.
The catalyst system of the present invention further comprises a hydrogen phosphite as the component (c). The hydrogen phosphite can be either an acyclic dihydrocarbyl hydrogen phosphite or a cyclic hydrocarbylene hydrogen phosphite.
The acyclic dihydrocarbyl hydrogen phosphite employed in the catalyst system of the present invention may be represented by the following keto-enol tautomeric structures: ##STR1## Wherein R 1 and R 2 , which may be the same or different, are hydrocarbyl radicals selected from the group consisting of alkyl, cycloalkyl, aryl, aralkyl, alkaryl, and allyl groups; each group preferably containing from 1, or the appropriate minimum number of carbon atoms (e.g. 3 or 6) to form such group, up to 20 carbon atoms. The acyclic dihydrocarbyl hydrogen phosphite exists mainly as the keto tautomer (shown on the left), with the enol tautomer (shown on the right) being the minor species. Either of the two tautomers or mixtures thereof can be used as the component (c) of the catalyst system of the present invention. The equilibrium constant for the above-mentioned tautomeric equilibrium is dependent upon such factors as the temperature, the types of R 1 and R 2 groups, the type of solvent, and the like. Both tautomers may be associated in dimeric, trimeric or oligomeric forms by hydrogen bonding.
Some representative examples of suitable acyclic dihydrocarbyl hydrogen phosphites are dimethyl hydrogen phosphite, diethyl hydrogen phosphite, dibutyl hydrogen phosphite, dihexyl hydrogen phosphite, dioctyl hydrogen phosphite, didecyl hydrogen phosphite, didodecyl hydrogen phosphite, dioctadecyl hydrogen phosphite, bis(2,2,2-trifluoroethyl) hydrogen phosphite, diisopropyl hydrogen phosphite, bis(3,3-dimethyl-2-butyl) hydrogen phosphite, bis(2,4-dimethyl-3-pentyl) hydrogen phosphite, di-t-butyl hydrogen phosphite, bis(2-ethylhexyl) hydrogen phosphite, dineopentyl hydrogen phosphite, bis(cyclopropylmethyl) hydrogen phosphite, bis(cyclobutylmethyl) hydrogen phosphite, bis(cyclopentylmethyl) hydrogen phosphite, bis(cyclohexylmethyl) hydrogen phosphite, dicyclobutyl hydrogen phosphite, dicyclopentyl hydrogen phosphite, dicyclohexyl hydrogen phosphite, dimenthyl hydrogen phosphite, diphenyl hydrogen phosphite, dinaphthyl hydrogen phosphite, dibenzyl hydrogen phosphite, bis(1-naphthylmethyl) hydrogen phosphite, diallyl hydrogen phosphite, dimethallyl hydrogen phosphite, dicrotyl hydrogen phosphite, ethyl butyl hydrogen phosphite, methyl hexyl hydrogen phosphite, methyl neopentyl hydrogen phosphite, methyl phenyl hydrogen phosphite, methyl cyclohexyl hydrogen phosphite, methyl benzyl hydrogen phosphite, and the like. Mixtures of the above dihydrocarbyl hydrogen phosphites may also be utilized.
The cyclic hydrocarbylene hydrogen phosphite employed in the catalyst system of the present invention can be either a cyclic alkylene hydrogen phosphite or a cyclic arylene hydrogen phosphite and may be represented by the following keto-enol tautomeric structures: ##STR2## Wherein R 3 is a divalent alkylene or arylene group, or a divalent substituted alkylene or arylene group preferably having from 2 or 6 to about 20 carbon atoms. The cyclic hydrocarbylene hydrogen phosphites exist mainly as the keto tautomer (shown on the left), with the enol tautomer (shown on the right) being the minor species. Either of the two tautomers or mixtures thereof can be used as the component (c) of the catalyst system of the present invention. The equilibrium constant for the above-mentioned tautomeric equilibrium is dependent upon such factors as the temperature, the types of R 3 group, the type of solvent, and the like. Both tautomers may be associated in dimeric, trimeric or oligomeric forms by hydrogen bonding.
Some specific examples of suitable cyclic alkylene hydrogen phosphites are 2-oxo-(2H)-5-butyl-5-ethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-5,5-dimethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-4-methyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-5-ethyl-5-methyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-5,5-diethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-5-methyl-5-propyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-4-isopropyl-5,5-dimethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-4,6-dimethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-4-propyl-5-ethyl-1,3,2-dioxaphosphorinane, 2-oxo-(2H)-4-methyl-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,5-dimethyl-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,4,5,5-tetramethyl-1,3,2-dioxaphospholane and the like. Mixtures of the above cyclic alkylene hydrogen phosphites may also be utilized.
Some specific examples of suitable cyclic arylene hydrogen phosphites are 2-oxo-(2H)-4,5-benzo-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,5-(3'-methylbenzo)-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,5-(4'-methylbenzo)-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,5-(4'-tert-butylbenzo)-1,3,2-dioxaphospholane, 2-oxo-(2H)-4,5-naphthalo-1,3,2-dioxaphospholane, and the like. Mixtures of the above cyclic arylene hydrogen phosphites may also be utilized.
The catalyst system of the present invention contains the above-described three components (a), (b), and (c) as the main components. In addition to the three catalyst components (a), (b), and (c), other catalyst components such as other organometallic compounds, which are known in the art, can also be added, if desired.
The catalyst system of the present invention has very high catalytic activity over a wide range of total catalyst concentrations and catalyst component ratios. The three catalyst components (a), (b), and (c) apparently interact to form the active catalyst species. Accordingly, the optimum concentration for any one catalyst component is dependent upon the concentrations of the other two catalyst components. While polymerization will occur over a wide range of catalyst concentrations and catalyst component ratios, the polymers having the most desirable properties are obtained within a narrower range of catalyst concentrations and catalyst component ratios.
The molar ratio of the organoaluminum hydride compound to the chromium-containing compound (Al/Cr) in the catalyst system of the present invention can be varied from about 1:1 to about 100:1. However, a more preferred range of Al/Cr molar ratio is from about 3:1 to about 50:1, and a most preferred range is from about 5:1 to about 20:1. The molar ratio of the hydrogen phosphite to the chromium-containing compound (P/Cr) can be varied from about 0.5:1 to about 50:1, with a more preferred range of P/Cr molar ratio being from about 1:1 to about 25:1 and a most preferred range being from about 2:1 to about 10:1.
The total catalyst concentration in the polymerization mass depends on such factors as the purity of the components, the polymerization rate and conversion desired, the polymerization temperature, and the like. Accordingly, specific total catalyst concentrations cannot be definitively set forth except to say that catalytically effective amounts of the respective catalyst components should be used. Generally, the amount of the chromium-containing compound used can be varied from about 0.01 to about 2 mmol per 100 g of 1,3-butadiene, with a more preferred range being from about 0.02 to about 1.0 mmol per 100 g of 1,3-butadiene and a most preferred range being from about 0.1 to about 0.5 mmol per 100 g of 1,3-butadiene. Certain specific total catalyst concentrations and catalyst component ratios that produce polymers having desired properties will be illustrated in the examples given to explain the teachings of the present invention.
The three catalyst components of this invention may be introduced into the polymerization system in several different ways. Thus, the catalyst may be formed in situ by adding the three catalyst components to the monomer/solvent mixture in either a stepwise or simultaneous manner; the sequence in which the components are added in a stepwise manner is not critical but the components are preferably added in the sequence of the organoaluminum hydride compound, the chromium-containing compound, and finally the hydrogen phosphite. Alternatively, the three catalyst components may also be premixed outside the polymerization system at an appropriate temperature (e.g., from about -20° C. to about 80° C.), and the resulting mixture then added to the polymerization system. Additionally, the catalyst may also be preformed, that is, the three catalyst components are premixed in the presence of a small amount of 1,3-butadiene monomer at an appropriate temperature (e.g., from about -20° C. to about 80° C.), prior to being charged to the main portion of the monomer/solvent mixture that is to be polymerized. The amount of 1,3-butadiene monomer which may be used during the preforming of the catalyst can range from about 1 to about 500 moles per mole of the chromium-containing compound, and preferably should be from about 4 to about 50 moles per mole of the chromium-containing compound. In addition, the three catalyst components may also be introduced to the polymerization system using a two-stage procedure. This procedure involves first reacting the chromium-containing compound with the organoaluminum hydride compound in the presence of a small amount, as specified above, of 1,3-butadiene monomer at an appropriate temperature (e.g., from about -20° C. to about 80° C.). The resultant reaction mixture and the hydrogen phosphite are then added to the main portion of the monomer/solvent mixture in either a stepwise or simultaneous manner. Further, an alternative two-stage procedure may also be employed. This involves first reacting the chromium-containing compound with the hydrogen phosphite at an appropriate temperature (e.g., from about -20° C. to about 80° C.) to form a chromium complex, followed by adding the resultant chromium complex and the organoaluminum hydride compound to the monomer/solvent mixture in either a stepwise or simultaneous manner.
When a catalyst solution is prepared outside the polymerization system, the organic solvent usable for the catalyst component solution may be selected from aromatic hydrocarbons, aliphatic hydrocarbons and cycloaliphatic hydrocarbons, and mixtures of two or more of the above-mentioned hydrocarbons. Preferably, the organic solvent consists of at least one selected from benzene, toluene, xylene, hexane, heptane and cyclohexane.
In accordance with the process of the present invention, the polymerization of 1,3-butadiene monomer in the presence of the above-described chromium-based catalyst may be carried out by means of bulk polymerization, wherein no solvents are employed. Such bulk polymerization can be conducted either in a condensed liquid phase or in a gas phase.
Alternatively and more typically, the polymerization of 1,3-butadiene according to the process of the present invention is carried out in an organic solvent as the diluent. In such cases, a solution polymerization system may be employed in which both the 1,3-butadiene monomer to be polymerized and the polymer formed are soluble in the polymerization medium. Alternatively, a suspension polymerization system may be employed by choosing a solvent in which the polymer formed is insoluble. In both cases, an amount of the organic solvent in addition to the organic solvent contained in the catalyst component solutions is usually added to the polymerization system. The additional organic solvent may be either the same as or different from the organic solvent contained in the catalyst component solutions. It is normally desirable to select an organic solvent that is inert with respect to the catalyst system employed to catalyze the polymerization reaction. Suitable types of organic solvents that can be utilized as the diluent include, but are not limited to, aliphatic, cycloaliphatic, and aromatic hydrocarbons. Some representative examples of suitable aliphatic solvents include n-pentane, n-hexane, n-heptane, n-octane, n-nonane, n-decane, isopentane, isohexanes, isoheptanes, isooctanes, 2,2-dimethylbutane, petroleum ether, kerosene, petroleum spirits, and the like. Some representative examples of suitable cycloaliphatic solvents include cyclopentane, cyclohexane, methylcyclopentane, methylcyclohexane, and the like. Some representative examples of suitable aromatic solvents include benzene, toluene, xylenes, ethylbenzene, diethylbenzene, mesitylene, and the like. Commercial mixtures of the above hydrocarbons may also be used. For environmental reasons, aliphatic and cycloaliphatic solvents are highly preferred.
The concentration of the 1,3-butadiene monomer to be polymerized is not limited to a special range. However, generally, it is preferable that the concentration of the 1,3-butadiene monomer present in the polymerization medium at the beginning of the polymerization be in a range of from about 3% to about 80% by weight, but a more preferred range is from about 5% to about 50% by weight, and the most preferred range is from about 10% to about 30% by weight.
In performing the polymerization of 1,3-butadiene according to the process of the present invention, a molecular weight regulator may be employed to control the molecular weight of the syndiotactic 1,2-polybutadiene to be produced. As a result, the scope of the polymerization system can be expanded in such a manner that it can be used for the production of syndiotactic 1,2-polybutadiene ranging from an extremely high molecular weight polymer to a low molecular weight polymer. Suitable types of molecular weight regulators that can be utilized include, but are not limited to, accumulated diolefins such as allene and 1,2-butadiene; nonconjugated diolefins such as 1,6-octadiene, 5-methyl-1,4-hexadiene, 1,5-cyclooctadiene, 3,7-dimethyl-1,6-octadiene, 1,4-cyclohexadiene, 4-vinylcyclohexene, 1,4-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,6-heptadiene, 1,2-divinylcyclohexane, 5-ethylidene-2-norbornene, 5-methylene-2-norbornene, 5-vinyl-2-norbornene, dicyclopentadiene, and 1,2,4-trivinylcyclohexane; acetylenes such as acetylene, methylacetylene and vinylacetylene; and mixtures thereof. The amount of the molecular weight regulator used, expressed in parts per hundred parts by weight of the 1,3-butadiene monomer (phm) employed in the polymerization, is in the range of about 0.01 to about 10 phm, preferably in the range of about 0.02 to about 2 phm, and most preferably in the range of about 0.05 to about 0.5 phm. In addition, the molecular weight of the syndiotactic 1,2-polybutadiene product to be obtained can also be effectively controlled by performing the polymerization of the 1,3-butadiene monomer in the presence of hydrogen. In this case, the partial pressure of hydrogen is appropriately chosen within the range of about 0.01 to about 50 atmospheres.
In accordance with the process of the present invention, the polymerization 1,3-butadiene may be carried out as a batch process, on a semi-continuous basis, or on a continuous basis. In any case, the polymerization is conducted under anaerobic conditions using an inert protective gas such as nitrogen, argon or helium, with moderate to vigorous agitation. The polymerization temperature employed in the practice of this invention may vary widely from a low temperature, such as -10° C. or below, to a high temperature such as 100° C. or above, with a preferred temperature range being from about 20° C. to about 90° C. The heat of polymerization may be removed by external cooling, cooling by evaporation of the 1,3-butadiene monomer or the solvent, or a combination of the two methods. Although the polymerization pressure employed in the practice of this invention also may vary widely, a preferred pressure range is from about 1 atmosphere to about 10 atmospheres.
The polymerization reaction of the present invention, on reaching a desired conversion, can be stopped by addition of a known polymerization terminator into the polymerization system to inactivate the catalyst system, followed by the conventional steps of desolventization and drying as are typically employed and are known to those skilled in the art in the production of conjugated diene polymers. Typically, the terminator employed to inactivate the catalyst system is a protic compound, which includes, but is not limited to, an alcohol, a carboxylic acid, an inorganic acid, and water or a combination thereof. An antioxidant such as 2,6-di-tert-butyl-4-methylphenol may be added along with, before or after addition of the terminator. The amount of the antioxidant employed is usually in the range of 0.2% to 1% by weight of the polymer product. When the polymerization reaction has been stopped, the syndiotactic 1,2-polybutadiene product may be isolated from the polymerization mixture by precipitation with an alcohol such as methanol, ethanol, or isopropanol or by steam distillation of the solvent and the unreacted 1,3-butadiene monomer, followed by filtration. The product is then dried under a constant vacuum at a temperature within the range of about 25° C. to about 100° C. (preferably at about 60° C.).
The syndiotactic 1,2-polybutadiene product produced by the process of the present invention has a higher melting temperature and increased syndiotacticity over some of the syndiotactic 1,2-polybutadiene products produced by the chromium-based catalysts of the prior art. Desirable melting temperature for claiming purposes is from about 100 to about 140° C. and more desirably from about 102 or 105 to about 125 or 130° C. Desirable 1,2-linkage content for claiming purposes is from about 75, 80 or 83 to about 90 or 95% of the total repeat units.
The syndiotactic 1,2-polybutadiene product produced by the process of the present invention has many uses. It can be blended with various rubbers in order to improve the properties thereof. For example, it can be incorporated into elastomers in order to improve the green strength of those elastomers, particularly in tires. The supporting carcass (reinforcing carcass) of tires is particularly prone to distortion during tire building and curing procedures. For this reason the incorporation of the syndiotactic 1,2-polybutadiene into rubber compositions, which are utilized in the supporting carcass of tires, has particular utility to prevent this distortion. In addition, the incorporation of the syndiotactic 1,2-polybutadiene into tire tread compositions can reduce the heat build-up and improve wear characteristics of tires. The syndiotactic 1,2-polybutadiene product is also useful in the manufacture of food films and in many molding applications.
The practice of the present invention is further illustrated by reference to the following examples, which however, should not be construed as limiting the scope of the invention. Parts and percentages shown in the examples are by weight unless otherwise indicated.
EXAMPLE 1
An oven-dried 1-liter glass bottle was capped with a self-sealing rubber liner and a perforated metal cap and purged with a stream of dry nitrogen. The bottle was charged with 245 g of a 1,3-butadiene/hexanes blend containing 20.4% by weight of 1,3-butadiene. The following catalyst components were added to the bottle in the following order: 0.50 mmol of diisobutylaluminum hydride, 0.050 mmol of chromium(III) 2-ethylhexanoate, and 0.20 mmol of bis(2-ethylhexyl) hydrogen phosphite. The bottle was tumbled for 4 hours in a water bath maintained at 50° C. The polymerization was terminated by addition of 10 ml of isopropanol containing 0.5 g of 2,6-di-tert-butyl-4-methylphenol. The polymerization mixture was added into 3 liters of isopropanol. The polymer was isolated by filtration and dried to a constant weight under vacuum at 60° C. The yield was 38.1 g (76%). As measured by differential scanning calorimetry (DSC), the polymer had a melting temperature of 105° C. 1 H and 13 C nuclear magnetic resonance (NMR) analysis of the polymer indicated a 1,2-linkage content of 81.1% and a syndiotacticity of 69.0%. As determined by gel permeation chromatography, the polymer has a weight average molecular weight (M w ) of 1,400,000, a number average molecular weight (M n ) of 647,000, and a polydispersity index (M w /M n ) of 2.2. The monomer charge, the amounts of catalyst components and the properties of the resultant syndiotactic 1,2-polybutadiene are summarized in Table I.
TABLE I__________________________________________________________________________Example No. 1 2 3 4__________________________________________________________________________20.4% 1,3-Bd/hexanes (g) 245 245 245 245i-Bu.sub.2 AlH (mmol) 0.50 0.55 0.60 0.65Cr(2-EHA).sub.3 (mmol) 0.050 0.050 0.050 0.050HP(O)(OCH.sub.2 CH(Et)(CH.sub.2).sub.3 CH.sub.3).sub.2 (mmol) 0.20 0.20 0.20 0.20Cr/Al/P molar ratio 1:10:4 1:11:4 1:12:4 1:13:4Polymer yield (%) after 4 h at 50° C. 76 77 77 42Melting point (° C.) 105 104 108 105% 1,2-Vinyl 81.1 80.6 80.8 81.0Syndiotacticity (%)* 69.0 68.8 69.2 69.1M.sub.w 1,400,000 1,479,000 1,106,000 734,005M.sub.n 647,000 750,000 503,000 346,365M.sub.w /M.sub.n 2.2 2.0 2.2 2.1__________________________________________________________________________ *Expressed in percentage of the racemic triad of the vinyl groups, excluding the vinyl groups adjacent to a monomer unit having a 1,4linkage
EXAMPLES 2-4
In Examples 2-4, the procedure in Example 1 was repeated with the catalyst ratio as shown in Table I. The monomer charge, the amounts of catalyst components and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table I.
EXAMPLES 5-8
In Examples 5-8, the procedure in Example 1 was repeated except that dineopentyl hydrogen phosphite was substituted for bis(2-ethylhexyl) hydrogen phosphite, having the monomer and the catalyst ratio as shown in Table II. The monomer charge, the amounts of catalyst components and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table II.
TABLE II__________________________________________________________________________Example No. 5 6 7 8__________________________________________________________________________20.4% 1,3-Bd/hexanes (g) 245 245 245 245i-Bu.sub.2 AlH (mmol) 0.45 0.50 0.55 0.60Cr(2-EHA).sub.3 (mmol) 0.050 0.050 0.050 0.050HP(O)(OCH.sub.2 CMe.sub.3).sub.2 (mmol) 0.20 0.20 0.20 0.20Cr/Al/P molar ratio 1:9:4 1:10:4 1:11:4 1:12:4Polymer yield (%) after 4 h at 50° C. 68 77 71 36Melting point (° C.) 112 113 117 121% 1,2-Vinyl 82.6 82.2 83.0 83.2Syndiotacticity (%) 71.0 70.5 70.9 71.2M.sub.w 1,268,000 1,159,000 1,258,000 996,000M.sub.n 689,000 532,000 420,000 369,000M.sub.w /M.sub.n 1.8 2.2 3.0 2.7__________________________________________________________________________
COMPARATIVE EXAMPLES 9-10
In Comparative Examples 9 and 10, the procedure in Example 1 was repeated except that triethyl aluminum was substituted for diisobutylaluminum hydride. The monomer charge, amounts of catalysts, and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table III
TABLE III__________________________________________________________________________Example No. 9 10 11 12__________________________________________________________________________25.0% 1,3-Bd/hexanes (g) 200 200 200 201Hexanes (g) 255 255 255 255AlEt.sub.3 (mmol) 0.20 0.30 0.50 0.75Cr(2-EHA).sub.3 (mmol) 0.050 0.050 0.050 0.050HP(O)(OCH.sub.2 CH(Et)(CH.sub.2).sub.3 CH.sub.3).sub.2 (mmol) 0.20 0.20 0 0HP(O)(OCH.sub.2 CMe.sub.3).sub.2 (mmol) 0 0 0.33 0.33Cr/Al/P molar ratio 1:4:4 1:6:4 1:10:6.7 1:15:6.7Polymer yield (%) after 4 h at 50° C. 70 92 97 96Melting point (° C.) 79 78 100 97% 1,2-Vinyl 80.1 80.0 83.1 81.1Syndiotacticity (%) 57.0 57.2 64.0 66.5M.sub.w 1,080,000 867,000 785,000 947,000M.sub.n 481.000 273,000 272,000 658,000M.sub.w /M.sub.n 2.2 3.1 2.8 1.4__________________________________________________________________________
COMPARATIVE EXAMPLES 11-12
In Comparative Examples 11 and 12, the procedure in Example 1 was repeated except that triethyl aluminum was substituted for diisobutylaluminum hydride, and dineopentyl hydrogen phosphite was substituted for bis(2-ethylhexyl) hydrogen phosphite. The monomer charge, amounts of catalysts, and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table III
Comparison of the analytical data of the syndiotactic 1,2-polybutadiene products obtained in Examples 1-8 with the analytical data of the products obtained in Examples 9-12 indicates that the catalyst system of the present invention produces syndiotactic 1,2-polybutadiene of higher quality as shown by the significantly higher melting temperature and higher syndiotacticity than are obtained with the chromium-based catalyst systems of the prior art.
EXAMPLES 13-16
In Examples 13-16, a series of polymerizations were carried out to evaluate the usefulness of 1,2-butadiene as a molecular weight regulator. The procedure is essentially identical to that described in Example 1 except that various amounts of 1,2-butadiene were added to a polymerization bottle containing the monomer solution before addition of the catalyst components. The monomer charge, the amounts of catalyst components and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table IV
TABLE IV__________________________________________________________________________Example No. 13 14 15 16__________________________________________________________________________20.4% 1,3-Bd/hexanes (g) 245 245 245 2451,2-Bd (phm) 0.05 0.10 0.15 0.20i-Bu.sub.2 AlH (mmol) 0.55 0.55 0.55 0.55Cr(2-EHA).sub.3 (mmol) 0.050 0.050 0.050 0.050HP(O)(OCH.sub.2 CH(Et)(CH.sub.2).sub.3 CH.sub.3).sub.2 (mmol) 0.20 0.20 0.20 0.20Cr/Al/P molar ratio 1:11:4 1:11:4 1:11:4 1:11:4Polymer yield (%) after 4 h at 50° C. 74 33 30 22Melting point (° C.) 103 105 104 103M.sub.w 356,000 239,000 202,000 160,000M.sub.n 159,000 103,000 96,000 80,000M.sub.w /M.sub.n 2.2 2.3 2.1 2.0__________________________________________________________________________
EXAMPLES 17-20
In Examples 17-20, a series of polymerizations were carried out to evaluate the usefulness of 1,2-butadiene as a molecular weight regulator. The procedure is essentially identical to that described in Examples 13-16 except that dineopentyl hydrogen phosphite was substituted for bis(2-ethylhexyl) hydrogen phosphite. The monomer charge, the amounts of catalyst components and the properties of the resultant syndiotactic 1,2-polybutadiene produced in each example are summarized in Table V
TABLE V__________________________________________________________________________Example No. 17 18 19 20__________________________________________________________________________20.4% 1,3-Bd/hexanes (g) 245 245 245 2451,2-Bd (phm) 0.05 0.10 0.15 0.20i-Bu.sub.2 AlH (mmol) 0.50 0.50 0.50 0.50Cr(2-EHA).sub.3 (mmol) 0.050 0.050 0.050 0.050HP(O)(OCH.sub.2 CMe.sub.3).sub.2 (mmol) 0.20 0.20 0.20 0.20Cr/Al/P molar ratio 1:10:4 1:10:4 1:10:4 1:10:4Polymer yield (%) after 4 h at 50° C. 63 28 25 1 9Melting point (° C.) 111 112 112 110M.sub.w 292,000 191,000 153,000 112,000M.sub.n 147,000 100,000 76,000 56,000M.sub.w /M.sub.n 2.0 1.9 2.0 2.0__________________________________________________________________________
Although the present invention has been described in the above examples with reference to particular means, materials and embodiments, it would be obvious to persons skilled in the art that various changes and modifications may be made, which fall within the scope claimed for the invention as set out in the appended claims. The invention is therefore not limited to the particulars disclosed and extends to all equivalents within the scope of the claims.
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A process for polymerizing 1,3-butadiene into syndiotactic 1,2-polybutadiene is described using a catalyst system comprising (a) a chromium-containing compound, (b) an organoaluminum hydride, and (c) a hydrogen phosphite. The use of the catalyst system avoids the use of environmentally detrimental components such as carbon disulfide and halogenated solvents. The syndiotactic 1,2-polybutadiene can be used as a plastic or as an additive for rubber compositions wherein it can crosslink with conventional rubbers using conventional crosslinking agents.
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BACKGROUND OF THE INVENTION
One commonly used system for communicating a multiplicity of telephonic messages includes multiplexing techniques wherein samples of a plurality of telephone circuits are rapidly sampled with the samples being interleaved in time sequence in a well-known fashion which permits these samples to be demultiplexed whereupon the original telephonic messages can be recovered. The multiplexed messages are often transmitted by a wireless transmission link at a suitable carrier frequency such as an X-band carrier frequency.
A problem arises in that it is frequently desirable to inject an additional data channel into the communication link at a point removed from the location of the aforesaid multiplexing and for removing this additional data at a point distant from the location of the aforesaid demultiplexing. Such a data channel is frequently referred to as a service channel and serves the function of allowing operators of the telephone equipment to communicate with each other without interfering with the multiplexed telephonic messages.
SUMMARY OF THE INVENTION
The aforesaid problem is overcome and other features are provided by a system which, in accordance with the invention, provides for a frequency or phase modulation of service channel data onto a carrier, such as an X-band carrier, which has a frequency much greater than the frequencies of the service channel which may be a multiplexed data channel, and means for modulating multiplexed telephonic data or other data having a bandwidth similar to that of multiplexed telephonic data of a multiplicity of telephone circuits onto the carrier which has been previously modulated with the service channel data. The bandwidth of the service channel is very much smaller than the bandwidth of the multiplexed data channel so that the modulation of the carrier with the service channel data does not interfere with the spectrum of the multiplexed data. Demodulation of the service channel data is accomplished by inverse modulation of the X-band signal, this inverse modulation being done preferably at a suitable intermediate frequency, this inverse modulation being done in a feedback loop utilizing detected multiplexed data to recover the carrier of this data. Such recovery permits the utilization of quadrature phase shift keying techniques in the modulation of the multiplexed data upon its carrier. A tracking filter comprising an inductor-capacitor circuit in which the capacitance is adjustably provided by a varactor is utilized in the preferred embodiment of the invention to provide a tracking filter capability with a reduced number of components and increased reliability. A phase detector compares the input and output signals of the tracking filter for developing a control signal which adjusts the capacitance of the varactor. This control signal contains the service channel data.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned aspects and other advantages of the invention are explained in the following description taken in connection with the accompanying drawings wherein:
FIG. 1 is a block diagram of a system employing the inverse modulator and tracking filter of the invention;
FIG. 2 is a block diagram of a signal processor of FIG. 1 further describing the inverse modulation and the tracking filter; and
FIG. 3 is a block diagram of an alternative filter for the signal processor of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is seen a system 20 which, in accordance with the invention, provides for the modulation of data of a first channel 22 upon a carrier which is modulated with data of a second channel 24. The first channel is seen to comprise, by way of example, a plurality of telephone hand sets 26 which are coupled to a multiplexer 28. The multiplexer 28 comprises well-known sampling circuitry which sequentially samples the signals of the individual hand sets 26 and interleaves these samples in a predetermined order to provide on line 30 a digital signal at a rate of 40 megabits per second. The signal on line 30 is then modulated by a modulator 32 onto a 70 megahertz carrier provided by an oscillator 34, the modulator 32 providing a 4-phase or quadrature phase shift keying modulation. Such a modulation is described in the book "Data Transmission" by William R. Bennett and James R. Davey which was published by McGraw-Hill Book Company in 1965. A feature of this modulation technique is good utilization of the available spectrum while the spectral line representing the carrier frequency is absent. The output of the modulator 32 is coupled along line 36 to a mixer 38.
The second channel 24 is seen to comprise, by way of example, a multiplexer 40 and an X-band oscillator 42. The oscillator 42 includes means for varying the frequency of the oscillations, and the multiplexer 40 provides a modulating voltage on line 44 for modulating the frequency of the oscillations. The output signal of the oscillator 42 is coupled by line 46 to the mixer 38 and serves as a carrier upon which the signal of line 36 is modulated by the mixer 38. The multiplexer 40 operates in a manner similar to that of the multiplexer 28 and includes well-known circuitry such as a digital-to-analog converter or delta modulator (not shown) for converting analog service data signals on lines 48 to digital signals at a 100 kilobits per second rate on line 44.
It is noted that the bandwidth of the signal on line 44 is very much smaller than the 70 megahertz frequency of the oscillator 34. Accordingly, the signal on line 46 may be considered as a carrier with a relatively slow modulation, the modulation being at a sufficiently slow rate to permit the signal of line 36 to be modulated onto the X-band signal of line 46 by the mixer 38 as if there were no modulation of the oscillator 42. The mixer 38 is understood to include an output filter which passes only one side band of the mixing operation so that a signal sent on a carrier of, for example, 11 gigahertz frequency, is provided on line 50.
The signal on line 50 is typically coupled via a wireless transmission path 52 which begins at a transmitting antenna 54, coupled to line 50, and terminates at a receiving antenna 56 which is coupled via line 58 to a receiver 60. The receiver 60 amplifies the signal on line 58 and translates it to an intermediate frequency, the translated signal being coupled via line 62 to a signal processor 64 which will be described with reference to FIG. 2. The signal processor 64 separates the service data of the second channel 24 from the telephonic data of the first channel 22, the first channel data appearing on line 66 and the second channel data appearing on line 68.
The service data provided on the lines 48 is typically telephonic communication between operators of the system 20 as well as other signals giving information on the availability of telephone circuits for the first channel 22. A feature of the invention is that the system 20 provides for the combining of the second channel 24 with the first channel 22 at a point that may be geographically removed from the multiplexer 28 and the modulator 32. This combining of the two channels, and the subsequent separation of the two channels by the signal processor 64, is accomplished without the utilization of any of the telephone circuits coupled to the multiplexer 28 and without creating any substantial interference with the spectrum of the modulated signal appearing on line 36 at the output of the modulator 32. And, as will be seen with reference to FIG. 2, the separation of the two channels 22 and 24 is accomplished in a manner which is relatively free of equipment complexity.
Referring to FIG. 2 there is seen a block diagram of the signal processor 64, the figure showing the lines 62, 66 and 68 which were previously seen in FIG. 1 and represent, respectively, the coupling of the signal from the receiver 60, the telephonic communications of the first channel 22 and the service data of the second channel 24. The signal processor 64 is seen to comprise a delay unit 70, an inverse modulator 72, a tracking filter 74, phase detectors 76 and 78, low-pass filters 80 and 82, amplifiers 84 and 86, demultiplexers 88 and 90 and a phase shifter 92 providing 90° of phase shift. The inverse modulator 72 comprises phase modulators 94 and 96, a phase shifter 98 similar to the phase shifter 92, and a summer 100 for summing together the outputs of the phase modulator 94 and the phase shifter 98. The tracking filter 74 comprises a bandpass filter 102 which includes means for varying the center frequency of the pass band, an amplifier 104 and a phase detector 106. The filter 102 comprises, in the preferred embodiment of the invention, a varactor having a capacitance which is varied in response to the amplitude of a signal on line 108, the varactor serving to tune an inductor (not shown) of the filter 102 to provide the variable passband.
As was mentioned with reference to FIG. 1, the quadrature phase modulation of the modulator 32 provides for a spectrum in which the carrier line is absent. The inverse modulator 72 regenerates the carrier frequency and passes the regenerated frequency signal via line 110 to the tracking filter 74. The tracking filter 74 tracks the frequency of the signal on line 110 and recovers the modulation associated with the second channel 24 of FIG. 1. The recovered modulation appears on line 112. The carrier, after having been filtered by the tracking filter 74, appears on line 114 and is utilized as a reference signal for operating the phase detector 76 and, via the phase shifter 92, for operating the phase detector 78.
It is noted that two feedback signals are provided along lines 116 and 118 which couple signals, respectively, from the amplifier 84 to the phase modulator 94, and from the amplifier 86 to the phase modulator 96. With respect to the feedback path on line 116, the phase detector 76 demodulates the signal on line 62 to provide, in cooperation with the low-pass filter 80, a digital waveform signal on line 120 having a sequence of voltage states corresponding to a logic 1 or a logic 0; these voltage states on line 120 correspond sequentially to alternate ones of the voltage states appearing on line 30 of FIG. 1. Similar comments apply to the action of the phase detector 78 and the low-pass filter 82 in providing a signal on line 122 in which the successive values of voltage or logic states correspond sequentially to the remaining ones of the logic states on line 30. As noted in FIG. 2, the line 116 is labelled "in-phase data" while the line 118 is labelled "quadrature data." This difference in the detected output results because of the 90° phase shift introduced by the phase shifter 92 in the reference signal of the phase detector 78 relative to the reference signal of the phase detector 76.
The use of the in-phase and quadrature signals on lines 116 and 118 in the inverse modulation by the modulator 72 corresponds to the quadrature phase shift keying by the modulator 32 of FIG. 1. Such modulation is typically accomplished by taking alternate bits of the bit stream on line 30 and applying them to in-phase and quadrature portions of the modulator 32, the in-phase portion providing either 0° or 180° phase shift while the quadrature portion provides ± 90° phase shift.
The inverse modulator 72 and the tracking filter 74 introduce a phase shift which is substantially invariant with the frequency modulation of the carrier on line 110. Thus, the phase modulators 94 and 96 as well as the summer 100 employ circuitry which is relatively wide-band as compared to the bandwidth of the modulation provided by the second channel 24 of FIG. 1. The phase shifter 98, the phase detector 106 and the amplifier 104 are of similarly wide bandwidth. The bandwidth of the variable filter 102 is of relatively narrow bandwidth as compared to the modulation of the second channel 24; however, the variable filter 102 is continuously tuned in response to a signal of the phase detector 106 so that, with the exception of a small phase shift which is typically less than approximately 2° as is required to generate a correction signal by the phase detector 106, the phase shift introduced by the variable filter 102 is essentially invariant with the frequency modulation introduced by the second channel 24.
The low-pass filters 80 and 82, in addition to the aforementioned filtering of the sidebands produced by the phase detectors 76 and 78, also introduce phase shifts to their respective digital signals. The low-pass filter 80 and its amplifier 84, as well as the low-pass filter 82 and its amplifier 86, are adjusted to provide a phase shift and loop gain to signals passing through the feedback paths on lines 116 and 118 to provide stable operation of the feedback loops in a manner well-known to feedback control theory. The adjustment of this phase shift is readily accomplished since substantially all of the phase shift in each of the feedback loops is accomplished respectively by the low-pass filters 80 and 82, the other components, namely, the inverse modulator 72, the tracking filter 74, the phase detectors 76 and 78, the phase shifter 92 and the amplifiers 84 and 86 being of sufficiently wide band to introduce substantially no phase shift at the carrier frequency. And, furthermore, as will now be explained, the digital modulation is absent on the line 110 so that the tracking filter 94 introduces no phase shift to the digital modulation.
In order to insure that the digital signals on lines 116 and 118 are in step with the respective portions of the digital signal on line 124 which are applied respectively to the phase modulators 94 and 96, the delay introduced by the delay unit 70 is adjusted to equal the delays introduced by the low-pass filters 80 and 82.
In operation, therefore, signals received from the receiver 16 of FIG. 1 along line 62 are applied by the delay unit 70 along line 124 to the phase modulators 94 and 96. The signal on line 124 comprises an intermediary frequency carrier which is phase modulated at the phases 0°, 90°, 180° and 270°. The 0° and 180° phases represent the digital signals of the in-phase data while the 90° and 270° phases represent digital signals of the quadrature data. The signal voltage on line 116 causes the phase modulator 94 to apply a phase shift of 0° or -180°, thereby canceling the in-phase modulation present on the line 124. Similarly, the signal voltage on line 118 causes the phase modulator 96 to apply a -90° phase shift and a -270° phase shift thereby nulling out the quadrature digital signal on line 124. The residue of uncanceled modulation components from the phase modulator 94 are then summed together by the summer 100 with a residue of uncanceled phase shift components from the phase modulator 96 as passed by the phase shifter 98 to result in a carrier at the intermediary frequency which is void of the digital modulation associated with the first channel 22 of FIG. 1. Inverse modulators such as the inverse modulator 72 are further described in Chapter 8 of "Theory of Synchronous Communications" by J. Stiffler which was published by Prentice Hall in 1971.
The carrier on line 110 is then stripped of the frequency modulation associated with the second channel 24 of FIG. 1, as will be further described, so that an unmodulated carrier appears on line 114. The carrier on line 114 then serves as a reference in the phase detection of the digital signals on line 62 by means of the phase detectors 76 and 78. These signals are then filtered by the low-pass filters 80 and 82 and fed back via the lines 116 and 118 to accomplish the inverse modulation by the modulator 72. It is noted that prior to the reception of a signal on line 62, the signal processor 64 is in an oscillatory or hunting mode which then locks in upon the signal at line 62 when the signal on line 62 appears. It is noted that at the inception of the lock on, there is a double ambiguity for the signals on lines 116 and 118, namely, either line may actually have the in-phase component while the other line has the quadrature component and, furthermore, the signals may be at a logic state of 0 or 1 depending on the phase of the reference on line 114. Accordingly, differential incoding (as described in chapter 10-3 of the aforementioned book by Bennett and Davey) is utilized at the input of the modulator 32 and at the input of the demultiplexer 88 to resolve these ambiguities. The digital signals in the two feedback branches on the lines 116 and 118 are recombined in the demultiplexer 88 so that they have the same form as was originally presented on line 30 of FIG. 1. The individual samples of the multiplexed data are separated out by the demultiplexer 88 to reform the original telephonic messages associated with each of the hand sets 26 of FIG. 1, this being done in a manner well-known in the art of demultiplexing. Similar comments apply to the operation of the demultiplexer 90 in utilizing the data samples on line 112 to regenerate the service data on line 68.
With respect to the operation of the variable bandpass filter 102, it is noted that, in a simple form of such filter employing an inductor and a capacitor which resonate at the center frequency of the passband, the phase shift varies in a well-known manner across the passband such that a positive phase shift is imparted to signals having a frequency at one side of the center frequency while a negative phase shift is imparted to signals having a frequency at the other side of the center frequency. The resultant phase shift is sensed by the phase detector 106 and amplified by the amplifier 104, as was previously mentioned, to provide a voltage which operates a varactor to alter the capacitance for continuously varying the center frequency of the passband.
Referring now to FIG. 3, there is shown a filter 74A which is an alternative embodiment to the tracking filter 74 of FIG. 2. In the filter 74A, a bandpass filter 126 is utilized to filter the signal on line 110 to attenuate modulation transients which may occur at the phase modulators 94 and 96. The discriminator 128 demodulates the frequency modulation of the signal on line 110 to provide the samples of service data on line 112. The filter 74A offers simplicity over the tracking filter 74, however, the passband of the filter 126 is fixed tuned and is wider than the passband of the filter 102 to provide a small shift of the carrier as a function of the frequency changes of the frequency modulated signal of the second channel 24.
It is understood that the above-described embodiments of the invention are illustrative only and that modifications thereof will occur to those skilled in the art. Accordingly, it is desired that this invention is not to be limited to the embodiments disclosed herein but is to be limited only as defined by the appended claims.
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A system for communicating a data channel composed of a multiplicity of telephone-type messages wherein the invention incorporates circuitry for modulating service channel data onto a carrier of the telephone channel data and for demodulating the service data without interfering with the telephone data. An inverse modulator driven by detected telephone data is utilized to recover a carrier which is then tracked by a tracking filter to recover the service data.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an analog buffer, and more particularly, to an analog buffer with voltage compensation mechanism.
[0003] 2. Description of the Related Art
[0004] Because liquid crystal display (LCD) devices are characterized by thin appearance, low power consumption, and low radiation, LCD devices have been widely applied in various electronic products for panel displaying. The operation of an LCD device is featured by varying voltage drops between opposite sides of the liquid crystal cells of the LCD device for twisting the angles of the liquid crystal molecules in the liquid crystal cells so that the transparency of the liquid crystal cells can be controlled for illustrating images with the aid of the light source provided by a backlight module.
[0005] In general, the LCD device comprises a plurality of pixel units, a plurality of data lines and a source driver. The source driver comprises a plurality of source driving circuits. The source driving circuits perform latching operations, level shifting operations, digital-to-analog converting operations and analog signal buffering operations on the digital image data signals inputted to the LCD device for generating a plurality of analog signals. Each source driving circuit is coupled to a corresponding data line for writing the generated analog signals into corresponding pixel units.
[0006] Accordingly, the analog buffer of each source driving circuit for performing the analog signal buffering operation functions as a key element for writing the generated analog signals into corresponding pixel units. With the aid of the analog buffers having enhanced driving ability for performing high-speed and accurate buffering operations, the LCD device is capable of providing high display quality. That is, the display quality of the LCD device is corresponding directly to the performance of the analog buffers. Furthermore, the source driver is installed with lots of analog buffers in that each source driving circuit should be installed with an individual analog buffer, and therefore a significant part of the layout area of the LCD device is required for accommodating the analog buffers. For that reason, simplified designs of the analog buffer and related control circuit without degrading the driving performance are required for realizing advanced low-cost LCD devices having thinner appearance.
[0007] FIG. 1 is a schematic diagram showing the circuit of a conventional analog buffer for use in an LCD device. As shown in FIG. 1 , the analog buffer 100 comprises an N-type metal-oxide-semiconductor (MOS) transistor 111 , a P-type MOS transistor 112 , a plurality of capacitors 121 - 124 , a plurality of switches 131 - 142 , and two current sources 181 and 182 . The analog buffer 100 is utilized to perform the analog signal buffering operation on an input voltage Vin for generating an output voltage Vout for charging the pixel capacitor Cpixel. However, the aforementioned conventional analog buffer is operated based on a variety of complicated control signals for controlling on/off states of the switches. Also, extra current control signals are required for controlling the current sources of the conventional analog buffer. That is, the circuit operation of the conventional analog buffer should be performed with the aid of complicated control circuits for generating the complicated control signals. In summary, the conventional analog buffer cannot meet the demand for designing advanced low-cost LCD devices having thinner appearance.
SUMMARY OF THE INVENTION
[0008] In accordance with an embodiment of the present invention, an analog buffer with voltage compensation mechanism is disclosed. The analog buffer comprises a first transistor, a second transistor, a first capacitor, a second capacitor, a first switch, a second switch, a third switch, a fourth switch, a fifth switch, and a sixth switch.
[0009] The first transistor comprises a drain for receiving a first supply voltage, a source for outputting an output voltage, and a gate. The second transistor comprises a drain for receiving a second supply voltage, a source coupled to the source of the first transistor, and a gate. The first capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The second capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The first switch comprises a first end coupled to the second end of the first capacitor, and a second end coupled to the source of the first transistor. The second switch comprises a first end coupled to the second end of the second capacitor, and a second end coupled to the source of the second transistor. The third switch comprises a first end for receiving a first reference voltage, and a second end coupled to the first end of the first capacitor. The fourth switch comprises a first end for receiving a second reference voltage, and a second end coupled to the first end of the second capacitor. The fifth switch comprises a first end for receiving an input voltage, and a second end coupled to the second end of the first capacitor. The sixth switch comprises a first end for receiving the input voltage, and a second end coupled to the second end of the second capacitor. The analog buffer performs a voltage compensation operation for generating the output voltage based on the first reference voltage and the second reference voltage.
[0010] In accordance with another embodiment of the present invention, an analog buffer with voltage compensation mechanism is disclosed. The analog buffer comprises a first transistor, a second transistor, a first capacitor, a second capacitor, a first switch, a second switch, a third switch, a fourth switch, a fifth switch, a sixth switch, a third capacitor, a fourth capacitor, a seventh switch, an eighth switch, a ninth switch, and a tenth switch.
[0011] The first transistor comprises a drain for receiving a first supply voltage, a source for outputting an output voltage, and a gate. The second transistor comprises a drain for receiving a second supply voltage, a source coupled to the source of the first transistor, and a gate. The first capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The second capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The first switch comprises a first end coupled to the second end of the first capacitor, and a second end coupled to the source of the first transistor. The second switch comprises a first end coupled to the second end of the second capacitor, and a second end coupled to the source of the second transistor. The third switch comprises a first end for receiving a first reference voltage, and a second end coupled to the first end of the first capacitor. The fourth switch comprises a first end for receiving a second reference voltage, and a second end coupled to the first end of the second capacitor. The fifth switch comprises a first end for receiving an input voltage, and a second end coupled to the second end of the first capacitor. The sixth switch comprises a first end for receiving the input voltage, and a second end coupled to the second end of the second capacitor. The third capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The fourth capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The seventh switch comprises a first end coupled to the first end of the fifth switch, and a second end coupled to the second end of the third capacitor. The eighth switch comprises a first end coupled to the first end of the sixth switch, and a second end coupled to the second end of the fourth capacitor. The ninth switch comprises a first end coupled to the second end of the third capacitor, and a second end coupled to the source of the first transistor. The tenth switch comprises a first end coupled to the second end of the fourth capacitor, and a second end coupled to the source of the second transistor. The analog buffer performs a voltage compensation operation for generating the output voltage based on the first reference voltage and the second reference voltage.
[0012] In accordance with another embodiment of the present invention, an analog buffer with voltage compensation mechanism is disclosed. The analog buffer comprises a first transistor, a second transistor, a first capacitor, a second capacitor, a first switch, a second switch, a third switch, a fourth switch, a fifth switch, a sixth switch, a third transistor, a fourth transistor, a seventh switch, an eighth switch, a ninth switch, and a tenth switch.
[0013] The first transistor comprises a drain for receiving a first supply voltage, a source for outputting an output voltage, and a gate. The second transistor comprises a drain for receiving a second supply voltage, a source coupled to the source of the first transistor, and a gate. The first capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The second capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The first switch comprises a first end coupled to the second end of the first capacitor, and a second end coupled to the source of the first transistor. The second switch comprises a first end coupled to the second end of the second capacitor, and a second end coupled to the source of the second transistor. The third switch comprises a first end for receiving a first reference voltage, and a second end coupled to the first end of the first capacitor. The fourth switch comprises a first end for receiving a second reference voltage, and a second end coupled to the first end of the second capacitor. The fifth switch comprises a first end for receiving an input voltage, and a second end coupled to the second end of the first capacitor. The sixth switch comprises a first end for receiving the input voltage, and a second end coupled to the second end of the second capacitor. The third transistor comprises a drain for receiving a third supply voltage, a source coupled to the source of the first transistor, and a gate. The fourth transistor comprises a drain for receiving a fourth supply voltage, a source coupled to the source of the second transistor, and a gate. The seventh switch comprises a first end coupled to the gate of the third transistor, and a second end coupled to the source of the third transistor. The eighth switch comprises a first end coupled to the gate of the fourth transistor, and a second end coupled to the source of the fourth transistor. The ninth switch comprises a first end coupled to the gate of the first transistor, and a second end coupled to the gate of the third transistor. The tenth switch comprises a first end coupled to the gate of the second transistor, and a second end coupled to the gate of the fourth transistor. The analog buffer performs a voltage compensation operation for generating the output voltage based on the first reference voltage and the second reference voltage.
[0014] In accordance with another embodiment of the present invention, an analog buffer with voltage compensation mechanism is disclosed. The analog buffer comprises a first transistor, a second transistor, a first capacitor, a second capacitor, a first switch, a second switch, a third switch, a fourth switch, a fifth switch, a sixth switch, a third capacitor, a fourth capacitor, a seventh switch, an eighth switch, a ninth switch, a tenth switch, a third transistor, a fourth transistor, an eleventh switch, a twelfth switch, a thirteenth switch, and a fourteenth switch.
[0015] The first transistor comprises a drain for receiving a first supply voltage, a source for outputting an output voltage, and a gate. The second transistor comprises a drain for receiving a second supply voltage, a source coupled to the source of the first transistor, and a gate. The first capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The second capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The first switch comprises a first end coupled to the second end of the first capacitor, and a second end coupled to the source of the first transistor. The second switch comprises a first end coupled to the second end of the second capacitor, and a second end coupled to the source of the second transistor. The third switch comprises a first end for receiving a first reference voltage, and a second end coupled to the first end of the first capacitor. The fourth switch comprises a first end for receiving a second reference voltage, and a second end coupled to the first end of the second capacitor. The fifth switch comprises a first end for receiving an input voltage, and a second end coupled to the second end of the first capacitor. The sixth switch comprises a first end for receiving the input voltage, and a second end coupled to the second end of the second capacitor. The third capacitor comprises a first end coupled to the gate of the first transistor, and a second end. The fourth capacitor comprises a first end coupled to the gate of the second transistor, and a second end. The seventh switch comprises a first end coupled to the first end of the fifth switch, and a second end coupled to the second end of the third capacitor. The eighth switch comprises a first end coupled to the first end of the sixth switch, and a second end coupled to the second end of the fourth capacitor. The ninth switch comprises a first end coupled to the second end of the third capacitor, and a second end coupled to the source of the first transistor. The tenth switch comprises a first end coupled to the second end of the fourth capacitor, and a second end coupled to the source of the second transistor. The third transistor comprises a drain for receiving a third supply voltage, a source coupled to the source of the first transistor, and a gate. The fourth transistor comprises a drain for receiving a fourth supply voltage, a source coupled to the source of the second transistor, and a gate. The eleventh switch comprises a first end coupled to the gate of the third transistor, and a second end coupled to the source of the third transistor. The twelfth switch comprises a first end coupled to the gate of the fourth transistor, and a second end coupled to the source of the fourth transistor. The thirteenth switch comprises a first end coupled to the gate of the first transistor, and a second end coupled to the gate of the third transistor. The fourteenth switch comprises a first end coupled to the gate of the second transistor, and a second end coupled to the gate of the fourth transistor. The analog buffer performs a voltage compensation operation for generating the output voltage based on the first reference voltage and the second reference voltage.
[0000] These and other objectives of the present invention will no doubt become apparent to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic diagram showing the circuit of a conventional analog buffer for use in an LCD device.
[0017] FIG. 2 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a first embodiment of the present invention.
[0018] FIG. 3 is a schematic circuit diagram showing a first embodiment of the reference voltage generator.
[0019] FIG. 4 is a schematic circuit diagram showing a second embodiment of the reference voltage generator.
[0020] FIG. 5 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 2 , having time along the abscissa.
[0021] FIG. 6 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a second embodiment of the present invention.
[0022] FIG. 7 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 6 , having time along the abscissa.
[0023] FIG. 8 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a third embodiment of the present invention.
[0024] FIG. 9 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 8 , having time along the abscissa.
[0025] FIG. 10 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a fourth embodiment of the present invention.
[0026] FIG. 11 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 10 , having time along the abscissa.
DETAILED DESCRIPTION
[0027] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, it is to be noted that the present invention is not limited thereto.
[0028] FIG. 2 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a first embodiment of the present invention. As shown in FIG. 2 , the analog buffer 200 comprises a first transistor 211 , a second transistor 212 , a first capacitor 221 , a second capacitor 222 , a first switch 231 , a second switch 232 , a third switch 233 , a fourth switch 234 , a fifth switch 235 , a sixth switch 236 , a seventh switch 237 , an eighth switch 238 , a ninth switch 239 , a tenth switch 240 , and a reference voltage generator 290 . The reference voltage generator 290 is powered between a third supply voltage Vdd 2 and a fourth supply voltage Vss 2 for generating a first reference voltage Vb 1 and a second reference voltage Vb 2 .
[0029] The first transistor 211 comprises a drain for receiving a first supply voltage Vdd 1 , a source for outputting an output voltage Vout, and a gate. The second transistor 212 comprises a drain for receiving a second supply voltage Vss 1 , a source coupled to the source of the first transistor 211 , and a gate. The first transistor 211 can be an N-type MOS transistor. The second transistor 212 can be a P-type MOS transistor, and the MOS transistor may be replaced by other components have similar functions. In the circuit operation of the analog buffer 200 , the first transistor 211 and the second transistor 212 are operated in the class-AB source-follower operation mode based on the common-drain configuration for lowering power consumption.
[0030] The seventh switch 237 comprises a first end and a second end respectively coupled to the gate and source of the first transistor 211 . The eighth switch 238 comprises a first end and a second end respectively coupled to the gate and source of the second transistor 212 . The ninth switch 239 comprises a first end and a second end. The second end of the ninth switch 239 is coupled to the gate of the first transistor 211 . The tenth switch 240 comprises a first end and a second end. The second end of the tenth switch 240 is coupled to the gate of the second transistor 212 . The third switch 233 comprises a first end coupled to the reference voltage generator 290 for receiving the first reference voltage Vb 1 , and a second end coupled to the first end of the ninth switch 239 . The fourth switch 234 comprises a first end coupled to the reference voltage generator 290 for receiving the second reference voltage Vb 2 , and a second end coupled to the first end of the tenth switch 240 .
[0031] The first capacitor 221 comprises a first end and a second end. The first end of the first capacitor 221 is coupled to the second end of the third switch 233 . The second capacitor 222 comprises a first end and a second end. The first end of the second capacitor 222 is coupled to the second end of the fourth switch 234 . The fifth switch 235 comprises a first end for receiving an input voltage Vin, and a second end coupled to the second end of the first capacitor 221 . The sixth switch 236 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the second capacitor 222 . The first switch 231 comprises a first end and a second end respectively coupled to the second end of the first capacitor 221 and the source of the first transistor 211 . The second switch 232 comprises a first end and a second end respectively coupled to the second end of the second capacitor 222 and the source of the second transistor 212 .
[0032] In one embodiment, the internal circuit structure of the reference voltage generator 290 in FIG. 2 can be designed as the reference voltage generator 300 shown in FIG. 3 , which is a schematic circuit diagram showing a first embodiment of the reference voltage generator. As shown in FIG. 3 , the reference voltage generator 300 comprises a first current source 311 , a second current source 312 , a first compensation diode 331 and a second compensation diode 332 . The first current source 311 comprises a first end for receiving the third supply voltage Vdd 2 , and a second end for providing a current 11 . The second current source 312 comprises a first end for receiving the fourth supply voltage Vss 2 , and a second end for providing a current 12 . The first compensation diode 331 comprises a positive end and a negative end. The positive end of the first compensation diode 331 is coupled to the second end of the first current source 311 . The second compensation diode 332 comprises a positive end coupled to the negative end of the first compensation diode 331 , and a negative end coupled to the second end of the second current source 312 . The first reference voltage Vb 1 and the second reference voltage Vb 2 are outputted respectively from the positive end of the first compensation diode 331 and the negative end of the second compensation diode 332 .
[0033] In another embodiment, the internal circuit structure of the reference voltage generator 290 in FIG. 2 can be designed as the reference voltage generator 400 shown in FIG. 4 . Please refer to FIG. 4 , which is a schematic circuit diagram showing a second embodiment of the reference voltage generator. As shown in FIG. 4 , the reference voltage generator 400 comprises a first current source 411 , a second current source 412 , a first transistor 431 and a second transistor 432 . The first current source 411 comprises a first end for receiving the third supply voltage Vdd 2 , and a second end for providing a current 11 . The second current source 412 comprises a first end for receiving the fourth supply voltage Vss 2 , and a second end for providing a current 12 . The first transistor 431 comprises a drain coupled to the second end of the first current source 411 , a gate coupled to the drain, and a source. The second transistor 432 comprises a drain coupled to the second end of the second current source 412 , a gate coupled to the drain, and a source coupled to the source of the first transistor 431 . The first reference voltage Vb 1 and the second reference voltage Vb 2 are outputted respectively from the drain of the first transistor 431 and the drain of the second transistor 432 . The first transistor 431 can be an N-type MOS transistor. The second transistor 432 can be a P-type MOS transistor, and the MOS transistor may be replaced by other components having similar functions.
[0034] FIG. 5 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 2 , having time along the abscissa. The signal waveforms in FIG. 5 , from top to bottom, are the input voltage Vin, the first control signal P 1 , the second control signal P 2 , the first enable control signal Ea, the second enable control signal Eab, and the output voltage Vout. The first switch 231 through the fourth switch 234 are turned on/off in response to the first control signal P 1 . The fifth switch 235 and the sixth switch 236 are turned on/off in response to the second control signal P 2 . The ninth switch 239 and the tenth switch 240 are turned on/off in response to the first enable control signal Ea. The seventh switch 237 and the eighth switch 238 are turned on/off in response to the second enable control signal Eab. In the following description of the circuit operation concerning the related signal waveforms in FIG. 5 , the enabled signal having high voltage level is utilized for turning on corresponding switches, and the disabled signal having low voltage level is utilized for turning off corresponding switches. The circuit operation of the analog buffer 200 is detailed as the followings.
[0035] When the first control signal P 1 and the first enable control signal Ea are set to be enabled signals and the second control signal P 2 and the second enable control signal Eab are set to be disabled signals during the interval T 10 , the output voltage Vout is changed from the previous voltage V 0 ±ΔV 0 to the preset voltage Vpreset; meanwhile, the first capacitor 221 is charged to have the capacitor voltage as the gate-source voltage of the first transistor 211 in turn-on state, and the second capacitor 222 is charged to have the capacitor voltage as the gate-source voltage of the second transistor 212 in turn-on state.
[0036] When the second control signal P 2 and the first enable control signal Ea are set to be enabled signals and the first control signal P 1 and the second enable control signal Eab are set to be disabled signals during the interval T 11 , the output voltage Vout is changed from the preset voltage Vpreset to the voltage V 1 ±ΔV 1 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages of the first capacitor 221 and the second capacitor 222 . Since the gate-source voltages of the first transistor 211 and the second transistor 212 in turn-on state are compensated by the capacitor voltages of the first capacitor 221 and the second capacitor 222 , the variation error ΔV 1 can be lowered to an acceptable tiny offset with respect to the input voltage Vin.
[0037] When the second enable control signal Eab is set to be an enabled signal and the first control signal P 1 , the second control signal P 2 and the first enable control signal Ea are set to be disabled signals during the interval T 12 , the first transistor 211 and the second transistor 212 are turned off for retaining the voltage V 1 ±ΔV 1 of the output voltage Vout and for saving power consumption corresponding to the first transistor 211 and the second transistor 212 .
[0038] When the first control signal P 1 and the first enable control signal Ea are set to be enabled signals and the second control signal P 2 and the second enable control signal Eab are set to be disabled signals during the interval T 20 , the output voltage Vout is changed from the voltage V 1 ±ΔV 1 to the preset voltage Vpreset; meanwhile, the first capacitor 221 and the second capacitor 222 are charged to have the capacitor voltages respectively equal to the gate-source voltages of the first transistor 211 and the second transistor 212 in turn-on state.
[0039] When the second control signal P 2 and the first enable control signal Ea are set to be enabled signals and the first control signal P 1 and the second enable control signal Eab are set to be disabled signals during the interval T 21 , the output voltage Vout is changed from the preset voltage Vpreset to the voltage V 2 ±ΔV 2 based on the voltage V 2 of the input voltage Vin in conjunction with the capacitor voltages of the first capacitor 221 and the second capacitor 222 . Since the gate-source voltages of the first transistor 211 and the second capacitor 222 in turn-on state are compensated by the capacitor voltages of the first capacitor 221 and the second capacitor 222 , the variation error ΔV 2 can be lowered to an acceptable tiny offset with respect to the input voltage Vin.
[0040] When the second enable control signal Eab is set to be an enabled signal and the first control signal P 1 , the second control signal P 2 and the first enable control signal Ea are set to be disabled signals during the interval T 22 , the first transistor 211 and the second transistor 212 are turned off for retaining the voltage V 2 ±ΔV 2 of the output voltage Vout and for saving power consumption corresponding to the first transistor 211 and the second transistor 212 .
[0041] Based on the above description, it is obvious that the seventh switch 237 through the tenth switch 240 are utilized to control on/off states of the first transistor 211 and the second transistor 212 for saving power consumption. If the design key issue of the analog buffer 200 is focused on production cost instead of power consumption, then the seventh switch 237 through the tenth switch 240 can be omitted for lowering production cost. That is, in another embodiment of the analog buffer 200 , the seventh switch 237 and the eighth switch 238 are replaced with open circuits, and the ninth switch 239 and the tenth switch 240 are replaced with short circuits, which is also applied to the following embodiments. It is noted that the enable signal and the disable signal are not limited to the signals having high voltage level and low voltage level respectively. In another embodiment, the enable signal and the disable signal can be set as the signals having low voltage level and high voltage level respectively without degrading the performance of the analog buffer.
[0042] FIG. 6 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a second embodiment of the present invention. As shown in FIG. 6 , the analog buffer 500 comprises a first transistor 511 , a second transistor 512 , a first capacitor 521 , a second capacitor 522 , a third capacitor 523 , a fourth capacitor 524 , a first switch 531 , a second switch 532 , a third switch 533 , a fourth switch 534 , a fifth switch 535 , a sixth switch 536 , a seventh switch 537 , an eighth switch 538 , a ninth switch 539 , a tenth switch 540 , an eleventh switch 541 , a twelfth switch 542 , a thirteenth switch 543 , a fourteenth switch 544 , a fifteenth switch 545 , and a reference voltage generator 590 . The reference voltage generator 590 is powered between a third supply voltage Vdd 2 and a fourth supply voltage Vss 2 for generating a first reference voltage Vb 1 and a second reference voltage Vb 2 .
[0043] The first transistor 511 comprises a drain for receiving a first supply voltage Vdd 1 , a source for outputting an output voltage Vout, and a gate. The second transistor 512 comprises a drain for receiving a second supply voltage Vss 1 , a source coupled to the source of the first transistor 511 , and a gate. The first transistor 511 can be an N-type MOS transistor. The second transistor 512 can be a P-type MOS transistor. In the circuit operation of the analog buffer 500 , the first transistor 511 and the second transistor 512 are operated in the class-AB source-follower operation mode based on the common-drain configuration for lowering power consumption.
[0044] The eleventh switch 541 comprises a first end and a second end respectively coupled to the gate and source of the first transistor 511 . The twelfth switch 542 comprises a first end and a second end respectively coupled to the gate and source of the second transistor 512 . The thirteenth switch 543 comprises a first end and a second end. The second end of the thirteenth switch 543 is coupled to the gate of the first transistor 511 . The fourteenth switch 544 comprises a first end and a second end. The second end of the fourteenth switch 544 is coupled to the gate of the second transistor 512 . The third capacitor 523 comprises a first end and a second end. The first end of the third capacitor 523 is coupled to the first end of the thirteenth switch 543 . The fourth capacitor 524 comprises a first end and a second end. The first end of the fourth capacitor 524 is coupled to the first end of the fourteenth switch 544 . The ninth switch 539 comprises a first end coupled to the second end of the third capacitor 523 , and a second end coupled to the source of the first transistor 511 . The tenth switch 540 comprises a first end coupled to the second end of the fourth capacitor 524 , and a second end coupled to the source of the second transistor 512 .
[0045] The seventh switch 537 comprises a first end for receiving an input voltage Vin, and a second end coupled to the second end of the third capacitor 523 . The eighth switch 538 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the fourth capacitor 524 . The third switch 533 comprises a first end coupled to the reference voltage generator 590 for receiving the first reference voltage Vb 1 , and a second end coupled to the first end of the thirteenth switch 543 . The fourth switch 534 comprises a first end coupled to the reference voltage generator 590 for receiving the second reference voltage Vb 2 , and a second end coupled to the first end of the fourteenth switch 544 .
[0046] The first capacitor 521 comprises a first end and a second end. The first end of the first capacitor 521 is coupled to the second end of the third switch 533 . The second capacitor 522 comprises a first end and a second end. The first end of the second capacitor 522 is coupled to the second end of the fourth switch 534 . The fifth switch 535 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the first capacitor 521 . The sixth switch 536 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the second capacitor 522 . The first switch 531 comprises a first end and a second end respectively coupled to the second end of the first capacitor 521 and the source of the first transistor 511 . The second switch 532 comprises a first end and a second end respectively coupled to the second end of the second capacitor 522 and the source of the second transistor 512 . The fifteenth switch 545 comprises a first end and a second end respectively coupled to the second end of the first capacitor 521 and the second end of the second capacitor 522 .
[0047] In one embodiment, the internal circuit structure of the reference voltage generator 590 in FIG. 6 can be designed as the reference voltage generator 300 shown in FIG. 3 . In another embodiment, the internal circuit structure of the reference voltage generator 590 in FIG. 6 can be designed as the reference voltage generator 400 shown in FIG. 4 .
[0048] FIG. 7 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 6 , having time along the abscissa. The signal waveforms in FIG. 7 , from top to bottom, are the input voltage Vin, the first control signal P 1 , the second control signal P 2 , the third control signal P 3 , the first enable control signal Ea, the second enable control signal Eab, and the output voltage Vout. The first switch 531 through the fourth switch 534 are turned on/off in response to the first control signal P 1 . The fifth switch 535 , the sixth switch 536 , the ninth switch 539 and the tenth switch 540 are turned on/off in response to the second control signal P 2 . The seventh switch 537 , the eighth switch 538 and the fifteenth switch 545 are turned on/off in response to the third control signal P 3 . The thirteenth switch 543 and the fourteenth switch 544 are turned on/off in response to the first enable control signal Ea. The eleventh switch 541 and the twelfth switch 542 are turned on/off in response to the second enable control signal Eab. The circuit operation of the analog buffer 500 is detailed as the followings.
[0049] When the first control signal P 1 and the first enable control signal Ea are set to be enabled signals and the second control signal P 2 , the third control signal P 3 and the second enable control signal Eab are set to be disabled signals during the interval T 10 , the output voltage Vout is changed from the previous voltage V 0 ±ΔV 02 to the preset voltage Vpreset; meanwhile, the first capacitor 521 is charged to have the capacitor voltage as the first gate-source voltage of the first transistor 511 in turn-on state, and the second capacitor 522 is charged to have the capacitor voltage as the second gate-source voltage of the second transistor 512 in turn-on state.
[0050] When the second control signal P 2 and the first enable control signal Ea are set to be enabled signals and the first control signal P 1 , the third control signal P 3 and the second enable control signal Eab are set to be disabled signals during the interval T 11 , the output voltage Vout is changed from the preset voltage Vpreset to the voltage V 1 ±ΔV 11 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages of the first capacitor 521 and the second capacitor 522 . Since the third gate-source voltage of the first transistor 511 in turn-on state is compensated by the capacitor voltage (the first gate-source voltage) of the first capacitor 521 and the fourth gate-source voltage of the second transistor 512 in turn-on state is compensated by the capacitor voltage (the second gate-source voltage) of the second capacitor 522 , the variation error is reduced to ΔV 11 . However, the third gate-source voltage and the fourth gate-source voltage are not completely compensated by the first gate-source voltage and the second gate-source voltage respectively. Consequently, the third capacitor 523 and the fourth capacitor 524 are charged to have the capacitor voltages respectively equal to the third gate-source voltage and the fourth gate-source voltage during the interval T 11 for the following compensation operation.
[0051] When the third control signal P 3 and the first enable control signal Ea are set to be enabled signals and the first control signal P 1 , the second control signal P 2 and the second enable control signal Eab are set to be disabled signals during the interval T 12 , the fifteenth switch 545 is turned on for shorting the second ends of the first capacitor 521 and the second capacitor 522 so that the third capacitor 523 and the fourth capacitor 524 are capable of holding the third gate-source voltage and the fourth gate-source voltage respectively for performing accurate compensation operation. Then, the output voltage Vout is changed from the voltage V 1 ±ΔV 11 to the voltage V 1 ΔV 12 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages (the third gate-source voltage and the fourth gate-source voltage) of the third capacitor 523 and the fourth capacitor 524 . That is, the accurate compensation operation reduces the variation error from ΔV 11 to ΔV 12 for generating the output voltage Vout having an acceptable tiny offset with respect to the input voltage Vin.
[0052] When the second enable control signal Eab is set to be an enabled signal and the first control signal P 1 , the second control signal P 2 , the third control signal P 3 and the first enable control signal Ea are set to be disabled signals during the interval T 13 , the first transistor 511 and the second transistor 512 are turned off for retaining the voltage V 1 ±ΔV 12 of the output voltage Vout and for saving power consumption corresponding to the first transistor 511 and the second transistor 512 . The circuit operations of the analog buffer 500 from the interval T 20 to the interval T 23 are similar to the aforementioned circuit operations from the interval T 10 to the interval T 13 , and for the sake of brevity, further similar description is omitted.
[0053] FIG. 8 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a third embodiment of the present invention. As shown in FIG. 8 , the analog buffer 600 comprises a first transistor 611 , a second transistor 612 , a third transistor 613 , a fourth transistor 614 , a first capacitor 621 , a second capacitor 622 , a first switch 631 , a second switch 632 , a third switch 633 , a fourth switch 634 , a fifth switch 635 , a sixth switch 636 , a seventh switch 637 , an eighth switch 638 , a ninth switch 639 , a tenth switch 640 , an eleventh switch 641 , a twelfth switch 642 , a thirteenth switch 643 , a fourteenth switch 644 and a reference voltage generator 690 . The reference voltage generator 690 is powered between a third supply voltage Vdd 2 and a fourth supply voltage Vss 2 for generating a first reference voltage Vb 1 and a second reference voltage Vb 2 .
[0054] The first transistor 611 comprises a drain for receiving a first supply voltage Vdd 1 , a source for outputting an output voltage Vout, and a gate. The second transistor 612 comprises a drain for receiving a second supply voltage Vss 1 , a source coupled to the source of the first transistor 611 , and a gate. The third transistor 613 comprises a drain for receiving a fifth supply voltage Vdd 3 , a source coupled to the source of the first transistor 611 , and a gate. The fourth transistor 614 comprises a drain for receiving a sixth supply voltage Vss 3 , a source coupled to the source of the second transistor 612 , and a gate. In the circuit operation of the analog buffer 600 , the fifth supply voltage Vdd 3 can be set to be greater than the first supply voltage Vdd 1 , and the sixth supply voltage Vss 3 can be set to be less than the second supply voltage Vss 1 for achieving high-speed voltage adjusting performance while performing auxiliary capacitor charge operations by making use of the third transistor 613 and the fourth transistor 614 .
[0055] The first transistor 611 and the third transistor 613 can be N-type MOS transistors. The second transistor 612 and the fourth transistor 614 can be P-type MOS transistors. In the circuit operation of the analog buffer 600 , the first transistor 611 , the second transistor 612 , the third transistor 613 and the fourth transistor 614 are operated in the class-AB source-follower operation mode based on the common-drain configuration for lowering power consumption.
[0056] The seventh switch 637 comprises a first end and a second end respectively coupled to the gate and source of the third transistor 613 . The eighth switch 638 comprises a first end and a second end respectively coupled to the gate and source of the fourth transistor 614 . The ninth switch 639 comprises a first end coupled to the gate of the first transistor 611 , and a second end coupled to the gate of the third transistor 613 . The tenth switch 640 comprises a first end coupled to the gate of the second transistor 612 , and a second end coupled to the gate of the fourth transistor 614 . The eleventh switch 641 comprises a first end and a second end respectively coupled to the gate and source of the first transistor 611 . The twelfth switch 642 comprises a first end and a second end respectively coupled to the gate and source of the second transistor 612 .
[0057] The thirteenth switch 643 comprises a first end and a second end. The second end of the thirteenth switch 643 is coupled to the gate of the first transistor 611 . The fourteenth switch 644 comprises a first end and a second end. The second end of the fourteenth switch 644 is coupled to the gate of the second transistor 612 . The third switch 633 comprises a first end coupled to the reference voltage generator 690 for receiving the first reference voltage Vb 1 , and a second end coupled to the first end of the thirteenth switch 643 . The fourth switch 634 comprises a first end coupled to the reference voltage generator 690 for receiving the second reference voltage Vb 2 , and a second end coupled to the first end of the fourteenth switch 644 .
[0058] The first capacitor 621 comprises a first end and a second end. The first end of the first capacitor 621 is coupled to the second end of the third switch 633 . The second capacitor 622 comprises a first end and a second end. The first end of the second capacitor 622 is coupled to the second end of the fourth switch 634 . The fifth switch 635 comprises a first end for receiving an input voltage Vin, and a second end coupled to the second end of the first capacitor 621 . The sixth switch 636 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the second capacitor 622 . The first switch 631 comprises a first end and a second end respectively coupled to the second end of the first capacitor 621 and the source of the first transistor 611 . The second switch 632 comprises a first end and a second end respectively coupled to the second end of the second capacitor 622 and the source of the second transistor 612 .
[0059] In one embodiment, the internal circuit structure of the reference voltage generator 690 in FIG. 8 can be designed as the reference voltage generator 300 shown in FIG. 3 . In another embodiment, the internal circuit structure of the reference voltage generator 690 in FIG. 8 can be designed as the reference voltage generator 400 shown in FIG. 4 .
[0060] FIG. 9 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 8 , having time along the abscissa. The signal waveforms in FIG. 9 , from top to bottom, are the input voltage Vin, the first control signal P 1 , the second control signal P 2 , the first enable control signal Ea, the second enable control signal Eab, the third enable control signal Q 1 , the fourth enable control signal Q 1 b, and the output voltage Vout. The first switch 631 through the fourth switch 634 are turned on/off in response to the first control signal P 1 . The fifth switch 635 and the sixth switch 636 are turned on/off in response to the second control signal P 2 . The thirteenth switch 643 and the fourteenth switch 644 are turned on/off in response to the first enable control signal Ea. The eleventh switch 641 and the twelfth switch 642 are turned on/off in response to the second enable control signal Eab. The ninth switch 639 and the tenth switch 640 are turned on/off in response to the third enable control signal Q 1 . The seventh switch 637 and the eighth switch 638 are turned on/off in response to the fourth enable control signal Q 1 b. The circuit operation of the analog buffer 600 is detailed as the followings.
[0061] When the first control signal P 1 , the first enable control signal Ea and the third enable control signal Q 1 are set to be enabled signals and the second control signal P 2 , the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be disabled signals during the interval T 10 , the output voltage Vout is changed from the previous voltage V 0 ±ΔV 0 to the preset voltage Vpreset; meanwhile, the first capacitor 621 is charged to have the capacitor voltage as the gate-source voltage of the first transistor 611 and the third transistor 613 in turn-on state, and the second capacitor 622 is charged to have the capacitor voltage as the gate-source voltage of the second transistor 612 and the fourth transistor 614 in turn-on state. Since the voltage adjustments of the capacitor voltages of the first capacitor 621 and the second capacitor 622 are performed via the first transistor 611 through the fourth transistor 614 , the charging operations for the first capacitor 621 and the second capacitor 622 can be carried out much faster for shortening the interval T 10 so that the analog buffer 600 is able to perform analog signal buffering operations at a higher speed.
[0062] When the second control signal P 2 , the first enable control signal Ea and the fourth enable control signal Q 1 b are set to be enabled signals and the first control signal P 1 , the second enable control signal Eab and the third enable control signal Q 1 are set to be disabled signals during the interval T 11 , the output voltage Vout is changed from the preset voltage Vpreset to the voltage V 1 ±ΔV 1 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages of the first capacitor 621 and the second capacitor 622 . Since the gate-source voltages of the first transistor 611 through the fourth transistor 614 in turn-on state are compensated by the capacitor voltages of the first capacitor 621 and the second capacitor 622 , the variation error ΔV 1 can be lowered to an acceptable tiny offset with respect to the input voltage Vin.
[0063] When the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be enabled signals and the first control signal P 1 , the second control signal P 2 , the first enable control signal Ea and the third enable control signal Q 1 are set to be disabled signals during the interval T 12 , the first transistor 611 through the fourth transistor 614 are turned off for retaining the voltage V 1 ±ΔV 1 of the output voltage Vout and for saving power consumption corresponding to the first transistor 611 through the fourth transistor 614 . The circuit operations of the analog buffer 600 from the interval T 20 to the interval T 22 are similar to the aforementioned circuit operations from the interval T 10 to the interval T 12 , and for the sake of brevity, further similar description is omitted.
[0064] In an alternative circuit operation of the analog buffer 600 , the second control signal P 2 , the first enable control signal Ea and the third enable control signal Q 1 are set to be enabled signals and the first control signal P 1 , the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be disabled signals during the interval T 11 so that the analog buffer 600 is able to perform analog signal buffering operations at a much higher speed by turning on the first transistor 611 through the fourth transistor 614 for fast changing the output voltage Vout from the preset voltage Vpreset to the voltage V 1 ±ΔV 1 for shortening the interval T 11 .
[0065] FIG. 10 is a schematic diagram showing the circuit of an analog buffer having voltage compensation mechanism in accordance with a fourth embodiment of the present invention. As shown in FIG. 10 , the analog buffer 700 comprises a first transistor 711 , a second transistor 712 , a third transistor 713 , a fourth transistor 714 , a first capacitor 721 , a second capacitor 722 , a third capacitor 723 , a fourth capacitor 724 , a first switch 731 , a second switch 732 , a third switch 733 , a fourth switch 734 , a fifth switch 735 , a sixth switch 736 , a seventh switch 737 , an eighth switch 738 , a ninth switch 739 , a tenth switch 740 , an eleventh switch 741 , a twelfth switch 742 , a thirteenth switch 743 , a fourteenth switch 744 , a fifteenth switch 745 , a sixteenth switch 746 , a seventeenth switch 747 , an eighteenth switch 748 , a nineteenth switch 749 and a reference voltage generator 790 . The reference voltage generator 790 is powered between a third supply voltage Vdd 2 and a fourth supply voltage Vss 2 for generating a first reference voltage Vb 1 and a second reference voltage Vb 2 .
[0066] The first transistor 711 comprises a drain for receiving a first supply voltage Vdd 1 , a source for outputting an output voltage Vout, and a gate. The second transistor 712 comprises a drain for receiving a second supply voltage Vss 1 , a source coupled to the source of the first transistor 711 , and a gate. The third transistor 713 comprises a drain for receiving a fifth supply voltage Vdd 3 , a source coupled to the source of the first transistor 711 , and a gate. The fourth transistor 714 comprises a drain for receiving a sixth supply voltage Vss 3 , a source coupled to the source of the second transistor 712 , and a gate. Similarly, in the circuit operation of the analog buffer 700 , the fifth supply voltage Vdd 3 can be set to be greater than the first supply voltage Vdd 1 , and the sixth supply voltage Vss 3 can be set to be less than the second supply voltage Vss 1 for achieving high-speed voltage adjusting performance while performing auxiliary capacitor charge operations by making use of the third transistor 713 and the fourth transistor 714 .
[0067] The first transistor 711 and the third transistor 713 can be N-type MOS transistors. The second transistor 712 and the fourth transistor 714 can be P-type MOS transistors. In the circuit operation of the analog buffer 700 , the first transistor 711 , the second transistor 712 , the third transistor 713 and the fourth transistor 714 are operated in the class-AB source-follower operation mode based on the common-drain configuration for lowering power consumption.
[0068] The eleventh switch 741 comprises a first end and a second end respectively coupled to the gate and source of the third transistor 713 . The twelfth switch 742 comprises a first end and a second end respectively coupled to the gate and source of the fourth transistor 714 . The thirteenth switch 743 comprises a first end coupled to the gate of the first transistor 711 , and a second end coupled to the gate of the third transistor 713 . The fourteenth switch 744 comprises a first end coupled to the gate of the second transistor 712 , and a second end coupled to the gate of the fourth transistor 714 . The fifteenth switch 745 comprises a first end and a second end respectively coupled to the gate and source of the first transistor 711 . The sixteenth switch 746 comprises a first end and a second end respectively coupled to the gate and source of the second transistor 712 .
[0069] The seventeenth switch 747 comprises a first end and a second end. The second end of the seventeenth switch 747 is coupled to the gate of the first transistor 711 . The eighteenth switch 748 comprises a first end and a second end. The second end of the eighteenth switch 748 is coupled to the gate of the second transistor 712 . The third capacitor 723 comprises a first end and a second end. The first end of the third capacitor 723 is coupled to the first end of the seventeenth switch 747 . The fourth capacitor 724 comprises a first end and a second end. The first end of the fourth capacitor 724 is coupled to the first end of the eighteenth switch 748 . The ninth switch 739 comprises a first end coupled to the second end of the third capacitor 723 , and a second end coupled to the source of the first transistor 711 . The tenth switch 740 comprises a first end coupled to the second end of the fourth capacitor 724 , and a second end coupled to the source of the second transistor 712 .
[0070] The seventh switch 737 comprises a first end for receiving an input voltage Vin, and a second end coupled to the second end of the third capacitor 723 . The eighth switch 738 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the fourth capacitor 724 . The first capacitor 721 comprises a first end and a second end. The first end of the first capacitor 721 is coupled to the first end of the seventeenth switch 747 . The second capacitor 722 comprises a first end and a second end. The first end of the second capacitor 722 is coupled to the first end of the eighteenth switch 748 . The third switch 733 comprises a first end coupled to the reference voltage generator 790 for receiving the first reference voltage Vb 1 , and a second end coupled to the first end of the first capacitor 721 . The fourth switch 734 comprises a first end coupled to the reference voltage generator 790 for receiving the second reference voltage Vb 2 , and a second end coupled to the first end of the second capacitor 722 .
[0071] The fifth switch 735 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the first capacitor 721 . The sixth switch 736 comprises a first end for receiving the input voltage Vin, and a second end coupled to the second end of the second capacitor 722 . The first switch 731 comprises a first end and a second end respectively coupled to the second end of the first capacitor 721 and the source of the first transistor 711 . The second switch 732 comprises a first end and a second end respectively coupled to the second end of the second capacitor 722 and the source of the second transistor 712 . The nineteenth switch 749 comprises a first end and a second end respectively coupled to the second end of the first capacitor 721 and the second end of the second capacitor 722 .
[0072] In one embodiment, the internal circuit structure of the reference voltage generator 790 in FIG. 10 can be designed as the reference voltage generator 300 shown in FIG. 3 . In another embodiment, the internal circuit structure of the reference voltage generator 790 in FIG. 10 can be designed as the reference voltage generator 400 shown in FIG. 4 .
[0073] FIG. 11 shows the related signal waveforms concerning the circuit operation of the analog buffer in FIG. 10 , having time along the abscissa. The signal waveforms in FIG. 11 , from top to bottom, are the input voltage Vin, the first control signal P 1 , the second control signal P 2 , the third control signal P 3 , the first enable control signal Ea, the second enable control signal Eab, the third enable control signal Q 1 , the fourth enable control signal Q 1 b, and the output voltage Vout. The first switch 731 through the fourth switch 734 are turned on/off in response to the first control signal P 1 . The fifth switch 735 , the sixth switch 736 , the ninth switch 739 and the tenth switch 740 are turned on/off in response to the second control signal P 2 . The seventh switch 737 , the eighth switch 738 and the nineteenth switch 749 are turned on/off in response to the third control signal P 3 . The seventeenth switch 747 and the eighteenth switch 748 are turned on/off in response to the first enable control signal Ea. The fifteenth switch 745 and the sixteenth switch 746 are turned on/off in response to the second enable control signal Eab. The thirteenth switch 743 and the fourteenth switch 744 are turned on/off in response to the third enable control signal Q 1 . The eleventh switch 741 and the twelfth switch 742 are turned on/off in response to the fourth enable control signal Q 1 b. The circuit operation of the analog buffer 700 is detailed as the followings.
[0074] When the first control signal P 1 , the first enable control signal Ea and the third enable control signal Q 1 are set to be enabled signals and the second control signal P 2 , the third control signal P 3 , the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be disabled signals during the interval T 10 , the output voltage Vout is changed from the previous voltage V 0 ±ΔV 02 to the preset voltage Vpreset; meanwhile, the first capacitor 721 is charged to have the capacitor voltage as the first gate-source voltage of the first transistor 711 and the third transistor 713 in turn-on state, and the second capacitor 722 is charged to have the capacitor voltage as the second gate-source voltage of the second transistor 712 and the fourth transistor 714 in turn-on state. Since the voltage adjustments of the capacitor voltages of the first capacitor 721 and the second capacitor 722 are performed via the first transistor 711 through the fourth transistor 714 , the charging operations for the first capacitor 721 and the second capacitor 722 can be carried out much faster for shortening the interval T 10 so that the analog buffer 700 is able to perform analog signal buffering operations at a higher speed.
[0075] When the second control signal P 2 , the first enable control signal Ea and the fourth enable control signal Q 1 b are set to be enabled signals and the first control signal P 1 , the third control signal P 3 , the second enable control signal Eab and the third enable control signal Q 1 are set to be disabled signals during the interval T 11 , the output voltage Vout is changed from the preset voltage Vpreset to the voltage V 1 ±ΔV 11 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages of the first capacitor 721 and the second capacitor 722 . Since the third gate-source voltage of the first transistor 711 and the third transistor 713 in turn-on state is compensated by the capacitor voltage (the first gate-source voltage) of the first capacitor 721 and the fourth gate-source voltage of the second transistor 712 and the fourth transistor 714 in turn-on state is compensated by the capacitor voltage (the second gate-source voltage) of the second capacitor 722 , the variation error is reduced to ΔV 11 . However, the third gate-source voltage and the fourth gate-source voltage are not completely compensated by the first gate-source voltage and the second gate-source voltage respectively. Consequently, the third capacitor 723 and the fourth capacitor 724 are charged to have the capacitor voltages respectively equal to the third gate-source voltage and the fourth gate-source voltage during the interval T 11 for the following compensation operation.
[0076] When the third control signal P 3 , the first enable control signal Ea and the fourth enable control signal Q 1 b are set to be enabled signals and the first control signal P 1 , the second control signal P 2 , the second enable control signal Eab and the third enable control signal Q 1 are set to be disabled signals during the interval T 12 , the nineteenth switch 749 is turned on for shorting the second ends of the first capacitor 721 and the second capacitor 722 so that the third capacitor 723 and the fourth capacitor 724 are capable of holding the third gate-source voltage and the fourth gate-source voltage respectively for performing accurate compensation operation. Then, the output voltage Vout is changed from the voltage V 1 ±ΔV 11 to the voltage V 1 ±ΔV 12 based on the voltage V 1 of the input voltage Vin in conjunction with the capacitor voltages (the third gate-source voltage and the fourth gate-source voltage) of the third capacitor 723 and the fourth capacitor 724 . That is, the accurate compensation operation reduces the variation error from ΔV 11 to ΔV 12 for generating the output voltage Vout having an acceptable tiny offset with respect to the input voltage Vin.
[0077] When the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be enabled signals and the first control signal P 1 , the second control signal P 2 , the third control signal P 3 , the first enable control signal Ea and the third enable control signal Q 1 are set to be disabled signals during the interval T 13 , the first transistor 711 through the fourth transistor 714 are turned off for retaining the voltage V 1 ±ΔV 12 of the output voltage Vout and for saving power consumption corresponding to the first transistor 711 through the fourth transistor 714 . The circuit operations of the analog buffer 700 from the interval T 20 to the interval T 23 are similar to the aforementioned circuit operations from the interval T 10 to the interval T 13 , and for the sake of brevity, further similar description is omitted.
[0078] In an alternative circuit operation of the analog buffer 700 , the second control signal P 2 , the first enable control signal Ea and the third enable control signal Q 1 are set to be enabled signals and the first control signal P 1 , the third control signal P 3 , the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be disabled signals during the interval T 11 so that the analog buffer 700 is able to perform analog signal buffering operations at a much higher speed by turning on the first transistor 711 through the fourth transistor 714 for fast changing the output voltage Vout from the preset voltage Vpreset to the voltage V 1 ±ΔV 11 for shortening the interval T 11 .
[0079] Furthermore, in an alternative circuit operation of the analog buffer 700 , the third control signal P 3 , the first enable control signal Ea and the third enable control signal Q 1 are set to be enabled signals and the first control signal P 1 , the second control signal P 2 , the second enable control signal Eab and the fourth enable control signal Q 1 b are set to be disabled signals during the interval T 12 so that the analog buffer 700 is able to perform analog signal buffering operations at a much higher speed by turning on the first transistor 711 through the fourth transistor 714 for fast changing the output voltage Vout from the voltage V 1 ±ΔV 11 to the voltage V 1 ±ΔV 12 for shortening the interval T 12 . However, the voltage difference between the voltage V 1 ±ΔV 11 and the voltage V 1 ±ΔV 12 is substantially quite small, and therefore the reduced time of the shortened interval T 12 are quite limited, which is paid by much higher power consumption caused by the third transistor 713 and the fourth transistor 714 in turn-on state. Accordingly, in a preferred circuit operation of the analog buffer 700 , the third transistor 713 and the fourth transistor 714 are turned off for saving power consumption during the interval T 12 .
[0080] The present invention is by no means limited to the embodiments as described above by referring to the accompanying drawings, which may be modified and altered in a variety of different ways without departing from the scope of the present invention. Thus, it should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alternations might occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
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An analog buffer having voltage compensation mechanism is disclosed for use in a source driving circuit of a liquid crystal display. The analog buffer includes a reference voltage generator, a plurality of capacitors, a plurality of switches, and a plurality of transistors. Each of the capacitors is utilized to store the gate-source voltage of the corresponding turn-on transistor for performing gate-source voltage compensation operation based on the reference voltages provided by the reference voltage generator. Each of the switches functions to control gate-source voltage compensation operation and is turned on/off in response to a corresponding control signal. The analog buffer is capable of compensating the gate-source voltages of turn-on transistors for generating an output voltage having an acceptable tiny offset with respect to an input voltage.
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FIELD OF THE INVENTION
The claimed invention relates to devices and methods for the stimulation of a patient's muscles using a probe.
BACKGROUND
Anorectal malformations are variety birth defects that may include (1) the absence of an anal opening, (2) the anal opening in the wrong place, (3), a connection, or fistula, joining the intestine and the urinary system, (4) a connection joining the intestine and vagina, or (5) the intestine can join with the urinary system and vagina in a single opening. During repair of the anorectal malformations, the colon is pulled down to a newly created anal opening, which must be properly situated between the anal sphincter muscles. Repair of anorectal malformations (ARM) using either posterior sagittal anorectoplasty (PSARP) or Georgeson's laparoscopic technique is optimally performed using a muscle stimulator to clearly delineate the anal and pelvic muscle complexes for precise anatomic placement of the rectal pull-through segment. Unfortunately, commercially available muscle stimulators for ARM surgery can be prohibitively expensive for many regions of the globe due as their cost may exceed 10,000 USD. Not surprisingly, this cost barrier limits the use of this critically important tool by surgeons in communities with limited resources to purchase this device.
BRIEF DESCRIPTION OF THE FIGURES
Exemplary embodiments are illustrated in referenced figures. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
FIG. 1 depicts, in accordance with various embodiments of the present invention, a cross sectional view of a probe and stimulator;
FIG. 2 depicts, in accordance with various embodiments of the present invention, a top view of a probe and stimulator; and.
FIG. 3 depicts, in accordance with various embodiments of the prevent invention, a method for performing a surgery with the disclosed devices.
SUMMARY OF THE INVENTION
Through various forms of experimentation, the inventors have determined that a suitable muscle stimulator may be constructed from (1) a widely available low cost (e.g., $200 per unit) peripheral nerve stimulators or similar stimulator and (2) a relatively simple, handheld surgical probe to provide a low cost muscle stimulator that is adequate for ARM surgeries. These two components could provide a low cost solution to allow doctors in developing countries feasibly perform ARM surgeries with minimal cost and manufacturing. Furthermore, a simple and durable probe stimulator may be easily detached from the device and sterilized using a steam (e.g. autoclave) sterilization procedure that is harsh but inexpensive. This is a drastic improvement over current muscle stimulators which have complex probes that cannot be steam sterilized and therefore require sterilization at a centralized hospital using potentially time intensive procedures.
Stimulator
In some embodiments, a commercially available “Peripheral Nerve Stimulator” commonly designed for use as a tool for anesthesiologists to determine the appropriate sedation levels for a given patient during surgery may be utilized to provide the appropriate electrical stimulation. There are various manufacturers of these devices, and they typically consist of an electronic device that is battery operated with some type of user interface controlling the amount of current that is delivered through various forms of metallic external connectors to the patient. The stimulator is activated through a button that delivers electrical current from the stimulator when depressed.
Probe
The second component of the presently disclosed device is the handheld surgery probe that may include a probe tool and an electrical connection to the stimulator that delivers the electrical current from the stimulator to the patient's skin. In some embodiments, such a handle held probe may include an electrically insulated handle with two metallic leads that protrude through the top of the device and deliver the electrical stimulation to a patient's skin. The probe may include a handle portion or casing that is made of an electrically insulating material to prevent the flow of current between the two metallic leads when not in contact with the patient's skin. The probe could be constructed from a material that can endure sterilization temperatures and is resistant to corrosion caused by the steam sterilization.
In some embodiments, the probe is connected to the stimulator through a pair of electrically insulated wires that connect from metallic leads on the pen probe to the two pins on the stimulator. The wires connecting the pen probe to the stimulation device may also be made of heat resistant and corrosion resistant materials so that the entire surgery probe unit can be separated from the stimulator device and sterilized and reused for multiple surgeries.
DETAILED DESCRIPTION OF THE INVENTION
All references cited herein are incorporated by reference in their entirety as though fully set forth. Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. One skilled in the art will recognize many methods and materials similar or equivalent to those described herein, which could be used in the practice of the present invention. Indeed, the present invention is in no way limited to the methods described herein. For purposes of the present invention, the following terms are defined below.
Overview
FIG. 1 illustrates an embodiment of the present disclosure that includes a simulator 100 and a probe 105 . The stimulator 100 may be connected to the probe 105 through a wire 130 and connector 150 or directly with just a wire 130 . The probe 105 includes an electrically insulated casing 110 that house two leads 120 that conduct electricity to the patient's skin or soft tissue in order to stimulate muscles and/or nerves. In some embodiments, the leads 120 may contain a spacer 140 to ensure separation of the two leads 120 on the patient's skin.
During usage for example in an ARM surgery, a surgeon may place the probe leads 120 on a patient's skin and activate the simulator 100 to deliver a sufficient amount of electricity to a localized area in order to cause a contraction of muscle in the vicinity of the probe leads 120 . If sufficiently electricity is delivered, the surgeon or a detector (for example with an EMG device) may record muscle contractions. Thus the surgeon will then be able to determine the location of certain muscles. For example, the device may be utilized to detect the location of the anal and pelvic muscles, so an appropriate placed incision can be made for the ARM surgery. If a contraction is detected, the intensity and direction of contraction will provide a surgeon or other caregiver with information regarding the location and orientation of muscles.
Stimulator
In some embodiments, stimulator 100 may be a conventional “Peripheral Nerve Stimulator” commonly designed for use as a tool for anesthesiologists to determine the appropriate sedation levels for a given patient during surgery. For example, the commercially available Micro Stim or SunStim peripheral nerve stimulators may be implemented. In other embodiments, any suitable stimulator 100 may be utilized that delivers an appropriate electrical pulse to two different leads as described herein.
The stimulator 100 may deliver a suitable pulse to cause contraction of muscles with a certain range of the leads 120 of the probe 105 . For instance, the stimulator 100 may deliver a constant mode 100 Hz square wave that ranges between 0-70 milliamps. In other embodiments, other shapes of waves may be utilized that various in amplitude and frequency. In some embodiments, the amplitude may be varied to compensate for different ages of patients' that require a different threshold of stimulation to contract local muscles. The amplitude of current may also determine the maximum distance from the leads 120 that will precipitate muscular contraction. In some embodiments, the stimulator 100 may be able to vary the amplitude to allow a doctor to customize the pulse for a particular patient.
FIG. 2 illustrates an embodiment of the stimulator 100 including the available options for waveforms. As illustrated, the options available for stimulation are relatively basic and include a 100 Hz and TDF wave.
Probe
The probe 105 may be simply constructed from durable materials in order to allow for harsher sterilization methods that may be employed in developing countries. For instance, the probe 105 may include leads 120 for delivering the electrical current to a patient's skin from the wires 130 . In some embodiments, the leads 120 may be elongated rods constructed of corrosion resistant metal or other conductors. In some embodiments, the leads 120 may be constructed from brass rods. In some embodiments, the ends of the leads 120 may be rounded at the tip 125 to avoid damaging a patient's skin. In some embodiments, the leads 120 may be 2-5 inches, 4 inches, 3 inches, 2 inches, or 1 inch, or other suitable lengths. FIG. 2 illustrates an embodiment of probe 105 that includes a relatively straight casing 110 .
As illustrated in FIG. 1 , casing 110 or other electrical insulating covering may enclose the leads 120 for handling by the physician and for preventing current from exiting the leads other than at the tip portion 125 of the leads. Various materials may be utilized for casing 110 that are preferably resistant to corrosive methods of sterilization, durable, and provide electrical insulation. For example, a polytretrafluoroethylene (PTFE) tube may be utilized, with holes or a channel for the leads 120 to be inserted through. In other embodiments, other materials may be utilized that are suitable.
In some embodiments, the casing 110 will have a channel 160 or hole that runs the longitudinal length of the tube. The leads 120 may be inserted through the hole and then a spacer 140 provided near the tip 125 to keep the leads 120 separated from each other. In some embodiments, spacer 140 may run the length of the casing 110 , a third of the casing 110 , or may be placed between the two leads 120 . In other embodiments, the leads 120 may be glued to the side or spacer 140 with a cement or adhesive. In some embodiments, a filler may be packed into the hole 160 that could harden and keep leads 120 in place. In some embodiments, to lengthwise holes 160 may be drilled, machined, or otherwise made that are sized to fit leads 120 . Casing may be rounded or sanded on the end nearest the tip 125 of the probes 120 to avoid a sharp protrusion.
The probes may be connected to connectors 150 or stimulator 100 through wires 130 . Wires 130 may be any suitable wires that are resistant to certain types of corrosive and/or harsh sterilization techniques. For instance, 24 AWG, stranded wire may be utilizes that is rated for high heat, for example up to 150 C, 160 C, 170 c, or 200 C, and 600V with FEB insulation. The wire 130 may be connected to probe 120 and connector 150 by any suitable connection, including for example wrapping and soldering the wire to the leads 120 and the connector. In other embodiments, simple heat shrink tubing may additionally or alternatively be utilized that is rated for 140 C, 150 C, 160 C or other suitable temperatures.
Methods
The device as presently disclosed may be utilized for the stimulation of muscles during surgeries or in other appropriate contexts. For example, the stimulator 100 and probe 105 may be utilized to perform (1) repair of anorectal malformations (ARM) or (2) precise identification of facial nerve branches when performing head and neck surgery. Other examples and methods of utilizing a probe and stimulator as disclosed herein may be utilized for the stimulation of muscles of a patient.
Repair of anorectal malformations (ARM) using either posterior sagittal anorectoplasty (PSARP) or Georgeson's laparoscopic technique are optimally performed using a muscle stimulator to clearly delineate the anal and pelvic muscle complexes for precise anatomic placement of the rectal pull-through segment. Examples of these operations are described in detail in: Georgeson K E, Inge T H, Albanese Conn. (2000) Laparoscopically-assisted anorectal pull-through for high imperforate-anus—a new technique. J. Pediatr. Surg. 35:927-931.
Operations in which the identification of nerve branches is essential to safe operation include superficial parotidectomy and complete parotidectomy particularly in cases of parotid tumors. An example of this surgery is described in: Spiro R H., The parotid gland. In Baker R J, Fischer J E, eds. Mastery of Surgery. Vol. 14th ed. Philadelphia: Lippincott Williams & Wilkins; 2001: 320-327; and Pena A (1988) Posterior Sagittal anorectoplasty: results in the management of 332 cases of anorectal malformations. Pediatr. Surg. Int. 3:94-104.
FIG. 3 illustrates an example of a method disclosed herein for utilizing the disclosed stimulating system. The methods disclosed may include providing a stimulator 100 that may be a conventional peripheral nerve stimulator, providing a probe as described herein. The stimulator 100 may be connected 200 to the probe 105 through a wire 130 and connector 150 or directly with just a wire 130 .
The probe 105 and stimulator 100 may be utilized to map out the limits of the anal and pelvic muscle complexes for precise anatomic placement of the rectal pull-through segment. Accordingly, the probe 105 includes an electrically insulated casing 110 that house two leads 120 that conduct electricity to the patient's skin or soft tissue in order to stimulate muscles and/or nerves. In some embodiments, the leads 120 may contain a spacer 140 to ensure separation of the two leads 120 on the patient's skin.
During usage, for example in an ARM surgery, a surgeon may place the probe leads 120 on a patient's skin or soft tissue 210 and activate the simulator 220 to deliver a sufficient amount of electricity to a localized area in order to cause a contraction of muscle in the vicinity of the probe leads 120 . If sufficiently electricity is delivered, the surgeon or a detector (for example with an EMG device), may record muscle contractions 230 . Thus, the surgeon will then be able to determine the location of certain muscles. For example, the device may be utilized to detect the location of the anal and pelvic muscles, so an appropriate placed incision can be made for the ARM surgery. If a contraction is detected, the intensity and direction of contraction will provide a surgeon or other caregiver with information regarding the location and orientation of muscles. After a contraction is detected 230 , the surgeon may relocate the probe on the patient 240 and repeat the process to map out the limits of the anal and pelvic muscles.
CONCLUSIONS
The various methods and techniques described above provide a number of ways to carry out the invention. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods can be performed in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein. A variety of advantageous and disadvantageous alternatives are mentioned herein. It is to be understood that some preferred embodiments specifically include one, another, or several advantageous features, while others specifically exclude one, another, or several disadvantageous features, while still others specifically mitigate a present disadvantageous feature by inclusion of one, another, or several advantageous features.
Furthermore, the skilled artisan will recognize the applicability of various features from different embodiments. Similarly, the various elements, features and steps discussed above, as well as other known equivalents for each such element, feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods in accordance with principles described herein. Among the various elements, features, and steps some will be specifically included and others specifically excluded in diverse embodiments.
Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the embodiments of the invention extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and modifications and equivalents thereof.
In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
In some embodiments, the terms “a” and “an” and “the” and similar references used in the context of describing a particular embodiment of the invention (especially in the context of certain of the following claims) can be construed to cover both the singular and the plural. The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can 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 with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
Preferred embodiments of this invention are described herein, including the best mode known to the inventor for carrying out the invention. Variations on those preferred embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. It is contemplated that skilled artisans can employ such variations as appropriate, and the invention can be practiced otherwise than specifically described herein. Accordingly, many embodiments of this invention include 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.
Furthermore, numerous references have been made to patents and printed publications throughout this specification. Each of the above cited references and printed publications are herein individually incorporated by reference in their entirety.
In closing, it is to be understood that the embodiments of the invention disclosed herein are illustrative of the principles of the present invention. Other modifications that can be employed can be within the scope of the invention. Thus, by way of example, but not of limitation, alternative configurations of the present invention can be utilized in accordance with the teachings herein. Accordingly, embodiments of the present invention are not limited to that precisely as shown and described.
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A muscle stimulator that may be used during ARM surgeries is disclosed that may be constructed from (1) a widely available low cost (e.g., $200 per unit) peripheral nerve stimulators or similar stimulator and (2) a relatively simple, handheld surgical probe to provide a low cost muscle stimulator that is adequate for ARM surgeries. These two components could provide a low cost solution to allow doctors in developing countries feasibly perform ARM surgeries with relatively minimal manufacturing and inexpensive maintenance.
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FIELD OF THE INVENTION
The present invention relates to wheeled carts used for carrying a payload such as baggage, particularly those used in the airport environment which is subject to wind and around equipment which is sensitive to impact damage.
BACKGROUND OF THE INVENTION
An airport tarmac is just one environment in which windy conditions can adversely affect the serviceability of utility carts. The airport tarmac is a utilitarian surface, used primarily by support personnel in the business of servicing aircraft and transporting baggage. Baggage is some times transported on carts towed behind small motorized vehicles. Other carts are hand-powered. In the case of commuter aircraft, passengers also access the tarmac for boarding the aircraft from the ground. In such cases, it is usual for the airline operator to park a small hand-powered cart between the terminal building and the aircraft.
Passengers place their baggage on this cart as they leave the terminal. Airline personnel may also place the baggage on such a cart for passengers to pick up as they deplane and approach the terminal.
The cart is manually pushed about the tarmac. When placed in the vicinity of aircraft, the cart is subject to aircraft jet blast, propeller wake, and general wind conditions unimpeded by barriers. Baggage carts present a large wind catching surface, particularly when loaded. The above incidents of wind can cause the carts to roll on their wheels, to overpower friction brakes, or to pivot or skid about a non-rotating wheel or wheels. A moving cart is a hazard for personnel, but more frequently becomes a hazard to aircraft. Incidents of an impact of a cart with an aircraft are known and damaging. Contact of a cart is typically between the top or roof of a cart and the highly engineered and easily damaged skin of an aircraft fuselage or with the propeller which can result expensive repair and service costs.
In U.S. Pat. No. 5,862,884 issued to Applicant, the problem of wind has been partially addressed in the implementation of an airfoil on a portable wheelchair lift for use on airport tarmacs. While the use of airfoils on a lift or a cart convert lateral wind loading to a downward force for resisting overturning, it does not address the eventual impact issues with a cart, whether during handling or due to wind.
A variety of prior art carts are in use, none of which have proven particularly satisfactory to the airlines in part because:
they are hard to push;
the carts are insufficiently resistant to being wind driven into the aircraft; or
regardless of the reason for an impact, the contact of a cart and an aircraft results in damage.
It is known to equip prior art carts with brakes, as described in U.S. Pat. No. 3,651,894 to Auriemma. Auriemma discloses a serving cart with friction brakes, operated with a dead-man arrangement of a handle and drum-brakes with an actuating cable therebetween. A spring normally applies braking pressure until the handle is pushed or pulled. In U.S. Pat. Nos. 3,986,582 to Dye and 4,084,663 to Haley, latching type dead-man braking arrangements disclosed for a serving cart and carriage respectively. Both Dye and Haley disclose braking systems which use spring-biased pins which engage complementary opening in the sides of supporting wheels. Dye locates supporting wheels mid-cart and both are fitted with the brakes to avoid rotation.
When the operator releases the brake however, operator inattention can result in a collision with other objects. In the context of an airport tarmac, accidental contact of lower portions of the cart are rarely significant, being with tires or other sturdy structures. However, contact of the top of the cart can happen and is usually with the sensitive aircraft fuselage or a propeller.
No known prior art utility carts employ energy absorbing means about the cart's upper periphery.
Accidental impact has been addressed by others is situation where the damage-sensitive object is moving. In U.S. Pat. No. 2,546,026 to Coon for instance, an early use of a closed coil spring is disclosed as a mounting between an antenna and an automobile. Lateral impact of the antenna causes the spring to deflect, absorbing the energy and avoiding damage to the antenna. In U.S. Pat. No. 5,199,814 to Clark et al., a signpost is fitted with coupling to a base, the coupling permitting the signpost to pivot over from an upright to a prone position when struck by a vehicle. Deflection of the signpost limits damage to the post and to the vehicle. The coupling arrangement utilizes a tension cable between the base and the signpost. Deflection of the signpost and cable compresses a spring within the signpost, allowing the signpost to move and creating a righting force. The top of the post can rotate to the ground if run completely over by the offending vehicle.
In the context of a utility cart used at an airport, the upper structure often serves also as a load-carrying platform. In the case of the prior art coil spring mounting of Coon, the spring is unsuitable for supporting vertical loads, tending to buckle or collapse upon itself. The signpost coupling of Clark et al. has a narrow point of contact which aids in its rotation but does not assist, nor anticipate incorporation of a load-supporting structure while continuing to permit energy-absorbing deflection when struck from the side.
Regarding the braking issue, prior art use of friction brakes is limited to instances where the lateral forces can exceed the frictional pre-load. The extraordinary wind loading imposed on a cart on an airport tarmac can easily overcome friction brakes, particularly if the effectiveness of the brakes depends on wear or maintenance.
Those prior art carts which are fitted with latching type brakes have not dealt with the impact issue which can also occur when an operator has consciously released the brakes.
Therefore, there is a demonstrated need for a utility cart which has a system of supporting wheels and brakes which ensures immobility when stopped and which has an energy absorbing periphery for minimizing or eliminating impact damage regardless of the state of the cart.
SUMMARY OF THE INVENTION
A novel utility cart is provided which permits safe operation around sensitive equipment, particularly due to the cart's ability to absorb the energy of accidental impact therewith. In the case of operation in windy environments, the cart is further resistant to induced movement which can contribute to such accidental impact. Induced movement includes that due to wheel skidding, cart rotation or brake failure. Factors contributing to the cart's newfound sure-footedness includes: concentrating the carts weight on two or more main wheels for minimizing wind-induced rotational moments and for lessening wheel skidding, implementing positive latching type brakes on those main wheels to avoid brake failure, and applying an airfoil roof for lessening the overturning moment and increasing the wheel loading for reinforcing the anti-skid advantages.
Therefore, in a broad apparatus aspect, a utility cart is provided which minimizes damage caused by impact with objects, the cart comprising a wheeled frame having a top structure extending horizontally above the frame, the top structure having a periphery which approximates the periphery of the frame; and supports for normally supporting the top structure above the frame, the supports being laterally collapsible for permitting the top structure to be displaced laterally while remaining substantially horizontal so as to minimize energy transfer upon lateral impact with the periphery of the top structure.
Preferably, three or more upright-biased supports are used to support the top structure, such as a roof, so that payloads can supported thereon yet, under lateral impact, they will still deflect laterally, absorbing the energy of the impact. The preferred support is a tubular member sandwiched between top and bottom plates and having a tensioning means secured between the top and bottom plates for elastically connecting the top and bottom plates. One such a tensioning member is a cable having a spring compressed between the bottom plate and the bottom end of the cable.
When a roof is employed as the top structure, it is preferably shaped as an airfoil for interacting with airflow flowing thereover so as to generate downward forces with the associated advantages therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a perspective view of a utility cart, typically used as an airport tarmac baggage cart, which implements several embodiments of the present invention, the top periphery being formed as a roof;
FIG. 1 b is partial perspective view of an alternate top structure for the cart of FIG. 1 a , the illustrated periphery having no roof but still having an energy-absorbing function;
FIG. 2 is a fanciful side view of a cart according to an embodiment of the invention which has impacted an aircraft fuselage wherein the roof structure has deflected, avoiding damage to the aircraft;
FIG. 3 a is a side view of a cart according to FIG. 1 a;
FIG. 3 b is an end view of a cart according to FIG. 1 a;
FIG. 4 a is a side, cross-sectional view of a simplified flat top structure mounted to supports depicted in the normally upright position;
FIG. 4 b is a side, cross-sectional view according to FIG. 4 a illustrating deflected top structure and supports after a lateral impact;
FIG. 5 a is a side, cross-sectional view according to FIGS. 4 a and 4 b illustrating the support in its normally upright (solid lines) and in the deflected position (phantom lines) positions;
FIG. 5 b is a side, cross-sectional view of an alternate form of the support using an elastic tensioning means;
FIG. 6 is a partial side view of the main supporting wheels, a dead-man braking system and a hand-actuating handle as applied to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Having reference to FIG. 1, a utility cart 1 comprises a rigid frame 2 supported on main pneumatic wheels 3 and secondary casters 4 . The cart is about an airport tarmac 5 on wheels 3 and 4 . The cart's frame 2 is substantially a rectangular parallelepiped stick-frame construction of a mixture of round and square tubing. Significant use of aluminum tubing material aids in minimizing the cart's weight.
Referring to FIGS. 1 a and 3 a , the cart's frame 2 is supported upon the two main wheels 3 which are fitted with a braking system 6 . The main wheels are located near the cart's center of gravity G, supporting about 85% of the cart's weight and ensuring low-rolling resistance. The secondary casters 4 pick up the remaining 15% and enable ease of turning. Tertiary safety casters 7 are normally not in contact with the tarmac 5 may do so if the cart is rocked or if improperly loaded.
Two parallel baggage-supporting shelves 8 are arranged in the cart's frame 2 , covered by a roof 9 . The roof 9 is a substantially horizontal top structure 10 which has peripheral edges 11 which extend beyond the plan or periphery of the frame 2 . Preferably, the profile of the roof 9 is formed as an airfoil—i.e. having a convex upper curved surface or peak.
Accordingly, when wind or jet blast impinges on the cart 2 , the central positioning of the main support wheels 3 tends to balance the resulting rotational torque produced. Further, as the bulk of the cart's weight is on the braking wheels 3 , maximal sliding resistance is generated between the wheels 3 and the tarmac 5 . Finally, the wind also flows over the airfoil roof 9 , producing a downward force and thereby adding to the wheel's normal force and further aiding in resisting overturning and rotation.
The roof 9 may also be used as an additional baggage-supporting shelf (see FIG. 2) and thus is also capable of supporting typical baggage loads. The roof 9 can be fitted with a small rail to prevent baggage from sliding off (not shown).
As shown in FIG. 2, the top of the cart 2 is typically the point of first contact with objects such as an aircraft 12 . Accordingly, the top structure 10 is designed to deflect laterally and absorb the energy of any contact or impact having a lateral component.
Referring to FIG. 1 b , the roof of FIG. 1 a is alternatively replaced with a mere bumper frame 13 . As is the case with a roof-type structure 9 , the periphery 11 of the top structure 10 of the bumper frame 13 extends laterally from the plan of the frame 2 , so as to increase the probability that the bumper 13 will be the first to contact the aircraft 12 and thus absorb impact-energy. Additional resilient nosing material (not detailed) can be added to the periphery 11 to provide additional contact protection.
In any case, the top structure 10 is itself rigid, but is supported on movable supports 15 .
Having reference to FIGS. 4 a , 4 b and 5 a , each support 15 comprises a base 16 , formed in the frame 2 , a bottom plate 19 , a tubular member 18 , a top plate 17 and a tensioning means 20 . The top plate 17 is mounted to the top structure 10 . Three or more supports 15 are provided so that the top structure 10 remains substantially horizontal when deflected laterally (FIGS. 2 , 4 b ) thereby preventing spillage of any supported baggage.
The tensioning means 20 extends between the top plate 17 and the bottom plate 19 , elastically sandwiching the tubular member 18 therebetween. The tubular member 18 is a tubular body having a bore 21 and parallel right planer top and bottom ends 22 , 23 . The top plate 17 has a planer surface 24 and the bottom plate 19 has a planer surface 25 which is parallel to and faces the top plate's planer surface 24 . The tubular member's planer top and bottom ends 22 , 23 are complementary to the top and bottom plate planer surfaces 24 , 25 . Without further structure, a vertical load on the top plate 17 is supported by the tubular member 18 and bottom plate 19 . Practically however, such an arrangement is unstable and slight lateral movement causes the tubular member 18 and the supported top structure to collapse side ways.
Accordingly, the tensioning means 20 comprises an elongated connector or cable 26 extending between the top and bottom plates 17 , 19 and through bore 21 , increasing the support's overall stability. Typically, the cable 26 is formed of wire rope which is substantially inextensible, but is weak laterally so that it may be readily deflected to the side.
The cable 26 has top and bottom ends 27 , 28 , the top end 27 being secured to the top plate 17 . The cable 26 extends through the bore 21 and through the bottom plate 19 . The bottom end 28 of cable 26 is affixed to the bottom of a compression spring 30 . The compression spring 30 is preloaded by sandwiching it between a spring stop 31 , which bears against the bottom plate, and the bottom end 28 of the inextensible cable 26 . For assembly purposes, the spring stop 31 is installed within the bore of a tubular portion of the frame 2 and affixed therein using a retaining pin 32 .
As shown in FIG. 4 b and the shadow lines in FIG. 5 a , upon lateral deflection of the top structure 10 , such as from impact, the tubular member 18 pivots and the tensioning means 20 absorbs the energy of the deflection.
It can be seen that use of a tensioning means 20 which extends through the bore 21 of the tubular member 18 also guides the member and prevents its dislodging from the top and bottom plates 17 , 19 . However, a more preferred arrangement is to provide a centrally-located protuberance 33 in the center of each of the top and bottom plates 17 , 19 . Accordingly, the bore 21 of the tubular member 18 is constrained substantially concentric with the top and bottom plates 17 , 19 , ensuring its return to its original upright position when the deflecting force is removed.
As stated above, incidents of accidental impact can be minimized if the cart 2 is not able to move except when consciously operated. To that end, a dead-man braking system 6 is provided. If an operator is not actively moving the cart 2 then the braking system 6 engages, positively locking the wheels 3 which then must skid if the cart 2 is to move at all.
As shown in FIG. 6, the braking system 6 utilizes latch-type brakes 40 fitted to each of the two main wheels 3 , and a hand-release push-handle or actuator 41 . Each brake 40 comprises a disc 42 co-rotating with each wheel 3 . A plurality of circumferentially-spaced index slots 43 are cut radially into the disc 42 . A spring-loaded latch 44 radially engages the slots 43 to positively prevent disc and wheel rotation. The latch 44 extends from a lever 45 , pivoted from the frame 2 . A spring 46 is affixed to the lever for biasing the latch into engagement with the disc slots 43 . The push-handle actuator 41 is connected to the lever using a release cable 47 . The release cable 47 is wrapped around a cam 48 on the actuator 41 . When the push-handle actuator 41 is rotated for pushing operation of the cart 2 , the rotation is converted into a release cable-pulling action. The release cable 47 extends about a pulley 49 and runs beneath the cart 2 to the brake's levers 45 . For operating the brakes 40 simultaneously, a bar and V-yoke 50 (not detailed) connects both levers 45 for both brakes 40 and the release cable 47 connects to the apex of the yoke 50 .
The apparatus of the invention may be employed whether the cart 2 is standing or is moving. When moving, the operator rotates the push-handle actuator 41 for releasing the brakes 40 and pushes or pulls the cart 2 which can subsequently impact an object 12 . When standing, the brakes 40 are positively engaged, minimizing the opportunity for the cart to move, but if it does skid, or another object 12 moves into contact with it, the structure 10 on the novel cart deflects.
When an impact of the top structure 10 results in a lateral force component, the top structure deflects laterally, rotating the supports 15 for absorbing the impact energy. Lateral deflection causes the tubular member 18 to rotate, laterally bending the cable 26 causing each top plate 17 to pull their respective cables 26 , drawing each cable 26 upwardly through their bottom plate 19 . The bottom end 28 of each inextensible cable 26 compresses its spring 30 , increasing the spring's compression and the tension in the cable 26 for producing increased resistance to deflection as the support 15 rotates. Depending upon whether baggage is also being carried on the top structure 10 it may or may not self-right itself under the increased tension in the cable 26 .
An example of a utility cart which is based upon the above elements is a 1.34 m high, 2.34 m long by 0.84 m cart, constructed substantially of 6061 T-6 aluminum and having a tare weight of about 85 kgs. With two shelves, the cart has a capacity of about 350 kgs and can be manipulated by one person. Fitted with latch-type brakes on the two main pneumatic wheels and using an airfoil roof as the top structure, the cart is stable in a 100 kph wind. Wind effect and stability is obviously a function of the nature and arrangement of the baggage on the cart.
As shown in FIG. 5 b , other tensioning means such as a low-creep elastic cord 51 could be utilized for tensioning the supports, thereby replacing both the inextensible cable and the compression spring.
While various embodiments to the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention as set forth in the following claims.
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A utility cart is provided which minimizes damage caused by impact with objects, particularly for use on a windy airport tarmac, the cart comprising a frame having main wheels bearing most of the cart's weight, these main wheels being fitted with latch-type brakes. The cart has a top structure, such as a roof, which extends horizontally above the frame, the periphery of which approximates or extends beyond the periphery of the frame. The top structure is normally supported above the cart's frame using three or more laterally collapsible supports for permitting the top structure to be displaced laterally while remaining substantially horizontal so as to minimize energy transfer upon lateral impact of the periphery of the top structure with an object. Each of the preferred collapsible supports comprises a tubular member elastically sandwiched between top and bottom plates mounted to the top structure and frame respectively.
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BACKGROUND
[0001] The present disclosure relates to a flushing unit, and more particularly, to a flushing unit cap assembly particularly suited for flushing vapor compression systems, such as HVAC and refrigeration systems.
[0002] Air conditioning and other systems require periodic flushing of refrigerants and/or contaminants such as during retrofits, refrigerant conversions and compressor burnouts, as well as for periodic maintenance. Non-flammable flushing solvents are typically used, that are generally compatible with CFC and HFC refrigerants and compressor oils. Such solvents must comply with stringent EPA Significant New Alternatives (SNAP) standards, and are capable of removing particulates, sludge, residue oil, moisture and acid from line sets and other system components.
[0003] For example, replacement of an air conditioner or heat pump and the concominant upgrade from R-22 to R-410A refrigerant can cause compatibility problems, as the mineral oil used in R- 22 systems is not compatible with the R-410A refrigerant and oil. R-22 is a hydrochlorofluorocarbon (HCFC), and the presence of chlorine results in the HCFC having an affinity for mineral oil. In contrast, R-410A is a hydrofluorocarbon (HFC) and has no affinity for mineral oil. Any mineral oil remaining in the system tends to hang up in the refrigerant lines and other system components. This reduces efficiency and can cause unwanted chemical reactions with R-410A refrigerant. It is also important to rid the system of moisture, since moisture can break down the synthetic oil used with R-410A and minimize or eliminate its lubrication properties, causing the compressor to fail.
[0004] Accordingly, systems have been developed that allow for the quick and easy flushing of HVAC and refrigeration system line sets and system components with flushing agents under pressure. However, safety concerns arise, as the cylinder containing the flushing agent can be inadvertently over-pressurized. This can result in explosion, causing personal and/or property damage.
SUMMARY
[0005] The problems of the prior art have been overcome by the assembly and apparatus set forth herein. In certain embodiments, a flushing unit includes a pressure relief member to ensure that the reservoir containing the flushing agent is not over-pressurized. In certain embodiments, the flushing unit is adapted to be in communication with a driving fluid or propellant, such as an inert gas or a flushing gas, and with a source of a flushing agent, such as a reservoir, which can be a refillable cylinder. The flushing unit includes a valve that, when opened, causes the driving fluid to flow into the reservoir containing the flushing agent and displace the flushing agent from the reservoir, causing it to ultimately flow into the system being flushed such as via a suitable hand-held injector. In the event the pressure in the reservoir exceeds a predetermined level, a pressure relief valve in the flushing unit is automatically actuated, thereby relieving pressure in the otherwise closed system. The flushing unit can be used with compression systems including but not limited to evaporators, condensers and line sets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front view of a flushing unit attached to a flushing agent cylinder in accordance with certain embodiments;
[0007] FIG. 2 is a front view of a flushing unit shown with a dip tube attached in accordance with certain embodiments;
[0008] FIG. 3 is a top view, partially exploded, of a flushing unit in accordance with certain embodiments;
[0009] FIG. 4 is a side cross-sectional view of a cap for a flushing unit in accordance with certain embodiments;
[0010] FIG. 5 is a top view, partially in section, of a cap for a flushing unit in accordance with certain embodiments;
[0011] FIG. 6 is a side view of a hose connection for a flushing unit in accordance with certain embodiments;
[0012] FIG. 6A is a front view of the hose connection of FIG. 6 in accordance with certain embodiments;
[0013] FIG. 7 is a side view of a flare connector for a flushing unit in accordance with certain embodiments;
[0014] FIG. 7A is a front view of the flare connector of FIG. 7 in accordance with certain embodiments;
[0015] FIG. 8 is a cross-sectional view of a safety valve cap for a flushing unit in accordance with certain embodiments;
[0016] FIG. 9 is a side view, partially in section, of a ball valve for a flushing unit in accordance with certain embodiments; and
[0017] FIG. 10 is a side view of a biasing member seat holder in accordance with certain embodiments.
DETAILED DESCRIPTION
[0018] Suitable flushing agents are not particularly limited, and include commercially available solvents in which contaminants are soluble or miscible, such as terpenes, esters, polyalkylene glycols, polyol esters, polyvinyl ethers, etc. The flushing agent may include one or more cleaning agents. Suitable driving fluids or propellants for forcing the flushing agent out of the reservoir and into the vapor compression system include inert gases. A preferred driving fluid is compressed nitrogen, most preferably dry nitrogen.
[0019] Turning to the drawings, where like numerals indicate like elements, FIG. 1 shows a flushing agent reservoir 10 , which in the embodiment shown is an aluminum cylinder. The reservoir 10 can be refillable, such as via an inlet in the reservoir 10 , or can be a single use reservoir that is disposed of when emptied. The reservoir 10 includes an opening 12 , providing access to the interior of the reservoir. In the embodiment illustrated, the opening 12 has internal threads (not shown), which can mate in sealing relationship with corresponding external threads 13 on connecting member 16 of the cap 20 of flush unit 15 . An O-ring 14 can be carried in the annular groove 18 of connecting member 16 to ensure an effective seal between the cap 20 of the flush unit 15 and the reservoir 10 . Those skilled in the art will appreciate that other means of sealingly attaching the flush unit 15 to the reservoir 10 can be used, and that the threaded connection illustrated is merely exemplary.
[0020] Turning now to FIG. 4 , there is shown an embodiment of the cap 20 . In the embodiment shown, cap 20 includes a first radial bore 21 and a second opposing radial bore 22 . Preferably each radial bore 21 , 22 is internally threaded, as shown. Bore 21 has an internal diameter configured to receive externally threaded hose connector 30 ( FIG. 6 ). Radial bore 21 is in fluid connection with axial bore 23 via axial passageway 24 . Passageway 24 preferably has an internal diameter slightly smaller than the internal diameter of axial bore 23 . Radial bore 22 has an internal diameter configured to receive externally threaded member 44 of ball valve 50 ( FIG. 9 ). Radial bore 22 is in fluid communication with axial bore 27 via axial passageway 28 . Passageway 28 preferably has an internal diameter slightly smaller than the internal diameter of axial bore 27 .
[0021] FIG. 5 illustrates a third radial bore 32 in cap 20 having a longitudinal axis X that is perpendicular to the plane defined by the longitudinal axes Y and Z of axial bores 23 , 27 and is also perpendicular to the coaxial longitudinal axes of radial bores 21 and 22 . The radial bore 32 is preferably internally threaded and configured to receive pressure relief valve 35 ( FIG. 3 ) described in further detail below. The bore 32 tapers radially inwardly to narrow passageway 33 , which extends between radial bores 21 , 22 and has an inlet in fluid communication with radial bore 22 at 34 .
[0022] Turning to FIGS. 2 , 6 and 6 A, hose connector 30 is shown. Connector 30 includes a hexagonal flare 31 for facilitating attachment of the connector to the radial bore 21 by rotation, such as with the aid of a wrench. Extending from the flare 31 is an externally threaded member 36 configured to receive a hose (not shown) that is in fluid communication with a dispensing or injecting device such as a blow gun (not shown). Also extending from the flare 31 coaxially with member 36 but in an opposite direction is an externally threaded member 37 configured to be received by radial bore 21 in cap 20 . The hose connector 30 has a central passageway 38 ( FIGS. 6 and 6A ) providing fluid communication between the connected hose and the radial bore 21 in cap 20 .
[0023] Ball valve 50 connects to cap 20 via externally threaded member 44 , which threads into radial bore 22 such as by rotation. As partially shown in phantom in FIG. 9 , ball valve 50 has a longitudinal passageway 51 , preferably centrally located, that can be opened or closed by actuation of lever 52 , causing semi-spherical member 53 to enter the passageway 51 , thereby allowing or blocking fluid flow through the passageway 51 . Those skilled in the art will appreciate that although a ball valve is shown, other valve types allowing selective fluid communication therethrough are within the scope of this disclosure. The longitudinal passageway 51 expands to an internally threaded inlet 54 that is configured to receive externally threaded member 46 of flare connector 43 ( FIGS. 7 and 7A ). Opposite coaxial externally threaded member 46 is a larger diameter externally threaded member 49 , which is configured to be in fluid communication with a source of flushing fluid such as nitrogen via suitable hosing, for example. The flare connector 43 includes a longitudinal passageway 45 , shown in phantom in FIG. 7 , allowing fluid flow therethrough.
[0024] As best seen in FIGS. 1 and 2 , a dip stick 55 is coupled to axial bore 23 of cap 20 , such as by press fitting. The dip stick 55 is a generally cylindrical elongated hollow tube. The length of the dip stick 55 should be sufficient to extend into reservoir 10 and be immersed in the fluid contained therein when in the assembled state, providing fluid communication between the interior volume of reservoir 10 and hose connector 30 via axial passageway 24 and radial bore 21 .
[0025] FIG. 3 illustrates the pressure relief valve assembly 35 in accordance with certain embodiments. The assembly 35 includes a generally cylindrical relief cap 61 , also shown in FIG. 8 . Relief cap 61 has a generally hollow interior 66 , and includes a head 62 having an aperture 63 that is preferably hexagonal so as to receive an Allen wrench for facilitating rotation thereof to secure the relief cap 61 in the axial bore 32 of cap 20 . The relief cap 61 also includes one or more ports 64 positioned on the side wall of the relief cap 61 . Preferably two diametrically opposed ports are present and are positioned so that when the relief cap 61 is coupled to the cap 20 , at least a portion of a port 64 is open to ambient. The port or ports 64 extend radially inwardly of externally threaded portion 65 as shown, and allow fluid communication between radial bore 22 and the ambient, via radial passageway 33 and radial bore 22 ( FIG. 5 ). The externally threaded portion 65 of relief cap 61 is configured to mate with the internal threads of radial bore 32 in cap 20 .
[0026] Relief valve assembly 35 also includes biasing member 70 , which is preferably a compression spring that is positioned during operation in the generally hollow interior 66 of the relief cap 60 . The biasing member 70 seats on seat holder 72 , best seen in FIG. 10 . The seat holder 72 includes a generally cylindrical portion 73 , preferably chamfered at its top, that has an outer diameter slightly smaller than an inner diameter of the biasing member 70 . An annular flange 74 extends radially outwardly from the base of the portion 73 , and preferably has a diameter substantially the same as the outer diameter of the biasing member 70 . Accordingly, the biasing member is supported on the flange 74 , with the portion 73 extending into the interior of the biasing member 70 when in the assembled condition. Extending axially from the flange 74 is a tapered portion 75 . Portion 75 tapers radially outwardly towards its free end 76 a distance sufficient to carry sealing member 77 , which is preferably an O-ring.
[0027] When the relief valve assembly 35 is in its assembled condition in cap 20 , in its normal (closed) state biasing member 70 forces seat holder 72 (and sealing member 77 ) against the opening between axial passageway 33 and axial bore 32 , blocking flow out of the passageway 33 . However, if the pressure in radial bore 22 is sufficient to overcome the force of the biasing member 70 , that pressure forces the seat holder 72 radially outwardly, thereby opening the pressure relief valve and allowing fluid communication between the axial passageway 33 , the axial bore 32 , and out the one or more ports 64 in relief cap 61 to ambient. As a result, the reservoir 10 is protected from over-pressurization. Those skilled in the art will appreciate that the biasing member 70 is thus selected to have a spring constant such that over-pressurization is prevented. A suitable spring constant is one where a pressure of about 200 - 210 psi is sufficient to overcome the bias of the biasing member 70 .
[0028] In operation, a suitable driving fluid or propellant such as nitrogen is placed in fluid communication with the flush unit 15 such as with suitable refrigeration hosing connecting to the inlet side (flare connector 43 ) of the ball valve 50 . The driving fluid is generally provided in a pressure regulated compressed gas cylinder having a valve. The cap 20 of the flush unit 15 is coupled to the flushing agent reservoir containing flushing agent, with dip stick 55 extending into the interior of the reservoir a sufficient distance so that it's open end is immersed in the flushing agent. The hose connector 30 is coupled to suitable hosing, which feeds an injector such as a blow gun or the like configured to introduce flushing agent into the compression system to be flushed. The pressure regulator on the driving fluid cylinder is set to a suitable pressure, such as 50-60 psi, and the ball valve 50 is opened slowly to pressurize the reservoir 10 . Driving fluid thus flows through the ball valve 50 into cap 20 via radial bore 22 , and into the reservoir via axial passageway and axial bore 27 . Once the reservoir 10 is properly pressurized, the ball valve 50 (and the valve on the driving fluid compressed cylinder) can be closed and the driving fluid connection can be disconnected from the ball valve inlet. The reservoir 10 is now pressurized for use.
[0029] In the event too much pressure (e.g., exceeding about 200-210 psi) is provided to the assembly, the excess pressure biases against biasing member 70 in the pressure relief assembly 35 , forcing the seat holder 72 radially outwardly and thereby relieving pressure through the ports 64 in the valve cap 61 .
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A flushing unit for flushing vapor compressions systems with a flushing agent. The flushing unit includes a pressure relief member to ensure that the reservoir containing the flushing agent is not over-pressurized. In certain embodiments, the flushing unit is adapted to be in communication with a driving fluid or propellant, such as an inert gas or a flushing gas, and with a source of a flushing agent, such as a reservoir. The flushing unit includes a valve that, when opened, causes the driving fluid to flow into the reservoir containing the flushing agent and displace the flushing agent from the reservoir, causing it to ultimately flow into the system being flushed such as via a suitable hand-held injector. In the event the pressure in the reservoir exceeds a predetermined level, a pressure relief valve in the flushing unit is automatically actuated, thereby relieving pressure in the otherwise closed system.
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RELATED APPLICATIONS
[0001] This application is a U.S. national phase application under 35 U.S.C. §371 of International Application Number PCT/EP2012/053595 filed Mar. 2, 2012 with claiming priority of Switzerland Application Number 00402/11 filed Mar. 9, 2011.
TECHNICAL FIELD
[0002] The present invention relates to an arrangement for climbing, for example, high-voltage and wind-turbine towers where at least extensive vertical distances must be overcome and to a method for climbing an, for example, high-voltage or wind-turbine tower.
BACKGROUND
[0003] Increased safety requirements are in force for maintenance and repair work on high towers, such as, for example, high-voltage power line towers, towers for wind installations and the like, and therefore complicated and expensive lift or ladder systems have to be arranged in or on said towers. However, it is hazardous to climb up and down ladders, and an investigation by Darmstadt Technical College, for example, revealed that approx. 70% of the accidents have taken place in conjunction with the climbing of ladders which are fixedly fitted, such as, for example, on the high-voltage towers mentioned.
[0004] The prior art describes a series of what are referred to as climbing aids which are proposed in order to climb high objects. For example, DE 102 01 965 describes a device for covering distances directed vertically upward. This describes a climbing aid which is actuable by means of muscular power and is movable up and down in the manner of a caterpillar on a ladder attached in a fixed position. Further climbing aids are described, for example, in U.S. Pat. No. 3,968,858, U.S. Pat. No. 4,310,070 and in WO2007/051 341.
[0005] Furthermore, U.S. Pat. No. 4,828,072 describes a rescue device, such as a rescue ladder or a rescue lift which can be moved up and down on a sliding surface designed in the manner of a rack on a house façade. In this case, the person who is to be rescued is held on the slider or lift by means of a strap system, wherein, furthermore, automatically responding braking systems are provided in order to permit safe rescue of a person. For the 500 000 high-voltage towers erected in Germany alone, a system of this type is not suitable, since it is too complicated, too expensive and also too awkward in operation.
[0006] Finally, WO 2005/016 461 describes an arrangement for climbing up and/or down, for example, high-voltage towers, wherein the climbing primarily takes place by means of two separate climbing consoles which can be used both manually and also by means of a motor drive. According to one variant embodiment, it is even proposed to operate the two climbing consoles coupled together as a lift.
[0007] All of the known systems have the disadvantage that, because of the exacting safety requirements, climbing, for example, of the high-voltage towers mentioned is very time-consuming and laborious, and the systems are too expensive in particular in respect of the anticipated costs, especially during operation.
[0008] A further disadvantage resides in the fact that the climbing devices or lifts are heavy in terms of weight, and therefore use on different towers necessitates laborious transportation from one tower to the next, for example with a transport vehicle.
SUMMARY
[0009] It is therefore an object of the present invention to propose a device which is cost-effective, is simple to install and is also simple to use and permits rapid, safe and uncomplicated climbing in particular of the high-voltage towers mentioned.
[0010] A further object consists in proposing a climbing device which is autonomous of, for example, climbing profiles arranged on the tower, is usable on different towers and is mobile and is easily transportable.
[0011] An arrangement is proposed for climbing towers, such as, in particular, high-voltage towers, towers of wind installations, such as for wind turbines, high buildings, high-bay warehouses, etc., which arrangement has a longitudinally extended, rail-like profile or guide member, and also at least one portable, mobile lift element which is fastenable re-releasably to the profile or guide member, consists of a driving part which is movable up and down along the profile or guide member and of a platform for receiving at least one person or loads, wherein the drive of the driving part is feedable by an energy accumulator arranged in the lift element or by an external power source, such as a storage battery, a battery or via a power transmission member.
[0012] The storage battery or the battery can be arranged in the lift element, preferably in the platform, so as to be removable again.
[0013] According to one alternative embodiment, it is proposed that the platform is connected to the driving part so as to be removable again.
[0014] In turn according to one alternative embodiment, it is proposed that the lift element is partially composed of lightweight construction materials, such as fiber-reinforced composite materials, aluminum, aluminum alloys and/or the like, in order to guarantee the portability as a whole or in parts.
[0015] According to a further alternative embodiment, it is proposed that the rail-like profile is of U-shaped design, V-shaped design or is designed extensively rectilinearly in the form of a band, and the driving part has securing members which engage laterally around the profile, as seen in the longitudinal direction, and are latchable in a fixing position in order to ensure secure holding of the driving part on the profile.
[0016] Furthermore, it is proposed that at least one gearwheel is provided on the driving part for the transmission of force from the drive to the profile which has perforations or openings which run in the longitudinal direction and are in the manner of a rack.
[0017] Furthermore, it is proposed that at least one emergency stopping member which is latchable into the rack is provided on the driving part, said emergency stopping member being operatively connected to a position, motion and/or speed sensor.
[0018] In turn according to a further alternative embodiment, it is proposed that the rail-like profile consists of at least two or more joinable or pluggable-together profile elements, having a rack division running in the longitudinal direction. Longitudinally running pattern elements are arranged in at least one wall of each profile element, with a uniformly spaced pattern of holes corresponding to the rack division. A connecting element is provided between every two profile elements, with a further wall provided in order to bear against the wall of each profile element and with further patterns of holes which likewise run longitudinally and are congruent to the pattern of the holes, said patterns of holes therefore being spaced in a corresponding manner. Profile elements and the connecting element are fixedly connected to one another by means of rivets, pins, screws and the like, which are arranged in the perforations of the patterns of holes, in such a manner that the rack division merges in an unchanging manner from one profile element to the other.
[0019] Instead of the longitudinally extended profile, the lift element can be moved upward and downward on a guide member, such as a pillar, one or more rod elements or one or more wire cables.
[0020] In turn, it is furthermore proposed that the securing members, such as, for example, sliding rollers, are automatically lockable or foldable inward, in each case engaging laterally behind the profile or guide member, when the driving part is placed against the profile or guide member.
[0021] Further alternative embodiments of the arrangement according to the invention are characterized in dependent claims.
[0022] A method for climbing towers, such as, in particular, high-voltage towers, towers for wind installations and the like, is furthermore proposed, wherein, on a longitudinally extended, rail-like profile or guide member fastened to the tower, a lift element, which is autonomous of the profile or guide member and is removable again, is arranged on the profile, which lift element is arranged fixedly on the profile by means of latchable securing members engaging laterally in each case behind the profile or guide member. A platform which is connected re-releasably to the driving part is accessed by at least one person, or is loaded with a load, and the driving part is fed/activated by an energy accumulator, such as a storage battery or a battery or by an external power source, in order to move upward on the tower by way of the profile, wherein the energy accumulator is optionally arranged in the lift element.
[0023] Alternative embodiments of the method according to the invention are characterized in dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention is now explained in more detail by way of example and with reference to the attached figures, in which:
[0025] FIGS. 1 a and 1 b show the lift element according to the invention in two different perspective views,
[0026] FIG. 2 shows the lift element according to the invention in figures a and b, likewise in a perspective view, and arranged on the longitudinally extended, rail-like profile together with an operator,
[0027] FIG. 3 shows, in a schematic perspective, two rail-like profiles which are to be connected and a connecting element provided for the connection,
[0028] FIG. 4 shows the lift element according to the invention dismantled into the most important component parts, including a detail of the rail-like profile,
[0029] FIG. 5 shows the driving motor schematically in a perspective of the lift element according to the invention,
[0030] FIG. 6 shows the platform of the lift element in a perspective view,
[0031] FIG. 7 shows schematically, with reference to figures a to d, the fixed arrangement of the lift element on the rail-like profile,
[0032] FIGS. 8 a and 8 b show, schematically in section, the manner of operation of an emergency stopping member of the lift element,
[0033] FIG. 9 shows an operating console of the lift element schematically in perspective,
[0034] FIGS. 10 a to 10 c schematically show the mobile units of the lift element,
[0035] FIG. 11 shows, schematically and in perspective, a fastening element for fastening the rail-like profile to a tower, and
[0036] FIG. 12 shows the illustration of a person climbing up a tower along the rail-like profile by means of the lift element according to the invention.
DETAILED DESCRIPTION
[0037] FIG. 1 shows, in perspective, two different views of the lift element 1 according to the invention which is provided in order to serve, for example, for the ascent and descent of a person when carrying out repair work to high-voltage towers. The lift element 1 according to the invention primarily has two main parts, namely a driving and guide part 3 and a platform 5 , provided in order to serve as a base for a person or a load.
[0038] FIG. 2 , in turn in two perspective views, illustrates the lift element 1 mounted on the longitudinally extended, rail-like profile 7 . The driving part 3 is fixedly connected to the profile 7 , wherein the manner of the fastening will be discussed later on. A person 2 who has to climb up, for example, for carrying out repair or installation work on a high-voltage tower is located on the platform 5 which is connected to the driving part 3 . Finally, a fastening element or a fastening clamp 9 is provided on the profile 7 , by means of which the profile or guide member is fixedly arranged on the tower. Of course, instead of a platform, a seat can also be provided for the person.
[0039] FIG. 3 , in turn schematically and in perspective, illustrates how two profile elements are connected to each other in order to produce the entire rail-like profile along the high-voltage tower for the ascent or descent of the lift element and, for example, of the person who has to use the lift for carrying out repair work. The two profile elements 101 ′ and 101 ″ illustrated in FIG. 3 have a U-shaped cross section with longitudinal tubes 115 ′ and 115 ″ arranged in the corners of the U-shaped profile. As can clearly be seen in FIG. 3 , the profile elements 101 ′ and 101 ″ have a longitudinally running rack division 105 ′ and 105 ″ which is provided so that the driving part can be moved upward and downward along the profile by means of gearwheels engaging in the rack division. For the joining together of the two profile elements 101 ′ and 101 ″, it is now essential for the rack division 105 ′ and 105 ″ to be continued from one profile to the next in a consistently spaced manner. For this reason, the use of at least one connecting element 121 is proposed in order to guarantee the consistent spacing of rack division 105 ′ and 105 ″. The two profile elements have patterns of holes 111 ′ and 111 ″ which run longitindally in two lateral limb surfaces 109 ′ and 109 ″ and have individual perforations 113 ′ and 113 ″. Patterns of holes 125 which likewise each run in the longitudinal direction and have individual perforations 127 are provided in the two side limbs 123 of the connecting element 121 which is likewise formed in a U-shaped manner mirror-symmetrically with respect to the two profiles. The individual perforations 127 have an at least approximately identical hole cross section as the perforations 113 ′ and 113 ″ and, in addition, are spaced identically. The patterns of holes are oriented lying precisely on one another, as a result of which a connection of the connecting element 121 to the two profile elements 101 ′ and 102 ′, for example, with the rivets 129 illustrated in FIG. 3 is then made possible. The rivets can be inserted in a very simple manner, for example, by means of a “storage battery-operated rivet gun”. The fact that the rack division 105 ′ and 105 ″ is continued at a uniform spacing from one profile to the next is achieved by the distance between the perforations in the side walls being aligned with the individual perforations 107 ′ and 107 ″ of the rack division 105 ′ and 105 ″ and, in addition, being spaced analogously. The connection of two profile elements that is illustrated in FIG. 3 is furthermore described in detail in WO 2009/034 010, the content of which is hereby included as part of the present invention. The profile elements 101 ′ and 101 ″ are plugged together by means of pins 133 .
[0040] FIG. 4 schematically illustrates the individual parts of the lift element and part of the longitudinally extended, rail-like profile 7 . The driving part 3 has, for example, two motor units 15 ′ and 15 ″ which serve to move the lift element upward and downward along the rail-like profile 7 . The motor unit is discussed separately in more detail in FIG. 5 .
[0041] A head part 13 which has, inter alia, handles, operating elements, displays and speed sensors, etc., is provided at the upper end of the driving part. Said head part is discussed in more detail in FIG. 9 . Various elements required for operating the driving part, such as safety relay, controller, radio, emergency stopping members, etc., are arranged in an electronic housing 19 with a cover 21 . FIG. 4 schematically illustrates two emergency stopping members 19 , the function of which is discussed in more detail in turn with respect to FIG. 8 . A platform support 23 , on which the platform 5 can be fixedly mounted, for example, by means of a mechanical or electric coupling, is provided at the lower end of the driving part. A holder for a battery or a storage battery, and also corresponding electronic charging means are provided in the platform 5 , which has a standing area for a person.
[0042] FIG. 5 illustrates, schematically in perspective, a driving motor 15 ′ or 15 ″, as seen in a view from the rail-like profile. Gearwheels 37 which can be connected, for example, to an integrated claw coupling are provided for the drive. The gearwheels 37 are driven by means of a driving motor which is laterally covered in each case by driving covers 31 . Running rollers 33 and 34 are provided for guiding the driving part or the lift element, wherein the running rollers 34 can each be pivoted about pivoting axes 42 , for example when the driving part is fixedly arranged on the rail-like profile or guide member. Cam-like pins 41 are provided for connecting the driving motor to the main housing or the electronic housing or for the connecting or the platform.
[0043] FIG. 6 shows the platform 5 illustrated from the lower side, for example with a transparent covering, thus enabling a storage battery cell 49 arranged in the platform 5 , for example lithium iron phosphate storage battery cells, to be visible. An electronic charging means is denoted laterally schematically by the reference number 47 , wherein, at the same time, a main switch can be provided in order to interrupt the power supply of the driving part. An electronic connection 51 to the driving part is provided on the front side of the platform 5 , and a limb 52 , in which a mechanical lock 45 can be arranged, is provided laterally in each case for the fastening to the driving part.
[0044] The advantage of this releasability of the platform 5 from the driving part resides in the fact that the storage battery can be removed at any time for charging together with the platform and can easily be transported, for example, by means of the handle 53 . The separation of the platform from the driving part also enables the entire lift element to be able to be transported substantially more simply, since two easily portable elements are therefore provided, whereas the entire lift element would be rather difficult to transport manually. The separability of the platform also makes it possible to be able to use different storage batteries, in particular if one storage battery is defective or if a new generation of storage batteries is intended to be used.
[0045] It is now schematically illustrated with reference to FIG. 7 how the lift element according to the invention is intended to be fixedly positioned on the rail-like profile 7 . The entire operation is illustrated schematically with reference to figures a to d.
[0046] FIG. 7 a shows the driving part 3 , as seen from above, i.e. the head part 13 with the operating element and the laterally protruding covers 31 of the driving motor are visible. The driving part 3 is intended now to be arranged fixedly on the rail-like profile 7 , in which a connecting element 121 is likewise visible, as are four longitudinal tubes 115 arranged in the corners of the profile. The profile 7 for its part, is arranged fixedly on a high-voltage tower 6 via an installation element 9 . For the fixed arrangement of the driving part 3 , two guide rollers 34 which are pivoted away laterally and engage laterally around the rail-like profile upon installation are provided.
[0047] First of all, as illustrated in figure b, the driving part is guided towards the rail-like profile 7 until the two longitudinal tubes 115 , which are located closer to the driving part, engage in the two running rollers 33 . Upon pressing against the rail-like profile 7 , the two running rollers 34 which are further away and engage around the two outer longitudinal tubes 115 , are automatically pivoted inward, as illustrated in figure c, in order to connect the driving part fixedly to the profile. At the same time as the inward movement, the rollers 34 are automatically latched, thus making it impossible to remove the driving part from the profile 7 .
[0048] If the driving part 3 is now arranged fixedly on the profile 7 , the platform 5 can also be connected to the driving part 3 , which is illustrated schematically in the two figures c and d. It is also provided during the arrangement of the platform 5 that the mechanical lock 45 , which is described with respect to FIG. 6 , automatically latches, thus making it impossible to remove the platform 5 . In the illustration according to FIG. 7 d , the lift element is fixedly connected to the profile 7 , and therefore, for example, an engineer can now climb a high-voltage tower.
[0049] FIGS. 8 ( a and b ) illustrates an important safety element which guarantees that an uncontrolled movement of the driving part on the rail-like profile is impossible. In particular, it is intended to be made impossible for the lift element to be moved downward in an uncontrolled manner and to be able to overshoot the upper or the lower end of the rail-like profile, likewise in an uncontrolled manner.
[0050] FIG. 8 a shows the pawl 151 in the rest state, freely movable in a mounting 152 and latched by the spring 153 into the grid structure 105 of the rail 101 . As a result, the driving part 3 is fixedly connected to the rail 101 —the lift cannot move. In the event of an emergency, the power supply to the pawl drive (magnet) 154 is interrupted and the spring 153 automatically pushes the pawl 151 into the grid structure 105 of the rail 101 .
[0051] FIG. 8 b shows a drive with energized magnet 154 , tensioned spring 153 and retracted/tensioned pawl 151 . During normal and undisturbed travel of the lift, the pawl 151 is tensioned in said rear position and the lift can move freely.
[0052] FIG. 9 shows the head part 13 according to FIG. 4 in detail with the various members and elements arranged thereon. An emergency push button switch 61 is provided at the top in the center and can be used to trigger an emergency braking of the driving part or lift element. It is also possible to see, for example, an ultrasonic sensor 63 for remote operation. The head part 13 has laterally a protective panel 625 , on which handles 75 are provided laterally so that a person in the lift can hold thereon. A rocker push button switch 73 for downhill or uphill travel is likewise provided laterally. Of course said rocker push button switch can be arranged laterally on the left and/or right.
[0053] Further operating elements 67 are provided for the operation of the lift element.
[0054] Various operating and operationally-relevant data, which are settable by means of further operating elements 71 , can be displayed on a display 69 . Various menus can also be selected with said operating elements 71 in order to display a very wide variety of information on the display 69 .
[0055] Finally, connecting pins 77 are provided for connecting the head part or the head console 13 to the driving housing.
[0056] FIG. 10 shows once again schematically the various parts of the lift element, wherein, in FIG. 10 a , the driving part 3 and the platform 5 are separated from each other for the transportation. For the operation, the platform 5 and the driving part 3 are connected to each other, and, according to FIG. 10 c , it is furthermore possible to arrange clip-on wheels laterally, for the transportation of the lift element, if the platform and the driving part are not intended to be separated.
[0057] FIG. 11 illustrates how the rail-like profile 7 can be fastened, for example, to a high-voltage tower by means of the fastening member 9 . As is known, in the region of two profile parts 101 butting against each other, the rail-like profile 7 has a connecting element 121 on which the fastening member can now be fixedly arranged by means of screw connections 143 . On the side opposite the profile, the fastening member 9 has a hole-like opening 145 , by means of which the profile can be fitted to the high-voltage tower in turn by means of, for example, a screw connection.
[0058] FIG. 12 finally shows, with reference to a basic view, how a person 2 can climb a high-voltage tower or a tower of a wind installation, or can descend therefrom again, along the rail-like profile 7 by means of the lift element 1 according to the invention. The lift element 1 according to the invention, consisting of the driving part 3 and the platform 5 , is used by a person 2 in order to move up a high-voltage tower 6 along the rail-like profile. It is essential here for the person to wear, for example, a helmet 84 and to be secured by means of a strap 85 , wherein the buckling-up of the strap can be ensured, for example, by means of a monitoring means 87 . The operation of the lift element is preferably coupled to said monitoring sensor in such a manner that the lift can be operated only when a person is buckled up. Further monitoring elements can be provided in order to ensure overloading of the platform is indicated by means of a load sensor 89 , in order to monitor the operation by means of a speed sensor 91 arranged, for example, in the region of the platform, etc.
[0059] The elements, profile parts and parts of the lift element etc., which are illustrated with reference to FIGS. 1 to 12 , merely constitute examples for better explanation of the present invention. Of course, the design can be adapted to the particular requirements, and the lift element illustrated according to the invention can be supplemented by further components. The configuration of the rail-like profile can also differ; the U-shaped configuration merely constitutes one example. Instead of the rail-like profile which is mentioned and is described in the figures, guide members configured in another manner are also conceivable for the upward and downward movement of the lift element described. For example, a stand-like guide member or single- or multi-part rod-like guide members, on which the lift element can be fastened and moved, is/are conceivable. However, guide cables arranged fixedly on, for example, high-voltage towers may optionally also be suitable for the re-releasable attachment of the lift element described according to the invention.
[0060] It is advantageous that the lift element can be at least in two parts, consisting of a driving part and a platform which is connectable re-releasably to the driving part. The lift element is intended to be independent, portable and mobile and to be brought from use location to use location (a plurality of fixedly installed rails). With regard to the portability, reference should be made to the respective legal regulations defining appropriate specifications, such as, for example, a weight of a maximum of 30 kg. The mobility is further assisted by the lift element being manufactured in a lightweight construction, for example by using lightweight construction materials, such as aluminum, aluminum alloys, fiber-reinforced composite materials, etc. It is also desirable for the drive to be fed by a storage battery or a fuel accumulator which is arranged on the lift element itself in order to guarantee complete autonomy of the lift element from the rail-like profile or guide member. Finally, it should be mentioned that the operation of the lift element can also take place by wireless remote control, that is to say, the drive can be operable by remote control.
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An arrangement for overcoming heights or vertical distances, such as, in particular, high-voltage towers, towers for wind installations, buildings, high-bay warehouses, etc., has a longitudinally extended, rail-like profile ( 7 ) or guide member, and at least one portable lift element which is fastenable re-releasably to the profile, consisting of a driving part ( 3 ) which is movable up and down along the profile or guide member and a platform ( 5 ) for receiving at least one person or loads.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/460,774, filed Dec. 8, 2011, and entitled ENERGY MONITORING AND UTILIZATION ENHANCEMENTS. The entirety of this application is incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure generally relates to enhancing premises monitor and/or control, for example, by facilitating enhanced features, convenience, and/or accessibility in connection with premises monitoring or control.
BACKGROUND
[0003] Existing home energy control and automation technology, or other premises monitor and control, was architected to operate relatively independently of other devices or technology. For example, such premises monitor devices are not designed to offload or share processing loads, share data storage, or otherwise interact with other systems or devices for which such might be beneficial. Likewise, conventional devices are not architected to take advantage of being part of a remote access networked system. As a result, most such devices have limited feature sets and/or high costs for the features that do exist.
[0004] For example, conventional thermostats or other premises monitor and control devices often rely upon legacy technology or outdated paradigms. As a result, programming or accessing these devices can be difficult and particularly counterintuitive to users who are much more familiar with modern paradigms and designs. Because these conventional devices are generally quite difficult to use, potential benefits, even if they exist, go unimplemented. For example, understanding the features and abilities of the thermostat can lead to energy-cost savings opportunities, can avoid unnecessary waste of natural resources, as well as other advantages. Unfortunately, most users do not have sufficient understanding of their thermostat(s) or other premises monitor and control devices to leverage such advantages. Generally, this situation exists because conventional devices do not provide adequate features, convenience, and/or accessibility.
SUMMARY
[0005] The following presents a simplified summary of the specification in order to provide a basic understanding of some aspects of the specification. This summary is not an extensive overview of the specification. It is intended to neither identify key or critical elements of the specification nor delineate the scope of any particular embodiments of the specification, or any scope of the claims. Its purpose is to present some concepts of the specification in a simplified form as a prelude to the more detailed description that is presented in this disclosure.
[0006] Certain subject matter disclosed herein relates to simplified programming or schedule editing of a premises monitor and/or control device. One system disclosed herein can include a premises monitor and/or control device that can facilitate a change to a state of a premises. The premises monitor and/or control device can include a processor that can execute computer executable components stored in a memory.
[0007] One such component can be a presentation component that can present a configuration display associated with a defined time period. The configuration display can include a threshold associated with the state of the premises. A data component can determine threshold data associated with the threshold based on input data input to the configuration display for the defined time period. A population component can populate multiple data structures included in the memory with the threshold data based on a type of the configuration display. A data structure from the multiple data structures can relate to a single defined time period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Numerous aspects, embodiments, objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0009] FIG. 1 illustrates a high-level functional block diagram of an example system that can facilitate simplified programming of a premises monitor and/or control device as well as additional features, convenience, or ease in accordance with certain embodiments of this disclosure;
[0010] FIG. 2 illustrates a block diagram of prior art device memory and the relationship of the memory structure to prior art device user interfaces;
[0011] FIG. 3 depicts an example illustration of a configuration display in accordance with certain embodiments of this disclosure;
[0012] FIG. 4 depicts an example illustration of a selection display in accordance with certain embodiments of this disclosure;
[0013] FIG. 5A depicts an example illustration of an example preference display in accordance with certain embodiments of this disclosure;
[0014] FIG. 5B depicts an example illustration of an example preference display that can facilitate abstraction selection of comfort versus efficiency in accordance with certain embodiments of this disclosure;
[0015] FIGS. 6A and 6B depict illustrations that relate to example occupancy schedules that can be associated with the occupancy of a portion of the premises during defined time period in accordance with certain embodiments of this disclosure;
[0016] FIG. 7 illustrates an example interface device with suitable display for presenting an editable view of occupancy data or other data detailed herein in accordance with certain embodiments of this disclosure;
[0017] FIG. 8 illustrates an example interface device that includes location information associated with a user of the premises monitor and/or control device in accordance with certain embodiments of this disclosure;
[0018] FIG. 9 illustrates an example methodology for providing for simplifying schedule programming of a premises management device;
[0019] FIG. 10 illustrates an example methodology for providing for additional aspects or features in connection with simplifying schedule programming for a premises management device in accordance with certain embodiments of this disclosure;
[0020] FIG. 11 illustrates a block diagram of a computer operable to execute or implement all or portions of the disclosed architecture in accordance with certain embodiments of this disclosure; and
[0021] FIG. 12 illustrates a schematic block diagram of an exemplary computing environment in accordance with certain embodiments of this disclosure.
DETAILED DESCRIPTION
Schedule Simplification And/Or Abstraction
[0022] Various aspects or features of this disclosure are described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In this specification, numerous specific details are set forth in order to provide a thorough understanding of this disclosure. It should be understood, however, that certain aspects of disclosure may be practiced without these specific details, or with other methods, components, materials, etc. In other instances, well-known structures and devices are shown in block diagram form to facilitate describing the subject disclosure.
[0023] Referring now to drawings, with initial reference to FIG. 1 , system 100 is depicted. System 100 can facilitate simplified programming to a premises monitor and/or control device as well as additional features, convenience, or ease. System 100 can include premise monitor and/or control device 102 that can facilitate a change to premises 104 . Device 102 can include memory 103 and a processor (not shown), examples of which are provided in connection with FIG. 11 . Moreover, the processor can be configured to execute various components described herein.
[0024] Premises 104 can be, for example, a residential area, a commercial area, an industrial area, or substantially any type of area or location and can include indoor portions or outdoor portions depending on a type of premises monitor and/or control device 102 . In many examples utilized herein, device 102 is depicted as a thermostat device that can, inter alia, facilitate monitoring and control of an indoor environment, particularly temperature, however, it is understood that device 102 is not necessarily limited to a thermostat. In other embodiments device 102 can relate to irrigation systems (indoors or outdoors); lighting control systems (e.g., lights, shades, etc.); pools, hot tubs, aquariums, water heaters, or other fluid- or water-based systems; and so on.
[0025] Moreover, in some embodiments device 102 can directly affect the change to the state of premises 104 , while in other embodiments device 102 can facilitate the change by instructing other devices, such as other existing thermostats or premises monitor and control devices or premise state control device(s) 105 , which can be, e.g., a heating, ventilation, and air conditioning (HVAC) system or another system suitable for the particular implementation.
[0026] One shortcoming of conventional thermostats or other monitor/control systems is that an associated user interface employed to program these devices is architected to imitate the memory structure as illustrated by FIG. 2 , which can now be referenced before continuing the description of FIG. 1 . FIG. 2 depicts an example of memory 200 associated with a prior art premises monitor and control device. A typical design includes enough memory to store a week's worth of information (e.g., 7 days), with four setpoints per day, creating a 7×4 grid. An associated user interface 220 is typically architecturally tied to this grid-based layout, a situation that arose because of limited device display size, cost-centric display technology (e.g., fixed segment liquid crystal display (LCD) instead of full color touchscreen), etc. Regardless, user interface 220 tends to mimic the storage layer, which can lead to difficulties when programming the device, which can result in little or inefficient use of the device.
[0027] Turning back to FIG. 1 , system 100 can operate to effectively separate the presentation layer from the storage/implementation layer. In other words, what is displayed by a user interface associated with system 100 can be a different, typically more intuitive, representation of data that is stored in the memory or in a remote memory. For example, system 100 can include presentation component 106 that can include all or a portion of a user interface (e.g., display, touchscreen, buttons, speaker, microphone, etc.) associated with device 102 .
[0028] Presentation component 106 can be configured to present configuration display 108 associated with defined time period 110 . For example, in some embodiments, defined time period 110 can be a day, which is typically a 24-hour period. In addition, configuration display 108 can include threshold 112 associated with the state of premises 104 . In embodiments where device 102 is a thermostat or a similar device, threshold 112 can be associated with a temperature measurement, which is further detailed in connection with FIG. 3 . In embodiments where device 102 is a lighting or appliance controller or a similar device, threshold 112 can be associated with an illumination level or on/off state.
[0029] Device 102 can also include data component 114 that can be configured to determine threshold data 116 . Threshold data 116 can be associated with threshold 112 , and data component 114 can determine threshold data 116 based on input data 118 that can be input, or derived from input to configuration display 108 for defined time period 110 . For example, in a simple case, data component 114 can determine threshold data 116 based upon an input to threshold 112 and/or defined time period (e.g., a user inputs a temperature of 75 degrees at a transition time of 7:00 am). In other examples, data component 114 can determine threshold data 116 based upon various other inputs, settings, and/or preferences, which is further described in connection with FIGS. 4-7 .
[0030] Additionally, device 102 can include population component 120 that can receive threshold data 116 . Population component 120 can be configured to populate multiple data structures 122 included in memory 103 with threshold data 116 . The number of data structures 122 populated with threshold data 116 can be based on a type associated with configuration display 108 and a given data structure 122 from the multiple data structures 122 can relate to a single defined time period 110 (e.g., a day).
[0031] It is understood that memory 103 is intended to be a repository of all or portions of data, data sets, or information described herein or otherwise suitable for use with the disclosed subject matter. Memory 103 can be centralized, either remotely or locally cached, or distributed, potentially across multiple devices and/or schemas. Furthermore, memory 103 can be embodied as substantially any type of memory, including but not limited to volatile or non-volatile, solid state, sequential access, structured access, random access and so on. It should be understood that all or portions of memory 103 can be included in device 102 , or can reside in part or entirely remotely from device 102 .
[0032] Turning now to FIG. 3 , graphical illustration 300 is depicted. Illustration 300 provides one example of configuration display 108 . Suppose memory 103 of device 102 is similar to that of prior art device memory 200 or, as another example, device 102 is configured to interface with prior art device memory 200 , in which case memory 103 can include prior art device memory 200 as well as other memory portions that are local or remote and can be accessed by way of a bus or hard line as well as wirelessly. In any suitable scenario, configuration display 108 can represent a portion of a user interface that separates the presentation layer (e.g., displays or other user interface features provided by presentation component 106 ) from the storage layer. Such can enable scheduling/programming that is more intuitive, more convenient, and simpler.
[0033] In this case, defined time period 110 is a day and within that day four transition labels 302 are provided, denoted “Morning,” “Day”, “Evening,” and “Night,” which, in embodiments where device memory 200 is used, can map to the four setpoints allowed per day in device memory 200 . It is understood that if device memory 200 only supports, e.g., two setpoints per day, then four transition labels 302 can still be provided by configuration display 108 . In that case, population component 120 can populate the first two setpoints with the associated values at suitable times, and then overwrite those same two memory locations with the next set of associated values after the first two transition times 304 are no longer active. In effect, configuration display 108 can provide substantially any number of transition labels 302 regardless of the limitation of the device memory 200 in a similar fashion, and each can seamlessly be translated to device memory 200 at the appropriate times.
[0034] Configuration display 108 can include thresholds 112 , that can represent a threshold temperature at which a change to the state of premises 104 is facilitated, and transition times 304 that can represent the time of day (or other defined time period 110 ) at which an associated threshold 112 is to begin its comparison with the ambient temperature to determine whether a change to the state of premises 104 is to be invoked (e.g., instructing a furnace or another component of an HVAC system to activate). Configuration display 108 can allow inputs to be made to thresholds 112 or transition times 304 or to other portions and can also allow for these and other values to be automatically populated based upon other data included in memory 103 . For example, as is further detailed in connection with FIGS. 5-7 , a user might simply input suitable times for transition times 304 , and data component 114 can determine the associated thresholds 112 , for example based upon energy preferences, comfort preferences, occupancy, and so forth. Moreover, all or portions of data included in configuration display 108 can be included in input data 118 and/or used to derive input data 118 .
[0035] Numerous advantages exist for this example configuration display 108 over similar prior art displays or user interfaces. As noted, system 100 can leverage other platforms and architectures that conventional devices are often incapable, which can lead to additional features. Furthermore, rather than programming setpoints for every day of the week, multiple days can be abstracted into a single day, which can simplify the tasks of programming and editing. In the provided example shown in FIG. 3 , Monday-Friday can be accessed via a single interface element as can Saturday-Sunday. Population component 120 can automatically copy data to the relevant data structures included in memory 103 for each of the respective defined time periods 110 .
[0036] Referring now to FIG. 4 , graphical illustration 400 is depicted. Illustration 400 represents an example of a selection display. For example, in some embodiments, configuration display 108 , or another portion of a user interface provided by presentation component 106 , can include selection display 400 that can facilitate selection of the type of configuration display 108 . As noted previously, population component 120 can populate multiple data structures included in memory 103 with threshold data 116 based upon the type of configuration display 108 .
[0037] In some embodiments, for example, based upon a selection denoted by reference numeral 402 , the type can be a 5-2 period display, so called because the display is divided into a 5 weekday period and a 2 weekend day period, an example of which was illustrated in FIG. 3 . A 5-2 type display can facilitate input of a first set of input data 118 from which data component 114 can determine threshold data 116 that population component 120 utilizes to populate five data structures 122 included in memory 103 (e.g., for the example in FIG. 3 , these five data structures 122 relate to Monday-Friday) and a second set of input data 118 from which data component 114 can determine threshold data 116 and population component 120 can utilize to populate two data structures 122 included in memory 103 (e.g., for the example in FIG. 3 , these two data structures 122 relate to Saturday-Sunday).
[0038] In some embodiments, the type can be a 5-1-1 period display, so called because the display is divided into a 5 weekday period, 1 Saturday period, and 1 Sunday period, as denoted by reference numeral 404 . A 5-1-1 period display can facilitate input of: a first set of input data 118 from which the data component 114 can determine the threshold data 116 that the population component 120 utilizes to populate five data structures 122 included in the memory 103 , a second set of input data 118 from which the data component 114 determines the threshold data 116 that the population component 120 utilizes to populate one data structure 122 included in the memory 103 , and a third set of input data 118 from which the data component 114 determines the threshold data 116 that the population component 120 utilizes to populate one data structure 122 included in the memory 103 .
[0039] In some embodiments, the type can be a 7 period display, typically selected for premises 104 for which the routine is similar all seven days of the week, as denoted by reference numeral 406 . A 7 period display can facilitate input of the input data 118 from which the data component 114 determines the threshold data 116 that the population component 120 utilizes to populate seven data structures 122 included in the memory 103 . As denoted by reference numeral 408 , other example types are possible.
[0040] With reference now to FIG. 5A , graphical illustration 500 is depicted. Illustration 500 represents an example of a preference display. For example, in some embodiments, configuration display 108 , or another portion of a user interface provided by presentation component 106 , can include preference display 500 that can facilitate input of preference data 502 . Preference data 502 can also include energy pricing information, and in those cases, preference display 500 can include features that relate to cost-benefits associated with efficiency relative to comfort, which is further detailed infra.
[0041] In any case, preference data 502 can be included in input data 118 , the aggregate of which can be employed by data component 114 to determine threshold data 116 . Accordingly, turning back to FIG. 3 , while a user can directly input values for thresholds 112 , the values of thresholds 112 can also be automatically populated based upon the various other data inputs, such as preferences, costs, comfort levels, and so forth as well as based upon occupancy, which is detailed in connection with FIGS. 6A-7 . It is understood that while configuration display 108 can provide a simplified and often more intuitive interface versus the traditional grid of conventional memory, configuration display 108 can also provide the full grid for advanced users or the like. When presenting the full grid, configuration display 108 can still provide advantageous over conventional systems given configuration display 108 can likely leverage a superior user interface than what is typically found on conventional devices.
[0042] In some embodiments, presentation component 106 can provide a display that can facilitate abstract selection of comfort versus efficiency, an example of which is provided by illustration 510 associated with FIG. 5B , which can now be referenced. As depicted, a sliding scale between comfort and efficiency can exist (e.g., sliding scale 512 ), so an associated user is not required to consider specific temperature values, but rather can simply indicate general preferences that data component 114 can interpret. Thus, a user of premises 104 can be provided a convenient means for quickly and easily updating preference data 502 in a manner that is relevant for many users. In addition to automatically updating preference data 502 based upon changes to the sliding scale 512 (or another suitable user interface element), all or a portion of relevant threshold data 116 can be updated as well. It is understood that data component 114 can determine a particular threshold 112 directly in response to such preference data 502 or further based upon the preference data 502 interpreted in the context of local weather, a thermal model of premises 104 , current energy prices and/or peak pricing or variable pricing indices, etc.
[0043] Turning now to FIGS. 6A and 6B , graphical illustrations 600 and 610 are depicted. Illustrations 600 and 610 relate to example occupancy schedules that can be associated with occupancy of a portion of premises 104 during defined time period 110 . As with preference data 502 , data component 114 can determine threshold data 116 further based on occupancy data 602 input to or otherwise included in occupancy displays 600 and 610 .
[0044] As depicted occupancy schedule 600 is related to informational aspects of occupancy data 602 that can be reviewed for accuracy or settings. Occupancy display 600 can include a user interface element that can facilitate editing of occupancy data 602 , such as edit button 604 . In response to selection of edit button 604 or another similar user interface element, example edit occupancy display 610 can be presented, wherein the occupancy data can be edited based upon defined portions of premises 104 and saved by way of save button 606 or a like user interface element. In another embodiment, the occupancy schedule 600 can be presented as a visual map that represents the physical regions of the premises 104 that can be individually managed by the premise monitor and control device 102 . In another embodiment, the occupancy schedule 600 includes a user interface element that facilitates editing of the occupancy zones (e.g., the physical regions of premises 104 that can be individually managed), including adding, removing, or renaming the zones.
[0045] In response to preference data 502 , occupancy data 602 , and/or other input data 118 , data component 114 can translate such input data 118 to set thresholds 112 and/or transition times 302 for all relevant premises state control devices 105 at premises 104 (e.g., thermostats, automated lighting, shades, etc.) based on various occupancy periods and premises 104 locations as well as comfort, efficiency, or other preference data 502 settings. In other words, configuration display 108 can be presented with data translated into specific transition times that each control device understands and stores locally (e.g., in device memory 200 ) or into transition times 304 and thresholds 112 that a master networked system uses to send control commands to other relevant control devices at appropriate times.
[0046] Referring now to FIG. 7 , system 700 is provided. System 700 can be a smart phone or any other suitable device with suitable display 702 for presenting an editable view of occupancy data 602 (or other data detailed herein). By way of example, suitable devices can include a home controller device, a personal computer, a mobile phone, a personal digital assistant, a tablet, a gaming console, and so on. Display 702 provides a further embodiment associated with accessing or updating occupancy data, but also introduces additional aspects, features, and/or concepts associated with the disclosed subject matter.
[0047] For example, system 100 can leverage resources associated with other devices (e.g., smart phone 700 ), including the user interface, memory, processing, communications of those devices. Inputs to device 700 can be remote from system 100 and/or premises 104 and, if necessary, can be translated appropriately for all or a portion of the associated premises control devices 105 by data component 114 , which can increase the features available to users as well as convenience.
[0048] In addition, display 702 is illustrated with set away button 704 and end away button 706 that relate to concepts that can be provided in other portions of configuration display 108 as well. Selection of set away button 704 (or another suitable user interface element) can essentially indicate to system 100 that all or a portion of premises 104 is not currently occupied according to the normal scheduling, such as during a vacation holiday or the like. Thus, data component 114 can manage threshold data 116 for example for maximum efficiency while occupants of premises 104 are away rather than according to the normal occupancy and preference settings. Hence, a single input stroke can initiate energy-saving modes for all suitable devices at premises 104 or multiple premises associated with a particular user. Energy-saving modes can differ based upon the particular device as well as based on various other settings or conditions such as weather (e.g., winter will likely be different than summer).
[0049] Similarly, changes that occur due to selection of set away button 704 can be deactivated by selection of end away button 706 (or a similar user interface element). Additionally or alternatively, away mode can be set for a predetermined length of time, until a previously scheduled non-away time (e.g., a subsequent schedule transition), indefinitely (e.g., until end away button 706 is selected or another indication that a user is at premises 104 is provided), or based upon location information associated with the user (e.g., location information indicates a user has arrived or is approaching premises 104 ), which is further detailed below. Additional aspects associated with the concept of setting and ending away statuses as well as an introduction to access sharing and other concepts are provided in connection with FIG. 8 . Moreover, it is understood that any given interface portion that includes button 704 or 706 can provide the single stroke ability set or end an associated away status. Accordingly, it is not necessary that both buttons be available or displayed simultaneously. Rather, set away button 704 can be enabled/displayed when the current status is not set to away, while end away button 706 can be enabled/displayed when the current status is set to away.
[0050] Turning now to FIG. 8 , system 800 is illustrated. System 800 can be a smart phone or another suitable device that includes location information associated with a user of system 100 and/or premises 104 . In some embodiments, a location of the user (in this case determined by a location of a smart phone associated with the user) can be utilized by system 100 to automatically set a status associated with all or a portion of premises 104 to away mode. Moreover, other suitable location-based data can be employed to determine an estimated time of arrival at premises 104 . Accordingly, changes to the state of premises (e.g., heating or cooling, lighting illumination, etc.) can be implemented for maximum efficiency or other parameters in view of current condition as well as the estimated time of arrival and/or based upon a distance threshold from premises 104 . In some embodiments, this distance threshold can be set by distance slider 802 or another suitable user interface element or location-based element. For example, thresholds 112 can be targeted and/or achieved based upon the estimated time of arrival rather than or in addition to being based upon an associated transition time 302 .
[0051] In some embodiments, a non-linear distance scale can be employed, which can be associated with distance slider 802 . For example, fine settings can be affected when the distance from premises 104 is small or the travel speed high, while coarser settings can be affected when the distance from premises 104 is large or the travel speed low. It is understood that multiple devices and/or location-based data sources can be employed for multiple different occupants or users of premises 104 , and each data set can be utilized to appropriately affect changes to the state of premises 104 or appropriate portions of premise 104 . Additionally or alternatively, a user can be provided with an option to set different detection radii and/or distance thresholds based on the day of the week and time of day to accommodate for travel patterns associated with a user of premises 104 .
[0052] Such also provides an introduction to the notion of shared access for system 100 . Briefly, a given premises 104 can routinely include multiple authorized users, each of whom might have access a local device such as premise monitor and/or control device 102 , but when other devices are leveraged such as smart phones, then difficulties arise in determining access privileges or the like. One solution is to create a remote management account with credentials that belong to one user (e.g., an accountholder) that can be shared with other users. However, in that case, several additional issues arise. For example, notifications (e.g., based on an accountholder email address) will typically only go to one party, or a given party is not likely to receive a specific notification. Also, customized preferences become difficult or impossible, such as programming a first set of preferences when only party A is at premises 104 and a second set of preferences when only party B is at premises 104 and a third set of preferences when both party A and B are at premises 104 . Furthermore, security hazards arise since an authentication credential is shared, particularly when one of the parties is only a temporary user of premises 104 (e.g., a houseguest) or only has access to a portion of premises 104 . In addition, access is an all-or-nothing proposition because by sharing the credential each user has access to all options and data as every other user.
[0053] According to the disclosed subject matter a different solution can be provided. Rather than sharing an account credential, each user can be provided separate accounts, which might include many premises or portions that do not have joint access even if joint access does exist for premises 104 . Hence, the concept of sharing disclosed herein minors use or ownership concepts associated with premises or portions of premises. Thus, an account can exist for, say, a homeowner, and another for the homeowner's spouse, and yet another for the homeowner's child, where the child's account might only include access privileges associated with his or her room or an entertainment room. Likewise, another account can be created for a houseguest with privileges associated with a guest room only. The homeowner can stop sharing premises 104 with the houseguest at any time, and can do so without sharing and/or later changing a password. Additionally or alternatively, the houseguest can remove his or her access as well (e.g., at the end of the stay) or the access can be provided for a predetermined period of time, after which access privileges can be automatically terminated.
[0054] Furthermore, the homeowner can open sharing to anyone at premises 104 . For example, users who connect to a local WI-FI network can be granted access and the ability to input information to device 102 . Such access can end when that particular user leaves premises 104 and/or goes beyond the range of the local WI-FI network. Such a feature can also provide for automatic changes based on presence and/or proximity to premise 104 by a particular user. For example, two users who share a location might have independent device settings (e.g., thermostat temperature). When combined with proximity detection, smart devices, such as system 100 in some embodiments, can automatically adjust to the settings desired for the current occupants of premises 104 or those users that are approaching and near to premises 104 . Similarly, when all users of premises 104 are absent, system 100 can facilitate the away mode that can include not only efficiency settings but also arming security systems, etc.
[0055] Due to the networking, integration, and other capabilities that can be provided by device 102 , conventional “dumb” thermostats and other premises monitor and control devices can be used as though they were full-featured smart devices. Moreover, conventional programmable thermostats and other premises monitor devices typically require a more complex user interface than the standard up/down buttons or round dial of the non-programmable thermostats. However, more complex user interfaces generally equate to a more expensive product such as more LCD segments or pixels on the display, more buttons, switches, or toggles, etc. Furthermore, enhancing features associated with remotely controlling premises monitor and/or control devices can introduce synchronization issues. For example, suppose an operation schedule is edited both remotely and on the device with conflicting inputs, or when the device is offline.
[0056] One potential solution is for a remote host to manage the schedule of the communicating device such that there is limited ability to change the schedule locally. Even though the schedule exists remotely, changes can be effectuated from devices at premises 104 (e.g., a web browser or mobile application connected to the remote system). Such avoids the potential local versus remote schedule conflict issue, and premises monitor and/or control device 102 itself can still allow for relatively simple or short-term overrides locally such as the case where a user wants to temporarily override a current scheduled setting (e.g., it's too hot right now) or hold, enable, or disable a scheduled setting. Therefore, parties without access to devices with sophisticated user interfaces (e.g., children, visitors, etc.) who have need to change the settings associated with device 102 can still have access to non-scheduling functions available through the simple user interface on device 102 or devices connected to device 102 such as raising or lowering a temperature threshold or starting or stopping a programmed schedule to hold current settings. By designing local monitor and control devices with limited user interface functionality, such devices can be particularly inexpensive, while very sophisticated user interfaces associated with other devices of a user can be employed to access the remote host allowing for a very rich feature set.
[0057] Moreover, even though local device (e.g., device 102 or a device that device 102 interfaces with) schedules are not fully editable through the local device's user interface alone, the local device can still store all or a portion of the schedule. In fact, the local device memory can be reduced to be a minimum to hold only a few elements of threshold data (e.g., a threshold and a transition time), which can drive costs down further. In that case, the remote host can feed threshold data to the local device at appropriate times, continually overwriting previous information to effectuate the complete schedule with minimal local memory. Such can also provide for adaptive recovery and failure prevention techniques that are not available for non-programmable monitor and control devices, such a non-programmable thermostat. Adaptive recovery relates to a feature in which a state (e.g., an ambient temperature) associated with premises 104 or a portion thereof reaches a threshold at the transition time as opposed to activating the state control device at the transition time, which can in some cases increase efficiency or occupant comfort. Failure prevention relates to a feature that can mitigate issues associated with a loss of communication between a local device and the remote host, especially in cases where the local device is a slave to the remote host and relies on the remote host to provide it with updated state or threshold information precisely at the transition time. With a portion of the schedule stored on the local device, transitions can still occur according to a most recent schedule stored in local memory. Additionally or alternatively, a “failure” schedule can be included to handle various situations such as long-term communication loss.
[0058] Furthermore, by managing the schedule at the remote host, the ability to perform sophisticated metrics in connection with very inexpensive local devices becomes feasible. For example, the remote host can analyze inputs associated with local overrides or inputs to detect, e.g., a user tends to change from 72 degrees to 76 degrees at 6 pm on weekdays. By determining this pattern, the remote host can automatically update the schedule and/or notify the user of the suggested update to the schedule.
Gateway Service And Provisioning Feature Enhancements
[0059] Provisioning premises monitor and control devices such as smart thermostats or wireless sensors can be difficult without a sophisticated user interface and data entry method that are appropriate to the provisioning aspect as well as the normal operation of the device after it has been provisioned and otherwise set up. Such devices do not typically have a fully interactive user interface to provide feedback and/or directions to users. Often there is no display at all associated with the user interface of the device because graphical user interfaces equate to additional expense. Moreover, because these devices are often “smart” devices that communicate with a server or other local smart devices, local user interface features are often omitted to reduce costs or the like. However, such can lead to difficulty when provisioning the device for communication setup.
[0060] One solution to this difficulty is to implement a first set of indicators such as light-emitted diode (LED) elements on the smart device and a second set of LED elements on an associated gateway/bridge. The two sets of LED elements can be coordinated and/or sequenced to provide feedback associated with where in the sequence the setup process is and/or how the setup process is progressing. In some embodiments, all smart devices and user interfaces in the ecosystem can use a common set of iconography to indicate progress. Moreover, it is noted that LED elements are typically of very low cost, yet in situations as those described above, the information a few LED elements (or other suitable indicators) can provide can be quite beneficial to users or service personnel.
[0061] For devices that are to be connected to multiple other devices, the associated indicators can show service status such as that for a wide area network, local devices, remote server 1 , remote server 2 , etc. Instead of implementing a single LED to indicate the overall health of the system, individual communication connection indicators can be advantageous for efficient setup and in the case of setup difficulties. Furthermore, smart devices can bridge two or more protocols such as, for example, WI-FI on one side and ZigBee Smart Energy on the other. As another example, the smart device can bridge two or more networks such as a network associated with a metering device or energy provider and a network associated with a home (e.g., a home automation network). The above-mentioned indicators (e.g., LED elements) can be employed to indicate communication activity on both sides of a communication bridge. For example, indicators on the smart device can represent the status of each of the multiple protocols or networks independently, which can expedite setup and/or mitigate troubleshooting issues.
[0062] Likewise, consider the scenario in which multiple smart devices are to be provisioned to a network. In those cases, it can be difficult to connect smart devices to the appropriate network. For example, connecting a limited user interface device to a home WI-FI network might require: 1) connecting to that device directly; 2) providing the device with the WI-FI network information; 3) disconnecting from the device; and possibly, 4) downloading WI-FI credentials to a flash drive or other suitable data storage device and booting the device with the flash drive connected. Since multiple devices are being employed, these or similar steps conventionally must be repeated for each device. Thus, setup of N devices typically requires N*t, where t is the time to set up a single device, which can be tedious and time-consuming, yet might be necessary when installing a broad home control solution or when replacing existing premises monitor and/or control devices with communicating, smart devices.
[0063] One potential solution to these difficulties can be to connect a first device to the network according to the above process or another suitable means. Once the first device is operating correctly, a copy-settings feature can be implemented. The copy-settings feature can include a security measure and can operate to transfer the correctly configured settings from the first device to the second device. The copy-settings feature can be invoked, for example, by pressing a button or other user interface element on one of the two devices after which a security time window (e.g., 30 seconds) exists for a similar button to be pressed on the other of the two devices. Assuming both buttons are pressed within the security time window, the configuration information can be copied to the second device, which can then be authenticated to the network. Such can potentially simplify setup and/or significantly reduce setup time for the multiple devices. It is appreciated that the security time window is merely one example. Such devices can be pre-programmed to have a secure method of exchanging network information, which can be according to any suitable means known in the art.
[0064] As yet another example enhancement associated with smart devices, consider the case of a smart appliance or other device that is advantageously intended to exchange information with multiple services. For example, the device might be intended to support consumer remote control functionality from service provider A; demand response functionality from service providers B and C; and operational information and/or diagnostic functionality from service provider D. Unfortunately, most smart devices today are designed to communicate by way of a client/server model with only one (preconfigured) remote service.
[0065] Based on the single-server model, even if the single server can pass-through services from other providers, industry observers worry about the significant potential for stranded assets in the event the single service provider fails to provide the service adequately or at all. On the other hand, enabling a multiple server model can lead to other difficulties such as the potential for conflicts similar to those detailed above in connection with scheduling conflicts. For example, consider the case in which demand response information or directives communicated to the smart device from provider B differ from those issued by provider C. Or the case in which demand response information communicated to the smart device from provider B or C conflict with user remote control commands communicated from provider A. As another example, consider a deeper level of abstraction, where a question arises as to whether “emergency” demand response information is handled differently than standard economic demand response information such as where one might take priority in conflicts, even if the other does not.
[0066] One potential solution to theses and other difficulties is to implement a multiple server model in connection with the smart device such that the smart device can receive multiple services from multiple providers rather than being configured to receive services directly from only a single provider. Conflict resolution can be managed locally according to determined settings, potentially selectable or configurable by the user. However, conflict resolution and other status information can be reported back to the relevant providers.
[0067] FIGS. 9-10 illustrate various methodologies in accordance with the disclosed subject matter. While, for purposes of simplicity of explanation, the methodologies are shown and described as a series of acts, it is to be understood and appreciated that the disclosed subject matter is not limited by the order of acts, as some acts may occur in different orders and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the disclosed subject matter. Additionally, it should be further appreciated that the methodologies disclosed hereinafter and throughout this specification are capable of being stored on an article of manufacture to facilitate transporting and transferring such methodologies to computers.
[0068] Referring now to FIG. 9 , exemplary method 900 is illustrated. Method 900 can provide for simplifying schedule programming for a premises management device. Generally, at reference numeral 902 , a configuration display associated with a defined time period and including a threshold associated with a state of premises can be presented by a system including at least one processor. For example, the threshold can relate to an air or water temperature or quality of the premises.
[0069] At reference numeral 904 , threshold data associated with the threshold can be determined based on input data that is input to the configuration display or derived from input to the configuration display as well as from other sources. For example, threshold data can include the threshold (e.g., temperature) and a transition time at which the threshold becomes “active” (e.g., at 7:00 am the threshold is set to 75 degrees), which can be based upon other data as well.
[0070] At reference numeral 906 , the threshold data can be translated in accordance with a data structure included in a memory associated with a premises management device (e.g., a thermostat) that facilitates a change to the state of the premises. The data structure can be configured to represent at least one transition point occurring during the defined time period. For example, if the defined time period is a day and the memory of the premises management device supports up to four setpoints for each day, then the threshold data can be translated for compliance with the memory, even if a different configuration or format is presented by the configuration display.
[0071] At reference numeral 908 , storage of the threshold data to a number of data structures of the memory can be facilitated. The number can be based on a type associated with the configuration display. For example, a first type of configuration display might indicate that the number is a first value, whereas a second type of configuration display might indicate that the number is a second value, possibly different from the first value.
[0072] With reference to FIG. 10 , exemplary method 1000 is depicted. Method 1000 can provide for additional aspects or features in connection with simplifying schedule programming for a premises management device. At reference numeral 1002 , a preference display for facilitating input of preference data relating to a preference associated with the change to the state of the premises can be presented. Hence, in some embodiments, the preference data can be included in the input data detailed in connection with reference numeral 904 of FIG. 9 . By way of illustration, the preference display can relate to various preferences or settings desired by a user. Such information can be employed to determine settings in a manner that can be simplified. For example, a user that inputs preference data that indicates the user is interested in efficiency over comfort can lead to different threshold data determinations than similar preference data from a user that indicates a preference of comfort versus efficiency.
[0073] At reference numeral 1004 , an occupancy display associated with occupancy of a portion of the premises during the defined time period can be presented. As with preference data, occupancy data can also be included in the input data described at reference numeral 904 . Thus, occupancy data can be employed in the determination of threshold data. For example, consider the case in which a schedule indicates a threshold should be a particular value at a particular time. However, based on occupancy data (e.g., a particular is/is not present at the premises), that threshold can be modified within the schedule data.
Example Operating Environments
[0074] With reference to FIG. 11 , a suitable environment 1100 for implementing various aspects of the claimed subject matter includes a computer 1102 . The computer 1102 includes a processing unit 1104 , a system memory 1106 , a codec 1135 , and a system bus 1108 . The system bus 1108 couples system components including, but not limited to, the system memory 1106 to the processing unit 1104 . The processing unit 1104 can be any of various available processors. Dual microprocessors and other multiprocessor architectures also can be employed as the processing unit 1104 .
[0075] The system bus 1108 can be any of several types of bus structure(s) including the memory bus or memory controller, a peripheral bus or external bus, and/or a local bus using any variety of available bus architectures including, but not limited to, Industrial Standard Architecture (ISA), Micro-Channel Architecture (MSA), Extended ISA (EISA), Intelligent Drive Electronics (IDE), VESA Local Bus (VLB), Peripheral Component Interconnect (PCI), Card Bus, Universal Serial Bus (USB), Advanced Graphics Port (AGP), Personal Computer Memory Card International Association bus (PCMCIA), Firewire (IEEE 1394), and Small Computer Systems Interface (SCSI).
[0076] The system memory 1106 includes volatile memory 1110 and non-volatile memory 1112 . The basic input/output system (BIOS), containing the basic routines to transfer information between elements within the computer 1102 , such as during start-up, is stored in non-volatile memory 1112 . In addition, according to present innovations, codec 1135 may include at least one of an encoder or decoder, wherein the at least one of an encoder or decoder may consist of hardware, a combination of hardware and software, or software. Although, codec 1135 is depicted as a separate component, codec 1135 may be contained within non-volatile memory 1112 . By way of illustration, and not limitation, non-volatile memory 1112 can include read only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory 1110 includes random access memory (RAM), which acts as external cache memory. According to present aspects, the volatile memory may store the write operation retry logic (not shown in FIG. 11 ) and the like. By way of illustration and not limitation, RAM is available in many forms such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), and enhanced SDRAM (ESDRAM).
[0077] Computer 1102 may also include removable/non-removable, volatile/non-volatile computer storage medium. FIG. 11 illustrates, for example, disk storage 1114 . Disk storage 1114 includes, but is not limited to, devices like a magnetic disk drive, solid state disk (SSD) floppy disk drive, tape drive, flash memory card, or memory stick. In addition, disk storage 1114 can include storage medium separately or in combination with other storage medium including, but not limited to, an optical disk drive such as a compact disk ROM device (CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RW Drive) or a digital versatile disk ROM drive (DVD-ROM). To facilitate connection of the disk storage devices 1114 to the system bus 1108 , a removable or non-removable interface is typically used, such as interface 1116 .
[0078] It is to be appreciated that FIG. 11 describes software that acts as an intermediary between users and the basic computer resources described in the suitable operating environment 1100 . Such software includes an operating system 1118 . Operating system 1118 , which can be stored on disk storage 1114 , acts to control and allocate resources of the computer system 1102 . Applications 1120 take advantage of the management of resources by operating system 1118 through program modules 1124 , and program data 1126 , such as the boot/shutdown transaction table and the like, stored either in system memory 1106 or on disk storage 1114 . It is to be appreciated that the claimed subject matter can be implemented with various operating systems or combinations of operating systems.
[0079] A user enters commands or information into the computer 1102 through input device(s) 1128 . Input devices 1128 include, but are not limited to, a pointing device such as a mouse, trackball, stylus, touch pad, keyboard, microphone, voice recognition microphone, joystick, game pad, satellite dish, scanner, TV tuner card, digital camera, digital video camera, web camera, and the like. These and other input devices connect to the processing unit 1104 through the system bus 1108 via interface port(s) 1130 . Interface port(s) 1130 include, for example, a serial port, a parallel port, a game port, and a universal serial bus (USB). Output device(s) 1136 use some of the same type of ports as input device(s) 1128 . Thus, for example, a USB port may be used to provide input to computer 1102 and to output information from computer 1102 to an output device 1136 . Output adapter 1134 is provided to illustrate that there are some output devices 1136 like monitors, speakers, and printers, among other output devices 1136 , which require special adapters. The output adapters 1134 include, by way of illustration and not limitation, video and sound cards that provide a means of connection between the output device 1136 and the system bus 1108 . It should be noted that other devices and/or systems of devices provide both input and output capabilities such as remote computer(s) 1138 .
[0080] Computer 1102 can operate in a networked environment using logical connections to one or more remote computers, such as remote computer(s) 1138 . The remote computer(s) 1138 can be a personal computer, a server, a router, a network PC, a workstation, a microprocessor based appliance, a peer device, a smart phone, a tablet, or other network node, and typically includes many of the elements described relative to computer 1102 . For purposes of brevity, only a memory storage device 1140 is illustrated with remote computer(s) 1138 . Remote computer(s) 1138 is logically connected to computer 1102 through a network interface 1142 and then connected via communication connection(s) 1144 . Network interface 1142 encompasses wire and/or wireless communication networks such as local-area networks (LAN) and wide-area networks (WAN) and cellular networks. LAN technologies include Fiber Distributed Data Interface (FDDI), Copper Distributed Data Interface (CDDI), Ethernet, Token Ring and the like. WAN technologies include, but are not limited to, point-to-point links, circuit switching networks like Integrated Services Digital Networks (ISDN) and variations thereon, packet switching networks, and Digital Subscriber Lines (DSL).
[0081] Communication connection(s) 1144 refers to the hardware/software employed to connect the network interface 1142 to the bus 1108 . While communication connection 1144 is shown for illustrative clarity inside computer 1102 , it can also be external to computer 1102 . The hardware/software necessary for connection to the network interface 1142 includes, for exemplary purposes only, internal and external technologies such as, modems including regular telephone grade modems, cable modems and DSL modems, ISDN adapters, and wired and wireless Ethernet cards, hubs, and routers.
[0082] Referring now to FIG. 12 , there is illustrated a schematic block diagram of a computing environment 1200 in accordance with this specification. The system 1200 includes one or more client(s) 1202 (e.g., laptops, smart phones, PDAs, media players, computers, portable electronic devices, tablets, and the like). The client(s) 1202 can be hardware and/or software (e.g., threads, processes, computing devices). The system 1200 also includes one or more server(s) 1204 . The server(s) 1204 can also be hardware or hardware in combination with software (e.g., threads, processes, computing devices). The servers 1204 can house threads to perform transformations by employing aspects of this disclosure, for example. One possible communication between a client 1202 and a server 1204 can be in the form of a data packet transmitted between two or more computer processes. The data packet can include a cookie and/or associated contextual information, for example. The system 1200 includes a communication framework 1206 (e.g., a global communication network such as the Internet, or mobile network(s)) that can be employed to facilitate communications between the client(s) 1202 and the server(s) 1204 .
[0083] Communications can be facilitated via a wired (including optical fiber) and/or wireless technology. The client(s) 1202 are operatively connected to one or more client data store(s) 1208 that can be employed to store information local to the client(s) 1202 (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) 1204 are operatively connected to one or more server data store(s) 1210 that can be employed to store information local to the servers 1204 .
[0084] The illustrated aspects of the disclosure may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.
[0085] Moreover, it is to be appreciated that various components described herein can include electrical circuit(s) that can include components and circuitry elements of suitable value in order to implement the embodiments of the subject innovation(s). Furthermore, it can be appreciated that many of the various components can be implemented on one or more integrated circuit (IC) chips. For example, in one embodiment, a set of components can be implemented in a single IC chip. In other embodiments, one or more of respective components are fabricated or implemented on separate IC chips.
[0086] What has been described above includes examples of the embodiments of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but it is to be appreciated that many further combinations and permutations of the subject innovation are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Moreover, the above description of illustrated embodiments of the subject disclosure, including what is described in the Abstract, is not intended to be exhaustive or to limit the disclosed embodiments to the precise forms disclosed. While specific embodiments and examples are described herein for illustrative purposes, various modifications are possible that are considered within the scope of such embodiments and examples, as those skilled in the relevant art can recognize. Moreover, use of the term “an embodiment” or “one embodiment” throughout is not intended to mean the same embodiment unless specifically described as such.
[0087] In particular and in regard to the various functions performed by the above described components, devices, circuits, systems and the like, the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary aspects of the claimed subject matter. In this regard, it will also be recognized that the innovation includes a system as well as a computer-readable storage medium having computer-executable instructions for performing the acts and/or events of the various methods of the claimed subject matter.
[0088] The aforementioned systems/circuits/modules have been described with respect to interaction between several components/blocks. It can be appreciated that such systems/circuits and components/blocks can include those components or specified sub-components, some of the specified components or sub-components, and/or additional components, and according to various permutations and combinations of the foregoing. Sub-components can also be implemented as components communicatively coupled to other components rather than included within parent components (hierarchical). Additionally, it should be noted that one or more components may be combined into a single component providing aggregate functionality or divided into several separate sub-components, and any one or more middle layers, such as a management layer, may be provided to communicatively couple to such sub-components in order to provide integrated functionality. Any components described herein may also interact with one or more other components not specifically described herein but known by those of skill in the art.
[0089] In addition, while a particular feature of the subject innovation may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” “including,” “has,” “contains,” variants thereof, and other similar words are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
[0090] As used in this application, the terms “component,” “module,” “system,” or the like are generally intended to refer to a computer-related entity, either hardware (e.g., a circuit), a combination of hardware and software, software, or an entity related to an operational machine with one or more specific functionalities. For example, a component may be, but is not limited to being, a process running on a processor (e.g., digital signal processor), a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a controller and the controller can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers. Further, a “device” can come in the form of specially designed hardware; generalized hardware made specialized by the execution of software thereon that enables the hardware to perform specific function; software stored on a computer readable medium; or a combination thereof.
[0091] Moreover, the words “example” or “exemplary” are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the words “example” or “exemplary” is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.
[0092] Computing devices typically include a variety of media, which can include computer-readable storage media and/or communications media, in which these two terms are used herein differently from one another as follows. Computer-readable storage media can be any available storage media that can be accessed by the computer, is typically of a non-transitory nature, and can include both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable storage media can be implemented in connection with any method or technology for storage of information such as computer-readable instructions, program modules, structured data, or unstructured data. Computer-readable storage media can include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or other tangible and/or non-transitory media which can be used to store desired information. Computer-readable storage media can be accessed by one or more local or remote computing devices, e.g., via access requests, queries or other data retrieval protocols, for a variety of operations with respect to the information stored by the medium.
[0093] On the other hand, communications media typically embody computer-readable instructions, data structures, program modules or other structured or unstructured data in a data signal that can be transitory such as a modulated data signal, e.g., a carrier wave or other transport mechanism, and includes any information delivery or transport media. The term “modulated data signal” or signals refers to a signal that has one or more of its characteristics set or changed in such a manner as to encode information in one or more signals. By way of example, and not limitation, communication media include wired media, such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media.
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Enhancements to premises monitor or control device (e.g., thermostats, etc) are detailed herein. For example, enhanced relating to simplification of scheduling, are described as well as other enhancements relating to reducing device costs or consumption costs, providing richer features or more robust feature sets, and/or delivering associated product or services with increased simplicity, convenience, or ease.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the labeling art.
2. Brief Description of the Prior Art
U.S. Pat. No. 2,569,140 to Avery granted Sept. 25, 1951 discloses a labeler in which labels releasably adhered to a carrier web are dispensed by a delaminator into underlying relationship with respect to an applicator roll. The carrier web is advanced by a pair of feed rolls mounted by the labeler casing. One of the feed rolls projects beyond the casing and can be rolled on the surface to be labeled.
U.S. Pat. No. 3,330,207 to De Man granted July 11, 1967 discloses a hand-held labeler for applying labels releasably adhered to a carrier web. This labeler includes a housing enclosing a toothed feed wheel for engaging the carrier both upstream and downstram of a label delaminator.
U.S. Pat. No. 4,116,747 to Hamisch, Jr. granted Sept. 26, 1978 discloses a hand-held labeler with a feed wheel and a die roller urged against the feed wheel by a pair of leaf springs.
SUMMARY OF THE INVENTION
This invention relates to a hand-held labeler that is adapted to hold a relatively large roll of pressure sensitive labels. The labeler includes a labeler body which has a delaminator, an applicator and a feed mechanism. The labeler includes a handle connected to the labeler body and to a label roll holder. The handle serves as a spacer between the labeler body and the holder and as a result, the labeler body is effectively lengthened. The labeler body has a socket. The handle has a projection and a socket. The holder has a projection. The holder can be connected directly to the socket of the labeler body. Alternatively, the projection of the holder can be connected to the socket of the handle and the projection of the handle can be connected to the socket of the labeler body. The connections are preferably detachable connections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a hand-held labeler according to the invention;
FIG. 2 is a perspective view of the labeler shown in FIG. 1, but shown assembled;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a top plan view of the labeler shown in FIG. 4;
FIG. 5 is a left side elevational view of the labeler;
FIG. 6 is a partly exploded perspective view of a fragmentary portion of a labeler body and a label roll holder with a winder in accordance with an alternative embodiment of the invention;
FIG. 7 is a side elevational view of the labeler body and holder shown in FIG. 6 with the one wall member removed for clarity and one of the closure members being shown in the open position;
FIG. 8 is a partly exploded view taken generally along line 8--8 of FIG. 7;
FIG. 9 is a sectional view taken along line 9--9 of FIG. 7;
FIG. 10 is a sectional view taken along line 9--9 of FIG. 7.
FIG. 11 is an exploded perspective view of a labeler in accordance with the invention;
FIG. 12 is a side elevational view of a fragmentary portion of the labeler, with the user gripping the handle; and
FIG. 13 is a sectional view taken generally along line 13--13 of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference initially to FIG. 1, there is shown a labeler generally indicated at 10 which includes a body or frame 11 having a pair of body or frame sections 12 and 13. Although the labeler 10 can be used to apply labels from a supply roll R carried in a label roll holder 14, in the event it is desired to apply labels in strip form, the holder 14 can be omitted during manufacture of the labeler 10.
The body sections 12 and 13 are shown to be identical according to a preferred embodiment, so the various portions of the body sections 12 and 13 are referenced using the same reference characters. Each body section 12 and 13 is shown to include an elongate portion 15 with spaced outer walls 16 and 17 and intervening guides or guide members 18 and 19. Each body section 12 and 13 has a delaminator portion 20, a deflector portion 21, a pair of leaf springs or spring portions 22 and 23, an applicator roll mounting portion or stud 24, and feed roll mounting shaft portions or studs 25, 26 and 27. The pair of aligned studs 25 and 27 together comprise a shaft that rotatably mounts a feed roll 28, the pair of aligned studs 26 and 26 together comprise a shaft that rotatably mounts a feed roll 29, the pair of aligned studs 27 and 25 together comprise a shaft that rotatably mounts a feed roll 30, and the pair of aligned studs 24 together comprise a shaft that rotatably mounts an applicator generally indicated at 31 shown to take the form of a roll 32. The studs 24, 25, 26 and 27 preferably have the same length and outside diameter. The rolls 28, 29, 30 and 32 have through-holes 28', 29', 30' and 32' and are preferably identical in size and shape and are composed of the same elastomeric material. The leaf springs 22 and 23 of each pair are molded in such a position or orientation that when the labeler 10 is assembled the feed rolls 28 and 29 are in pressure contact because the related pair of leaf springs 22 and 23 are sprung slightly away from their as-molded positions. As shown, the studs 25 and 27 have respective relieved or cutaway portions 25' and 27' adjacent the nip of pairs of rollers 28 and 29, and 29 and 30 to enable the rolls 28 and 30 to better yield under the urging of leaf springs 22 and 23. The studs 25 and 27 of each pair, the pair of studs 26, and the pair of studs 24 are preferably in end-to-end abutting relationship and the delaminator portions 20 are preferably in end-to-end abutting relationship. Together the delaminator portions 20 provide a delaminator 20'.
The wall 18 of body section 12 is in end-to-end abutting relationship with wall 19 of body section 13, and correspondingly the wall 19 of body section 12 is in end-to-end abutting relationship with wall 18 of body section 13. The walls 16 and 17 are shown to be relieved or cut away through almost their entire lengths as indicated at 16' and 17' to provide a gap to facilitate threading the labeler. One abutting pair of walls 18 and 19 and the adjacent pair of walls 16 and 17, and the other abutting pair of walls 18 and 19 and the adjacent pair of walls 16 and 17 define grooves which provide a guideway generally indicated at 33 (FIG. 3). A carrier web W has a series of labels L releasably adhered to it by pressure sensitive adhesive. Label separation occurs at the delaminator 20' provided by a label-separating edge where the carrier web W is caused to undergo a sharp change of direction as best shown in FIG. 3. The carrier web W can enter the guideway 33 of the labeler body 11 either from the holder 14 or through an opening or port 34 and the carrier web W (from which labels L have been delaminated at the delaminator 20') can exit the passageway 33 through the other opening or port 35. As is apparent, the upper and lower portions of the labeler 10 are identical in all respects so that the carrier web W can be threaded through the passageway 33 in the direction illustrated in FIGS. 1, 2 and 3 or in the opposite direction. In the event the labeler 10 is threaded in the direction illustrated, the carrier web passes into the passageway 33 either from the holder 14 or through port 34 and is guided between the nip of feed rolls 28 and 29. From there the carrier web W passes about the delaminator 20' where label separation occurs as the carrier web W is advanced. The leading label L' is deflected by deflector 21', composed of deflector portions 21, into underlying label applying relationship with respect to the applicator roll 32. In the orientation shown in FIG. 3 deflection is effected by a deflector 15' on each body section 12 and 13 and thereafter by surface 36 of the deflector 21'. After passing about the delaminator 20' the carrier web W passes into the nip of feed rolls 29 and 30 and from there the carrier web W passes along the remainder of the guideway 33 and exits at the port 35. The carrier web W is advanced by rolling the feed roll 30 along surface S to which the leading label L' is shown in FIG. 3 to be in the process of being applied. The feed roll 30 cooperates with the feed roll 29 at a location downstream of the delaminator 20'. The advancing motion of the carrier web W causes rotation of the feed roll 29. The feed roll 29 is in contact with the crarier web W upstream of the delaminator 20' as well as downstream of the delaminator 20'. Motion of the portion of the carrier web W upstream of the delaminator 20' causes the feed roll 28 to rotate. The two pairs of spring arms 22, 23 and 22, 23 cause feed rolls 28 and 30 to be urged against feed roll 29 which is in common cooperation with feed rolls 28 and 30. The construction and arrangement of the feed rolls 28, 29 and 30 is simple and yet effective and does not required any gearing between feed rolls 28, 29 and 30. The center of rotation of the rolls 28, 29 and 32 are at the vertices of a first equilateral triangle, and the centers of rotation of the rolls 29, 30 and 32 are at the vertices of a second equilateral triangle having the same size and shape as the first triangle. If desired, the labeler can be threaded in a direction opposite to the direction shown, namely, the labeler 10 could be turned upside down from the position shown and the carrier web W could be passed either from the holder 14 or through port 35 into the passageway 33. In such an orientation the label supply roll R would, of course, also be turned around. The carrier web W first passes between feed rolls 29 and 30, from there to and about the delaminator 20', from there between feed rolls 28 and 29, and from there along the remainder of the passageway 33 from where it exits at port 34. The leading label L' is deflected by two deflectors 15' and thereafter by surface 37 of the deflector 21' into label applying relationship with respect to the applicator roll 32. With this threading pattern, the feed roll 28 contacts the surface S.
The labeler 10 has an axis which passes through the feed roll 29 and the applicator roll 32. The feed roll 28 is on one side of the axis A and the feed roll 30 is on the other side of the axis. The labeler 10 is symmetrical about the vertical plane and also about a horizontal plane through the axis A.
The labeler 10 is easy to hold between the user's fingers. Each body section 12 and 13 has a side wall 38 with a longitudinally extending concave, finger-receiving contour or groove 38. For a right-handed person, the thumb of the user's right hand will be received in the groove 38 in the side plate 12 in the labeler position shown in FIG. 2 for example and the remaining fingers of the user's right hand will be received in the groove 38 of the body section 13. The reverse would apply to a left-handed person, so the labeler 10 can be used with equal facility by both right and left-handed persons regardless of the direction of threading of the carrier web W.
The body sections 12 and 13 have holes 39 and 40. Semi-tubular studs 41 and 42 on the body sections have grooves 43 and 44. The grooves 43 of one pair of studs 41 are aligned with the holes 39 in body sections 12 and 13, and the grooves 44 of the other pair of studs 42 are aligned with holes 40 in the body sections 12 and 13. When the body sections 12 and 13 are brought together into abutting relationship during assembly, identical expandable fasteners 45 are inserted into the respective holes 39 and 40 in, for example, body section 12, through respective pairs of grooves 43 and 44 and into respective holes 39 and 40 in the body section 13. Thereafter an expander pin 46 is passed into each fastener 45 to expand its respective shank 47 and retain the body sections 12 and 13 in assembled relationship.
The holder 14 in the illustrated embodiment is comprised of two identical one-piece molded plastics body sections 48 and 48'. Each body section 48 and 48' has a wall 49. The walls 49 are arranged in spaced side-by-side generally parallel relationship and straddle the roll R. Leaf springs 50 and 51 are connected to each wall 49 by respective connectors 52 and 53. The leaf springs 50 and 51 are curved and extend in the plane of the roll R. The leaf springs 50 and 51 of each body section 48 and 48' are flexible and resilient enough to be spread apart during loading and removal of a roll R from between walls 49. When spread apart, end portions 54 and 55 of each body section 48 and 48' are moved apart to enable the circular outer periphery of the roll R to pass therebetween. Thereafter, the end portions 54 and 55 of each body section 48 and 48' spring toward each other again into the position shown in the drawings. It is apparent that essentially one-half the holder 14 extends on one side of the axis above the horizontal plane and the other one-half extends on the other side of the axis A below the horizontal plane.
Each body section 12 and 13 has a socket 56 for receiving a respective stud 57 of a respective holder body section 48 and 48'. When the body sections 48 and 48' are ready to be assembled as described above, each stud 57 is inserted into its respective socket 56, and thereafter the body sections 12 and 13 are moved into abutment with each other and connected or coupled by means of fasteners 45 and pins 46.
The illustrated embodiment uses very few parts as is readily apparent from the foregoing. The body sections 12, 13, 48, 48', the fasteners 45 and pins 46 are each of one-piece molded plastics material. The rolls 28, 29, 30 and 32 each are either molded or extruded from elastomeric material. The body sections 12 and 13 are identical, the body sections 48 and 48' are identical and rollers 28, 29, 30 and 32 are identical, thus reducing mold costs to a minimum.
FIGS. 6 through 10 disclose an alternative embodiment of a label roll holder 60 for use with the labeler 10'. The holder 60 is detachably connectable to the labeler 10' by the user. The labeler 10' is identical to the labeler 10 except that the labeler 10' has a rear portion 60' with a through hole 61. The holder 60 constitutes an enclosure 62 having a pair of spaced walls or wall members 63 which straddle a label roll R. The wall members 63 are identical for economy of manufacture. Each wall member 63 has a hole 64. The holes 64 are axially aligned. Each wall member 63 has a pair of holes 65. A pair of identical closure members 66 are pivotally connected to the wall members 63 by projections 67 received in an opposed pair of the holes 65. Each closure 66 has a generally arcuate portion 68 strengthened by integral ribs 69. Each arcuate portion 68 has a pair of U-shaped members 70. Each wall member 63 has a pair of latch portions 71 with outwardly extending projections 72. Each U-shaped member 70 has a pair of flexible resilient arms 73 and each arm has a recess 74 (FIG. 10). The recesses 74 of each member 70 are opposed and are adapted to receive the projections 72 as best shown in FIG. 10 when the closure member 66 is in the closed position. Each member 70 and respective latch portion 71 constitutes a latch generally indicated at 75. The latch 75 of each closure 66 is released by pulling on the member 76. The member 76 functions both as a guide for the carrier web and as a handle by which the closure member can be opened or closed.
The holder 60 also includes tubular projections 77 having reversed semi-tubular studs 78 having grooves 79. The grooves 79 of one pair of studs 78 are aligned with the holes 80 in tubular projections 77. When the wall members 63 are brought together in assembled relationship, identical expandable fasteners 81 are inserted into holes 80 and grooves 79. The fasteners 81 are the same in construction as the fasteners 45. Pins 81' are used to expand and hold fastener 81. The pins 81' are the same as pins 46.
Each wall member 63 has a detent 82 with a pair of flexible resilient spring fingers or detent members 83. Each detent members 83 has a pair of teeth 84 received in a recess 85. Each pair of teeth 84 cooperates with a respective shoulder 86. In FIG. 8 one of the detents 82 is shown to be exploded away for clarity. Because identical wall members 63 with integral detents 82 are used, there are actually two detents 82. One detent 82 prevents the holder 60 from becoming detached accidentally by resisting transverse movement of the holder 60 relative to the body 10' in one direction and the other detent 82 prevents the holder 60 from becoming detached accidentally by resisting transverse movement of the holder 60 relative to the body 10' in the opposite direction. In any event, the holder 60 can be removed from the labeler 10' by shifting the holder 60 in either direction so that the detents move out of the hole 61. Conversely, the holder 60 can be attached by sliding the detents 82 into the hole 61.
The labeler 10' with its holder 60 has the feature that not only can a strip of labels be wound into a roll, but the roll can thereafter be used as the supply roll for the labeler 10'. A winder generally indicated at 83' includes a spool or spindle 84" with a pair of knobs 85. Either knob 85 can be rotated manually or either knob 85 can be rotated by power by an electric motor drive (not shown) for example. The spool 84 has a slot 86 and core holes 87 to save plastics material. The spool 84" have a pair of reduced diameter bearing surfaces 88 rotatably received in the holes 64. End portions of the spool 84" have shoulders 89 which contact the inside of the wall members 63 to prevent axial shifting movement of the spool 84". FIG. 7 shows one of the closure members 66 in the open position and a carrier web W with labels L releasably adhered thereto. End portion W' of the carrier web W is inserted in the slot 86 and one of the knobs 85 is turned in the direction of arrow 91 to wind the carrier web W with the labels L into a label supply roll R. The free end of the carrier web can then by threaded through the pathway 33 in the body 10 (or 10') as described above in connection with FIGS. 1 through 5. It is apparent that both closures 66 are in their closed positions when the labeler 10' is being used. If the winding feature is not needed for a certain application, then the holder 60 is assembled without a winder 83', and in that event a label supply roll can be inserted or removed (assuming one closure member 66 is in the open position) and when both closure members 66 are closed the roll R is confined in the space between wall members 63 and closure members 66.
In assembling the holder 60, the wall members 63 are brought into generally parallel relationship with respect to each other, projections 67 are aligned with respective holes 65, the winder 83' is aligned with holes 64 and the wall members 63 are brought toward each other into the position shown in FIG. 9. Thereupon fasteners 81 are used to connect wall members 63 to each other as shown.
The entire holder 60, namely wall members 63, closure members 66, the winder 83', fastener 81 and pins 81' are composed of molded plastics material.
With reference to FIG. 11, there is shown a handle generally indicated at 400. The handle 400 includes a pair of mirror-image handle portions 401 and 402 connected by suitable means such as connectors 403. The hole or socket 61 in the body 11 is adapted to releasably receive a projection 404 disposed on handle 400 and having detent members 405. The handle 400 also has a hole or socket 406 identical to the hole or socket 61 which is adapted to receive the projection 82'. Detent members 83 are adapted to be releasably received in the socket 406. The socket 406 is identical to the socket 61 and the projection 82' with its detent members 83 is identical to the projection 404 with its detent members 405. Thus, the holder 60 can be connected directly to the labeler body 11, or the handle 400 can be used to connect the holder 60 and the labeler body 11. The detent 83 members enable the holder 60 to be released from the handle 400, and the detent members 405 to be released from the labeler body 11. The detent members 83 and 405 are configured to prevent accidental release. As shown the handle 400 has an opening indicated at 407 that enables passage of the web W from the holder 60 to the labeler body 11. As shown, there is a spacer or spacer portion 408 which adds length to the holder 10. The added length is especially desirable where the label roll holder 60 is of large diameter. The spacer 408 can be considered to be part of the handle.
Other embodiments and modifications of this invention will suggest themselves to those skilled in the art and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims.
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There is disclosed a hand-held labeler which uses labels releasably adhered to a carrier web. The labeler has a body with a pair of identical body sections. The body mounts first, second and third feed rolls. The first and third feed rolls project beyond the body and cooperate respectively with the second feed roll. The body has a delaminator and a guideway for the carrier web. The carrier web can be threaded through the guideway and about the delaminator in either direction. In either event, the first, second and third feed rolls cooperate with the carrier web to advance it and effect label delamination. Depending on the direction of threading, either the first or the third feed roll is used to advance the carrier web by rolling that feed roll along the surface to be labeled. A label roll is held captive in a holder having two identical body sections. In an alternative embodiment, a label strip winding feature enables a strip of labels to be wound into a roll for subsequent use in the labeler. Common identical molded parts enable low-cost construction. There are also disclosed method of making a labeler and method of labeling. A handle connects the holder and the labeler body.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an electrical machine for generating an output voltage, and more particularly to a generator having a permanent magnet rotor, which generator is capable of producing a voltage output which is variable over a large range in a machine that is relatively compact, efficient, and economical both in construction and in operation.
There are two basic types of generators which may be categorized by the way in which they are excited, or by the way poles are provided in the rotor. The first type of generator is the electromagnetic (EM) generator, which is excited by a direct current supplied to field coils located on the rotor, thereby producing a flux in the ferromagnetic poles of the rotor. Electromagnetic generators typically use brushes and slip rings to provide field current to the field coils located on the rotor poles. Brush-type designs are generally seen as undesirable in many applications today, since they are subject to maintenance required by normal wear, as well as for a number of other reasons mandated by the particular application.
While electromagnetic generators can be made brushless by the use of special equipment carried on the rotor (generally a solid-state rectifier fed by an exciter armature) as well as additional stationary coils (to generate a stationary field caused by direct current excitation of the additional stationary coils), the complexity of such a system is undesirable. In addition, such a system is also both expensive and unduly large in size, and the use of rotor windings result in thermal and structural problems well known in the art. Another approach used to make an electromagnetic generator brushless requires the employment of a longer magnetic circuit with inferior magnetic coupling. This approach results in a large weight penalty being incurred, and is therefore undesirable except in the case of very small generators and a limited number of special applications.
The main advantage of an electromagnetic generator is that it may easily be controlled to vary the AC output voltage of the generator. This advantage is particularly significant in situations requiring accurate control of the output voltage to compensate for changes in machine speed or load, or for changes in temperature.
The second type of generator is the permanent magnet (PM) generator, which uses permanent magnets mounted on the rotor to provide the poles on the rotor. Permanent magnet generators have a compact, rugged rotor without windings, so the thermal and structural problems of rotor windings are completely avoided. A permanent magnet generator is also intrinsically brushless, a significant advantage over electromagnetic generators.
Unfortunately, it is quite difficult to achieve a widely variable output voltage from a permanent magnet generator. The excitation of a permanent magnet generator is fixed by the properties of the permanent magnet material used in the rotor. In order to control output voltage of the permanent magnet generator, it has been necessary to greatly increase the complexity and the weight of the machine.
If only a small range of variation in the output voltage of the machine is required (on the order of 15% to 20%), then an electrical scheme which saturates or shunts a portion of the ferromagnetic circuit may be employed. When a larger degree of control is necessary (as in the case where rotor speed may vary by a factor of two), the only option has been a mechanical regulation scheme which varies the magnetic coupling of the magnets with respect to the stator or with respect to one another.
Such control schemes for permanent magnet generators are parasitic. An additional element of mechanical or electrical nature has been added, which element can reduce intrinsic excitation flux but cannot increase it. The result is a machine with a greatly reduced efficiency to weight ratio, with significantly increased costs of manufacturing and operating the machine.
It may therefore be appreciated that it is desirable to have all the advantages and features of a permanent magnet generator, with the additional feature of voltage regulation such as that in an electromagnetic generator. The machine should be of the least possible size and weight, and should be capable of highly efficient operation and economical construction. Finally, it must not be parasitic in operation, but rather selectively decrease or increase intrinsic excitation flux.
SUMMARY OF THE INVENTION
The present invention utilizes both permanent magnet excitation and electromagnetic excitation in a light weight, brushless machine. This combination of excitations in a single machine may be referred to as a hybrid excited generator. In the preferred embodiment the hybrid excited generator is composed of two permanent magnet machines having their rotors connected together by a magnetic shunt and in closely adjacent proximity. In the area between the ends of the two permanent magnet machine stators, a field coil like those used in certain electromagnetic machines is installed.
This electromagnetic field coil functions essentially as a control coil for varying the voltage output from the hybrid excited machine. The coil is wound on a bobbin, and is wound around the axis of the rotor of the hybrid excited machine. An essentially cylindrical ferromagnetic frame closely surrounding the two permanent magnet machine stators provides a flux shunt through which the control coil changes flux linkage between the various components.
The excitation flux of the hybrid excited generator may thus be varied by varying the direction and magnitude of the current flowing in the control coil, resulting in a variance in output voltage generated by the machine. The control flux (the electromagnetic portion of the excitation supplied by the control coil) is implemented by the use of a rotor design referred to as a consequent pole rotor. This rotor design is described in detail in my copending U.S. patent application Ser. No. 810,967, filed concurrently with the present application and assigned to the assignee of the present application, which application is hereby incorporated herein by reference.
In particular, the consequent pole rotor has a profound magnetic assymetry which allows the use of electromagnetic excitation from the control coil. The consequent pole rotor has high reluctance permanent magnet poles which excite low reluctance ferromagnetic poles at alternating pole locations. The electromagnetic excitation from the control coil can therefore change the flux in the magnetic poles only a very small amount compared to the change affected in the ferromagnetic poles by the electromagnetic excitation. This assymmetry is essential to controlling the output voltage of the hybrid excited machine of the present invention. The consequent pole rotor works particularly well with high energy product materials such as samarium-cobalt and neodymium-iron-boron.
Two types of double rotors are disclosed in the present application, with the rotors working equally well in either case. Additionally, two single section machines are also disclosed, one of which is radial and the other of which is axial in flux coupling with the respective stators.
It may thus be appreciated that the present invention presents an advantageous hybrid excited generator having the advantages of both electromagnetic excited generators and permanent magnet generators, with the disadvantages of neither. The hybrid excited generator is brushless and produces a voltage output which is variable over a wide range. The machine is relatively compact and light in weight, and economical both in construction and in operation.
DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention are best understood with reference to the drawings, in which:
FIG. 1 is a cutaway view of the preferred embodiment of the present invention showing the construction of a hybrid excited machine comprising the two permanent magnet machines in tandem with an electromagnetic machine field or control coil located between the permanent magnet machine stators;
FIG. 1A is an enlarged view of a portion of the right stator showing the laminated construction of the right stator core;
FIG. 2 is a cross-sectional view of the machine of FIG. 1 showing the left stator configuration;
FIG. 3 is a view of left end of the rotor of the machine of FIG. 1 with the end rings removed;
FIG. 4 is a first cross-sectional view of the rotor of FIG. 3;
FIG. 5 is a second cross-sectional view of the rotor of FIG. 3;
FIG. 6 is a diagram of the electrical analog of the magnetic circuit for the machine of FIG. 1;
FIG. 7 is a chart of machine output voltage V, ferromagnetic pole flux φ P , control MMF F C , and magnet flux φ M for various values of control flux φ C ;
FIG. 8A is a plot of air gap flux swing for the first value of control flux φ C in the chart of FIG. 7.
FIG. 8B is a plot of air gap flux swing for the second value of control flux φ C in the chart of FIG. 7;
FIG. 8C is a plot of air gap flux swing for the third value of control flux φ C in the chart of FIG. 7;
FIG. 8D is a plot of air gap flux swing for the fourth value of control flux φ C in the chart of FIG. 7;
FIG. 9 is a schematic drawing showing the relationship of the magnetic poles and the ferromagnetic poles, and a typical stator conductor at maximum flux linkage of the rotor for the machine of FIG. 1;
FIG. 10 is an end view of an alternate embodiment for the rotor of the machine shown in FIG. 1 with the end rings removed;
FIG. 11 is a cross-sectional view of the rotor of FIG. 10;
FIG. 12 is a schematic drawing showing the relationship of the magnetic poles and the ferromagnetic poles, and a typical stator conductor at maximum flux linkage of the rotor for a machine having the rotor of FIGS. 10 and 11;
FIG. 13 is a cutaway view of an alternate embodiment of the present invention showing the construction of a radially configured hybrid excited machine comprising one permanent magnet machine in tandem with an electromagnetc machine field or control coil;
FIG. 14 is a cross-sectional view of the rotor of the machine shown in FIG. 13;
FIG. 15 is a cross-sectional view of the rotor of an alternate embodiment of the present invention; and
FIG. 16 is a cutaway view of the alternate embodiment of the present invention, the rotor of which is shown in FIG. 15, showing the construction of an axially configured hybrid excited machine comprising one permanent magnet machine in tandem with an electromagnet machine field or control coil.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is illustrated in FIG. 1, in which a rotor 20 is rotatably mounted inside a stator 22. The stator 22 includes two conventional polyphase winding stators, defined by a right stator core 26 and a left stator core 24. Both the right stator core 26 and the left stator core 24 are essentially cylindrical with a series of radially inwardly extending T-shaped stator teeth 28, as shown in the cross-sectional view of the left stator in FIG. 2. Between the stator teeth 28 are slot areas into which the stator windings 30 are wound. In the machine illustrated in FIGS. 1 and 2, for example, there are 24 slot areas between the 24 teeth 28. The example used is for a four pole machine, but it should be noted that it is equally applicable to machines with other numbers of poles.
The right stator core 26 and the left stator core 24 are typically constructed of a plurality of laminations of electrical steel, which stator laminations 34 are shown in FIG. 1A. It should be noted that the stator windings 30 are shown schematically in the drawings, and that they are conventional, as is well known in the permanent magnet machine art. One detail not illustrated in the drawings is the presence of insulation, both between the stator windings 30 and the stator cores 24, 26, and between the stator windings laid into a single slot area between stator teeth 26.
It should be noted that the stator windings 30 in the preferred embodiment illustrated in FIGS. 1 and 2 passes straight through between the left stator core 24 and the right stator core 26. This configuration is possible because of the configuration of the rotor 20, which will be discussed in detail below. It is important to keep in mind that the stator windings 30 may also mechanically jog between the left stator core 24 and the right stator core 26, and such a configuration will be discussed as an alternate embodiment in conjunction with FIGS. 10 and 11. Finally, it is also possible that the stator windings 30 in the left stator core 24 and the right stator core 26 may be externally connected, if it is desirable to do so to simplify construction of the machine.
The left stator core 24 and the right stator core 26 are mounted around the same axis (the axis of the rotor 20), but separated from each other by a space into which a control coil 40 mounted on a bobbin 42 is mounted. The bobbin 42 is made of non-magnetic, non-conductive material, preferably a high temperature engineering plastic such as Torlon, which bobbin 42 fits between the left stator core 24 and the right stator core 26. The inner diameter of the bobbin 24 is large enough to prevent interference with the portion of the stator windings 30 extending between the left stator core 24 and the right stator core 26.
The control coil 40 is wound around the axis of the rotor 20 onto the bobbin 42, and is selectively supplied with a D.C. control current of variable magnitude and direction to generate a control flux. It should be noted that the MMF of one-half of the control coil 40 is shown schematically in FIG. 6 as F C . Completing the stator 22 is a ferromagnetic frame 44, which is cylindrical and which surrounds the left stator core 24, the control coil 40, and the right stator core 26. The ferromagnetic frame functions to complete the magnetic circuit, which will be discussed in detail below.
The rotor 20 comprises two permanent magnet rotors mounted together on a single common frame, which is a ferromagnetic yoke or core 50. The rotor 20 is illustrated in FIGS. 1 and 3-5, and is a consequent pole rotor having two sets of high reluctance permanent magnet poles alternating with low reluctance ferromagnetic consequent poles, as disclosed in the above-incorporated by reference disclosure. As will become apparent later, the alternating high and low reluctance poles are critical to the operation of the present invention.
The rotor 20 thusly comprises in the example illustrated in the drawings two four pole rotors on the common ferromagnetic yoke 50. The rotors are separated, to correspond with the left and right stator cores 26, 24, which are separated by the control coil 40. Attached to and rotatably supporting the ferromagnetic yoke 50 at the ends thereof are two shaft stubs 52, 54 (FIG. 1).
A first pair of permanent magnets 56, 58 are mounted on the ferromagnetic frame 50 at one end thereof, and a second pair of permanent magnets 60, 62 are mounted at the other end thereof. Located intermediate the permanent magnets are consequent poles; consequent poles 64 and 66 are intermediate the permanent magnets 56 and 58, and consequent poles 68 and 70 are intermediate the permanent magnets 60 and 62.
Also included in the rotor 22 are damper bars made of conductive, non-ferromagnetic material. A damper bar 72 is between the permanent magnet 56 and the consequent pole 64, a damper bar 74 is between the permanent magnet 56 and the consequent pole 66, a damper bar 76 is between the permanent magnet 58 and the consequent pole 64, and a damper bar 78 is between the permanent magnet 58 and the consequent pole 66. Four similar damper bars (not shown) also are located similarly between the permanent magnets 60, 62 and the consequent poles 68, 70.
The first pair of permanent magnets 56, 68, the consequent poles 64, 66, the damper bars 72, 74, 76, and 78, and the left end of the rotor 20 are surrounded by the left end of a retaining hoop 80 made of non-ferromagnetic material. The second pair of permanent magnets 60, 62, the consequent poles 68, 70, the other four damper bars (not shown), and the right end of the rotor 20 are surrounded by the right end of the retaining hoop 80.
In addition, damper rings are used to prevent axial movement of the permanent magnets 56, 58, 60, 62 on the rotor 20. A damper ring 84 is used on the left end of the rotor 20, and a damper ring 86 is used on the right end of the rotor 20. Two additional damper rings (not shown) may be used to prevent the permanent magnets 56, 58, 60, 62 from sliding axially toward the center of the rotor, or damper spacers may be used. In the preferred embodiment, four damper spacers 88, 90, 92, and 94 are used instead of the two additional damper rings. The damper spacers 88, 90, 92, 94 are preferably touching one another. All the damper bars, rings and spacers are made of a highly conductive, non-ferromagnetic material such as aluminum.
Note that the retaining hoop 80 also covers the damper spacers 88, 90, 92, 94. In the event the two additional damper rings mentioned above were used instead of the damper spacers 88, 90, 92, 94, there would be two retaining hoops instead of the single retaining hoop 80, with each of the two retaining hoops covering one end of the rotor 20.
To understand the operation of the machine of the present invention it is important to note that the ferromagnetic poles 64, 66, 68, 70 in the rotor 20 provide a low reluctance path for the flux from the control coil 40. However, the permanent magnets 56, 58, 60, 62, creating magnet poles, present a very high reluctance (essentially the same as free space). Therefore, the electromagnetic control field provided by the control coil 40 can change the magnetic flux in the magnet poles only a small amount as compared to the change effected in the ferromagnetic poles. The control flux generated by the control coil 40 is sent through the various poles of the rotor 20, with the ferromagnetic yoke 50, the ferromagnetic frame 44, and the various poles comprising the path taken by the control flux.
This asymmetry is essential to control the output voltage of the hybrid excited generator because the control flux has the same direction in the ferromagnetic poles as in the permanent magnet poles. Thus, only the difference in magnitude of the control flux at these sites will affect the output voltage. Consider the magnetic circuit schematic of FIG. 6, in which F M is the intrinsic (constant) magnetizing force of one of the permanent magnets 56, 58, 60, 62; F L is the (variable) demagnetizing force of load current; F C is the (variable) magnetizing force of half the control coil 40; φ M is the (slightly variable) flux in the magnetic poles; φ P is the (highly variable) flux in ferromagnetic poles 64, 66, 68, 70; φ C is the (variable) flux of the control coil 40; R P is the reluctance of the ferromagnetic poles 64, 66, 68, 70, which is approximately zero; R EM and R EP are equivalent reluctances of the stator core, teeth, airgap, hoop, and yoke, which are nonlinear functions of fluxes φ M and φ P ; R M is the (constant) reluctance of the permanent magnets 56, 58, 60, 62; and R R and R S are the reluctances of the rotor and stator shunts, respectively, which are approximately zero.
In FIG. 6 leakage paths for flux through and below the control coil 40 and from the rotor 20 to the stator 22 in the interpole zone between the magnets and the ferromagnetic poles has been omitted for clarity. Referring to FIG. 7 in conjunction with FIG. 6, a table is shown for various values of control flux φ C . Note that V is the output voltage of the machine, and that V PM is the intrinsic output voltage due to the permanent magnets, with reluctances R P , R R , and R S negligible in comparison to R M , R EM , and R EP .
Referring now to FIGS. 8A, 8B, 8C, and 8D, plots of the air gap flux swing for the left half of the machine are shown for values of control flux φ c shown in the chart of FIG. 7. Note that the interpole leakage flux is not shown in the flux density waves of FIGS. 8A, 8B, 8C, and 8D, and that the areas of iron shunts must be sufficient to carry the leakage fluxes and the control flux without saturation. Note also that the second harmonic is neutralized in the stator winding because all even harmonics induced in a coil over a magnetic pole are 180 degrees out of phase with those induced in a coil over a ferromagnetic pole when such coils are connected to be series aiding with respect to the fundamental voltage.
FIG. 9 illustrates the relationship of rotor poles to a typical stator winding conductor at the maximum flux linkage position of the rotor 20.
The present invention thereby allows a wide variation in the output voltage from the machine at a given speed. It is then apparent that it is also possible to vary the control flux to maintain a given output voltage while speed of the rotor varies widely. This gives the present invention a tremendous advantage over machines previously known in the art.
An alternative embodiment using a different construction for a double rotor 120 having a ferromagnetic yoke 150 is illustrated in FIGS. 10 and 11. The rotor 120 illustrated is again a four pole rotor, but the construction described below is applicable to other rotors as well. Permanent magnets 156 and 158 are on the left end of the rotor 120 on opposite sides of the rotor 120, with their magnetic poles oriented in a common radial direction, here South pole radially outermost. Located intermediate the permanent magnets 156, 158 are consequent poles 164 and 166.
However, as may be seen in FIG. 11, the consequent pole 164 is made of a segment of the ferromagnetic yoke 150 extending across the length of the rotor 120. The left end of this section is the consequent pole 164, and the right end of this section is a consequent pole 168. The right end of the rotor has two permanent magnets 160, 162 (the latter of which is not shown), axially aligned with the permanent magnets 156, 158, respectively.
The permanent magnets 160, 162 also have their magnetic poles oriented in a common radial direction, but opposite to the orientation of the permanent magnets 156, 158. Here the permanent magnets 160, 162 are oriented with the North poles outermost. The consequent pole 168 is located between the permanent magnets 160, 162. An additional consequent pole 170 (not shown) would also be located between the permanent magnets 160, 162, and would be formed by a segment extending across the length of the rotor 120, which segment would also form the consequent pole 166.
Note that the segment forming the consequent poles 164, 168 has material removed to form lightening spaces 196, 197 at each end. This material may be removed without affecting the magnetic performance of the rotor 120 significantly. Likewise, additional lightening spaces may be provided in the segment forming consequent poles 166 and 170 (not shown).
A damper bar 172 is between the permanent magnet 156 and the consequent pole 164, a damper bar 174 is between the permanent magnet 156 and the consequent pole 166, a damper bar 176 is between the permanent magnet 158 and the consequent pole 164, and a damper bar 178 is between the permanent magnet 158 and the consequent pole 166. The damper bars 172, 174, 176, 178 shown in FIG. 10 are of an alternate configuration which will work equally well as the configuration of the damper bars 72, 74, 76, 78 shown in FIG. 3.
A damper ring 184 is used on the left end of the rotor 120, and a damper ring 186 is used on the right end of the rotor 120. A damper spacer 188 is used between the permanent magnets 156, 160, and a similar damper spacer 192 (not shown) is used between the permanent magnets 158, 162. The damper spacers 188, 192 may have material removed to form lightening spaces 198, 199 (the latter of which is not shown) therein. A retaining hoop 180 made of non-ferromagnetic material surrounds the rest of the rotor 120 similarly to the retaining hoop 80 shown in FIGS. 3-5.
Fabrication of the rotor 120 is simpler than the rotor 20 (FIGS. 3-5). Transport distance for the control flux is shorter, and more control flux can be transported between sections. Even more significant is the fact that rotor stiffness is enhanced.
Since the rotor poles are aligned rather than being displaced by 180 electrical degrees (for a four pole machine 90 mechanical degrees), the required displacement is provided by jogging stator windings. Rather than proceeding in a straight axial direction between the left and right stators as shown in FIG. 9, the stator winding is jogged or pitched over to enter a slot position displaced by 180 electrical degrees. Such a relationship of rotor poles to a typical stator winding conductor at the maximum flux linkage position of the rotor 120 is shown in FIG. 12.
In some applications it is convenient to have independent right and left windings with a relationship that allows the two windings to be series-connected to achieve the same result as the jogged winding installation.
In the rotor 120 less iron is required in the ferromagnetic yoke 150 than in the ferromagnetic yoke 50 of the rotor 20 of FIGS. 3-5. A flux component due to the magnet flows in iron needed to transport axially directed flux flow. However, the component from the South magnets is neutralized by the flux from the North magnets. Therefore, the axial ferromagnetic yoke 150 length under the ferromagnetic poles may be shortened and the pole ends tapered (as by the lightening holes 196, 197). This reduces weight and inertia of the rotor 120.
To suppress slot harmonics and cogging, skewed stator slots need not be used because a similar effect can be achieved by reducing the 180 electrical degree displacement by the skew pitch that was desired. Generally, this would be one slot pitch. A similar strategy can be used with the machine of FIGS. 1-5 with the option that the displacement reduction desired may be implemented in either the stator or the rotor sections.
Referring once again to FIG. 6, it is evident that perfect symmetry of the left and right halves results in nodes A and B being equipotential nodes, which may be joined by a low reluctance magnetic bus with no discernible effect but to simplify analysis. This makes possible the single section machines shown in FIGS. 13-16.
The machine shown in FIGS. 13-14 is a radial air gap machine having a rotor 220 and a stator 222. Stator windings 230 are wound into the stator core 224, and a control coil 240 is wound onto a bobbin 242. The control coil 240 is carried on a ferromagnetic frame 244 surrounding the stator core 224 and extending radially inwardly to surround a portion of a ferromagnetic yoke 250 making up the frame of the rotor 220.
The ferromagnetic yoke 250 is attached to a shaft stub 262, and the rotor 220 is rotatable. A pair of permanent magnets 256, 258 are mounted on the ferromagnetic frame 250. Located intermediate the permanent magnets 256, 258 are consequent poles 264 and 266. A damper bar 272 is between the permanent magnet 256 and the consequent pole 264, a damper bar 274 is between the permanent magnet 256 and the consequent pole 266, a damper bar 276 is between the permanent magnet 258 and the consequent pole 264, and a damper bar 278 is between the permanent magnet 258 and the consequent pole 266. A retaining hoop 280 surrounds the rotor 220. With the exception of the added control coil 240 and the ferromagnetic frame 244, the machine shown in FIGS. 13 and 14 is a permanent magnet radially configured consequent pole machine.
The machine shown in FIGS. 15-16 is an axial air gap machine having a rotor 320 and a stator 322. Stator windings 330 are wound onto the stator core 324, and a control coil 340 is wound onto a bobbin 342. The control coil 340 is carried on a ferromagnetic frame 344 adjacent to the stator core 324 on the side of the stator core 324 away from the rotor 320. The ferromagnetic frame 344 then extends radially inwardly to surround a portion of a ferromagnetic shaft 349.
A ferromagnetic yoke 350 is attached to the ferromagnetic shaft 349, and the rotor 320 is rotatable. A pair of permanent magnets 356, 358 are mounted on the ferromagnetic frame 350 and in a damper cage 372. Located intermediate the permanent magnets 356, 358 are consequent poles 364 and 366. The damper cage 372 surrounds the permanent magnets 356, 358 and the consequent poles 364, 366. A retaining hoop 380 surrounds the rotor 320. With the exception of the added control coil 340 and the ferromagnetic frame 344, the machine shown in FIGS. 15 and 16 is an axial configured permanent magnet consequent pole machine.
It may thus be appreciated that the present invention presents several configurations for a hybrid excited generator having the advantages of both electromagnetic excited generators and permanent magnet generators, with the disadvantage of neither. The hybrid excited generator, which is brushless, produces a voltage output which is variable over a wide range at a given speed, or which may be kept constant while driven at various speeds. The machine is relatively compact and light in weight, and economical both in construction and in operation.
It will be apparent to those skilled in the art that a number of changes, modifications, or alterations to the present invention as described herein may be made, none of which depart from the spirit of the present invention. All such changes, modifications, and alterations should therefore be seen as within the scope of the present invention.
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An electrical machine utilizes a consequent pole rotor with a polyphase stator assembly and a control coil to produce a widely variable voltage output. Either constant-speed--variable-voltage performance, or variable-speed--constant-voltage performance may be easily achieved by varying the magnitude and level of D.C. current supplied to the control coil. Single and double rotor embodiments are disclosed, with cogging being easily suppressible in the double rotor embodiments.
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FIELD OF THE INVENTION
This invention relates to cardiac pacing systems with the capability of responding to episodes of atrial fibrillation and other atrial arrhythmias and, in particular, implantable pacing systems which respond to such an episode by controllably inhibiting conduction of at least some of the atrial signals to the ventricle until the episode terminates naturally.
BACKGROUND OF THE INVENTION
Modern cardiac pacing systems have incorporated substantial capability for detecting and dealing with various arrhythmias. Of particular importance are atrial arrhythmias such as atrial fibrillation (AF), which may lead to serious complications. Atrial fibrillation is manifested as an irregular disorganized activity of the heart, and in the absence of complete AV block, the ventricular response is irregular and random. The irregularity of the resulting cardiac rhythm adversely affects the contractile performance of the heart. It is a source of considerable morbidity and mortality; AF is the leading cause of embolic stroke. As used hereinafter, the term atrial fibrillation, or AF, refers broadly to the class of dangerous atrial arrhythmias, during episodes of which it is desired to inhibit conduction of most of the atrial signals to the ventricles. Pacemakers have attempted to deal with such arrhythmias by simply switching into an asynchronous mode, such that ventricular pacing does not try to track the dangerous atrial excitations. However, with ordinary asynchronous ventricular pacing and continued conduction of the atrial signals through the AV node, a certain percentage of the atrial signals will get through to the ventricle and thus cause chaotic spontaneous ventricular contractions and paced contractions, resulting in an undesirable cardiac condition. Patients with paroxysmal or chronic AF and intact AV conduction who are highly symptomatic and drug refractory are presently candidates for His ablation. This is, of course, a procedure which stops conduction of all atrial signals to the ventricle permanently. The result is that the ventricle needs to be paced permanently even though the atrium contracts normally most of the time.
Another technique that is in use is that of delivering a cardioversion shock to the patient's heart. This can be done during general anesthesia, which of course is impractical for a patient who has repeated and rather long-occurring episodes. Such a patient would also be a candidate for an implantable cardioverter device. However, such devices are very expensive, and the shocks are not welcome to the patient, i.e., they may be painful. Further, if the episodes occur too frequently, these devices have a limited lifetime due to the energy expenditure of each shock.
Another approach known in the literature is to cool the atrium, thereby slowing conduction in the atrial tissue to the point of terminating the atrial fibrillation. See Abstract, Scaglione et al, PACE, Vol. 16, p 880, April 1993, Part II. In this approach, the entire atrium is cooled by introduction of a bolus of cold saline solution. See also U.S. Pat. No. 5,876,422, issued Mar. 2, 1999, showing a system for Peltier cooling of the AV node during which the ventricle must be paced asynchronously for the duration of the AF episode.
Another approach to the problem is for the pacemaker to respond by aggressively pacing at a higher, but more stable rate. See, for example, U.S. Pat. No. 5,480,413. See also U.S. Pat. No. 5,792,193, which smooths the ventricular rate by an algorithm that allows some spontaneous ventricular contractions, and delivers some pace pulses which overdrive the spontaneous rate.
However, there remains a substantial need for an improved system and technique for effectively regulating the ventricular rate until the atrium can return on its own to a normal sinus rhythm, and without requiring a high ventricular rate so that the ventricle be paced asynchronously.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a stimulating system, preferably an implantable system such as a pacemaker system, which is responsive to atrial fibrillation by regulating the rate of atrial signals which are conducted through the AV node, thereby regulating the rate of ventricular contractions. The invention is thus aimed at cardiac patients who have normal AV conduction but are susceptible to episodes of atrial fibrillation, and provides for limiting the ventricular rate by allowing passage of enough signals through to the ventricle to maintain at least a predetermined rate, and for inhibiting passage of other atrially generated excitation signals through the AV node. In this manner, the ventricle contracts synchronously with some of the atrial beats, but does not receive others, resulting in synchronous ventricular beats at a regulated rate.
The above object is achieved by responding to an episode of atrial fibrillation by generating and delivering subthreshold bursts of pulses to the patient's AV node, the bursts being controlled in energy level and frequency to inhibit conduction of signals through the node while they are being applied. Each burst is timed relative to a last sensed ventricular contraction so as to inhibit AV conduction for a period that is related to a desired V—V interval, or ventricular rate. The start of the burst, and the end of the burst are automatically adjusted to provide a desired burst duration; and the energy level of the burst is also automatically adjusted to ensure inhibition while minimizing energy expenditure. Inhibition threshold is tested by determining the percentage of ventricular contractions that occur at intervals shorter than that which corresponds to the predetermined regulation rate; when the percentage is too high, pulse level and/or frequency of pulses within the burst are adjusted to regain optimum inhibition. When the AF episode stops of its own accord, the system returns to a normal mode of pacing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic diagram of a pacemaker system in accordance with this invention, illustrating positioning of leads in the right atrium and the right ventricle, and also showing the positioning of at least one electrode for delivering bursts of inhibiting pulses proximate to the AV node; FIG. 1B is a detailed diagram of the distal end of an atrial lead in accordance with this invention; and FIG. 1C is a detailed diagram of a preferred screw-in lead embodiment in accordance with this invention.
FIG. 2 is a block diagram of a pacemaker system in accordance with this invention, illustrating the primary functional blocks, including a burst generator for generating inhibiting bursts which are delivered proximate to the patient's AV node.
FIG. 3 is a timing diagram showing the timing of an inhibiting burst relative to a prior ventricular sense.
FIG. 4A is a flow diagram showing the relationship of the main AF therapy algorithm to the normal pacemaker routine; FIG. 4B is a flow diagram showing the main flow of the AF therapy algorithm of this invention.
FIG. 5 is a flow diagram illustrating the determination of the burst duration.
FIG. 6A is a flow diagram of a routine for determining when burst inhibition threshold should be tested; FIG. 6B is a flow diagram illustrating the test for determining inhibition energy level and frequency to provide optimum inhibition; and FIG. 6C is a state transition diagram for determining inhibition threshold, which further illustrates the test for setting the inhibition burst parameters.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1A, there is shown a diagram of a pacing system in accordance with this invention. Pacemaker 30 is suitably a dual chamber pacemaker, providing pacing pulses at least for delivery to the patient's ventricle, and preferably also providing for atrial pacing pulses. The pacemaker is encased in a pacemaker “can” 30 -C, of conventional material. Ventricular pacing pulses are delivered from pacemaker 30 on lead 32 , which is illustrated as being positioned with its distal end at about the apex of the right ventricle. Lead 32 may be unipolar or bipolar, and has at least one electrode, shown at 33 , substantially at the distal tip, and may have a second ring electrode shown diagrammatically at 34 . A second lead 31 is an atrial lead, for positioning against the inner wall of the atrium, as shown. This lead has a distal tip electrode 36 , and suitably may also have a ring electrode 38 indicated as being displaced proximally from the distal end. It also carries at least one electrode 37 , having a surface positioned for placement in proximity to the AV node, as indicated. Electrode 37 can be positioned on or proximate to the AV node, and the term “proximate” as used herein also refers to a position sufficiently close to the His, which enables inhibition of the excitation signal as it exits the AV node. It is important that the lead be fixed permanently proximate to the AV node, which can be done best by placing it in the triangle of Koch. It is known that in this area it is difficult to attach leads passively, and accordingly in the preferred embodiment a screw-in lead is used, as illustrated in FIG. 1 C. Screwing a helical tip element into the AV node itself may or may not prove to be desirable; a safe procedure is for the physician to manipulate the separate atrial lead 31 into position so as to screw the tip end into the heart wall just proximate to the AV node or the His. As used hereinafter, reference to the AV node includes the exit area of the heart proximate to the AV node.
Referring now to FIG. 1B, there is shown a more detailed diagrammatic sketch of an atrial lead in accordance with this invention, carrying AV electrode 37 . It is to be understood that FIG. 1B is illustrative only of electrode placement, and that the screw-in embodiment of FIG. 1C is presently a preferred embodiment. FIG. 1B shows details of the distal end of lead 31 , which otherwise has a conventional outer casing and has a proximal end (not shown) for attachment to pacemaker 30 in a known manner. The AV electrode 37 is connected electrically to the pacemaker by conductor 43 , and is positioned adjacent to distal end of the lead 31 so that it is in good contact with the AV node when the lead is fixed within the atrium. The burst may be delivered in unipolar fashion, i.e., between electrode 37 and the pacemaker can, or in a bipolar arrangement, in which case two AV ring electrodes are used. Also, as shown in FIG. 1B, conductor 41 connects to tip electrode 36 , providing for delivery of pacing pulses from the pacemaker and delivery of sensed signals from the atrium back to the pacemaker, in a known fashion.
Referring to FIG. 1C, there is shown diagrammatically a preferred embodiment of lead 31 , having a distally carried screw element 49 which can be pushed out from the distal tip for fixation into or around the AV node. The lead has a first ring electrode 37 B at the tip end, and a second ring electrode 38 positioned about 10 mm proximal from the tip. Screw element 49 is held within the lead casing during introduction, and can be extended axially outward in a known manner; both ring electrodes and the screw element are connected by conductors to the pacemaker, or stimulator device. The physician may search the vicinity of the AV node to find the optimal position for fixating the lead in order to inhibit the AV node, at which time the screw is then pushed out and fixated. Stimulation can be performed with any desired combination of the 3 electrode elements. Additionally, for dual chamber pacemaker operation, any combination of one or more of the lead electrodes, as well as the pacemaker can, can be used for delivering pacing pulses and sensing atrial signals.
Referring now to FIG. 2, there is shown a block diagram of a pacemaker system in accordance with this invention. A generator 15 is provided for generating ventricular pace pulses, under control of control block 20 . The ventricular pace pulses are delivered on lead 32 to one or more ventricular electrodes 33 , 34 . Likewise, generator 18 is provided for generating atrial pulses, which are delivered by lead 31 to atrial electrodes 37 , 38 (or 49 ). Both generators 15 and 18 are controlled by control block 20 , which preferably incorporates a microprocessor, for control of timing, amplitude, pulse width, etc. in a known manner. Memory 21 is interconnected with control block 20 , for providing software for logic control, as well as pacing parameters and other data. Programmer receiver 29 is used to receive downloaded program data from an external programmer in a known fashion, and such received data is connected through control block 20 to storage in memory 21 . A sensor 28 may be employed for obtaining one or more rate-indicating parameters, in a known manner.
Signals sensed from ventricular electrodes 33 , 34 are connected through to QRS sense block 24 , for appropriate signal processing and delivery to control block 20 . Although not shown, the pacemaker may also sense T wave portions of the signals received from the ventricular electrodes. Likewise, signals from the atrial electrodes 37 , 38 , 49 are connected through to P wave sense block 25 , for appropriate processing and connection through to control block 20 .
Of specific importance to the pacemaker system of this invention, burst generator 26 is controlled by block 20 to provide inhibiting bursts of subthreshold pulses to the AV node, in the event of an atrial arrhythmia. The bursts are delivered on conductor 43 to AV electrode 37 (or 49 ). The electrical parameters of the bursts, and the control of burst generation, are discussed in detail in connection with FIGS. 3-6B. Referring now to FIG. 3, there is shown a timing diagram illustrating the timing of an inhibiting burst relative to a ventricular sense (VS) and the ventricular refractory period. A burst is shown having a duration which extends from a start time (BST) to an end time (BET). The BST is timed to occur after an atrial signal is conducted through the AV node and produces a ventricular contraction, which is sensed (VS) by the device. Note that following a QRS there is a ventricular refractory interval, and BST is suitably timed to occur just before the end of this refractory period. As shown, after BET another atrial, or AF signal can be conducted through the AV node, producing a next VS. In this situation, the V—V interval is greater than the burst duration by the patient's natural AV interval plus the time from the prior VS to BST, showing that the patient ventricular rate can be controlled by controlling time of BST and BET, i.e., the burst duration and its timing relative to the last VS. This control can be achieved by adjusting the timing of both BST and BET.
If the monitored V—V interval is shorter than expected based on the burst duration and the AV delay, the BST may need adaptation; it may be that AF signals are slipping through between the end of the ventricular refractory period and BST. In a preferred embodiment, BST is caused to continually drift (e.g., in 10 microsecond steps) towards BET, in order to decrease the burst duration; but if BST is found to be too late it is set back with a much larger step (e.g., 10 ms). Drifting away from the VS stops when BST reaches a maximum programmable start time, and adaptation towards the VS stops at a programmable minimum. Alternately, BST can be set relative to the T wave, which is an indicator of the end of the ventricular refractory period. The value of BET depends on the desired ventricular interval, which may be programmed: by increasing the burst length, the AV node is inhibited longer, and ventricular rate is decreased. As is seen from the timing diagram, the first AF wave that is no longer inhibited is conducted to the ventricle with the AV delay. Assuming the atrial rate is very high compared to the V—V rate, BET is determined by the equation: BET=VV_int−AV_int, where BET is timed from the prior VS. The patient's AV_int can be determined, and thus BET can be set. Burst duration is then adjusted by adjusting BST, as is discussed further in connection with FIG. 5 .
In a preferred embodiment, the available energy levels and frequencies of the burst pulses are programmable. Typical values are:
voltage-from 0.1 V to 5.0 V, in steps of 0.1V;
pulse width-from 0.1 ms to 10.0 ms, in steps of 0.1 ms;
current-from 0.5 mA to 5.0 mA, in steps of 0.1 mA; and
pulse interval-from 10 to 200 ms, in steps of 0.5 ms.
Referring now to FIG. 4A, there is shown a simplified flow diagram showing the relationship of the AF therapy algorithm of this invention to the normal handling routine of a cardiac pacemaker. It is to be noted that the preferred environment of the invention is that of being incorporated into a pacemaker. However, it can likewise be used in other stimulating systems, e.g., as part of a pacemaker-cardioverter-defibrillator, or any other system dedicated to treatment of cardiac arrhythmias. In FIG. 4A, the normal pacemaker event detection and handling is illustrated at 50 . Each cardiac cycle, the system tests for AF, as indicated at 51 . Assuming no AF, the system remains in a conventional pacemaker mode. However if AF is detected, the system goes to the AF main flow 52 , and regulates conduction of atrial signals to the ventricles. As long as AF continues, the system stays in this flow; if AF ceases, the system returns to the normal mode of operation.
Referring now to FIG. 4B, there is illustrated a flow diagram showing the primary routines carried out in the main flow 52 . Starting at the top of the diagram, the Tune Burst Duration routine 54 is entered after a VS. This determines the start and end times of the burst with respect to the conducted VS. Next, at 55 , the system carries out the Determine Inhibition Threshold routine. This controls the output pulse characteristics and frequency of the burst, to insure that AV conduction is inhibited during the burst. After this, at 56 , the BST timer is started, to time out the start of the burst. BST may be timed out relative to the just sensed VS, or relative to the T wave, as discussed above. After this, the flow goes to the Event Detection routine, shown at 57 . The next event can be time out of the BST timer; a VS; or an AS. The T wave may also be detected here, for use in setting the BST timer. If there is BST time out, the flow goes to routine 58 , and controls generation and delivery of the burst from burst gen 26 . After this, the next event is awaited at 57 . When a VS occurs, it is interpreted at 62 . Operations such as distinguishing ventricular extra systoles can be done here. The VV interval is saved. If the event detected at 57 is an atrial sense, it is interpreted at 59 . The AA interval is saved, and it is determined whether AF has terminated. If there is no longer AF, the main flow is exited.
After VS interpretation at 62 , the flow goes to a diagnostics block shown at 64 . The diagnostics that are particularly important for this invention are those that indicate the efficacy of the therapy. For example, ventricular stability from beat to beat is important. The number of conducted ventricular senses (Vses) during the inhibition phase (i.e., conducted atrial signals during and despite the burst) is stored, preferably as a function of the burst output characteristics in histogram form. Also, test results when tuning and adjusting the burst can be stored. This data can be downloaded to a programmer for analysis by the physician, who then can re-program the burst control accordingly. Finally, at 65 , various miscellaneous operations are performed, and the flow returns to block 54 .
Referring now to FIG. 5, there is shown a flow diagram for the tune burst duration routine 54 . At 70 , the VV_int is compared to BST+AV_int. If it is less, this means that an AF signal got started through the AV node before the burst was initiated at BST, such that BST needs to be shortened. At 71 it is determined whether BST is greater than the programmed minimum BST value. If no, this means that it is already at the minimum value, and the routine exits. If yes, at 72 BST is moved to the left (as seen in FIG. 3 ), or shortened, by a programmable decrement. Returning to block 70 , if the answer is no, the routine goes to 75 , and determines whether BST is less than the programmable maximum value. If no, meaning that it is already at the maximum, the routine exits; if yes, then at 76 BST is moved to the right (extended), i.e., BST drifts to minimize energy expenditure.
Referring now to FIG. 6A, there is shown a routine for determining when an inhibition threshold test should be undertaken, and for placing the pacemaker into a test phase. The object is to monitor the efficacy of the inhibition bursts, and if too many VS events are found, adjust the burst output level required to inhibit conduction through the AV node during the burst delivery. At 80 , it is determined whether the latest VV_int was less than the value of BET+AV_int. If yes, this indicates that an atrial signal slipped through the AV node during the last burst. In this case, the routine goes to 81 and increments a YES counter, tallying the number of such failures to inhibit. If no, then the NO buffer is incremented, as shown at 82 . At 84 , the buffer is evaluated, e.g., the percentage of YES events is determined. At 85 , the test status is determined, i.e., whether the test_phase flag is set FALSE. If no, the routine branches directly to the test phase, which is illustrated in FIG. 6 B. However, if the test phase flag is FALSE, the routine goes to block 86 and determines whether the percentage of YES events is greater than a predetermined percentage T. If no, the routine exits. But if Yes, then the conclusion is that too many early VSs are occurring, i.e., the inhibition rate is unacceptably low, and threshold should be tested and the burst parameters reset. The object of the test is to tune the burst output so as to achieve a reliably high inhibition efficacy rate, without raising output too greatly, which would result in wasted energy and possibly raising the pulse level above the AV node excitation threshold.
The pacemaker prepares for the test by setting certain flags, as seen at 91 ; the purpose of these flags is discussed in connection with FIG. 6 B. At 92 , the burst pulse amplitude is set to its lowest available level, and the burst pulse frequency to the highest value. A VS_test_counter is set to zero at 93 , to enable counting of VS events. The pacemaker then goes to the test phase, illustrated in FIG. 6 B.
At 94 , the VS_test counter is compared with predetermined criteria, to see if enough VS events have taken place to test the burst parameters. If not, the routine goes to block 95 and increments the counter. When the count reaches the predetermined number, the counter is reset to zero at 96 . At 97 , it is determined whether the amplitude flag is set to TRUE. If yes, this means that the test is to proceed with adjustment of burst pulse amplitude. The routine goes to 98 where it checks to see if there is a reference percentage to compare to (save 2% means save percentage for the second test cycle). If yes, the routine branches to block 103 ; but if no, the routine goes to block 99 and determines whether the current % Yes is greater than the previously calculated %. If no, this means that amplitude is still below excitation threshold, and the pacemaker can try to raise it. At 103 , the burst frequency and burst amplitude are saved, and then at 104 the burst amplitude is raised one step. At 106 the save 2% flag is set FALSE (meaning that there is no reference set), and at 107 the value of previous % is set equal to % Yes. At 108 the burst amplitude is compared to a programmed maximum value. If the amplitude has been raised to this max value, this means that maximum allowable amplitude has been reached without finding inhibition threshold, in which case the therapy must be stopped. The Error flag is set TRUE, and the routine exits. But, assuming that max amplitude has not been reached, the routine exits.
At the next pacemaker cycle, the pacemaker enters the routine of FIG. 6A at 80 , and updates the % yes at 81 . Since test phase is now TRUE, the pacemaker proceeds to the test phase of FIG. 6B, and runs another loop to determine if the increase in amplitude has raised % Yes greater than the previous % Yes (at 99 ). When the answer becomes yes, this means that amplitude has been raised too high; the bursts have an energy level above the AV node threshold, and are conducted through to the ventricle. The routine branches to block 100 , and restores the previous burst frequency and burst amplitude (which had been saved at 103 , before amplitude was increased one step). Then, at 101 the burst frequency is decreased one step, to start the test of looking to see how much the burst energy can be reduced without making the burst energy too low to achieve inhibition. At 102 , the Amplitude flag is set false, and the routine exits.
During the next cycles, the required number of VS events are collected, until the VS_test counter reaches the required number at 94 . The test branches at 97 , and goes to the right as seen in the flow, to test for the desired frequency. At 112 , the % Yes is compared to previous % Yes. Assuming it is not greater, at 115 the values of burst frequency and amplitude are saved, and at 116 frequency is decreased by one step. At 117 , the value of prev % Yes is set equal to the current % Yes. At 118 , the burst frequency is checked to see if it has been reduced to the minimum value. If yes, the frequency can not be lowered any more, so the test phase flag is set FALSE, and the routine exits. But if frequency remains above the programmed minimum value, the routine exits directly, and runs the test again at the decreased frequency. When the % Yes becomes greater than prev % Yes at 112 , the routine branches to 114 and restores the burst parameters that had been previously saved at 115 . Test phase or status is set FALSE at 120 , and the test is over.
Referring now to FIG. 6C, there is shown a state transition diagram which further illustrates the inventive feature of determining inhibition threshold. The disclosure of FIG. 6C augments that of FIGS. 6A and 6B. As seen, after monitoring of VS, the percentage of early VS events is determined at 126 . If there are too many such VS events, the burst amplitude is tested at 127 . When a valid higher percentage is determined at 128 , the pacemaker then goes into a state of testing frequency, at 129 . When the frequency test produces an increased percentage, the settings are restored, and the test is concluded.
There is thus disclosed a system and method for intermittently inhibiting the AV node by stimulating it with subthreshold bursts of pulses. The system monitors to determine whether the inhibition efficacy rate has decreased to an unacceptable level, and when this is found to be the case, an inhibition threshold test is carried out to readjust the pulse parameters so as to restore reliable inhibition. As seen, the pulses of the bursts can be adjusted in terms of both energy level and frequency. Although the invention has been illustrated by showing amplitude adjustment, it is to be understood that pulse width can also be adjusted. Further, while bursts of pulses are the preferred way of providing the inhibiting stimulation, other waveforms can be used in an equal manner. Thus, the term “burst” as used in claiming the invention embraces other waveforms than that used in illustrating the preferred embodiment, e.g., continuous and aperiodic waveforms.
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There is provided a system for regulating ventricular rate in the presence of abnormally high atrial rates, e.g., during episodes of atrial fibrillation. During such an episode, the system, preferably incorporated into an implantable pacemaker, applies subthreshold bursts of stimulus pulses to or proximate to the patient's AV node so as to inhibit conduction of electrical signals through to the ventricle during the bursts. The bursts are timed in relation to the last conducted ventricular signal, and in terms of burst length, to provide a rate of conducted signals through the AV node which results in a substantially regular and reduced ventricular rate. During the inhibition mode of operation, the system monitors to determine the efficacy of inhibition, by tracking the percentage of ventricular senses that occur during the burst periods. When inhibition is found to be below an acceptable percentage, the system carries out an inhibition test and re-adjusts the burst parameters to provide bursts of optimized stimulation energy.
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FIELD OF THE INVENTION
[0001] This invention relates to the control of a heater associated with the crankcase of a compressor. In particular, this invention relates to monitoring the status of such a crankcase heater.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] Compressors are utilized in many modem heating, cooling, and refrigeration applications. These compressors require oil to lubricate the moving parts of the compressor. The oil is often housed in a crankcase where it can be drawn up into the moving parts of the compressor. Heaters have been previously provided to heat the crankcase oil so as to boil off liquid refrigerant in the oil and maintain an appropriate viscosity of the oil for lubricating the moving parts of the compressor. The crankcase heater may run continuously or it may be activated in response to sensed conditions either in the crankcase or in other areas of either the compressor or the system in which the compressor operates. An example of the latter type of control is disclosed in commonly assigned U.S. Pat. No. 5,012,652 entitled “Crankcase Heater Control for Hermetic Refrigerant Compressors” issued to Kevin Dudley. The above described crankcase heater control as well as other heater controls all require one or more invasive sensors to sense conditions that are to be fed back to the control. These controls also do not necessarily provide a quick check as to whether a crankcase heater is operating properly shortly after it has been turned on since there is a lag between activation and changes to the sensed conditions fed back to the control.
[0003] It would be preferable to obtain information as to the operation of a crankcase heater without resorting to the use of invasive sensors. It would also be preferable to be able to quickly determine whether a crankcase heater is operating properly even if other systems may be deployed that use invasive sensors.
[0004] Briefly, the present invention senses the current flowing through a resistance heater. The resistance heater may be either located in the crankcase or external to the crankcase. The sensing is preferably accomplished by a transformer in combination with an amplifier providing a feedback signal to the programmed microprocessor. The transformer is installed in the line which carries the electrical current flowing through the resistance heater. The microprocessor checks for the presence of an appropriate voltage level from the amplifier. In the event that the voltage level is not above a threshold level, the microprocessor sends an alarm signal indicating that the crankcase heater is not operating properly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] For a fuller understanding of the invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings, wherein:
[0006] [0006]FIG. 1 illustrates a system for monitoring the operation of a heater, which heats crankcase oil for a compressor; and
[0007] [0007]FIG. 2 illustrates the process implemented by a processor within the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0008] Referring to FIG. 1, a crankcase heater in the form of a resistance heater 10 is disposed within the crankcase 12 of a compressor 14 . It is to be appreciated that the resistance heater could be external to the crankcase 12 and still heat the oil. In this regard, the heater could for instance be wrapped or mounted to the outer shell of the crankcase. It is also to be appreciated that the crankcase heater could be an inductance heater or any other type of heater that draws electrical current.
[0009] A microprocessor 16 switches a triac 18 on so as to cause current from an AC power source 20 to flow through the resistance heater 10 . It is to be appreciated that switching devices other than a triac could be used to cause the current to flow from the AC power source 20 . For example a relay contact switch could be used. Current flowing through the resistance heater 10 also flows through the primary winding of a transformer 22 located downstream of the resistance heater 10 . An amplifier 24 associated with the secondary winding of the transformer 22 provides a voltage level signal to the microprocessor 16 indicative of the amount of current flow through the primary winding. As will be explained in detail hereinafter, the processor 16 examines the voltage produced by the amplifier 24 in order to determine whether the resistance heater 10 is operating properly. In the event that the heater is not operating properly, the processor sends an alarm signal to an alarm display 26 . The alarm display 26 may be a light emitting diode on a control panel, a computer screen having the ability to display an alarm message, or any other suitable communication device capable of transmitting an appropriate message.
[0010] Referring now to FIG. 2, a flow chart of the process executed by the microprocessor 16 in controlling the resistance heater 10 or any other type of heater that draws electrical current is shown. The process begins with a step 30 wherein the microprocessor inquires as to whether the crankcase heater is on. This is preferably a check as to whether a signal has been sent to the output triac 18 so as to authorize power to the resistance heater 10 . In the event that a command to the output triac is not present, then the microprocessor will proceed along the no path to a step 32 and inquire as to whether a call has been initiated to turn the crankcase heater on. It is to be appreciated that such a call could occur as a result of any number of different processes being implemented by either the microprocessor 16 or some other control device. These processes could include a process which initiates a call in response to one or more sensors providing information indicating that the resistance heater should be turned on. These processes could also be an authorization to turn the resistance heater on before turning the compressor 14 on. It is to be appreciated that the routine of FIG. 2 could be implemented with respect to any of these external processes.
[0011] The processor proceeds from step 32 to step 34 in the event that a call has been noted to turn the crankcase heater on. Referring to step 34 , the microprocessor turns the crankcase heater on by issuing a signal to the triac 18 . The processor proceeds in step 36 to initiate a time delay, which is preferably a clocked time count of a predetermined amount of time that would allow for the AC power to be applied to the crankcase heater 10 and for any transient current conditions to have passed. The processor proceeds from step 36 to a step 38 , which terminates the routine of FIG. 2. It is to be appreciated that the processor will execute various other control procedures before again returning to the routine of FIG. 2. At such time, the processor will again inquire in step 30 as to whether the crankcase heater is on. Assuming that the microprocessor 16 has issued a signal to the triac 18 so as to turn the crankcase heater on, the processor will proceed to a step 40 and inquire as to whether there is a call for turning off the crankcase heater. It is to be appreciated that such a call could originate from other processes being implemented by the microprocessor such as has been previously described. When such a call is noted, the processor will proceed to a step 42 and turn the crankcase heater off before continuing to step 38 and terminating the routine of FIG. 2.
[0012] Referring again to step 40 , in the event that there is not a call to turn the crankcase heater off, the microprocessor will proceed along the no path to a step 44 and inquire as to whether the time delay of step 36 has passed. In the event that this time delay has not passed, the processor will proceed out of step 44 to step 38 and terminate the routine of FIG. 2. On the other hand, if the time delay has passed, the processor will proceed from step 44 along the yes path to a step 46 and read the output of the amplifier 24 . The processor will proceed to a step 48 and inquire as to whether the read amplifier output indicates the presence of current flow through the primary winding 22 of the current transformer. This is preferably a comparison of the read amplifier output to a threshold number stored in the microprocessor 16 indicative of the amount of voltage that should be present during a normal current flow situation in the primary winding of the transformer 22 . In the event that the read amplifier output does not favorably compare with the stored threshold value, then the processor will proceed along the no path from step 48 to a step 50 and issue an alarm signal to the display 26 . It is to be appreciated that the signal transmitted in step 50 can be either the authorization to a light emitting diode on a display panel or an authorization to display a message on a computer screen or an authorization to provide an appropriate message on some other communication device. In any event, the processor will proceed from step 50 to step 38 and terminate the routine of FIG. 2.
[0013] Referring again to step 48 , in the event that the amplifier output does indicate the appropriate amount of current flow, then the processor will proceed along the yes path to step 38 and again terminate the routine of FIG. 2.
[0014] It is to be appreciated that the microprocessor will execute other processes for which it has been programmed before returning to the routine of FIG. 2. These processes preferably include the microprocessor determining whether the resistance heater is to be turned on or off. The execution of these processes should occur in a short period of time preferably less than five milliseconds before returning to step 30 of the routine in FIG. 2. It is to be appreciated that this period of time is substantially less than the time delay implemented in step 36 so as to cause several executions of the logic after initiating the time delay of step 36 .
[0015] Although a preferred embodiment of the present invention has been described and illustrated, it will be apparent to those skilled in the art that changes or modifications may be made without departing from the scope of the present invention. It is therefore intended that the scope of the invention be limited only by the following claims.
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A controller for controlling a heater associated with the crankcase of a compressor senses electrical current flowing through the heater. The sensing is preferably accomplished by a transformer in combination with an amplifier providing a feedback signal to the controller. The transformer is installed in the line which carries the electrical current flowing through the heater. The controller checks for the presence of an appropriate voltage level from the amplifier. In the event that the voltage level is not above a threshold level, the controller sends an alarm signal indicating that the heater is not operating properly.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application Ser. No. 12/691,307 filed on Sep. 10, 2013 entitled HIGH RATE PULSING WING ASSEMBLY LINE having a common assignee with the present application, the disclosure of which is incorporated herein by reference as though fully set forth.
BACKGROUND INFORMATION
[0002] 1. Field
[0003] Embodiments of the disclosure relate generally to the field of manufacturing of aircraft subassemblies and more particularly to embodiments for high rate pulsing of an assembly line through multiple positions employing interchangeable automated guide vehicles with task specific headers for transfer to multi-access position systems for subassembly support at each position for determinant assembly.
[0004] 2. Background
[0005] Existing Aircraft wings are assembled in a vertical orientation and are held in large floor mounted assembly fixtures that control the location of the major components until they are fastened together and become sufficiently stable. Wings are then transported with overhead building cranes and placed in a horizontal orientation in a lay down fixture or dolly to continue the assembly process. Mechanics and their tools are transported between floors of scaffolding and between the multiple rate fixtures. Operations are batch processed and drilling and installation of the thousands of high tolerance fasteners are done manually. They use large expensive dock assembly systems that are not capable of pulsing the wing to specialized assembly stations. They all use overhead building cranes that require specialized crews to attach and move the wing. They also require a “high bay” (40′-75′ high) facility. The time to move as well as scheduling delays makes this approach impractical for a takt time paced assembly line.
[0006] Recurring labor associated with existing production systems can be thirty expensive and requires non-value added time for rotating the wing, setting up the portable drilling equipment and removing, deburring and reinstalling the lower panel. Additionally, it is not possible to use “C” frame or Yoke automatic fastening systems on closed wing structure such as a wing box with both panels attached. Manual drilling and fastening which is therefore required may have undesirable ergonomic and quality issues.
[0007] Prior art practice for production of aircraft wing assembly uses large floor mounted “end gate” castings at multiple dock or stationary locations to clamp and hold the various sub-assemblies together until they are drilled, disassembled, deburred, reassembled and permanently fastened. These multi-ton large weldments or cast tools which locate the side of body components together are expensive and impractical to move through a horizontal pulsing assembly line.
[0008] Existing production assembly systems for aircraft wing moving lines rotate the wing so that the upper and lower panel drilling is done manually or via portable semi-automated drilling systems from above the wing. In traditional monument based vertical assembly systems wings are drilled and countersunk manually or with portable equipment that is moved from fixture to fixture. Both systems require the panel to be removed and debuted and then reassembled. Existing systems that do not require disassembly and deburring must employ large “C” frame or Yoke riveters that work on part that have access on both sides.
[0009] It is therefore desirable to provide horizontal pulsing assembly lines with automated transport systems for a partially assembled wing and automated systems to drill and install fasteners for the main wing box of commercial airplanes. It is further desirable that the transport system be reconfigurable for right hand and left hand wings as well as be segmented to provide a smaller storage footprint and allow mechanics access to temporarily secure the lower panel to the wing box. It is also desirable that the transport system load the lower panel from under the wing box.
[0010] If is additionally desirable that the side of body geometry be located and held in configuration as it progresses through the different assembly positions until it is fully fastened without the use of large heavy traditional tooling.
SUMMARY
[0011] A single piece pulsed flow wing assembly method providing for horizontal wing manufacture uses synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.
[0012] Exemplary embodiments provide a method and apparatus wherein determinant assembly of an aircraft structure is accomplished in three assembly positions with loading a front spar with attached mechanical equipment interface fittings (MEs) and a rear spar with attached MEs onto multiple front and rear Multi-Axis Positioning Systems (MAPS) of a first assembly position. The MAPS supporting the front spar in 3 axes are then adjusted to place the front spar in a wing reference frame and ribs are stacked on the front and rear spars. The ribs are attached to the front spar and the MAPS supporting the rear spar are adjusted to align determinant assembly (DA) holes in the ribs and rear spar for proper positioning in the wing reference frame. Fasteners are then installed to secure the ladder assembly of the wing structure.
[0013] At predetermined assembly points, a planar laser is used to determine relative displacement from the wing reference frame of defined measurement points on the wing structure assembly due to flexing of the assembly and tooling resulting from addition of mass to the assembly. The MAPS are then adjusted to bring the measurement points back into wing reference frame position.
[0014] In an exemplary embodiment, a wing side of body geometry tool is installed as a dummy rib and the tool is pinned to the spar terminal fittings. The forward web and aft web are installed and accurately located to the front spar and rear spar with DA holes in common to the spar terminal fittings. The upper panel is loaded onto the ribs and flexed by pushers mounted on the applied tool until the DA holes in the webs and chords are aligned. Temporary fasteners are then installed.
[0015] Movement of the wing structure between assembly positions is accomplished by mounting location specific headers on identical AGVs for inner and outer wing structure support with left and right wing designations. The header type sensed and each AGV is synchronously controlled based on header type.
[0016] For continued processing, the AGVs are positioned under the wing structure as supported in the MAPS of the first position. The headers are raised with point support mechanisms controllable in multiple axes to engage the wing structure. The MEs are released from the MAPS in the first position and retracted. The AGVs supporting the wing structure are then synchronously moved to a second assembly position. In one exemplary configuration, prior to releasing the MEs, load cells in the point support mechanisms and fixture receivers are used to confirm that load of the wing structure is being borne by the AGV headers.
[0017] For continued assembly, the headers on the AGVs are positioned for engagement of the MEs attached to the wing structure with the fixture receivers of a plurality of MAPS in a second assembly position. The MAPS in the second assembly position are extended to engage ME headers with fixture receivers in the MAPS and the fixture receivers are clamped to the ME headers. The AGV headers are then withdrawn. The planar laser is then employed again to determine relative displacement from the wing reference frame of the defined measurement points on the wing assembly and the MAPS are adjusted to bring the measurement points back into wing reference frame position.
[0018] The lower wing panel is then loaded onto the header assemblies of the AGV pair and synchronously moved with the AGVs to position the lower wing panel under the wing structure supported in the MAPS in the second assembly position. The combined headers and the AGVs are controlled to accomplish a synchronized multi-axis coordinated motion to insert the lower skin into position on the wing structure aligning DA holes in the lower skin panel with spar fitting attachment points. The lower skin panel is then urged against the wing structure using the support point mechanisms for firm engagement with the wing structure. Press up forces of the panel to the main wing box structure are monitored using the load cells to assure that excessive forces are not used and if force limits are exceeded audible and visual alarms are set off and motion of the AGVs and associated fixtures is stopped. The lower skin panel is then flexed using the pushers on the wing side of body tool until DA holes in the forward and aft web are aligned with corresponding DA holes in the lower panel cord to set the contour. The lower wing panel is sealed and permanent tack fasteners are installed. The AGV headers are then adjusted to assume the wing structure load and the MEs are released from the MAPS in the second assembly position. The MAPS are retracted and the wing structure is synchronously moved with the AGVs to a third assembly position.
[0019] A plurality of MAPS are suspended from a positioning truss mounted to a Floor Mounted Universal Holding Fixture (FUHF). The headers on the AGVs are positioned for engagement of the MEs on the wing structure with the fixture receivers of the MAPS in the third assembly position. The MAPS are extended to engage the ME headers with the fixture receivers and the fixture receivers are clamped on the ME headers. The AGV headers are then withdrawn.
[0020] The planar laser may again be used to determine relative displacement from the reference frame of defined measurement points on the wing structure assembly and the MAPS adjusted in the third assembly position to bring the measurement points back into wing reference frame position.
[0021] Multiple Automated Wing Fastener Installation Systems (AWFIS) are provided and brought into operating position on positioning guideways under the FUHF. The surface of the lower wing panel is contacted with the automated fastening head on each AFWIS from the outside of the wing structure. Upward force is provided by the head in conjunction with an electromagnet energized to create an electromagnetic field pulling a steel backing plate inside the wing structure to provide sufficient clamping force to close any gaps between the structure. The AFWIS systems each accomplish drilling, countersinking, applying sealant and inserting ho km into the lower wing panel and ribs or spars with the head.
[0022] The wing structure is then dihedrally canted with the MAPS actuators and the wing structure is lowered onto a transfer dolly. The MEs are released from the MAPS and the MAPS are retracted. The transfer dolly is then pulsed to the next assembly position for the aircraft.
[0023] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the present invention or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a multi-position wing assembly employing an exemplary embodiment;
[0025] FIG. 2 is a detailed view of an exemplary Multi-Axis Positioning system (MAPS) element;
[0026] FIG. 3 is a detailed view of a Mechanical Equipment (ME) interface fitting for support of the fabricated structure by the MAPS elements;
[0027] FIG. 4 is a detailed view of a pair of Automated Ground Vehicles (AGV) integrated into the system for movement of fabricated structures between positions;
[0028] FIG. 5 is a detailed view of the fabricated wing structure in position 2 with addition of a wing side of body geometry truss tool;
[0029] FIG. 6 is a detailed view isometric view of the truss tool;
[0030] FIG. 7 is a detailed side view of the truss tool demonstrating determinant assembly (DA) location holes;
[0031] FIG. 8 is a detailed isometric view of the AGV pair supporting a lower skin panel for assembly into the wing structure at position 2 ;
[0032] FIG. 9 is a detailed isometric view of the AGV pair transporting the fabricated wing structure from position 2 to position 3 ;
[0033] FIG. 10 is a perspective view of the fabricated wing structure as supported by the MAPS suspended from the gantry elements of the Floor Mounted Universal Holding Fixture (FUHF) in position 3 with exemplary location of Automated Wing Fastener Installation Systems (AWFIS);
[0034] FIG. 11 is a perspective view of the attachment head of the AWFIS engaging the wing structure with the steel backing plate for clamping;
[0035] FIGS. 12A-12C are a flow chart of the operational sequence in the pulsing assembly line.
DETAILED DESCRIPTION
[0036] The embodiments described herein employ determinant assembly (DA) techniques to assemble exemplary main wing components, thereby allowing the assembly fixtures to be smaller and more flexible. The system is a single piece flow, takt time paced pulsing assembly line that moves the wings to positions where mechanics and automated machines perform specialized work. The embodiments described may be mirrored for two linear assembly lines (right and left hand) that have three specialized assembly stations where the mechanics have tools that are optimized to perform efficient location (using determinant assembly features such as surfaces and coordination holes), drilling and fastening operations to the ribs, spars, panels and various structural fittings. The holding fixtures at each position are programmable and retract to provide clearance for the wing moves and to allow compensation for tooling deflection and tooling inaccuracies. A planar locating laser system measures key targets of the wing and communicates the inaccuracies to a fixture controller which adjusts the holding fixtures until the errors are eliminated. When the takt time clock reaches 0, the partially assembled wings automatically pulse to the next position using two electronically synchronized AGVs that are not physically connected. In Position 1 initial assembly of wing structure front spars, ribs and the upper panel is accomplished. In Position 2 the lower panel is loaded automatically via the AGVs and is located to the ladder structure via DA holes. The panel is sealed, permanent tack fasteners are installed and the wing is transported to Position 3 were it is held from above. In position 3 a one sided automated system is used to electromagnetically clamp-up the lower wing panel to spar or ribs, drill and countersink, install sealant, insert interference fit bolts. The side of body webs are fastened while the side of body panel fittings and spar terminal fittings are held in engineering configuration by a small light weight tool that uses a combination of determinant assembly holes in the chords, web and terminal fittings as well as an applied tool that acts as a dummy rib to set the distance and angularity between the front and rear spar terminal fittings. Mechanics can work concurrently on the wing with the automated fastening machines once a zone is completed and vacated. Once the wing is fastened it is lowered onto a wheeled cart, is pulsed out of position 3 and continues down the associated aircraft assembly line. The wing can be pulsed or can continually move down the assembly line as major fittings as well as leading and tailing edge components are installed to the wing box.
[0037] Referring to the drawings, FIG. 1 is a pictorial representation of an exemplary embodiment for assembly showing a first position 10 , second position 12 and third position 14 for horizontal wing structure assembly. In each position multi-axis positioning system (MAPS) elements 16 support the components and wing during the assembly process. As shown in detail in FIG. 2 , each MAPS 16 incorporates a support pedestal 18 . Pedestal length is determined by access requirements for the assembly steps at each position allowing over and under wing access in position 1 and under wing access in position 2 . Pedestals in position 3 are suspended from above to allow even greater under wing access. A three axis motion assembly 20 is mounted to each pedestal. A longitudinal positioning drive 22 is mounted on tracks 24 on surface plate 26 on the pedestal. A lateral positioning drive 28 is mounted to tracks 30 on top plate 32 of the longitudinal position drive 22 . A fixture receiver 40 is mounted to the support table. Positioning of the fixture receiver 40 in the x-axis is accomplished by the longitudinal positioning drive 22 , in the y-axis by the lateral positioning drive 28 . Servo motors associated with each track set provide motion of the drives in each axis.
[0038] The fixture receiver 40 on each MAPS provides an interface to support a mechanical equipment (ME) interface tool 42 . For the embodiment shown in greater detail in FIG. 3 , clevis hooks 44 on the fixture receiver 40 engage a horizontal support rod 46 received through bore 48 on an end boss 50 of the ME 42 . Positioning plates 52 straddle the clevis hooks 44 for lateral stability in the fixture receiver. The rod 46 and positioning plates 52 in each ME provide for lateral and longitudinal self centering on the fixture receiver clevis hooks 44 . Clamps engaged by the fixture receiver on the rod after engagement in the clevis hooks rigidly retain the ME and thus the supported structure to preclude uplift forces from the lower panel load and automated fastening operations from inducing vertical wing structure movement. Multiple MEs having standard end boss interfaces for the MAPS fixture receivers support the wing structure 54 as shown in the drawings. Each ME has a body 56 adapted for attachment to specific attach features in an associated component or portion of the wing structure. Vertical tracks 34 are supported within mating runners 36 on the MAPS support pedestals 18 for vertical positioning.
[0039] Returning to FIG. 1 , forward MAPS of position 1 engage MEs attached to a front spar 60 by appropriate 3-axis positioning of each MAP. The front spar is then held rigidly by the MAPS in all three axes in a wing reference frame. A rear spar 62 having attached MEs is engaged by the aft MAPS of position 1 and positioned in the z-axis of the wing reference frame. Ribs 63 are then assembled to the front spar 60 . Mating determinant assembly (DA) reference holes in the ribs 63 and rear spar 62 are then aligned by manipulation of the aft MAPS in the longitudinal axis and the ribs are then mounted to the rear spar forming a ladder structure.
[0040] As components are added to the wing assembly potentially resulting in deflection of the components and tooling due to the added mass, a planar locating laser 65 positioned below the wing at front and rear spar locations is employed to located defined reference points on the structure as defined in application Ser. No. 12/550,666 filed on Aug. 31, 2009 now U.S. Pat. No. 8,539,658 entitled Autonomous Carrier For Continuously Moving Wing Assembly Line having a common assignee with the present application the disclosure of which is incorporated herein by reference.
[0041] The MAPS 16 are then adjusted to compensate for the deflection to allow accurate assembly of subsequent components in the structure. The laser locating process is employed multiple times to assure continued conformity to the wing reference frame. Determinant assembly using the motion capability of the MAPS precludes the need for massive and expensive rigid tooling to maintain.
[0042] Upon completion of assembly steps in position 1 at the defined takt time, a pair of Automated Guide Vehicles (AGV) 64 , 66 , shown in FIG. 4 , are employed for movement of the partially assembled wing structure to position 2 (for both the right and left wing assembly lines). Each AGV has a wheeled base 68 for lateral and longitudinal positioning on the assembly floor 70 . A scissors elevation mechanism 72 provides gross vertical positioning of an attached support header 74 , 75 . For the embodiment shown, the AGV base and scissor mechanisms are identical and have a standard interface to the support header allowing interchangeability. A spare AGV can be swapped with any of the four AGVs in the event of a failure. Four support headers dedicated for inner and outer wing assembly portions of left and right hand wing assemblies are mountable to the AGVs. The support headers 74 , 75 attached to the AGVs FIG. 4 have two axes of motion for each support point mechanism 76 (X-side to side for panel width and Z-vertical), which are NC programmable and controlled by an onboard processor system 78 on each AGV.
[0043] Each support point mechanism 76 employs a vacuum chuck support pad 80 to support the wing structure elements at various handling points as described. Each header incorporates a bunion fitting 82 for rotating and placing the wing lower skin from an overhead crane to the headers. The support point mechanisms in each header and the fixture receivers in the MAPS incorporate load cells for determining weight bearing of the wing structure by the MAPS or the AGVs during transfer. As the wing assembly is lowered by the MAPS load cells in both the AGVs and the fixture receivers verify that the wing load has been transferred to the fixture before the AGVs retract and move away from the wing to return to their parking position. The load cells are also used to verify that the AGV has received the wing structure from the fixture receivers before it begins the transfer to the next assembly position/fixture.
[0044] FIG. 5 shows the wing structure assembly in Position 2 as supported by the MAPS 16 . The pedestals 18 which support the 3 Axis motion assemblies 20 are higher for position 2 allowing easy access to the underside of the wing structure for operations to be performed in position 2 . A wing side of body geometry tool 84 has been installed as a dummy rib to accurately locate the front spar 60 and rear spar 62 with determinant assembly holes (generally designated 85 ) in the forward web 86 and aft web 88 common to the spar terminal fittings and the upper and lower panel chords 90 and 92 to accurately control the contour of the side of body chord profiles as shown in detail in FIGS. 6 and 7 . After the spars 60 , 62 are loaded into the assembly position 1 as previously described, the side of body tool 84 is pinned to the spar terminal fittings 94 , 96 . After the upper panel 98 is loaded, the forward and aft webs 86 and 88 are loaded and pinned to the DA holes in the terminal fittings. The upper panel chord 90 is flexed up or down by pushers 100 mounted on the applied tool until the DA holes in the webs and chords are aligned, then temporary fasteners are installed. The small size of this applied tool 84 allows the AGVs access to move wing structure from position to position as well as allowing automated fastening equipment full access to the panels.
[0045] FIG. 8 shows the lower skin panel 102 loaded on the headers of the AGVs fix installation into the wing structure assembly in position 2 . Upon loading of the lower skin panel, the location of the AGV's is indexed and installation of the lower skin is accomplished by synchronous positioning of the AGV pair to precisely locate underneath the wing structure as supported by the MAPS in Position 2 . The lower skin is then raised by vertical motion of the AGV scissors and lateral motion by the header support point mechanisms to achieve a preset position with respect to the wing structure. Measurements are then taken manually to confirm the position and fine positioning of the AGVs and headers responsive to the measurements are then made. The combined headers and the AGVs then accomplish a synchronized multi-axis coordinated motion to insert the lower skin into position on the wing structure aligning DA holes in the lower skin panel with spar fitting points. During lower skin panel loading the load cells in the support point mechanisms monitor the press up forces of the panel to the main wing box structure to assure that excessive forces are not used. Force limits are programmable and if exceeded will set off audible and visual alarms as well as stop the motion of the AGVs and associated fixtures. After positioning, the lower skin panel is flexed using the pushers 101 of the wing side of body tool 84 until DA holes in the forward and aft web 86 , 88 are aligned with corresponding DA holes in the lower panel cord 92 to set the contour. The lower wing panel is then sealed, permanent tack fasteners are installed, and the wing structure is ready for movement to Position 3 .
[0046] FIG. 9 shows the assembled wing structure after retrieval from the Position 2 MAPS by the AGVs The AGVs then synchronously transport the wing structure to position 3 . In position 3 , as shown in FIG. 10 , MAPS 16 are supported by a positioning truss 106 which is carried by the Floor Mounted Universal Holding Fixture (FUHF) 108 (shown in FIG. 1 ). MAPS 16 structure for position 3 is identical to that previously described, however, the structure is inverted to allow clearance underneath the supported wing structure for assembly operations. In position 3 multiple Automated Wing Fastener Installation Systems (AWFIS) 107 operating on positioning guideways 109 are used to electromagnetically clamp-up the lower wing panel to spar or ribs, drill and countersink, install sealant and insert interference fit bolts. As shown in FIG. 11 , the automated fastening head 110 contacts the surface of the lower wing panel from the outside of the wing structure and applies upward force in conjunction with the electromagnet 112 that is energized and creates an electromagnetic field that pulls a steel backing plate 114 from the inside of the wing to provide sufficient clamping three to close any gaps between the structure to allow the head to conduct fastener installation operations on the lower wing panel for connection to ribs and spars. Each AFWIS incorporates an operator control panel 116 which provides for programming input of automated tasks and manual control for non-automated tasks. As shown in FIG. 11 as an exemplary embodiment, the head incorporates multiple fastener installation systems including a drill spindle 118 , hole inspection probe 120 and bolt inserter 122 , each having a fine positioning mechanism for displacement for multiple operations in a single clamping position of the head. Gross positioning of the head is accomplished with three dimensional actuators affixed from the carrying plate 124 of the head and the AFWIS body 126 A resync camera 128 is provided for location of the permanent tack fasteners, which are used as a reference system to locate the remaining fastener placement. Placement of the head 110 is accomplished and the electromagnet 112 is activated to secure the surface for operations between the electromagnet and backing plate 114 . The fastener installation systems are then manipulated to drill, locate holes and insert bolts or other fasteners automatically with the structure firmly clamped. While two AWFIS machines are shown in the drawings, up to four AWFIS machines can work on each wing concurrently while still allowing mechanics to work in parallel due to safe stay out zones.
[0047] Once the assembly operations are complete for position 3 the wing structure is canted dihedrally by the MAPS and lowered onto a transfer dolly. The transfer dolly then pulses to the next assembly position for the aircraft.
[0048] As represented in FIGS. 12A-12C , the operational method employing the disclosed embodiments commences in position 1 wherein a front spar with attached MEs and a rear spar with attached MEs are loaded onto the front and rear MAPS of position 1 , step 1202 . The MAPS supporting the front spar are adjusted in 3 axes to place the front spar in a wing reference frame, step 1204 . The ribs are then loaded on the front and rear spars and attached to the front spar, step 1206 . The MAPS supporting the rear spar are adjusted to align determinant assembly (DA) holes in the ribs and rear spar for proper positioning in the wing reference frame, step 1208 . Fasteners are then installed to secure the ladder assembly of the wing structure, step 1210 . A wing side of body geometry tool (SBGT) is installed as a dummy rib and pinned to the spar terminal fittings, step 1212 . The upper panel is loaded onto the ribs, step 1214 , and the forward and aft webs are loaded, step 1216 and pinned to the DA holes in the terminal fittings and upper panel chord, step 1218 . The upper panel chord is flexed up or down by pushers mounted on the applied tool until the DA holes in the webs and chords are aligned, step 1220 , and temporary fasteners are installed in the side of body webs and, fasteners are installed in the upper panel common to the spars and ribs via manual or automated methods, step 1221 . At predetermined assembly points, a planar laser determines relative displacement from the wing reference frame of defined measurement points on the wing assembly due to flexing of the assembly and tooling resulting from addition of mass to the assembly, step 1222 . The MAPS 3-axis motion assemblies are then adjusted to bring the measurement points back into wing reference frame position, step 1223 .
[0049] Identical AGVs have location specific headers mounted for inner and outer wing structure support with lei and right wing designations, step 1224 . The AGV computer control systems sense the header type and synchronously control the AGV based on header type, step 1226 . The AGVs position under the wing structure as supported in the MAPS of position 1 , the headers, with point support mechanisms controllable in multiple axes are raised to engaged the wing structure, step 1228 . When the load cells in the point support mechanisms and fixture receivers confirm that load of the wing structure is being borne by the AGV headers, the MEs are released from the MAPS in position 1 , step 1230 , the MAPS 3-axis motion assemblies retract, step 1232 and the AGVs synchronously move the wing structure to position 2 , step 1234 . The headers on the AGVs position the wing structure for engagement of the MEs with the fixture receivers of the MAPS in position 2 , step 1236 . The MAPS 3-axis motion assemblies in position 2 extend to engage the ME headers with the fixture receivers, step 1238 . The fixture receivers clamp the ME headers and the AGV headers are withdrawn, step 1240 . The planar laser determines relative displacement from the wing reference frame of defined measurement points on the wing assembly, step 1242 . The MAPS 3-axis motion assemblies are then adjusted to bring the measurement points back into wing reference frame position, step 1244 .
[0050] The lower wing panel is loaded onto the header assemblies of the AGV pair, step 1246 and the AGVs synchronously move to position the lower wing panel under the wing structure supported in the MAPS of position 2 , step 1248 . The combined headers and the AGVs then accomplish a synchronized multi-axis coordinated motion to insert the lower skin into position on the wing structure aligning DA holes in the lower skin panel with spar attachment points, step 1250 . The lower skin panel is then loaded using the support point mechanisms for firm engagement with the wing structure, step 1252 . Monitoring of press up forces of the panel to the main wing box structure is accomplished using the load cells to assure that excessive forces are not used and if force limits are exceeded set off audible and visual alarms and stop the motion of the AGVs and associated fixtures 1254 . The lower skin panel is flexed using the pushers on the wing side of body tool until DA holes in the forward and aft web are aligned with corresponding DA holes in the lower panel cord to set the contour, step 1256 . The lower wing panel is then sealed and permanent tack fasteners are installed, step 1258 .
[0051] The AGV headers are then adjusted and the MEs are released from the MAPS in position 2 , step 1260 , the MAPS 3-axis motion assemblies retract, step 1262 and the AGVs synchronously move the wing structure to position 3 , step 1264 . The headers on the AGVs position the wing structure for engagement of the MEs with the fixture receivers of the MAPS in position 3 , step 1266 . The MAPS 3-axis motion assemblies in position 3 extend to engage the ME headers with the fixture receivers, step 1268 . The fixture receivers clamp the ME headers and the AGV headers are withdrawn, step 1270 . The planar laser determines relative displacement from the wing reference frame of defined measurement points on the wing assembly, step 1272 . The MAPS 3-axis motion assemblies are then adjusted to bring the measurement points back into wing reference frame position, step 1274 .
[0052] Multiple Automated Wing Fastener installation Systems (AWFIS) are brought into operating position on positioning guideways, step 1276 . The automated fastening head contacts the surface of the lower wing panel from the outside of the wing structure and applies upward force in conjunction with the electromagnet that is energized and creates an electromagnetic field that pulls a steel backing plate from the inside of the wing to provide sufficient clamping force to close any gaps between the structure, step 1278 . The head drills, countersinks, applies sealant and inserts bolts into the lower wing panel and ribs or spars, step 1280 . Once the assembly operations are complete for position 3 the wing structure is canted dihedrally with the Position 3 MAPS, step 1282 and lowered onto a transfer dolly, step 1284 . The MEs are released from the MAPS in position 3 , step 1286 , the MAPS 3-axis motion assemblies retract, step 1288 . The transfer dolly then pulses to the next assembly position for the aircraft, step 1290 .
[0053] Having now described various embodiments of the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.
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A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.
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This application is a divisional application of U.S. Ser. No. 11/579,656 filed on Mar. 12, 2008, now allowed which is a 371 of PCT/1B2005/001237 filed on Apr. 25, 2005, which claims benefit of provisional application U.S. Ser. No. 60/568,379 filed on May 5, 2004, all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to novel salt forms of atorvastatin which is known by the chemical name [R—(R*,R*)]-2-(4-fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, useful as pharmaceutical agents, to methods for their production and isolation to pharmaceutical compositions which include these compounds and a pharmaceutically acceptable carrier, as well as methods of using such compositions to treat subjects, including human subjects, suffering from hyperlipidemia, hypercholesterolemia, benign prostatic hyperplasia, osteoporosis, and Alzheimer's Disease.
BACKGROUND OF THE INVENTION
The conversion of 3-hydroxy-3-methylglutaryl-coenzyme A (HMG-CoA) to mevalonate is an early and rate-limiting step in the cholesterol biosynthetic pathway. This step is catalyzed by the enzyme HMG-CoA reductase. Statins inhibit HMG-CoA reductase from catalyzing this conversion. As such, statins are collectively potent lipid lowering agents.
Atorvastatin calcium is currently sold as Lipitor® having the chemical name [R—(R*,R*)]-2-(4-fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid calcium salt (2:1) trihydrate and the formula:
The nonproprietary name designated by USAN (United States Adopted Names) is atorvastatin calcium and by INN (International Nonproprietary Name) is atorvastatin. Under the established guiding principles of USAN, the salt is included in the name whereas under INN guidelines, a salt description is not included in the name.
Atorvastatin calcium is a selective, competitive inhibitor of HMG-CoA reductase. As such, atorvastatin calcium is a potent lipid lowering compound and is thus useful as a hypolipidemic and/or hypocholesterolemic agent, as well as in the treatment of osteoporosis, benign prostatic hyperplasia, and Alzheimer's disease.
A number of patents have issued disclosing atorvastatin calcium, formulations of atorvastatin calcium, as well as processes and key intermediates for preparing atorvastatin calcium. These include: U.S. Pat. Nos. 4,681,893; 5,273,995; 5,003,080; 5,097,045; 5,103,024; 5,124,482; 5,149,837; 5,155,251; 5,216,174; 5,245,047; 5,248,793; 5,280,126; 5,397,792; 5,342,952; 5,298,627; 5,446,054; 5,470,981; 5,489,690; 5,489,691; 5,510,488; 5,686,104; 5,998,633; 6,087,511; 6,126,971; 6,433,213; and 6,476,235, which are herein incorporated by reference.
Atorvastatin calcium can exist in crystalline, liquid-crystalline, non-crystalline and amorphous forms.
Crystalline forms of atorvastatin calcium are disclosed in U.S. Pat. Nos. 5,969,156, 6,121,461, and 6,605,729 which are herein incorporated by reference.
Additionally, a number of published International Patent Applications have disclosed crystalline forms of atorvastatin calcium, as well as processes for preparing amorphous atorvastatin calcium. These include: WO 00/71116; WO 01/28999; WO 01/36384; WO 01/42209; WO 02/41834; WO 02/43667; WO 02/43732; WO 02/051804; WO 02/057228; WO 02/057229; WO 02/057274; WO 02/059087; WO 02/072073; WO 02/083637; WO 02/083638; and WO 02/089788.
Atorvastatin is prepared as its calcium salt, i.e., [R—(R*,R*)]-2-(4-fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-1-heptanoic acid calcium salt (2:1). The calcium salt is desirable since it enables atorvastatin to be conveniently formulated in, for example, tablets, capsules, lozenges, powders, and the like for oral administration.
U.S. Pat. No. 5,273,995 discloses the mono-sodium, mono-potassium, hemi-calcium. N-methylglucamine, hemi-magnesium, hemi-zinc, and the 1-deoxy-1-(methylamino)-D-glucitol (N-methylglucamine) salts of atorvastatin.
Also, atorvastatin free acid, disclosed in U.S. Pat. No. 5,273,995, can be used to prepare these salts of atorvastatin.
Additionally, U.S. Pat. No. 6,583,295 B1 discloses a series of amine salts of HMG-CoA reductase inhibitors which are used in a process for isolation and/or purification of these HMG-CoA reductase. The tertiary butylamine and dicyclohexylamine salts of atorvastatin are disclosed.
We have now surprisingly and unexpectedly found novel salt forms of atorvastatin including salts with ammonium, benethamine, benzathine, dibenzylamine, diethylamine, L-lysine, morpholine, olamine, piperazine, and 2-amino-2-methylpropan-1-ol which have desirable properties. Additionally, we have surprisingly and unexpectedly found novel crystalline forms of atorvastatin which include salts with erbumine and sodium which have desirable properties. As such, these salt forms are pharmaceutically acceptable and can be used to prepare pharmaceutical formulations. Thus, the present invention provides basic salts of atorvastatin that are pure, have good stability, and have advantageous formulation properties compared to prior salt forms of atorvastatin.
SUMMARY OF THE INVENTION
Accordingly, a first aspect of the invention is directed to atorvastatin ammonium and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >30% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>30%)
3.5
49.0
4.4
34.8
7.4
36.5
7.8
58.0
8.8
53.9
9.3
44.1
9.9
43.8
10.6
80.3
12.4
35.1
14.1
30.1
16.8
54.5
18.3
56.2
19.0
67.8
19.5
100.0
20.3
81.4
21.4
69.0
21.6
63.8
23.1
65.5
23.9
63.8
24.8
69.0
In a second aspect, the invention is directed to Form A atorvastatin benethamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >8% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>8%)
4.7
42.2
5.3
21.7
6.0
12.9
7.8
9.6
8.9
53.3
9.5
84.4
10.5
10.6
12.0
11.5
13.8
12.1
14.3
13.3
15.6
20.1
16.7
24.6
16.9
19.9
17.6
52.7
17.8
53.1
18.1
59.7
18.8
100.0
19.1
39.1
19.9
42.4
21.3
36.2
21.9
22.8
22.7
19.8
23.6
52.4
24.3
23.5
25.9
23.5
26.3
36.2
27.0
13.5
27.9
11.8
28.8
9.4
29.6
9.8
In a third aspect, the invention is directed to Form A atorvastatin benethamine and hydrates thereof characterized by the following solid-state 13 C nuclear magnetic resonance (SSNMR) spectrum wherein chemical shift is expressed in parts per million (ppm):
Peak #
ppm*
1
180.1
2
178.8
3
165.1
4
164.1
5
162.8
6
161.7
7
160.7
8
140.6
9
139.6
10
137.9
11
136.1
12
133.0
13
129.6
14
127.3
15
126.4
16
125.4
17
123.1
18
122.5
19
121.6
20
121.1
21
119.9
22
116.4
23
115.4
24
114.5
25
114.0
26
66.0
27
65.5
28
64.6
29
53.6
30
51.5
31
51.0
32
47.8
33
44.6
34
43.3
35
41.4
36
40.9
37
38.5
38
37.7
39
36.8
40
34.0
41
32.7
42
26.5
43
25.1
44
23.5
45
23.1
46
19.7
47
19.1
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a fourth aspect, the present invention is directed to Form A atorvastatin benethamine and hydrates thereof characterized by the following solid-state 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−113.2
2
−114.2
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a fifth aspect, the invention is directed to Form B atorvastatin benethamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >6% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>6%)
4.1
9.8
5.0
11.3
5.8
8.8
7.1
10.4
8.4
13.3
8.9
53.2
10.0
8.1
11.6
13.6
12.6
16.6
14.4
46.3
14.8
13.5
16.5
15.4
17.7
23.6
18.6
20.2
20.2
100.0
21.4
30.6
21.6
24.7
22.3
5.9
22.7
6.3
23.4
8.4
23.6
12.8
25.0
10.2
25.2
12.2
25.9
19.2
26.2
30.1
28.0
6.9
28.3
5.4
29.3
6.4
29.7
5.9
31.8
5.3
33.5
12.1
35.2
6.6
35.8
5.9
In a sixth aspect, the invention is directed to Form B atorvastatin benethamine and hydrates thereof characterized by the following solid-state 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
179.4
2
165.6
3
162.4
4
140.1
5
138.6
6
133.6
7
132.8
8
129.9
9
128.2
10
125.7
11
123.6
12
114.8
13
69.6
14
69.0
15
52.3
16
49.8
17
43.1
18
42.2
19
39.6
20
38.9
21
31.5
22
26.5
23
23.5
24
19.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a seventh aspect, the invention is directed to Form B atorvastatin benethamine and hydrates thereof characterized by the following solid-state 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−113.7
2
−114.4
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a eighth aspect, the invention is directed to Form A atorvastatin benzathine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >12% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>12%)
9.1
97.5
14.0
40.3
15.1
13.8
15.5
13.7
16.1
15.3
16.4
16.8
18.2
40.0
19.1
58.5
19.6
18.1
20.5
100.0
21.3
66.3
22.1
15.5
22.5
21.7
23.0
43.8
25.2
18.8
25.9
12.9
26.1
15.6
26.5
14.4
28.0
14.2
28.6
17.1
In a ninth aspect, the invention is directed to Form B atorvastatin benzathine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >9% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>9%)
8.3
100.0
9.1
9.4
10.2
62.6
11.7
9.1
13.2
10.2
14.4
21.1
15.8
18.1
16.6
20.0
17.1
14.8
18.6
34.0
19.1
40.7
19.4
23.0
19.7
14.8
20.6
24.0
20.9
13.1
21.4
28.8
21.8
29.3
22.3
24.9
22.6
29.2
23.3
46.1
23.5
31.3
24.3
11.0
25.0
18.9
26.5
14.8
26.8
11.6
27.4
13.2
27.9
12.3
28.2
9.3
28.9
9.3
29.1
9.8
29.7
10.9
In a tenth aspect, the invention is directed to Form C atorvastatin benzathine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >13% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>13%)
3.9
59.5
6.9
23.3
7.9
30.5
9.7
70.6
11.9
100.0
12.8
17.8
13.2
41.4
15.5
15.3
16.3
13.1
16.8
17.4
17.2
39.5
18.9
18.4
19.5
31.5
19.9
31.7
20.4
58.2
20.7
43.9
21.4
29.2
23.0
19.0
23.4
18.7
24.0
26.6
24.3
33.6
24.6
41.4
25.9
21.5
26.2
28.4
In an eleventh aspect, the invention is directed to atorvastatin dibenzylamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >8% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>8%)
4.6
10.6
8.3
50.8
9.6
13.8
9.8
10.0
10.3
14.9
10.4
12.1
10.6
19.8
11.8
13.9
12.4
7.7
13.3
10.0
14.5
10.2
14.9
11.6
15.9
11.8
16.7
10.4
17.4
23.6
18.4
19.7
18.7
38.5
19.4
24.2
19.8
48.0
20.7
100.0
21.3
56.4
21.6
26.7
22.1
13.4
22.5
21.9
23.0
9.7
23.4
29.5
23.7
29.7
24.3
11.0
24.6
13.6
25.1
13.0
25.8
31.9
26.7
8.5
28.0
10.8
29.2
12.2
33.4
9.8
34.6
8.1
34.8
9.1
In a twelfth aspect, the invention is directed to atorvastatin dibenzylamine and hydrates thereof characterized by the following solid-state 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
179.1
2
166.2
3
163.1
4
160.8
5
140.6
6
135.2
7
134.3
8
133.4
9
131.9
10
131.1
11
129.4
12
128.3
13
125.6
14
124.2
15
122.9
16
119.7
17
115.4
18
69.7
19
68.6
20
52.6
21
51.3
22
43.0
23
41.9
24
38.8
25
38.2
26
26.7
27
23.3
28
20.0
*Vaues in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a thirteenth aspect, the invention is directed to atorvastatin dibenzylamine and hydrates thereof characterized by the following solid-state 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−107.8
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a fourteenth aspect, the invention is directed to Form A atorvastatin diethylamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >20% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>20%)
7.0
53.0
8.2
32.0
10.8
59.3
12.3
36.0
13.3
60.8
14.4
56.0
16.1
35.5
16.5
39.3
17.0
40.0
18.2
49.3
18.4
100.0
19.4
23.0
20.0
20.5
21.0
54.5
21.7
24.5
22.3
30.5
23.0
68.8
24.3
25.5
25.1
38.5
25.4
26.9
26.3
41.3
26.8
21.8
28.4
23.8
In an fifteenth aspect, the invention is directed to Form B atorvastatin diethylamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >8% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>8%)
6.1
8.3
7.0
10.6
8.3
26.0
10.8
8.5
11.5
21.4
12.2
28.2
12.5
12.7
13.4
16.5
14.5
10.0
15.3
34.2
16.1
17.1
16.6
12.8
16.8
16.6
17.4
17.3
17.9
8.1
18.4
12.8
18.7
8.5
19.3
52.2
20.5
21.4
21.0
100.0
22.3
13.0
23.2
34.2
24.6
23.7
25.4
8.2
25.9
8.1
26.4
16.9
27.6
25.6
29.2
10.6
31.2
8.5
32.8
9.1
In an sixteenth aspect, the invention is directed to atorvastatin erbumine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >6% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>6%)
5.4
11.9
7.3
12.0
9.5
100.0
12.6
14.3
15.2
15.6
16.6
13.7
17.8
21.0
18.6
20.2
19.2
77.6
20.0
28.3
20.4
8.2
20.9
22.3
21.6
14.3
22.2
26.6
22.4
13.3
22.6
14.5
23.7
8.7
24.2
31.6
25.0
15.5
26.5
12.3
28.2
7.9
29.5
6.3
30.6
6.5
In a seventeenth aspect, the invention is directed to atorvastatin erbumine and hydrates thereof characterized by the following solid-state 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
179.3
2
164.5
3
163.0
4
160.9
5
141.3
6
140.9
7
135.3
8
134.5
9
132.8
10
129.0
11
127.7
12
124.5
13
121.8
14
120.2
15
116.5
16
115.5
17
112.4
18
71.3
19
50.3
20
47.7
21
42.6
22
41.0
23
28.5
24
26.4
25
22.6
26
21.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a eighteenth aspect, the invention is directed to atorvastatin erbumine and hydrates thereof characterized by the following solid-state 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−110.4
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a nineteenth aspect, the invention is directed to atorvastatin L-lysine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the and relative intensities with a relative intensity of >40% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>40%)
6.7
100.0
9.5
62.1
9.8
74.3
17.1
80.4
18.7
86.5
19.6
76.8
21.1
77.1
22.1
72.1
22.5
77.9
24.0
59.5
In a twentieth aspect, the invention is directed to atorvastatin morpholine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the and relative intensities with a relative intensity of >9% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>9%)
4.8
15.9
5.7
10.7
6.4
11.6
8.6
9.2
9.7
52.5
12.8
6.8
14.1
10.3
14.6
22.5
16.0
42.1
16.3
26.7
16.5
21.3
17.3
19.6
17.5
29.3
18.1
16.5
18.9
46.1
19.2
27.3
19.6
85.9
19.9
19.8
20.8
42.2
21.2
16.9
22.1
89.9
23.1
19.6
23.9
100.0
24.6
26.0
25.0
39.0
25.7
11.0
27.0
14.1
28.1
10.1
28.5
25.8
29.6
11.8
30.1
9.9
30.9
13.4
31.0
14.1
32.0
13.0
32.4
16.5
33.4
14.1
33.9
11.0
34.6
18.0
35.4
14.3
36.8
18.2
37.6
11.4
In a twenty-first aspect, the invention is directed to atorvastatin morpholine and hydrates thereof characterized by the following solid-state 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in carts car million:
Peak #
ppm*
1
179.3
2
165.9
3
162.7
4
160.5
5
139.6
6
137.8
7
134.3
8
131.2
9
129.6
10
128.7
11
127.4
12
122.9
13
120.8
14
117.9
15
116.3
16
70.8
17
69.5
18
63.4
19
42.4
20
41.2
21
40.5
22
24.8
23
20.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a twenty-second aspect, the invention is directed to atorvastatin morpholine and hydrates thereof characterized by the following 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−117.6
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a twenty-third aspect, the invention is directed to atorvastatin olamine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the and relative intensities with a relative intensity of >15% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>15%)
8.5
100.0
9.8
74.7
11.4
17.3
12.0
15.6
16.3
27.7
17.4
43.9
18.6
85.5
19.6
45.8
20.1
43.9
20.9
96.0
21.4
31.6
22.0
30.5
22.5
66.1
22.8
35.6
23.5
20.5
24.1
42.7
25.1
23.3
25.9
25.0
26.2
33.1
27.8
19.3
28.8
27.5
29.6
20.0
31.7
20.5
37.7
22.5
In a twenty-fourth aspect, the invention is directed to atorvastatin olamine and hydrates thereof characterized by the following 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
182.0
2
178.9
3
165.4
4
161.6
5
159.5
6
137.4
7
134.8
8
133.8
9
131.0
10
128.7
11
128.0
12
127.0
13
123.1
14
122.6
15
121.9
16
120.9
17
120.1
18
117.3
19
115.6
20
114.3
21
66.5
22
66.0
23
65.2
24
58.5
25
58.2
26
51.1
27
47.8
28
46.0
29
43.9
30
42.4
31
41.3
32
40.6
33
39.8
34
25.7
35
23.1
36
21.1
37
20.7
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a twenty-fifth aspect, the invention is directed to atorvastatin olamine and hydrates thereof characterized by the following 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−118.7
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
In a twenty-sixth aspect, the invention is directed to atorvastatin piperazine and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >20% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>20%)
4.4
20.4
7.8
25.5
9.3
27.2
11.8
29.7
13.2
22.9
16.1
30.0
17.7
30.9
19.7
100.0
20.4
55.0
22.2
31.9
22.9
36.2
23.8
30.7
26.4
32.6
In a twenty-seventh aspect, the invention is directed to atorvastatin sodium and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the and relative intensities with a relative intensity of >25% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>25%)
3.4
57.8
4.1
29.2
4.9
53.0
5.6
32.4
6.8
25.2
7.6
68.5
8.0
75.7
8.5
42.0
9.9
66.1
10.4
51.5
12.8
25.5
18.9
100.0
19.7
64.5
21.2
32.8
22.1
33.3
22.9
45.4
23.3
43.6
24.0
42.7
25.2
26.1
In a twenty-eighth aspect, the invention is directed to atorvastatin 2-amino-2-methylpropan-1-ol and hydrates thereof characterized by the following x-ray powder diffraction pattern expressed in terms of the 2θ and relative intensities with a relative intensity of >20% measured on a Bruker D5000 diffractometer with CuK α radiation:
Relative
Degree
Intensity
2θ
(>20%)
4.2
95.2
6.0
59.9
6.2
43.7
8.3
26.3
11.5
20.9
12.5
36.5
12.6
31.1
16.0
44.4
17.5
54.3
18.3
52.8
18.8
34.0
19.4
55.3
19.7
100.0
21.3
26.7
22.0
31.3
22.8
21.7
23.4
29.7
23.8
28.6
In a twenty-ninth aspect, the invention is directed to atorvastatin 2-amino-2-methylpropan-1-ol and hydrates thereof characterized by the following 13 C nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
179.8
2
166.3
3
163.3
4
161.5
5
161.2
6
140.5
7
139.5
8
134.4
9
132.3
10
131.6
11
129.8
12
128.1
13
126.1
14
125.1
15
122.2
16
120.7
17
116.4
18
114.0
19
113.4
20
72.6
21
71.4
22
67.6
23
66.3
24
64.7
25
64.4
26
53.1
27
46.9
28
43.9
29
43.5
30
42.7
31
39.7
32
36.1
33
26.8
34
26.3
35
24.3
36
23.8
37
23.1
38
22.0
39
20.4
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
In a thirtieth aspect, the invention is directed to atorvastatin 2-amino-2-methylpropan-1-ol and hydrates thereof characterized by the following 19 F nuclear magnetic resonance spectrum wherein chemical shift is expressed in parts per million:
Peak #
ppm*
1
−113.6
2
−116.5
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic add (50% V/V in water) at −76.54 ppm.
As inhibitors of HMG-CoA reductase, the novel salt forms of atorvastatin are useful as hypolipidemic and hypocholesteroiemic agents, as well as agents in the treatment of osteoporosis, benign prostatic hyperplasia, and Alzheimer's Disease.
A still further embodiment of the present invention is a pharmaceutical composition for administering an effective amount of an atorvastatin salt in unit dosage form in the treatment methods mentioned above. Finally, the present invention is directed to methods for production of salt forms of atorvastatin.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by the following nonlimiting examples which refer to the accompanying FIGS. 1 to 30 , short particulars of which are given below.
FIG. 1
Diffractogram of atorvastatin ammonium carried out on a Bruker D5000 diffractometer.
FIG. 2
Diffractogram of Form A atorvastatin benethamine carried out on a Bruker D5000 diffractometer.
FIG. 3
Solid-state 13 C nuclear magnetic resonance spectrum of Form A atorvastatin benethamine.
FIG. 4
Solid-state 19 F nuclear magnetic resonance spectrum of Form A atorvastatin benethamine.
FIG. 5
Diffractogram of Form B atorvastatin benethamine carried out on a Bruker D5000 diffractometer.
FIG. 6
Solid-state 13 C nuclear magnetic resonance spectrum of Form B atorvastatin benethamine.
FIG. 7
Solid-state 19 F nuclear magnetic resonance spectrum of Form B atorvastatin benethamine.
FIG. 8
Diffractogram of Form A atorvastatin benzathine carried out on a Bruker D5000 diffractometer.
FIG. 9
Diffractogram of Form B atorvastatin benzathine carried out on a Bruker. D5000 diffractometer.
FIG. 10
Diffractogram of Form C atorvastatin benzathine carried out on a Bruker D5000 diffractometer.
FIG. 11
Diffractogram of atorvastatin dibenzylamine carried out on a Bruker D5000 diffractometer.
FIG. 12
Solid-state 13 C nuclear magnetic resonance spectrum of atorvastatin dibenzylamine.
FIG. 13
Solid-state 19 F nuclear magnetic resonance spectrum of atorvastatin dibenzylamine.
FIG. 14
Diffractogram of Form A atorvastatin diethylamine carried out on a Bruker. D5000 diffractometer.
FIG. 15
Diffractogram of Form B atorvastatin diethylamine carried out on a Bruker D5000 diffractometer.
FIG. 16
Diffractogram of atorvastatin erbumine carried out on a Bruker D5000 diffractometer.
FIG. 17
Solid-state 13 C nuclear magnetic resonance spectrum of atorvastatin erbumine.
FIG. 18
Solid-state 19 F nuclear magnetic resonance spectrum of atorvastatin erbumine.
FIG. 19
Diffractogram of atorvastatin L-lysine carried out on a Bruker D5000 diffractometer.
FIG. 20
Diffractogram of atorvastatin morpholine carried out on a Bruker D5000 diffractometer.
FIG. 21
Solid-state 13 C nuclear magnetic resonance spectrum of atorvastatin morpholine.
FIG. 22
Solid-state 19 F nuclear magnetic resonance spectrum of atorvastatin morpholine.
FIG. 23
Diffractogram of atorvastatin olamine carried out on a Bruker D5000 diffractometer.
FIG. 24
Solid-state 13 C nuclear magnetic resonance spectrum of atorvastatin olamine.
FIG. 25
Solid-state 19 F nuclear magnetic resonance spectrum of atorvastatin olamine.
FIG. 26
Diffractogram of atorvastatin piperazine carried out on a Bruker. D5000 diffractometer.
FIG. 27
Diffractogram of atorvastatin sodium carried out on a Bruker D5000 diffractometer.
FIG. 28
Diffractogram of atorvastatin 2-amino-2-methylpropan-1-ol carried out on a Bruker D5000 diffractometer.
FIG. 29
Solid-state 13 C nuclear magnetic resonance spectrum of atorvastatin 2-amino-2-methylpropan-1-ol.
FIG. 30
Solid-state 19 F nuclear magnetic resonance spectrum of atorvastatin 2-amino-2-methylpropan-1-ol.
DETAILED DESCRIPTION OF THE INVENTION
The novel salt forms of atorvastatin may be characterized by their x-ray powder diffraction patterns and/or by their solid-state nuclear magnetic resonance spectra.
Powder X-Ray Diffraction
Atorvastatin salts were characterized by their powder x-ray diffraction patterns. Thus, the x-ray diffraction pattern was carried out on a Bruker D5000 diffractometer using copper radiation (wavelength 1:1.54056). The tube voltage and amperage were set to 40 kV and 50 mA, respectively. The divergence and scattering slits were set at 1 mm, and the receiving slit was set at 0.6 mm. Diffracted radiation was detected by a Kevex PSI detector. A theta-two theta continuous scan at 2.4°/min (1 sec/0.04° step) from 3.0 to 40° 2θ was used. An alumina standard was analyzed to check the instrument alignment. Data were collected and analyzed using Bruker axis software Version 7.0. Samples were prepared by placing them in a quartz holder. It should be noted that Bruker Instruments purchased Siemens; thus, Bruker D5000 instrument is essentially the same as a Siemens D5000.
The following tables list the 2θ and intensities of lines for the atorvastatin salts and hydrates thereof. Additionally, there are tables which list individual 2θ peaks for the atorvastatin salts and hydrates thereof. In cases were there are two or more crystalline forms of an atorvastatin salt or hydrate thereof, each form can be identified and distinguished from the other crystalline form by either a single x-ray diffraction line, a combination of lines, or a pattern that is different from the x-ray powder diffraction of the other forms.
Table 1 lists the 2θ and relative intensities of all lines that have a relative intensity of >30% in the sample for atorvastatin ammonium and hydrates thereof:
TABLE 1
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES IN
ATORVASTATIN AMMONIUM AND HYDRATES THEREOF
Relative
Degree
Intensity
2θ
(>30%)
3.5
49.0
4.4
34.8
7.4
36.5
7.8
58.0
8.8
53.9
9.3
44.1
9.9
43.8
10.6
80.3
12.4
35.1
14.1
30.1
16.8
54.5
18.3
56.2
19.0
67.8
19.5
100.0
20.3
81.4
21.4
69.0
21.6
63.8
23.1
65.5
23.9
63.8
24.8
69.0
Table 2 lists individual peaks for atorvastatin ammonium and hydrates thereof:
TABLE 2
ATORVASTATIN AMMONIUM AND HYDRATES THEREOF
DEGREE
2θ
7.8
8.8
9.3
9.9
10.6
12.4
19.5
Table 3 lists the 2θ and relative intensities of all lines that have a relative intensity of >8% in the sample for atorvastatin benethamine Forms A and B and hydrates thereof:
TABLE 3
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN BENETHAMINE, FORMS A AND B AND
HYDRATES THEREOF
Form A
Form B
Relative
Relative
Degree
Intensity
Degree
Intensity
2θ
(>8%)
2θ
(>6%)
4.7
42.2
4.1
9.8
5.3
21.7
5.0
11.3
6.0
12.9
5.8
8.8
7.8
9.6
7.1
10.4
8.9
53.3
8.4
13.3
9.5
84.4
8.9
53.2
10.5
10.6
10.0
8.1
12.0
11.5
11.6
13.6
13.8
12.1
12.6
16.6
14.3
13.3
14.4
46.3
15.6
20.1
14.8
13.5
16.7
24.6
16.5
15.4
16.9
19.9
17.7
23.6
17.6
52.7
18.6
20.2
17.8
53.1
20.2
100.0
18.1
59.7
21.4
30.6
18.8
100.0
21.6
24.7
19.1
39.1
22.3
5.9
19.9
42.4
22.7
6.3
21.3
36.2
23.4
8.4
21.9
22.8
23.6
12.8
22.7
19.8
25.0
10.2
23.6
52.4
25.2
12.2
24.3
23.5
25.9
19.2
25.9
23.5
26.2
30.1
26.3
36.2
28.0
6.9
27.0
13.5
28.3
5.4
27.9
11.8
29.3
6.4
28.8
9.4
29.7
5.9
29.6
9.8
31.8
5.3
33.5
12.1
35.2
6.6
35.8
5.9
Table 4 lists individual 2θ peaks for atorvastatin benethamine, Forms A and B and hydrates thereof.
TABLE 4
FORMS A and B ATORVASTATIN BENETHAMINE AND
HYDRATES THEREOF
Form A
Form B
Degree
Degree
2θ
2θ
4.7
5.0
5.3
7.1
9.5
8.4
12.0
10.0
15.6
11.6
18.1
12.6
19.9
14.8
20.2
Table 5 lists the 2θ and relative intensities of all lines that have a relative intensity of >9% in the sample for atorvastatin benzathine Forms A, B, and C and hydrates thereof:
TABLE 5
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN BENZATHINE, FORMS A, B, AND C AND
HYDRATES THEREOF
Form A
Form B
Form C
Relative
Relative
Relative
Intensity
Intensity
Intensity
Degree 2θ
(>12%)
Degree 2θ
(>9%)
Degree 2θ
(>13%)
9.1
97.5
8.3
100.0
3.9
59.5
14.0
40.3
9.1
9.4
6.9
23.3
15.1
13.8
10.2
62.6
7.9
30.5
15.5
13.7
11.7
9.1
9.7
70.6
16.1
15.3
13.2
10.2
11.9
100.0
16.4
16.8
14.4
21.1
12.8
17.8
18.2
40.0
15.8
18.1
13.2
41.4
19.1
58.5
16.6
20.0
15.5
15.3
19.6
18.1
17.1
14.8
16.3
13.1
20.5
100.0
18.6
34.0
16.8
17.4
21.3
66.3
19.1
40.7
17.2
39.5
22.1
15.5
19.4
23.0
18.9
18.4
22.5
21.7
19.7
14.8
19.5
31.5
23.0
43.8
20.6
24.0
19.9
31.7
25.2
18.8
20.9
13.1
20.4
58.2
25.9
12.9
21.4
28.8
20.7
43.9
26.1
15.6
21.8
29.3
21.4
29.2
26.5
14.4
22.3
24.9
23.0
19.0
28.0
14.2
22.6
29.2
23.4
18.7
28.6
17.1
23.3
46.1
24.0
26.6
23.5
31.3
24.3
33.6
24.3
11.0
24.6
41.4
25.0
18.9
25.9
21.5
26.5
14.8
26.2
28.4
26.8
11.6
27.4
13.2
27.9
12.3
28.2
9.3
28.9
9.3
29.1
9.8
29.7
10.9
Table 6 lists individual 2θ peaks for atorvastatin benzathine, Forms A, B, and C and hydrates thereof.
TABLE 6
FORMS A, B, and C ATORVASTATIN BENZATHINE AND
HYDRATES THEREOF
Form A
Form B
Form C
Degree
Degree
Degree
2θ
2θ
2θ
14.0
8.3
3.9
15.1
10.2
6.9
14.4
7.9
15.8
9.7
18.6
12.8
21.8
23.3
Table 7 lists the 2θ and relative intensities of all lines that have a relative intensity of >8% in the sample for atorvastatin dibenzylamine and hydrates thereof:
TABLE 7
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN DIBENZYLAMINE AND HYDRATES
THEREOF
Relative
Degree
Intensity
2θ
(>8%)
4.6
10.6
8.3
50.8
9.6
13.8
9.8
10.0
10.3
14.9
10.4
12.1
10.6
19.8
11.8
13.9
12.4
7.7
13.3
10.0
14.5
10.2
14.9
11.6
15.9
11.8
16.7
10.4
17.4
23.6
18.4
19.7
18.7
38.5
19.4
24.2
19.8
48.0
20.7
100.0
21.3
56.4
21.6
26.7
22.1
13.4
22.5
21.9
23.0
9.7
23.4
29.5
23.7
29.7
24.3
11.0
24.6
13.6
25.1
13.0
25.8
31.9
26.7
8.5
28.0
10.8
29.2
12.2
33.4
9.8
34.6
8.1
34.8
9.1
Table 8 lists the individual 2θ peaks for atorvastatin dibenzylamine and hydrates thereof:
TABLE 8
ATORVASTATIN DIBENZYLAMINE AND HYDRATES THEREOF
Degree
2θ
8.3
18.7
19.8
20.7
21.3
25.8
Table 9 lists the 2θ and relative intensities of all lines that have a relative intensity of >8% in the sample for atorvastatin diethylamine Forms A and B and hydrates thereof:
TABLE 9
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN DIETHYLAMINE, FORMS A AND B AND
HYDRATES THEREOF
Form A
Form B
Relative
Relative
Degree
Intensity
Degree
Intensity
2θ
(>20%)
2θ
(>8%)
7.0
53.0
6.1
8.3
8.2
32.0
7.0
10.6
10.8
59.3
8.3
26.0
12.3
36.0
10.8
8.5
13.3
60.8
11.5
21.4
14.4
56.0
12.2
28.2
16.1
35.5
12.5
12.7
16.5
39.3
13.4
16.5
17.0
40.0
14.5
10.0
18.2
49.3
15.3
34.2
18.4
100.0
16.1
17.1
19.4
23.0
16.6
12.8
20.0
20.5
16.8
16.6
21.0
54.5
17.4
17.3
21.7
24.5
17.9
8.1
22.3
30.5
18.4
12.8
23.0
68.8
18.7
8.5
24.3
25.5
19.3
52.2
25.1
38.5
20.5
21.4
25.4
26.9
21.0
100.0
26.3
41.3
22.3
13.0
26.8
21.8
23.2
34.2
28.4
23.8
24.6
23.7
25.4
8.2
25.9
8.1
26.4
16.9
27.6
25.6
29.2
10.6
31.2
8.5
32.8
9.1
Table 10 lists individual 2θ peaks for atorvastatin diethylamine, Forms A, B, and C and hydrates thereof.
TABLE 10
FORMS A AND B ATORVASTATIN DIETHYLAMINE AND
HYDRATES THEREOF
Form A
Form B
Degree
Degree
2θ
2θ
17.0
6.1
18.2
11.5
20.0
15.3
21.7
17.4
23.0
20.5
23.2
27.6
Table 11 lists the 2θ and relative intensities of all lines that have a relative intensity >6% in the sample for atorvastatin erbumine and hydrates thereof:
TABLE 11
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN ERBUMINE AND HYDRATES THEREOF
Relative
Degree
Intensity
2θ
(>6%)
5.4
11.9
7.3
12.0
9.5
100.0
12.6
14.3
15.2
15.6
16.6
13.7
17.8
21.0
18.6
20.2
19.2
77.6
20.0
28.3
20.4
8.2
20.9
22.3
21.6
14.3
22.2
26.6
22.4
13.3
22.6
14.5
23.7
8.7
24.2
31.6
25.0
15.5
26.5
12.3
28.2
7.9
29.5
6.3
30.6
6.5
Table 12 lists individual 2θ peaks for atorvastatin erbumine and hydrates thereof:
TABLE 12
ATORVASTATIN ERBUMINE AND HYDRATES THEREOF
Degree
2θ
5.4
7.3
9.5
17.8
19.2
20.0
22.2
24.2
Table 13 lists 2θ and relative intensities of all lines that have a relative intensity of >40% in the sample for atorvastatin L-lysine and hydrates thereof:
TABLE 13
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN L-LYSINE AND HYDRATES THEREOF
Relative
Degree
Intensity
2θ
(>40%)
6.7
100.0
9.5
62.1
9.8
74.3
17.1
80.4
18.7
86.5
19.6
76.8
21.1
77.1
22.1
72.1
22.5
77.9
24.0
59.5
Table 14 lists individual 2θ peaks for atorvastatin L-Lysine and hydrates thereof:
TABLE 14
ATORVASTATIN L-LYSINE AND HYDRATES THEREOF
Degree
2θ
6.7
9.8
17.1
24.0
Table 15 lists the 2θ and relative intensities of all lines that have a relative intensity of >9% in the sample for atorvastatin morpholine and hydrates thereof:
TABLE 15
INTENSITIES AND PEAK LOCATIONS OF DIFFRACTION LINES
FOR ATORVASTATIN MORPHOLINE AND HYDRATES THEREOF
Relative
Degree
Intensity
2θ
(>9%)
4.8
15.9
5.7
10.7
6.4
11.6
8.6
9.2
9.7
52.5
12.8
6.8
14.1
10.3
14.6
22.5
16.0
42.1
16.3
26.7
16.5
21.3
17.3
19.6
17.5
29.3
18.1
16.5
18.9
46.1
19.2
27.3
19.6
85.9
19.9
19.8
20.8
42.2
21.2
16.9
22.1
89.9
23.1
19.6
23.9
100.0
24.6
26.0
25.0
39.0
25.7
11.0
27.0
14.1
28.1
10.1
28.5
25.8
29.6
11.8
30.1
9.9
30.9
13.4
31.0
14.1
32.0
13.0
32.4
16.5
33.4
14.1
33.9
11.0
34.6
18.0
35.4
14.3
36.8
18.2
37.6
11.4
Table 16 lists individual 2θ peaks for atorvastatin morpholine and hydrates thereof:
TABLE 16
ATORVASTATIN MORPHINE AND HYDRATES THEREOF
Degree 2θ
9.7
16.0
18.9
19.6
20.8
22.1
23.9
25.0
Table 17 lists the 2θ and relative intensities of all lines that have a relative intensity of >15% in the sample for atoravstatin olamine and hydrates thereof:
TABLE 17
INTENSITIES AND PEAK LOCATIONS OF
DIFFRACTION LINES FOR ATORVASTATIN
OLAMINE AND HYDRATES THEREOF
Degree
Relative Intensity
2θ
(>15%)
8.5
100.0
9.8
74.7
11.4
17.3
12.0
15.6
16.3
27.7
17.4
43.9
18.6
85.5
19.6
45.8
20.1
43.9
20.9
96.0
21.4
31.6
22.0
30.5
22.5
66.1
22.8
35.6
23.5
20.5
24.1
42.7
25.1
23.3
25.9
25.0
26.2
33.1
27.8
19.3
28.8
27.5
29.6
20.0
31.7
20.5
37.7
22.5
Table 18 lists individual 2θ peaks for atorvastatin olamine and hydrates thereof:
TABLE 18
ATORVASTATIN OLAMINE AND HYDRATES THEREOF
Degree 2θ
8.5
9.8
17.4
18.6
20.9
22.5
24.1
Table 19 lists the 2θ and relative intensities of all lines that have a relative intensity of >20% in the sample for atorvastatin piperazine and hydrates thereof:
TABLE 19
INTENSITIES AND PEAK LOCATIONS OF
DIFFRACTION LINES FOR ATORVASTATIN
PIPERAZINE AND HYDRATES THEREOF
Degree
Relative Intensity
2θ
(>20%)
4.4
20.4
7.8
25.5
9.3
27.2
11.8
29.7
13.2
22.9
16.1
30.0
17.7
30.9
19.7
100.0
20.4
55.0
22.2
31.9
22.9
36.2
23.8
30.7
26.4
32.6
Table 20 lists the individual 2θ peaks for atorvastatin piperazine and hydrates thereof:
TABLE 20
ATORVASTATIN PIPERAZINE AND HYDRATES THEREOF
Degree 2θ
7.8
9.3
11.8
16.1
19.7
Table 21 lists the 2θ and relative intensities of all lines that have a relative intensity of >25% in the sample for atoravastatin sodium and hydrates thereof:
TABLE 21
INTENSITIES AND PEAK LOCATIONS OF
DIFFRACTION LINES FOR ATORVASTATIN
SODIUM AND HYDRATES THEREOF
Degree
Relative Intensity
2θ
(>25%)
3.4
57.8
4.1
29.2
4.9
53.0
5.6
32.4
6.8
25.2
7.6
68.5
8.0
75.7
8.5
42.0
9.9
66.1
10.4
51.5
12.8
25.5
18.9
100.0
19.7
64.5
21.2
32.8
22.1
33.3
22.9
45.4
23.3
43.6
24.0
42.7
25.2
26.1
Table 22 lists individual 2θ peaks for atorvastatin sodium and hydrates thereof:
TABLE 22
ATORVASTATIN SODIUM AND HYDRATES THEREOF
Degree 2θ
3.4
4.9
7.6
8.0
9.9
18.9
19.7
Table 23 lists the 2θ and relative intensities of all lines that have a relative intensity of >25% in the sample for atorvastatin 2-amino-2-methylpropan-1-ol and hydrates thereof:
TABLE 23
INTENSITIES AND PEAK LOCATIONS OF
DIFFRACTION LINES FOR ATORVASTATIN
2-AMINO-2-METHYLPROPAN-1-OL
AND HYDRATES THEREOF
Degree
Relative Intensity
2θ
(>20%)
4.2
95.2
6.0
59.9
6.2
43.7
8.3
26.3
11.5
20.9
12.5
36.5
12.6
31.1
16.0
44.4
17.5
54.3
18.3
52.8
18.8
34.0
19.4
55.3
19.7
100.0
21.3
26.7
22.0
31.3
22.8
21.7
23.4
29.7
23.8
28.6
Table 24 lists individual peaks for atorvastatin 2-amino-2-methylpropan-1-ol and hydrates thereof:
TABLE 24
ATORVASTATIN 2-AMINO-2-METHYLPROPAN-1-OL
AND HYDRATES THEREOF
Degree 2θ
4.2
8.3
16.0
17.5
18.3
19.4
19.7
Solid State Nuclear Magnetic Resonance
The novel salt forms of atorvastatin may also be characterized by their solid-state nuclear magnetic resonance spectra. Thus, the solid-state nuclear magnetic resonance spectra of the salt forms of atorvastatin were carried out on a Bruker-Biospin Avance DSX 500 MHz NMR spectrometer.
19 F SSNMR
Approximately 15 mg of sample were tightly packed into a 2.5 mm ZrO spinner for each sample analyzed. One-dimensional 19 F spectra were collected at 295 K and ambient pressure on a Bruker-Biospin 2.5 mm BL cross-polarization magic angle spinning (CPMAS) probe positioned into a wide-bore Bruker-Biospin Avance DSX 500 MHz NMR spectrometer. The samples were positioned at the magic angle and spun at 35.0 kHz with no cross-polarization from protons, corresponding to the maximum specified spinning speed for the 2.5 mm spinners. The fast spinning speed minimized the intensities of the spinning side bands and provided almost complete decoupling of 19 F signals from protons. The number of scans were individually adjusted for each sample to obtain adequate single/noise (S/N). Typically, 150 scans were acquired. Prior to 19 F acquisition, 19 F relaxation times were measured by an inversion recovery technique. The recycle delay for each sample was then adjusted to five times the longest 19 F relaxation time in the sample, which ensured acquisition of quantitative spectra. A fluorine probe background was subtracted in each alternate scan after presaturating the 19 F signal. The spectra were referenced using an external sample of trifluoroacetic acid (diluted to 50% V/V by H 2 O), setting its resonance to −76.54 ppm.
13 C SSNMR
Approximately 80 mg of sample were tightly packed into a 4 mm ZrO spinner for each sample analyzed. One-dimensional 13 C spectra were collected at ambient pressure using 1 H- 13 C CPMAS at 295 K on a Bruker 4 mm BL CPMAS probe positioned into a wide-bore Bruker-Biospin Avance DSX 500 MHZ NMR spectrometer. The samples were spun at 15.0 kHz corresponding to the maximum specified spinning speed for the 7 mm spinners. The fast spinning speed minimized the intensities of the spinning side bands. To optimize the signal sensitivity, the cross-polarization contact time was adjusted to 1.5 ms, and the proton decoupling power was set to 100 kHz. The number of scans were individually adjusted for each sample to obtain adequate S/N. Typically, 1900 scans were acquired with a recycle delay of 5 seconds. The spectra were referenced using an external sample of adamantane, setting its upfield resonance at 29.5 ppm.
Table 25 and Table 25a lists the 13 C NMR chemical shifts for Form A and B atorvastatin benethamine and hydrates thereof:
TABLE 25
FORM A BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
180.1
2
178.8
3
165.1
4
164.1
5
162.8
6
161.7
7
160.7
8
140.6
9
139.6
10
137.9
11
136.1
12
133.0
13
129.6
14
127.3
15
126.4
16
125.4
17
123.1
18
122.5
19
121.6
20
121.1
21
119.9
22
116.4
23
115.4
24
114.5
25
114.0
26
66.0
27
65.5
28
64.6
29
53.6
30
51.5
31
51.0
32
47.8
33
44.6
34
43.3
35
41.4
36
40.9
37
38.5
38
37.7
39
36.8
40
34.0
41
32.7
42
26.5
43
25.1
44
23.5
45
23.1
46
19.7
47
19.1
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
TABLE 25a
FORM B BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
179.4
2
165.6
3
162.4
4
140.1
5
138.6
6
133.6
7
132.8
8
129.9
9
128.2
10
125.7
11
123.6
12
114.8
13
69.6
14
69.0
15
52.3
16
49.8
17
43.1
18
42.2
19
39.6
20
38.9
21
31.5
22
26.5
23
23.5
24
19.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 26 lists individual 13 C NMR chemical shifts for Form A atorvastatin benethamine:
TABLE 26
FORM A ATORVASTATIN BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
180.1
2
178.8
3
165.1
4
164.1
5
161.7
6
160.7
7
26.5
8
25.1
9
23.5
10
23.1
11
19.7
12
19.1
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 27 lists individual 13 C NMR chemical shifts for Form B atorvastatin benethamine:
TABLE 27
FORM B ATORVASTATIN BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
179.4
2
165.6
22
26.5
23
23.5
24
19.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 28 and 28a lists the 19 F NMR chemical shifts for Forms A and B atorvastatin benethamine and hydrates thereof:
TABLE 28
FORM A ATORVASTATIN BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
−113.2
2
−114.2
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
TABLE 28a
FORM B ATORVASTATIN BENETHAMINE
AND HYDRATES THEREOF
Peak #
ppm*
1
−113.7
2
−114.4
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Table 29 lists the 13 C NMR chemical shifts for atorvastatin dibenzylamine and hydrates thereof:
TABLE 29
ATORVASTATIN DIBENZYLAMINE AND HYDRATES THEREOF
Peak #
ppm*
1
179.1
2
166.2
3
163.1
4
160.8
5
140.6
6
135.2
7
134.3
8
133.4
9
131.9
10
131.1
11
129.4
12
128.3
13
125.6
14
124.2
15
122.9
16
119.7
17
115.4
18
69.7
19
68.6
20
52.6
21
51.3
22
43.0
23
41.9
24
38.8
25
38.2
26
26.7
27
23.3
28
20.0
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 30 lists individual 13 C NMR chemical shifts for atorvastatin dibenzylamine and hydrates thereof:
TABLE 30
ATORVASTATIN DIBENZYLAMINE AND HYDRATES THEREOF
Peak #
ppm*
1
179.1
2
166.2
3
163.1
4
160.8
26
26.7
27
23.3
28
20.0
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 31 lists the 19 F NMR chemical shifts for atorvastatin dibenzylamine and hydrates thereof:
TABLE 31
ATORVASTATIN DIBENZYLAMINE AND HYDRATES THEREOF
Peak #
ppm*
1
−107.8
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Table 32 lists the 13 C NMR chemical shifts for atorvastatin erbumine and hydrates thereof:
TABLE 32
ATORVASTATIN ERBUMINE AND HYDRATES THEREOF
Peak #
PPm*
1
179.3
2
164.5
3
163.0
4
160.9
5
141.3
6
140.9
7
135.3
8
134.5
9
132.8
10
129.0
11
127.7
12
124.5
13
121.8
14
120.2
15
116.5
16
115.5
17
112.4
18
71.3
19
50.3
20
47.7
21
42.6
22
41.0
23
28.5
24
26.4
25
22.6
26
21.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 33 lists individual 13 C NMR chemical shifts for atorvastatin erbumine and hydrates thereof:
TABLE 33
ATORVASTATIN ERBUMINE AND HYDRATES THEREOF
Peak #
ppm*
1
179.3
2
164.5
3
163.0
4
160.9
23
28.5
24
26.4
25
22.6
26
21.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 34 lists the 19 F NMR chemical shifts for atorvastatin erbumine and hydrates thereof:
TABLE 34
ATORVASTATIN ERBUMINE AND HYDRATES THEREOF
Peak #
ppm*
1
−110.4
*Vaues in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Table 35 lists the 13 C NMR chemical shifts for atorvastatin morpholine and hydrates thereof:
TABLE 35
ATORVASTATIN MORPHOLINE AND HYDRATES THEREOF
Peak #
ppm*
1
179.3
2
165.9
3
162.7
4
160.5
5
139.6
6
137.8
7
134.3
8
131.2
9
129.6
10
128.7
11
127.4
12
122.9
13
120.8
14
117.9
15
116.3
16
70.8
17
69.5
18
63.4
19
42.4
20
41.2
21
40.5
22
24.8
23
20.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 36 lists individual 13 C NMR chemical shifts for atorvastatin morpholine and hydrates thereof:
TABLE 36
ATORVASTATIN MORPHOLINE AND HYDRATES THEREOF
Peak #
ppm*
1
179.3
2
165.9
4
160.5
22
24.8
23
20.6
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 37 lists individual 19 F NMR chemical shifts for atorvastatin morpholine and hydrates thereof:
TABLE 37
ATORVASTATIN MORPHOLINE AND HYDRATES THEREOF
Peak #
ppm*
1
−117.6
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Table 38 lists the 13 G NMR chemical shifts for atorvastatin olamine and hydrates thereof:
TABLE 38
ATORVASTATIN OLAMINE AND HYDRATES THEREOF
Peak #
ppm*
1
182.0
2
178.9
3
165.4
4
161.6
5
159.5
6
137.4
7
134.8
8
133.8
9
131.0
10
128.7
11
128.0
12
127.0
13
123.1
14
122.6
15
121.9
16
120.9
17
120.1
18
117.3
19
115.6
20
114.3
21
66.5
22
66.0
23
65.2
24
58.5
25
58.2
26
51.1
27
47.8
28
46.0
29
43.9
30
42.4
31
41.3
32
40.6
33
39.8
34
25.7
35
23.1
36
21.1
37
20.7
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfieid resonance to 29.5 ppm.
Table 39 lists the individual 13 C NMR chemical shifts for atorvastatin olamine and hydrates thereof:
TABLE 39
ATORVASTATIN OLAMINE AND HYDRATES THEREOF
Peak #
PPM#
1
182.0
2
178.9
3
165.4
4
161.6
5
159.5
34
25.7
35
23.1
36
21.1
37
20.7
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 40 lists the 19 F NMR chemical shifts for atorvastatin olamine and hydrates thereof:
TABLE 40
ATORVASTATIN OLAMINE AND HYDRATES THEREOF
Peak #
ppm*
1
−118.7
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Table 41 lists the 13 C WAR chemical shifts for atorvastatin 2-amino-2-methyl-propan-1-ol and hydrates thereof:
TABLE 41
ATORVASTATIN 2-AMINO-2-METHYL-PROPAN-1-OL
AND HYDRATES THEREOF
Peak #
ppm*
1
179.8
2
166.3
3
163.3
4
161.5
5
161.2
6
140.5
7
139.5
8
134.4
9
132.3
10
131.6
11
129.8
12
128.1
13
126.1
14
125.1
15
122.2
16
120.7
17
116.4
18
114.0
19
113.4
20
72.6
21
71.4
22
67.6
23
66.3
24
64.7
25
64.4
26
53.1
27
46.9
28
43.9
29
43.5
30
42.7
31
39.7
32
36.1
33
26.8
34
26.3
35
24.3
36
23.8
37
23.1
38
{dot over (2)}{dot over (2)}{dot over (.)}{dot over (0)}
39
{dot over (2)}{dot over (0)}{dot over (.)}{dot over (4)}
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 42 lists individual 13 C NMR chemical shifts for atorvastatin 2-amino-2-methyl-propan-1-ol and hydrates thereof:
TABLE 42
ATORVASTATIN 2-AMINO-2-METHYL-PROPAN-1-OL
AND HYDRATES THEREOF
Peak #
ppm*
1
179.8
2
166.3
3
163.3
38
{dot over (2)}{dot over (2)}{dot over (.)}{dot over (0)}
39
{dot over (2)}{dot over (0)}{dot over (.)}{dot over (4)}
*Values in ppm with respect to trimethylsilane (TMS) at 0 ppm; referenced using an external sample of adamantane, setting is upfield resonance to 29.5 ppm.
Table 43 lists the 19 F NMR chemical shifts for atorvastatin 2-amino-2-methyl-propan-1-ol and hydrates thereof:
TABLE 43
ATORVASTATIN 2-AMINO-2-METHYL-PROPAN-1-OL
AND HYDRATES THEREOF
Peak #
ppm*
1
−113.6
2
−116.5
*Values in ppm with respect to CCl 3 F at 0 ppm, referenced using an external standard of trifluoroacetic acid (50% V/V in water) at −76.54 ppm.
Additionally, Form A & B atorvastatin benethamine, atorvastatin dibenzylamine, atorvastatin erbumine, atorvastatin morpholine, atorvastatin olamine, and atorvastatin 2-amino-2-methyl-propan-1-ol or a hydrate thereof of the aforementioned salts may be characterized by an x-ray powder diffraction pattern or a solid state 19 F nuclear magnetic resonance spectrum.
For example:
An atorvastatin ammonium or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 7.8, 8.8, 9.3, 9.9, 10.6, 12.4, and 19.5.
A Form A atorvastatin benethamine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 4.7, 5.3, 9.5, 12.0, 15.6, 18.1, and 19.9, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts expressed in parts per million: −113.2 and −114.2.
A Form B atorvastatin benethamine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 5.0, 7.1, 8.4, 10.0, 11.6, 12.6, 14.8, and 20.2, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts expressed in parts per million: −113.7 and −114.4.
A Form A atorvastatin benzathine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 14.0 and 15.1.
A Form B atorvastatin benzathine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 8.3, 10.2, 14.4, 15.8, 18.6, 21.8, and 23.3.
A Form C atorvastatin benzathine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 3.9, 6.9, 7.9, 9.7, and 12.8.
An atorvastatin dibenzylamine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 8.3, 18.7, 19.8, 20.7, 21.3, and 25.8, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts expressed in parts per million: −107.8.
A compound selected from the group consisting of:
(a) Form A atorvastatin diethylamine or hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 17.0, 18.2, 20.0, 21.7, and 23.0; and (b) Form B atorvastatin diethylamine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 6.1, 11.5, 15.3, 17.4, 20.5, 23.2, and 27.6.
An atorvastatin erbumine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 5.4, 7.3, 9.5, 17.8, 19.2, 20.0, 22.2, and 24.2, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts expressed in parts per million: −110.4.
An atorvastatin L-lysine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 6.7, 9.8, 17.1, and 24.0.
An atorvastatin morpholine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 9.7, 16.0, 18.9, 19.6, 20.8, 22.1, 23.9, and 25.0, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts expressed in parts per million: −117.6.
An atorvastatin olamine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 8.5, 9.8, 17.4, 18.6, 20.9, 22.5, and 24.1, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts measured in parts per million: −118.7.
An atorvastatin piperazine or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 7.8, 9.3, 11.8, 16.1, and 19.7.
An atorvastatin sodium or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 3.4, 4.9, 7.6, 8.0, 9.9, 18.9, and 19.7.
An atorvastatin 2-amino-2-methylpropan-1-ol or a hydrate thereof having an x-ray powder diffraction pattern containing the following 2θ peaks measured using CuK α radiation: 4.2, 8.3, 16.0, 17.5, 18.3, 19.4, and 19.7, or a solid state 19 F nuclear magnetic resonance having the following chemical shifts measured in parts per million: −113.6 and −116.5.
The salt forms of atorvastatin of the present invention, regardless of the extent of hydration and/or salvation having equivalent x-ray powder diffractograms, or SSNMR, are within the scope of the present invention.
The new salt forms of atorvastatin described herein have advantageous properties. For example, the benethamine, benzathine, dibenzylamine, diethylamine, erbumine, and morpholine salts were determined to be anhydrous, high melting as well as considered to be non-hygroscopic compounds. The olamine and 2-amino-2-methylpropan-1-ol salts were determined to be anhydrous and high melting as well. Also, the diethylamine, erbumine, morpholine, olamine, and 2-amino-2-methylpropan-1-ol salts of atorvastatin exhibited higher aqueous solubility compared to Form I atorvastatin calcium (disclosed in U.S. Pat. No. 5,969,156).
The present invention provides a process for the preparation of the salt forms of atorvastatin which comprises preparing a solution of atorvastatin free acid (U.S. Pat. No. 5,213,995) in one of the following solvents: acetone, acetonitrile, THE, 1:1 acetone/water (v/v), isopropanol (IPA), or chloroform. The cationic counterion solutions were prepared using either 0.5 or 1.0 equivalent in the same solvent. Water was added to some counterions to increase their solubility. The atorvastatin free acid solution was added to the counterion solution while stirring. The reaction was stirred for at least 48 hours at ambient temperature. Samples containing solids were vacuum filtered, washed with the reaction solvent, and air-dried overnight at ambient conditions. If precipitation was not present after ˜2 weeks, the solution was slowly evaporated. All samples were stored at ambient temperature and characterized as described hereinafter.
TABLE 44
Structure of Counterions used in the preparation of Atorvastatin salts.
Structure
Name
Common Name
+NH 4
Ammonium
Ammonium
N-benzyl-2- Phenylethylamine
Benethamine
N,N′- Bis(phenylmethyl)- 1,2-ethanediamine
Benzathine
N-(Phenylmethyl) benzenemethanamine
Dibenzylamine
N-Ethylethanamine
Diethylamine
tert-butylamine
Erbumine
(S)-2,6- diaminohexanoic acid
L-Lysine
Tetrahydro- 2H-1,4-oxazine
Morpholine
2-aminoethanol
Olamine
Na
Sodium
Sodium
Hexahydropyrazine
Piperazine
2,2- Diethylethanolamine
2-amino- 2methylpropan- 1-ol
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. Thus, the compounds of the present invention can be administered by injection, that is, intravenously, intramuscularly, intracutaneously, subcutaneously, intraduodenally, or intraperitoneally. Also, the compounds of the present invention can be administered by inhalation, for example, intranasally. Additionally, the compounds of the present invention can be administered transdermally.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from two or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component, with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, retention enemas, and emulsions, for example water or water propylene glycol solutions. For parenteral injection, liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing, and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted from 0.5 mg to 100 mg, preferably 2.5 mg to 80 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
In therapeutic use as hypolipidemic and/or hypocholesterolemic agents and agents to treat osteoporosis, benign prostatic hyperplasia, and Alzheimer's disease, the salt forms of atorvastatin utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 2.5 mg to about 80 mg daily. A daily dose range of about 2.5 mg to about 20 mg is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstance is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
The following nonlimiting examples illustrate the inventors' preferred methods for preparing the compounds of the invention.
EXAMPLE 1
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, ammonium salt (atorvastatin ammonium)
The ammonium salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (ACN) (0.634 g in 25 mL of ACN). A solution was prepared by dissolving 12.04 mg of ammonium hydroxide (1.0 equivalents) in acetonitrile (0.5 mL). The stock solution of atorvastatin free acid (2.24 mL) was added to the counterion solution with stirring. If a gel formed, additional acetonitrile and water was added as necessary. After 2 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with acetonitrile and air dried at ambient conditions to afford atorvastatin ammonium.
EXAMPLE 2
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, N-benzyl-2-phenylethylamine (atorvastatin benethamine)
Method A: The benethamine salt of atorvastatin (Form A) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of N-benzyl-2-phenylethylamine (benethamine) was prepared by dissolving 378.59 mg (1.0 equivalents) in acetonitrile (10 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Over time, an additional 40 mL of acetonitrile was added to prevent the formation of a gel. After 5 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25′C oven under nitrogen to dry overnight to afford atorvastatin benethamine Form A.
Method B: The benethamine salt of atorvastatin (Form B) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in 2-propanol (IPA) (1 g in 40 mL of IPA). A solution of N-benzyl-2-phenylethylamine (benethamine) was prepared by dissolving 388.68 mg (1.1 equivalents) in 2-propanol (100 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Seed crystals of the benethamine salt were added. The mixture was reduced to a wet solid under a nitrogen bleed, and the resulting solids were slurried in 2-propanol (40 mL). After 7 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with 2-propanol (25 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford atorvastatin benethamine Form B.
EXAMPLE 3
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid,N,N 1 -bis(phenylmethyl)-1,2-ethanediamine (atorvastatin benzathine)
Method A: The benzathine salt of atorvastatin (Form A) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of N,N′-bis(phenylmethyl)-1,2-ethanediamine (benzathine) was prepared by dissolving 220.64 mg (0.5 equivalents) in acetonitrile (80 mL) and water (20 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. After 2 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford benzathine Form A.
Method B: The benzathine salt of atorvastatin (Form B) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of N,N′-bis(phenylmethyl-1,2-ethanediamine (benzathine) was prepared by dissolving 220.64 mg (0.5 equivalents) in acetonitrile (80 mL) and water (20 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. After 2 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL) to afford atorvastatin benzathine Form B. Note that this procedure is the same as above except that the sample was not oven dried.
Method C: The benzathine salt of atorvastatin (Form C) was synthesized by adding Form A atorvastatin benzathine to 3 mL of deionized water in excess of its solubility. The slurry was stirred at room temperature for 2 days, isolated by vacuum filtration, and dried under ambient conditions to yield atorvastatin benzathine Form C.
EXAMPLE 4
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid,N-(phenylmethyl)benzenemethanamine (atorvastatin dibenzylamine)
The dibenzylamine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of dibenzylamine was prepared by dissolving 351.05 mg (1.0 equivalents) in acetonitrile (100 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Over time, additional acetonitrile was added to prevent formation of a gel (100 mL), and the solid was allowed to stir. After 4 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford atorvastatin dibenzylamine.
EXAMPLE 5
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[phenylamino)carbonyl]1H-pyrrole-1-heptanoic acid,N-ethylethanamine (atorvastatin diethylamine)
Method A: The diethylamine salt of atorvastatin (Form A) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of diethylamine was prepared by dissolving 132.33 mg (1.0 equivalents) in acetonitrile (20 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Over time, an additional 40 mL of acetonitrile was added to prevent the formation of a gel. After 5 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford atorvastatin diethylamine Form A.
Method B: The diethylamine salt of atorvastatin (Form B) was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of diethylamine was prepared by dissolving 132.33 mg (1.0 equivalents) in acetonitrile (20 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Over time, an additional 40 mL of acetonitrile was added to prevent the formation of a gel. After 5 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL) to afford atorvastatin diethylamine Form B. Note that this procedure is the same as above except that the sample was not oven dried.
EXAMPLE 6
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, tertiary-butylamine (atorvastatin erbumine)
The erbumine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of tert-butylamine (erbumine) was prepared by dissolving 128.00 mg (1.0 equivalents) in acetonitrile (10 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Over time, an additional 120 mL of acetonitrile was added to prevent the formation of a gel. After 5 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford atorvastatin erbumine.
EXAMPLE 7
[R—(R*,R)]-2-(4-Fluorophenyl)-8,6-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, L-lysine (atorvastatin L-lysine)
The L-lysine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in isopropyl alcohol (IPA) (2.577 g in 50 mL of IPA). A solution of L-lysine was prepared by dissolving 28.0 mg (1.0 equivalents) in isopropyl alcohol (1 mL). The stock solution of atorvastatin free acid (2.08 mL) was added to the counterion solution with stirring. After 7 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with IPA and allowed to air dry at ambient temperature to afford L-lysine.
EXAMPLE 8
[R—(R*,R*)]-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, tetrahydro-2H-1,4-oxazine (atorvastatin morpholine)
The morpholine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of morpholine was prepared by dissolving 160.28 mg (1.1 equivalents) in acetonitrile (100 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. No salt formed, so the solution was evaporated under N 2 until a white solid formed. Acetonitrile was then added to the solid (50 mL), and the solid was allowed to stir. After 3 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (25 mL), and placed in a 25° C. oven under nitrogen to dry overnight to afford atorvastatin morpholine.
EXAMPLE 9
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, 2-aminoethanol (atorvastatin olamine)
Method A—The olamine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (0.8 g in 25 mL of ACN). A solution of olamine was prepared by dissolving 15.0 mg of olamine (˜2.7 equivalents) in 0.5 mL of acetonitrile. The stock solution of atorvastatin free acid (3.0 mL) was added to the counterion solution with stirring. If a gel formed, additional acetonitrile was added as necessary. After 6 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with acetonitrile and air dried at ambient conditions to afford atorvastatin olamine.
Method B—The olamine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of 2-aminoethanol (olamine) was prepared by dissolving 139.77 mg (1.1 equivalents) in acetonitrile (100 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Seed crystals of the olamine salt were added. Over time, additional acetonitrile was added to aid in stirring (300 mL), and the solid was allowed to stir. After 4 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry for two days to afford atorvastatin olamine.
EXAMPLE 10
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, piperazine (atorvastatin piperazine)
The piperazine salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in isopropyl alcohol (2.577 g in 50 mL of IPA). A solution of piperazine was prepared by dissolving 14.4 mg (1.0 equivalents) in isopropyl alcohol (1 mL). The stock solution of atorvastatin free acid (1.85 mL) was added to the counterion solution with stirring. After 7 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with isopropyl alcohol and air dried at ambient conditions to afford atorvastatin piperazine.
EXAMPLE 11
[R—(R*,R*)]2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, sodium (atorvastatin sodium)
The sodium salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (0.634 g in 25 mL of ACN). A solution was prepared by dissolving 2.67 mg of sodium hydroxide (1.0 equivalents) in 0.5 mL of acetonitrile and 0.05 mL of water. The stock solution of atorvastatin free acid (1.55 mL) was added to the counterion solution with stirring. If a gel formed, additional acetonitrile and water was added as necessary. After 6 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with acetonitrile and air dried at ambient conditions to afford atorvastatin sodium.
EXAMPLE 12
[R—(R*,R*)]-2-(4-Fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid, 2-amino-2-methylpropan-1-ol (atorvastatin 2-amino-2-methylpropan-1-ol)
Method A—The 2-amino-2-methylpropan-1-ol salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (0.8 g in 25 mL of ACN). A solution of 2-amino-2-methylpropan-1-ol was prepared by dissolving 6.1 mg of 2-amino-2-methylpropan-1-ol (1 equivalents) in 0.5 mL of acetonitrile. The stock solution of atorvastatin free acid (1.21 mL) was added to the counterion solution with stirring. If a gel formed, additional acetonitrile was added as necessary. After 6 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a 0.45 μm nylon 66 membrane filter. The solids were rinsed with acetonitrile and air dried at ambient conditions to afford atoravastatin 2-amino-2-methylpropan-1-ol.
Method B—The 2-amino-2-methylpropan-1-ol salt of atorvastatin was synthesized by preparing a stock solution of the free acid of atorvastatin (U.S. Pat. No. 5,273,995) in acetonitrile (1 g in 40 mL of ACN). A solution of 2-amino-2-methylpropan-1-ol was prepared by dissolving 173.08 mg (1.1 equivalents) in acetonitrile (100 mL). The stock solution of atorvastatin free acid was added to the counterion solution with stirring. Seed crystals of the 2-amino-2-methylpropan-1-ol salt were added. Over time, additional acetonitrile was added to aid in stirring (100 mL), and the solid was allowed to stir. After 4 days of stirring at ambient temperature, the solids were isolated by vacuum filtration using a Buchner funnel fitted with a paper filter (#2 Whatman). The solids were rinsed with acetonitrile (75 mL), and placed in a 25° C. oven under nitrogen to dry for two days to afford atorvastatin 2-amino-2-methylpropan-1-ol.
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Novel salt forms of [R—(R*,R*)]-2-(4-fluorophenyl)-β,δ-dihydroxy-5-(1-methylethyl)-3-phenyl-4-[(phenylamino)carbonyl]-1H-pyrrole-1-heptanoic acid characterized by their X-ray powder diffraction pattern and solid-state NMR spectra are described, as well as methods for the preparation and pharmaceutical composition of the same, which are useful as agents for treating hyperlipidemia, hypercholesterolemia, osteoporosis, benign prostatic hyperplasia, and Alzheimer's Disease.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to controlling the implementation or operation of a blasting system and, more particularly, to protecting a blasting system.
SUMMARY OF THE INVENTION
[0002] The invention provides a method of controlling the operation of a blasting system which includes the steps of continuously and automatically monitoring for the occurrence of electromagnetic interference (EMI) within a defined zone within which the blasting system is located and initiating an alarm condition upon detecting electromagnetic interference, within the zone, at a predetermined level, or of a predetermined type.
[0003] The alarm condition may be notified to an operator of the blasting system. Positive input from the operator may be required, in response to such notification, in order for the operation of the blasting system to be continued.
[0004] Thus, upon initiation of an alarm condition, the implementation of the operation of the blasting system or the continued operation thereof may be automatically inhibited or suspended.
[0005] The occurrence of EMI may be monitored on any particular basis e.g. on a time, incidence or location basis. EMI activity may be recorded and correlated with significant steps in the implementation of the blasting system. For example, an operator may elect to continue with the implementation of a blasting system in the presence of EMI. Aspects of the performance of the blasting system, such as misfires, which may occur may, subsequently, be correlated to measurements made of EMI activity.
[0006] Lightning constitutes a particular form of electromagnetic interference. In many instances the effect of a lightning stroke is more significant than EMI from other sources such as manmade activity. Thus, particularly in respect of lightning, measurements may be made of the number of strokes, the closeness to the blasting system of the strokes, and so on. A measure may also be obtained of the energy per lightning stroke. This type of information may be used in an attempt to establish a link between lightning energy and activity and the effect thereof on detonators within the blasting system.
[0007] Similar observations may be made, in general, of all forms of EMI despite the fact that in most cases lightning activity poses the primary danger to an electronically based blasting system. Manmade electromagnetic noise however can nonetheless have a significant effect on an electronically based blasting system for such EMI can lead to malfunctioning, misfires, unwanted initiation, and so on. Thus, techniques used to monitor lightning activity can be used on a broader basis to monitor EMI activity in general. Of particular concern here is EMI activity at a particular frequency range or which gives rise to a signal level which could be high enough to interfere with the reliable working of a blasting system. It therefore falls within the scope of the invention to monitor EMI activity for signal level and for a dominant frequency of the interference. Those parameters are however exemplary and are non-limiting for if other factors are determined which could adversely affect the working of a blasting system arrangements would be made to monitor for their occurrence.
[0008] As the incidence of EMI raises the noise level in a blasting system adjustments may be effected, preferably automatically, to electronic components in the blasting system to compensate for the effect of such noise.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention is further described by way of example with reference to the accompanying drawing which illustrates in block diagram form the use of the method of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] The accompanying drawing illustrates in block diagram form a blasting system 10 which is under the control of equipment 12 . Typically the system 10 includes at least one electronic detonator located in a respective borehole in which explosives are positioned. The control equipment 12 may be linked by conductors, or through the use of wireless techniques, to the individual detonators. The control equipment exercises timing and firing control, at least, over the detonators. These aspects are generally known in the art and for this reason are not further described herein.
[0011] The control equipment 12 is linked to one or more EMI sensors 16 which are configured to monitor the occurrence of electromagnetic noise, including lightning, in a defined region, automatically and continuously. The sensors may be provided separately from the control equipment. Alternatively the sensors may form part of or may be integrated into the control equipment. The blasting system 10 is located within that region. The extent of the region depends, at least, on the sensitivity of each sensor. In order to enlarge the region it may be necessary to link various sensors together with each sensor being positioned at a defined position. Such linking may be effected using conductors, fibre optic links or the like, or by using wireless techniques.
[0012] Each sensor is capable of detecting electromagnetic noise which may be generated by diverse means. Typically certain types of human activity and the operation of some electrical machinery and equipment can lead to the production of electromagnetic noise. Atmospheric factors give rise to electromagnetic noise in the form of lightning strokes. Depending on the nature of the source which generates electromagnetic interference a sensor can be used to provide an estimation of the distance between the source and the sensor. In the case of lightning for example it is possible to use the sensor to give an indication of the energy released during a lightning stroke. At the least the sensor provides an indication of the strength of the electromagnetic interference, at the sensor. Optionally this is related to the frequency of the interference.
[0013] The sensor embodies an algorithm which is capable of validating an incoming signal pattern so that manmade disturbances can be distinguished from lightning strokes. The sensor is set to monitor the level of the interference so that an activity which is potentially harmful to the reliable operation of the blasting system, whether such activity is the result of human activity or arises from natural causes, can be detected and, as appropriate, action can be taken if necessary.
[0014] Information relating to EMI activity detected by the sensor 16 is made available on a display 18 and such information is also recorded or logged in a memory 20 . The information is also applied to the control equipment 12 . The control equipment, optionally, includes a comparator which includes data related to an energy threshold level which must be exceeded, by energy released by the EMI, in order for the interference to present a danger to the blasting system. When this threshold level is exceeded then the functioning of the control equipment 12 is automatically inhibited in the sense that implementation of the blasting system 10 is suspended. Information on this occurrence is presented to an operator 22 who is then required to acknowledge this information and, if the blasting process is to be continued, the operator must positively input a signal to the control equipment which overrides the inhibiting effect of the EMI.
[0015] Lightning constitutes a form of electromagnetic noise and, in the presence of lightning, noise rejection techniques embodied in the control equipment may be enhanced. This is an important aspect for the equipment may be automatically adjusted to work in a high noise environment so that communications are thereby automatically improved.
[0016] The EMI sensor or sensors exercise a form of direct control over the execution of a blasting process. Additionally data relating to detected EMI is made available and is logged in the memory 20 . If a blasting sequence is not stopped but is continued, under the guidance of an operator, despite the presence of EMI then the performance of the blasting system e.g. misfires, execution of timing intervals and the like can be compared to the EMI level recorded in the memory so that the effect of EMI on the functioning of a blasting arrangement can be assessed.
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A method of controlling the operation of a blasting system which includes the steps of monitoring for the occurrence of electromagnetic interference (EMI) within a defined zone and initiating an alarm upon detection of such interference wherein the initiation of the alarm can automatically inhibit or suspend the operation of the blasting system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device for discharging overflows and water which are flooded over from a cooking ware in a cooking compartment of a microwave oven during cooking.
2. Description of the Related Art
In cooking a food to be boiled such as rice and a pot stew with a microwave oven, the cooking materials and water may be generally boiled over and fallen down to be scorched or burnt on the flat bottom of the cooking compartment by cooking heat.
A ventilation system for exhausting water vapor generated in the cooking compartment has been known from Japanese utility Laid-Open Publication No. 53-44339, which discloses a microwave oven including a cabinet having a ceiling, which is provided with openings matched with exhaust openings in an oven ceiling, an exhaust opening plate formed with openings for preventing electric wave leakage and inserted in the oven ceiling, and a door formed with openable and shutable openings and having an upper end close to the openings in the cabinet ceiling and a lower end mounted on the oven ceiling. The microwave oven can, however, exhaust water vapor generated in the cooking compartment outwards, but can not discharge the cooking materials and water overflowed on the bottom of the cooking compartment.
In the existing microwave ovens, the overflows fallen on the bottom are left as they are to be scorched thereon by heating in the cooking compartment, requiring hard scrubbing to be removed. Moreover, in electrostatic focusing areas, the overflows may be burnt to generate sparking carbon particles leading to the shortened life and deteriorated reliability of the system.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a derice enabling overflows in a microwave oven to be drained out along bottom sides of a cooking compartment.
The object is attained according to the invention by a device for discharging overflows, comprising:
a bottom of a cooking compartment declined from the middle to the sides except for the region of a tray;
guide grooves formed along the bottom sides respectively, at least one of them being deeper than the others to receive fluid materials from the others;
at least a discharge opening formed downwards in the deeper guide groove and leading to the outside of the compartment;
a receiving vessel provided under the compartment and covering the discharge opening to receive the fluid materials therethrough; and
a supporting means consisting of a set of guiding flanges formed under the compartment and supporting a slidable receiving vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view showing a microwave oven according to the invention;
FIG. 2 is an exploded perspective view showing the mounting of a receiving vessel on the microwave oven according to the invention;
FIG. 3 is a schematic sectional view illustrating the construction and function of the invention; and
FIG. 4 is a schematic front view of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be seen in FIG. 1, showing a microwave oven 1 according to the invention in a perspective view, a cooking compartment 2, whose door is removed to provide easy observation, has a bottom declined from the middle to the sides except for the region of a tray 8. The four sides of the bottom are formed with guide grooves 2a, and the front side has also a plurality of discharge openings 2b formed therein. The guide grooves 2a in the right and left sides are declined from the rear side toward the front side to make it easy for overflows flooded over during cooking to find their way to the front side. Thereby, the overflows run down along the guide grooves 2a and are led to the front guide groove 2a.
The discharge openings 2b provided in the front guide groove 2a, which is the lowest one of the guide grooves 2a, discharge the overflows accumulated in the front guide groove 2a to outside of the microwave oven 1, and have, preferably, a diameter less than 1 cm to prevent high frequency radio waves from leakage.
To receive the overflow discharged through the discharge openings 2b, as shown in FIG. 2, a receiving vessel 4 is provided under the front end region of the microwave oven 1. The receiving vessel 4 is made from a material which can isolate penetration of high-frequency waves, and has an opened top side having a length and width enough to cover all of the discharge openings 2b in the front guide groove 2a.
The mounting of the receiving vessel 4 on the microwave oven 1 is attained by a web 4a extended rearwards from the top side of the receiving vessel 4 along the longitudinal direction thereof, and a guide flange 3 having a cross section of "L" shape is correspondingly provided under the microwave oven 1 to be engaged with the web 4a. When mounting the receiving vessel 4 on the microwave oven 1, the receiving vessel 4 is inserted into the guide flange 3 with its web 4a from the right or left side of the microwave oven 1. To this end, the right or left end of the guide flange 3 is opened to allow the insertion of the receiving vessel 4 and the other end is closed to form a stopper wall 7 for defining the insertion position. In addition, under the front end region of the microwave oven 1, a supporting flange 9 is provided being analog! with but opposite to the guide flange 3 to prevent the receiving vessel 4 from escaping from the guide flange 3.
The depth of the receiving vessel 4 shall be naturally lower than that of legs of the microwave oven 1, so that it can be easily mounted on or dismounted from the microwave oven 1 left on a table.
The derice according to the invention for discharging overflows in cooking compartment 2, having the construction as described above, functions as follows:
A cooking were containing water and materials for a food to be boiled such as rice or pot stews is put on the tray 8 in the cooking compartment 2 to be heated by turning-on the microwave oven. With the lapse of time, the heated water and cooking materials come to the point of boiling over to overflow on to the base of the cooking compartment 2, as shown in FIG. 3.
The fallen overflow of the water and cooking material run down the declined base to the four guide grooves 2a and then along the also both declined side guide grooves 2a to accumulate in the front guide groove 2a. The overflow reached in the front guide groove 2a are discharged through the discharge openings 2b to be received by the receiving vessel 4 provided under the space of the front guide groove 2a.
The receiving vessel 4 slidably mounted in the guide flange 3 by its web 4a can be easily dismantled therefrom, so that the user can do away with the accunulated overflow therein on demands and then slide it into the guide flange 3 to remount it. The supporting flange 9 formed opposite to the guide flange 3 prevents the inserted receiving vessel 4 from moving forward.
In another embodiment of the invention, it is of course possible that the discharge openings are provided in all of the four guide grooves 2a or in one or more of them, not restricted to the front guide groove 2a as in the above-described embodiment. At this time, the receiving vessel(s) 4 is(are) correspondingly disposed under the microwave oven 1.
The receiving vessel 4 may also have different constructions from the illustrated embodiment, for example a front drawing out and pushing back mechanism in the mounting, an application of discharging tubes extended from the discharge openings 2b to an exterior receiving vessel.
As stated above, the equipment according to the invention enables overflow, flooded over from the cooking ware in cooking to be run down along the bottom sides of the cooking compartment 2 to the receiving vessel 4 under the microwave oven 1, so that the cooking compartment 2 keeps clean and the overflow can no longer be scorched or burnt.
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A microwave oven includes a bottom having a groove arrangement in which food overflows ar collected. The groove has discharge openings less than 1 cm in diameter through which the collected overflows can drain. A removable tray is mounted on the exterior of the oven beneath the discharge openings to receive the draining overflows.
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BACKGROUND OF THE INVENTION
This invention generally relates to the field of areaways, that is, enclosures for basement windows and the like. Specifically, the invention involves escapable areaway systems and concerns improvements which ease installation and can permit the areaway to float with expansion or contraction of the adjacent soil.
For more than a century, the technique of admitting light through a basement window has existed. This can make the space more desirable and can meet other requirements. To admit the light, an areaway enclosure is often used, that is a structure that acts to hold the earth away from the window or door so that light can be admitted. In spite of the fact that areaways have existed for a long period of time, in the late 1980's a number of advances were made which greatly improved desirability and safety. These changes resulted in, not only improving the structure itself, but also its function such that escape and egress were accommodated. These improvements, detailed in U.S. Pat. Nos. 4,876,833 and 5,107,640 (hereby incorporated by reference), were so easily accepted that some states have made such egress designs mandatory through uniform building code changes and the like.
In utilizing these improved areaways as well as others, it has become obvious that typical areaway design, that it is a design that is generally fixed to the foundation face of the building, has not always been entirely acceptable. A number of problems have become evident ranging from the challenges of backfilling the areaway structure after construction to the attachment of the areaway structure itself to dealing with expansion, contraction or settling of the soil surrounding the areaway. As a result of these challenges, there has developed a need not only to facilitate installation but also to more appropriately accommodate both the construction nuances and the actual character of the soil typically surrounding such a structure. Perhaps surprisingly, although the field of areaway structures might be considered mature in some regards, prior to the present invention, the needs both during installation and in actual use have not been entirely met.
The present invention shows that with available arts and elements such needs can be easily met through proper design. The fact that others have not, until the present invention, solved these problems may be the result of two general tendencies. First, many areaway structures were not designed to facilitate egress. As a result those types of structures may have actually had vertical boundaries where settling or expansion and contraction of the soil did not present a particularly acute problem. A second tendency is that of the preconceptions of those skilled in the art. In instances where soil settling or expansion and contraction were of concern, prior to the present invention those skilled in the art seemed to accept such problems and not consider that a solution might be possible through proper design of the areaway system itself. The present invention shows that in fact proper design can greatly facilitate not only installation of an areaway structure but also its actual function.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides an areaway system which has a continuously adjustable attachment element. This attachment element may allow free motion of the areaway so that it can float and actually move as soil conditions dictate. The invention also allows a design which can include an escape element and which is efficient to both manufacture and install. A modular and component-based system is disclosed. This can permit easy changes in configuration for both new and retrofit installations.
One of the objects of the inventions is thus to enhance the ease of the initial installation of the areaway structure. In keeping with this objective a goal is to avoid the challenge of specific and precise ground alignment and to even allow adjustment of the areaway level after it has been installed. Another goal is to provide a system which can be either preconfigured or configured by the user to accommodate existing window bucks and foundations. In keeping with this goal, it is desired to provide a reversible system which can be configured as desired for both installation and aesthetic reasons.
Another object of the invention is to allow the areaway to move with the ground surrounding it. Thus is it a goal for the areaway to accommodate expansion and contraction of soil conditions, to accommodate settling (as might be incidental to a new construction), and to accommodate sort conditions where there might be freezing and thawing of the soil throughout the course of the year. It is also a goal for such an areaway design to allow for movement that is not restricted when freezing occurs and thus some designs have as a goal keeping the movement features free and unencumbered throughout the years.
Yet another object of the invention is to provide a design which easily accommodates escape system improvements. As mentioned such improvements are becoming increasingly required by code changes and the like. Thus a goal for the invention is to provide a system which is particularly designed for escapable areaways. It is also a goal to present a design which may be utilized in larger areaways.
A further object of the invention is to provide a design which can easily be retrofit to existing areaways. In instances where the newer code changes are desired to be complied with, the entire areaway structure might be replaced with one having an escape feature. Accordingly, it is a goal to provide a design where such retrofit desires are accommodated. Generally the designs are such that homeowners may easily replace such structures by themselves. In instances where the old areaway is still desired to be used, it is also a goal to provide for designs which can be easily reconfigured so that they may be utilized with the existing areaway structure.
Another practical object of the invention is for the design to be very economical to manufacture. The design thus presents a number of integral features which allow for an efficient and inexpensive design.
Naturally further objects of the invention are disclosed throughout other areas of the specification and claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of one areaway design according to the present invention.
FIG. 2 is a side cross sectional view of an installed design such as shown in FIG. 1.
FIG. 3 is a cross-sectional top view through one of the slide designs shown in FIGS. 1 and 2 with one side showing the addition of a shield arrangement.
FIG. 4 is a schematic illustration of a wheel-based free moving element design.
FIG. 5 is a schematic illustration of a pivoting free movement design.
FIG. 6 is a schematic illustration of a flexible free movement design.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen from the drawings, the basic concepts of the present invention may be embodied in many different ways. FIG. 1 shows the areaway system (1) in an exploded view. FIG. 2 shows the same areaway system assembled and installed in a cross-sectional view. As can be understood from these figures, the areaway system (1) has a top edge (2) which is designed to be open to allow light and/or egress through a window opening (3). The window opening (3) may actually be some type of cutout in foundation face (4) of a building (5). As can be understood, the areaway enclosure (6) will be situated below the top edge (2) and may abut the foundation face (4) along at least two foundation face edges (7).
As shown in the figures, this particular design has two side mounts (8) which allow for attachment of the areaway enclosure (6) to the foundation face (4). As those involved in this field readily understand the side mounts (8) may present one type of a great variety of means for detachably connecting some type of structure to the foundation face (4) wall. Thus, it should be understood that while a great variety of designs are possible only one may be shown. This should not be interpreted as limiting the scope of this patent. It is intended and does encompass all varieties of possible attachment designs; all that is necessary is that the attachment somehow restrict the areaway enclosure (6) with respect to the foundation face (4). Thus, the two side mounts (8) present just one type of areaway attachment and one means which acts to attach. In keeping with this general concept it should also be understood that while the areaway enclosure (6) is shown as some type of enclosure, a great variety of other types of enclosures are also possible. Such enclosures may or may not include an escape element such as the steps (9) shown. Additionally, it should be understood that the areaway enclosure (6) need not be strictly mounted to a foundation portion of the building (5). While, naturally, foundation mounting is the primary type of mounting and a particular mounting which the designs shown are intended to accommodate, other types or locations of mounting are also possible.
As shown in FIG. 2 it can be seen that the areaway enclosure (6) may also be designed to accommodate some type of drain (10), also referred to as a means for draining. As shown in FIG. 2, the drain (10) is an exposed opening at the bottom of the areaway enclosure (6). This opening may merely be a natural drain as shown. This is equivalently referred to as a means for accessing the earth. It may also be an aesthetic feature such as some type of means for planting, may be a formal drain design, or may merely be an unsealed bottom portion.
From FIG. 1 it can be understood that the areaway enclosure (6) may be modular. As shown, the design may utilize side elements (11) which might be designed to be attached in some fashion to step faces (12). The elements of any design may be manufactured in a variety of ways from virtually any material although at present a blow molded plastic design is preferred. As those skilled in the art could easily understand, the element(s) may also be simply molded, milled, stamped, hollow, solid, or the like. As shown, a modular design may be assembled by some generic type of means for affirmatively retaining the step faces (12) to the side elements (11) or by the specific mating system shown. Through such a design the areaway enclosure (6) may easily accommodate being disassembled for shipment. As is known, such designs may also be configured so as to allow nesting for shipment and retailing. Importantly, the designs shown can provide some type of continuously adjustable attachment. As shown in FIGS. 1 and 2 this continuously adjustable attachment may be a pair of slidable retainers (13) which provide for a number of features. First, by being continuously adjustable they allow the exact positioning of the areaway enclosure (6) with respect to the foundation face (4). This allows the areaway to be positioned at any level even after it has been attached to the foundation face (4). Second, by being positioned vertically, the continuously adjustable attachments, such as the slidable retainers (13) shown, can allow for vertical movement. This is particularly important because most settling and changes to the soil are of concern in the vertical direction. It also allows for back filling to occur and then for the areaway to be positioned on top at the desired fill level. As can be understood these attachments may be positioned as shown between the areaway enclosure (6) and the building (5).
As shown in the figures, the areaway enclosure (6) may be attached to the foundation face (4) through some sort of foundation face attachment (14). This element could be a portion of a continuously adjustable attachment which is designed to mate with some portion of the building (5). As shown in FIG. 1, the foundation face attachment may consist of numerous holes so that a variety of mounting locations can be selected as appropriate for that particular installation. Importantly it should be noted that through the use of the term foundation face attachment, it is not intended that such attachment portion be limited to only a portion which mounts directly to the foundation. As those skilled in the art could easily understand, the foundation face attachment (14) can be configured to mate with a window buck or some other portion of the building (5) as well.
It can also be understood that the areaway enclosure (6) can be responsive to the foundation face attachment (14). This can be accomplished by mounting the foundation face attachment (14) to the areaway enclosure so as to hold the areaway enclosure (6) in at least one direction. In the embodiments shown, it can be appreciated that the attachment restricts the movement of the areaway enclosure (6) so that it has only one degree of freedom--vertical motion. Through the slide elements discussed later the areaway enclosure (6) can move up or down while simultaneously being retained in other directions. This may include designing the foundation face attachment (14) so that it both laterally and orthogonally retains the areaway enclosure (6).
As shown in FIG. 3, the slidable retainers (13) may form tracks (21) and may not permit the side elements (11) to move sideways with respect to the foundation face (4). Similarly, by including lips (18) which engage the side elements (11) in slots (20), the areaway enclosure (6) can be orthogonally retained against the foundation face (4) so that the areaway enclosure (6) cannot pull away from the foundation face (4). Thus, the design can provide both a lateral retainer and an orthogonal retainer to which the areaway enclosure (6) is responsive and which in turn is responsive to the foundation face attachment (14).
One feature of the design which is important commercially is that the product be efficient to manufacture. In this regard the design shown includes a number of integral features. As shown in FIG. 1, the areaway enclosure (6), or in this case more specifically the side element (1 1) may have designed into it an integral side mount such as the slots (20). This integral side mount may be designed so as to mate in some coordinated fashion with an integral mount such as lips (18). Lips (18) may be part of the continuously adjustable vertical element, in this case, the slidable retainer (13). By making all such elements integral, namely one portion of a unitary formed element, the designs can be more efficiently manufactured and can be priced more favorably. Again, as those skilled in the art could easily understand, any manufacture of a foundation face attachment this can be accomplished using a variety of manufacturing techniques ranging from molding to willing to extruding and the like. Similarly, the element can also be manufactured from virtually any material although at present aluminum is preferred.
As mentioned earlier, the continuously adjustable vertical element facilitates installation of the areaway enclosure (6). In some designs it might be possible to loosely attach the enclosure, adjust the height and then tighten the attachment to hold it firmly in place. The areaway enclosure (6) might also be permitted to float or move freely in at least one direction after it has been installed. This floating or free movement is accomplished in the design shown through the use of the slidable retainer (13) which acts as some type of free motion support.
As a free motion support, this design can act to support the areaway enclosure (6) so that it is restricted in at least one direction. The free motion support is also some type of element which permits the areaway enclosure (6) to move freely in at least one direction. In the design shown, the slidable retainer (13) acts as a free motion support by restricting the areaway enclosure (6) both laterally and orthogonally while simultaneously permitting it to move freely in a vertical direction. As mentioned earlier, this free motion support can also be designed to have an integral mount. Obviously, the slidable retainer (13) may be made from separate components, as well. It may also be designed to allow free motion in other directions including lateral and even orthogonal directions depending upon the application desired. As should be generally understood, while one type of free motion support is shown, certainly there are a host of other designs possible ranging from baffles to bellows to even overlapping elements. The important features are merely that the designs selected permit motion to the degree desired. While it is presently believed that vertical motion will be desired in most applications, other directions and numbers of directions of free motion are also possible and would still fall within the scope of this patent. The motion also may or may not be linear. While a slide design seems efficient and does present vertically linear motion, other designs might permit arcuate or some other direction or path of motion and still fall within the scope of this patent.
As mentioned earlier one of the problems which the present invention is designed to address is motion of the ground surrounding the areaway enclosure (6). Through its design, the embodiment is configured to be responsive to ground motion at least in the vertical direction. By situating the areaway enclosure (6) adjacent to the ground (17), the areaway enclosure (6) actually moves responsive to the ground and will maintain its position adjacent to it. Thus, if the ground were to settle, expand through the addition of moisture, or expand through freezing the areaway enclosure (6) would react appropriately.
In instances such as where the ground might become frozen and the like it may also be important to assure that the free motion support to remain free. This can be accomplished by using particular movement surfaces such as some nonporous surfaces, by using particular materials such as an anti-icing surface (Teflon, silicone or the like), or by even using some type of shield arrangement so that moisture cannot significantly impair the motion of the areaway enclosure (6) relative to the foundation face (4).
As shown on one side of the alternative design in FIG. 3, the unit may also include some type of shield (24). This can be an integral or separately affixed component which may act to protect the free motion support from the ground (17). Naturally, this shield (24) might be incorporated in any other design and might be utilized to protect not only an element such as the slidable retainer (13) but other elements such as the wheels (26) shown in FIG. 4. This shield (24) might be designed to be either flexible or waterproof or both so that the motion can continue unencumbered throughout the course of use. In instances in which the appropriate surface is selected so that water will not tend to encumber the motion of the areaway enclosure (6), the shield (24) might only limit the movement of dirt to sensitive areas. The shield (24) might be designed to be integral to the free motion support as well.
As also shown in the figures, it can be seen that the areaway enclosure (6) may be designed to incorporate some type of means for escaping, literally any escape element. In the design shown this escape element consists of a variety of steps (9). Naturally, other elements are possible as shown in some of the patents referenced earlier. This invention, however, has particular value in applications involving steps because there is some element of overhang on the areaway enclosure (6) making it more potentially important for the areaway enclosure (6) to constantly reposition itself adjacent to the ground (17).
As mentioned, FIG. 3 shows a top cross-sectional view of a sliding free motion support. As can be seen the slidable retainer (13) includes an integral mount for the foundation face attachment (14). The design also shows the lips (18) at the end of the guides (19). Since these guides (19) act to retain the areaway enclosure (6) laterally, the areaway enclosure (6) is responsive to the free motion support. In order to retain the areaway enclosure (6) orthogonally, the guides (19) may have lips (18). These lips (18) may be coordinated to fit within the slots (20) and may form tracks (21) as shown. Most areaway enclosures are designed to abut a foundation face (4) along a left and a right side, namely at two vertical foundation face edges (7). By providing at least two tracks (21) and at least two guides (19), one guide and one track can be provided for each side of the enclosure. Through this design it can be seen that the slidable retainer (13) actually forms a track (21) for each side within which the areaway enclosure (6) may be positioned and to which it may be responsive.
As mentioned earlier there are a variety of alternative designs possible for both the continuously adjustable attachment and the free motion support. As shown in FIG. 4, the free motion support may include some type of rotating element. This is shown as the inclusion of wheels (26). These wheels may include some type of bearing through which friction can be minimized. In this design the motion of the areaway enclosure (6) is accomplished by rotating some type of element. Naturally, as those skilled in the art would easily understand a variety of other rotating designs are also possible including such rotating elements as ball beatings and the like.
Yet another type of design is shown in FIG. 5. This shows a pivoting design where the attachment includes at least one pivot (22). This might be a rigid arm which is attached to rotate about some point or it might even be some type of flexible or even an elastic element through which pivoting is possible. Similarly, some type of flexible element (23) might be included as shown in FIG. 6.
In any design it might be desirable to in corporate some type of movement stop (25). This is shown in FIGS. 1 and 2 as merely the end of the slot (20). The stop (25) has the effect of limiting the movement of the free moving support or continuously adjustable support with respect to the areaway enclosure (6). This can be important when there is free vertical movement and can also be important during installation. As shown it can be seen that the stop (25) can act to restrict downward motion. Thus, during installation, the areaway can be attached without sliding down too low. It then can be raised and the ground filled in beneath it and lowered until it contacts the ground. While naturally the stop might act in any direction (or both directions) limiting movement in only one direction has an advantage during installation in that the supports can be attached and then the areaway slid into the direct position. It may then be adjusted with respect to the foundation by the mount of ground placed below the areaway enclosure (6).
In keeping with the goal of providing a design which is efficiently manufactured, it is possible that the stop (25) be an integral tab of some sort or other. This integral tab might be positioned on either the areaway enclosure (6) (as shown) or adjacent one end of the free motion support. In designs where there are at least two lips on the free motion support, as shown in the figures, it is possible to have the integral tab adjacent these lips when assembled.
An efficient design should also accommodate varying installation needs. In the embodiments shown this is accomplished by providing a design which is reversible. As shown in FIGS. 1, 2 and 3, it can be understood that the free motion supports shown as the slidable retainers (13) can be reversed so that they may attach either on the inside of the areaway enclosure (6) or on the outside of the areaway enclosure (6). This can be simply accomplished by removing the slidable retainers (13) and then placing them on different sides of the areaway. As shown, the slidable retainers (13) can be configured so as to have axially opposite configurations. Through this design, each can face an opposite direction about the vertical axis (the axis along which vertical movement takes place after installation). During installation the user may select the desired orientation, position the continuously moveable attachments adjacent to the foundation opening and then retain the areaway to the foundation opening. Thus the slidable retainers (13) can serve as two removable elements. These elements might even be axially symmetric as well as axially opposite such as in instances where the mounting holes might be merely circles rather than the keyhole-shaped holes presently preferred.
In applications where different types of foundation face attachments (14) are desired, it may even be possible to completely replace the slidable retainers (13) with ones which have been specifically manufactured for that particular application. Thus, if there were different window bucks or other types of locations where it was deskable to attach the areaway enclosure to the foundation face, different attachments could be purchased. As shown in FIG. 1, the slidable retainers (13) include a variety of holes. These holes may be adjustable by sliding the slidable retainers (13). They also might have a number of holes placed on them so that any number of holes might be selected. This can greatly aid in accommodating a less precise installation effort. To achieve installation, the continuously moveable attachments may either be attached to the foundation face first or attached to the areaway enclosure (6) first and then attached to the foundation face.
Another important aspect of the invention is it features which allow easy retrofitting to existing foundations. This can be accomplished by locating the foundation opening and then removing the old areaway enclosure and either replacing the same enclosure utilizing the free motion supports of this invention or entirely replacing the areaway enclosure with a more deskable one. By utilizing the free motion supports of this invention the owner can thus establish an ability for continuous movement either during installation or free movement during use of the areaway to accommodate the soil conditions as mentioned earlier. As those skilled in the art would easily understand the design may be configured to accommodate standard attachments for areaway enclosures and thus minimize reinstallation effort. As mentioned earlier the reinstallation can either involve installing the free motion support against the foundation and then attaching the areaway enclosure (6) to that free motion support or installing the free motion support to the areaway enclosure (6) and then installing the combined unit on the foundation face. Similarly, other designs can be provided where a portion of the free motion support is installed to the foundation and that portion is installed to the areaway enclosure (6). These two portions can then be joined either by sliding or some other attachment technique.
The foregoing discussion and the claims which follow describe the preferred embodiments of the present invention. Particularly with respect to the claims, it should be understood that changes may be made without departing from the essence of the invention. In this regard, it is intended that such changes would still fall within the breadth of protection encompassed by this patent. It simply is not practical to describe and claim all possible revisions to the present invention which may be accomplished. This is particularly true for the present invention since it involves basic concepts and understandings which are fundamental in nature and can be broadly applied.
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A floating areaway system which can respond to changing soils conditions (such as freezing, expansion, settling, or the like) utilizes a continuously adjustable attachment to the foundation or a free motion support. The system is particularly adapted to overhanging areaway enclosures such as may include an escape dement. The designs can range from slidable retainers to elastic members to rotating elements so that the areaway enclosure can move up or down with the soil. Shields, low friction surfaces, and waterproof elements can be included to assure continuous operation. Installation, whether new or retrofit, is facilitated through individual free motion support brackets which can accommodate previously installed areaway enclosures as well as a new enclosure. The brackets can be designed to be specific to particular designs, generic, removable, and reversible so that the mounting can be in either the interior or the exterior of the enclosure. Integral designs afford efficient manufacture and installation.
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TECHNICAL FIELD
The present invention relates to novel polyhydroxyamide compounds which, in the form of their oxazoles, are suitable as a coating material, in particular of electronic components, a process for their preparation and their use.
BACKGROUND
In microelectronics, highly heat-resistant polymers are required as protective and insulating coats. These polymers can be used as a dielectric between chip and metalization or between two metal planes of the chip, e.g. in multichip modules, memory chips and logic chips. The metal planes may be present below or above the inorganic passivation of the chip. Moreover, such polymers can also be used as a buffer coating between the chip and its housing. Among these polymers, the polyhydroxyamides have good solubility in organic solvents and good film formation properties and can be applied to the electronic components by means of the economical spin-coating technique. These polyhydroxyamides are cyclized after a thermal treatment (curing) to give polybenzoxazoles and, according to the following equation, thus acquire their final properties:
The requirements with respect to the end product are, for example, good insulation properties and sufficient thermal stability. Good adhesion of the material to all relevant substrates, for example silica, silicon nitride, titanium, titanium nitride, tantalum or tantalum nitride, is also particularly important. Titanium, titanium nitride, tantalum and tantalum nitride are proven adhesion-promoting and barrier coats for aluminum or copper metalizations.
If the polymer is used as an insulating coat, for example below the uppermost coat of metal, i.e. the outer wiring, further properties are important. These are in particular the adhesion of the metallic conductors or of the corresponding adhesion-promoting and barrier coats to the insulating coat and high resilience or extensibility of this insulating coat so that the different expansions of the chip and of the circuit board are compensated. FIG. 1 shows a flip-chip contact, wherein the upper part of the chip points toward the circuit board. The abovementioned properties are, however, also important in other metalization coats of the chip.
Polyhydroxyamides which are readily soluble and have good thermal stability are described, for example, in EP 0 317 942 A2, DE 3 718 212 A1 or U.S. Pat. No. 5,077,378. However, the materials described in these publications have very low resilience or elongation and only moderate adhesion, in particular to titanium nitride or tantalum nitride.
Chemical Abstracts Vol. 83, 1975, report 81475x describes coating materials for cables, but these are not polyhydroxyamides.
Patent Abstracts of Japan C-991, Oct. 2, 1992, Vol. 16/No. 473 describes fluorinated aromatic polyhydroxyamides and polybenzoxazoles having high thermal stability. Particular adhesion properties of these compounds are not mentioned.
SUMMARY
It is an object of the present invention to provide readily soluble polyhydroxyamides which, after application to a substrate and drying, if required with a thermal treatment, form a heat-stable and highly resilient coat with very good adhesion to metallic and nonmetallic substrates.
It is a further object of the present invention to provide electronic components which have heat-stable and highly resilient coats with very good adhesion to metallic and nonmetallic substrates.
This object is achieved, according to the invention, by polyhydroxyamide compounds as described herein. Preferred embodiments of the invention are evident from the description and the claims.
The present invention furthermore relates to polybenzoxazoles which are obtained by cyclization of hydroxyamide units of the polyhydroxyamides according to the invention, and their use.
The invention also includes electronic components which have the polybenzoxazole coats according to the invention.
The present invention furthermore relates to a preparation process for the polyhydroxyamides according to the invention and the corresponding polybenzoxazoles thereof.
The invention furthermore includes compositions which contain the polyhydroxyamides according to the invention and an organic solvent.
DESCRIPTION
The present invention relates to novel polyhydroxyamides and polybenzoxazoles derived therefrom by cyclization. In the form of their polybenzoxazoles, the compounds according to the invention can be used for coating substrates, in particular electronic components.
According to the invention, compounds of the following formula I or II are claimed:
in which:
a=0 or 1, with the proviso that, if a is 0, c must be ≧1, b=0–100, c=0–50, with the proviso that, if c is 0, a must be =1, d=1–100, e=0–100, f=0–100, g=0–50, h=0–100, k=0–100, m=0–100, n=0–50, p=0 or 1;
in which:
q=1–100, r=1–100, s=0–100, t=0–100, u=0–100, v=0–50, w=0–100, x=0–100, y=0–100, z=0–50; X, independently of one another, are:
in which R1 in each case may be identical to or different from R2 and α is 0–100 and β is 0–100, α and β not simultaneously being 0;
R 1 and R 2 are: substituted or unsubstituted alkylene, arylene or cycloalkylene groups; Q is —O—, —S— and/or —NH—; A 1 and/or A 2 , where A 1 may be identical to or different from A 2 if A 1 and/or A 2 are bonded to Q or —NH—, are: H, substituted or unsubstituted alkylcarbonyl, alkenylcarbonyl, cycloalkenylcarbonyl, arylcarbonyl, aralkylcarbonyl, aralkenylcarbonyl or aralkynylcarbonyl, it being possible for the carbonyl group to be bonded to the aromatic or to the alkyl or alkenyl or alkynyl group; A 1 and/or A 2 , where A 1 may be identical to or different from A 2 if A 1 and/or A 2 are bonded to —CO—, are: hydroxyl, substituted or unsubstituted alkoxy, alkenyloxy, aryloxy, cycloalkenyloxy, amino, alkylamino, alkenylamino, arylamino, arylalkenyloxy, arylalkylamino; A 3 is: H, substituted or unsubstituted alkylcarbonyl, alkenylcarbonyl, cycloalkenylcarbonyl, arylcarbonyl, aralkylcarbonyl, aralkenylcarbonyl or aralkynylcarbonyl, it being possible for the carbonyl group to be bonded to the aromatic or to the alkyl or alkenyl or alkynyl group; Y 1 and Y 2 , where Y 1 may be identical to or different from Y 2 , are: substituted or unsubstituted aryl, a substituted or unsubstituted polynuclear aromatic hydrocarbon compound, substituted or unsubstituted alkyl, alkenyl, alkynyl, aryl or aralkyl, aralkenyl, aralkynyl; Z 1 and Z 2 , where Z 1 may be identical to or different from Z 2 , are: aryl, aralkyl, aralkenyl, aralkynyl, heteroaryl or a polynuclear aromatic hydrocarbon compound.
According to the invention, X 1 to X 6 may be identical to or different from one another. According to the invention, polyhydroxyamides where X═X 1 and/or X═X 3 are preferred. It is furthermore preferred according to the invention if, in X, α is 0–10 and/or β is 0–10. In the polyhydroxyamides according to the invention, it is preferable if, in formula I, b=0–20, c=0–10, d=4–40, e=0–20, f=0–20, g=0–10, h=0–20, k=0–20, m=0–20 and/or n=0–10;
and in formula II, q=3–40, r=1–40, s=0–40, t=0–20, u=0–20, v=0–10, w=0–20, x=0–20, y=0–20 and/or z=0–10.
According to the invention, polyhydroxyamides in which R 1 and/or R 2 have the following meaning are furthermore preferred:
—(CH 2 ) χ —
χ=1–20
where δ=0–20, ε=0–20, and R 3 and R 4 : —H, —(CH 2 ) φ —CH 3 ;
φ=0–10 or —OH, where R 3 and R 4 cannot simultaneously be —OH
The following radicals are particularly preferred for R 1 and/or R 2 :
—(CH 2 ) χ —
χ=1–20
where δ=0–20, ε=0–20, and R 3 and R 4 : —H, —(CH 2 ) φ —CH 3 ;
φ=0–10 or —OH, where R 3 and R 4 cannot simultaneously be —OH
According to the invention, Q is preferably —O— and/or —NH—, furthermore preferably —O— and —NH—.
According to the invention, further preferred polyhydroxyamides are those in which A 1 and/or A 2 , if A 1 and/or A 2 are bonded to Q or —NH—, and A 3 have the following meaning:
where φ=0–10 and W═—CN, —C(CH 3 ) 3 , —(CH 2 ) φ —CH 3 , —(CF 2 ) 100 —CF 3 , —O—(CH 2 ) 100 —CH 3 , —O—(CF 2 ) φ —CF 3 ,
—CH═CH 2 , —C≡CH or
Among these, the following are particularly preferred:
If A 1 and/or A 2 are bonded to —CO—, A 1 and/or A 2 preferably have the following meaning:
—OH —O—(CH 2 ) φ —CH 3 —O—CH 2 —CH═CH 2
—NH 2 —NH—(CH 2 ) φ CH 3 —NH—CH 2 —CH═CH 2
where φ=0–10 and W=—CN, —C(CH 3 ) 3 , —(CH 2 ) φ —CH 3 , —(CF 2 ) φ —CF 3 , —O—(CH 2 ) φ —CH 3 , —O—(CF 2 ) φ —CF 3 ,
—CH═CH 2 , —C≡CH or
Among these, the radicals —OH and —NH 2 are particularly preferred.
Y 1 and Y 2 , where Y 1 may be identical to or different from Y 2 , are preferably:
Y 1 and/or Y 2 are particularly preferably:
According to the invention, preferred polyhydroxyamides are those in which the radical
R 5 in Y 1 and/or Y 2 is —H, —CN, —C(CH 3 ) 3 , —(CH 2 ) φ —CH 3 , —(CF 2 ) φ —CF 3 , —O—(CH 2 ) φ 'CH 3 , —O—(CF 2 ) φ —CF 3 and/or is:
—C≡CH
—O—CH 2 —CH═CH 2
where φ=0–10 and W=—CN, —C(CH 3 ) 3 , —(CH 2 ) φ —CH 3 , —(CF 2 ) φ —CF 3 , —O—(CH 2 ) φ —CH 3 , —O—(CF 2 ) φ —CF 3 ,
—CH═CH 2 , —C≡CH or
Particularly preferred radicals R 5 are:
—C≡CH
According to the invention, R 6 in Y 1 and/or Y 2 is preferably —O—, —CO—, —NR 7 —, —S—, —SO 2 —, —S 2 —, —CH 2 — or:
—C═C— —C≡C—
Particularly preferred radicals R 6 among these are: —O—, —CO—, —NR 7 —, —CH 2 — and:
—(CF 2 ) η —
η=1–10
According to the invention, R 7 in Y 1 and/or Y 2 is preferably —H and/or:
—(CH 2 ) φ —CH 3
(φ=0–10)
—(CF 2 ) φ —CF 3
(φ=0–10)
When it denotes R 6 , R 8 is, according to the invention, preferably alkyl having 1 to 10 carbon atoms or aryl.
According to the invention, Z 1 and Z 2 are preferably the following radicals, it being possible for Z 1 to be identical to or different from Z 2 :
Here, R 6 is defined as above.
Particularly preferred radicals Z 1 and/or Z 2 are:
The polyhydroxyamides according to the invention can be substantially controlled with respect to the indices by the stoichiometry of the reactants or the prepolymerization. The characterization of the polyhydroxyamides is expediently effected by means of 1 H-NMR, gel permeation chromatography (GPC) and/or thermogravimetry (TGA). On the basis of the different chemical shifts of individual protons of the individual components and the corresponding integrals, the indices of the individual components can be substantially determined via the molar mass distribution of the polymer (obtained by GPC).
The polyhydroxyamides of the present invention can also be converted into polybenzoxazoles by cyclization of hydroxyamide units. According to the invention, polybenzoxazoles are to be understood as meaning those compounds which are obtained by cyclization of the hydroxyamide units of the compounds according to the invention. According to the invention, the term includes not only oxazole rings which are present in the vicinity of phenyl rings but alternatively also those compounds in which the oxazole ring is present, for example, in the vicinity of thiophene or furan rings.
These polybenzoxazoles also included according to the invention have outstanding adhesion to metallic and nonmetallic substrates, in particular to silica, silicon nitride, titanium, titanium nitride, tantalum or tantalum nitride. The polybenzoxazoles according to the invention are moreover extremely heat-resistant and can be used as protective and/or insulating coats in microelectronics. A further particular advantage is the high resilience or extensibility of the polybenzoxazole insulating coats of the present invention. The following may be mentioned as examples of electronic components that have a polybenzoxazole coat according to the invention: flip-chips, memory chips, logic chips, flash memories, multichip modules, circuit boards, microprocessors, and embedded DRAMs.
The polyhydroxyamides according to the invention can be prepared by conventional processes. Here, a compound of the formula Z 1 (NH 2 ) 2 (OH) 2 and/or Z 2 (NH 2 ) 2 (OH) 2 is reacted with a compound of the formula Y 1 (COCl) 2 and/or Y 2 (COCl) 2 , which is preferably used in excess, and the product obtained is then reacted with a compound of the formula X(QOH) 2 or X(QNH 2 ) 2 and the product obtained thereby is then optionally reacted with a precursor compound for A 1 , A 2 and/or A 3 , A 1 , A 2 and/or A 3 being bonded at the chain ends. Here, Z 1 , Z 2 , Y 1 , Y 2 , X, A 1 , A 2 and A 3 are defined as above. The fact that A 1 , A 2 and/or A 3 are bonded at the chain ends is evident simply from the fact that the products can be completely cyclized. Products which cannot be completely cyclized are still partly soluble after the cyclization treatment, i.e. swell, which does not occur in the case of completely cyclized products.
For the synthesis of copolymers where Y 1 is different from Y 2 , a mixture of Y 1 (COCl) 2 and Y 2 (COCl) 2 can be reacted with Z 1 (NH 2 ) 2 (OH) 2 or Z 2 (NH 2 ) 2 (OH) 2 , the stoichiometry of total Y being appropriately distributed over Y 1 and Y 2 . A reaction with X(QOH) 2 or X(QNH 2 ) 2 is then effected.
Another possibility for the preparation of copolymers mixed with respect to Z 1 , Z 2 , Y 1 and Y 2 is to prepolymerize two separate batches in which, for example, on the one hand Y 1 and Z 1 and on the other hand Y 2 and Z 2 are combined. The two batches are then combined and are polymerized with X(OH) 2 . Blocks, for example according to the scheme -Z 1 -Y 1 —X—Y 2 -Z 2 -, can thus be prepared in a defined manner.
The synthesis gives straight-chain polyhydroxyamides, as can be shown by 1 H-NMR spectroscopy (cf. example 4 and FIG. 2 ). Moreover, crosslinked chains would not give good solubility, as in the examples according to the invention.
The conversion of polyhydroxyamides into polybenzoxazoles is usually effected by a thermal treatment (curing). This thermal treatment is effected, according to the invention, at 250–450° C., preferably 300–400° C., most preferably at about 300–350° C.
The thermal treatment usually takes 0.5–3 hours, preferably 1–3 hours, most preferably 1–2 hours.
The invention also relates to a process for coating substrates, the polyhydroxyamides according to the invention being applied to the substrate to be coated, and the coated substrate then being heated in order to form a polybenzoxazole coat on the substrate. During the heating, the above parameters for the thermal treatment are preferably used.
The polymers according to the invention are readily soluble in many organic solvents, e.g. acetone, cyclohexanone, diethylene glycol mono- or diethyl ether, N-methylpyrrolidone, γ-butyrolactone, ethyl lactate, tetrahydrofuran or ethyl acetate, and can be applied without problems to substrates by means of conventional methods, for example the spin coating technique. After the thermal treatment (curing) of the substrate provided with the polyhydroxyamides, the film obtained exhibits substantially higher resilience or extensibility and substantially better adhesion to various substrates, in particular to titanium, titanium nitride, tantalum and tantalum nitride, in comparison with other comparable materials.
The invention also relates to compositions which contain the polyhydroxyamides according to the invention in an organic solvent, preferably in one of the solvents acetone, cyclohexanone, diethylene glycol mono- or diethyl ether, N-methylpyrrolidone, γ-butyrolactone, ethyl lactate, tetrahydrofuran, ethyl acetate or mixtures thereof. According to the invention, compositions in which the polyhydroxyamide is present in an amount of 10–50% by weight, more preferably 20–40% by weight, most preferably about 20% by weight, based on the total composition, are preferred.
The substrates which were coated using the novel material according to the invention withstand a substantially larger number of thermal cycles than those which were produced using materials according to the prior art. Suitable substrates for the polymers according to the invention are, for example, silicon chips ( 1 ) which have the insulating material ( 2 ) according to the invention with a metal coat ( 3 ) present thereon and are (spot) soldered ( 5 ) or adhesively bonded with a conductive adhesive to a circuit board ( 4 ) (cf. FIG. 1 ).
The polybenzoxazole coats according to the invention preferably serve, according to the invention, as protective and/or insulating coats in electrical components.
The invention is described in more detail below with reference to embodiments. However, these are not intended to limit the scope of the present invention.
DESCRIPTION OF DRAWINGS
FIG. 1 shows the structure of a flip-chip contact.
FIG. 2 shows a 1H-NMR spectrum of the polyhydroxyamide from example 4.
DETAILED DESCRIPTION
Chemicals Used:
Bisaminophenols:
9,9′-Bis(4-((3-hydroxy-4-amino)phenoxy)phenyl)fluorene [sic]—(bisaminophenol 1)
2,2-Bis(3-amino-4-hydroxyphenyl)hexafluoropropane—(bisaminophenol 2)
3,3′-Diamino-4,4′-dihydroxybiphenyl—(bisaminophenol 3)
Bisaminophenol 4:
Bisaminophenol 5: 3,3′-dihydroxybenzidine
Dicarboxylic acid chlorides:
5-Ethynylisophthaloyl chloride—(dicarboxylic acid chloride 1)
4,4′-Di(chlorocarbonyl)diphenyl ether—(dicarboxylic acid chloride 2)
Terephthaloyl chloride—(dicarboxylic acid chloride 3)
Isophthaloyl chloride—(dicarboxylic acid chloride 4)
1,8-Anthracenedicarboxylic acid chloride (dicarboxylic acid chloride 5)
2,6-Naphthalenedicarboxylic acid chloride (dicarboxylic acid chloride 6)
Endcap:
cis-5-Norbornene-endo-2,3-dicarboxylic anhydride—(endcap 1)
Methacryloyl chloride (endcap 2)
Bishydroxycarbonates:
UC-Carb 100 (UBE Industries, LTD.)—(bishydroxycarbonate 1)
n=3–6
UH-Carb 300 (UBE Industries, LTD.)—(bishydroxycarbonate 2)
n=10–14
Bishydroxyester:
Poly[di(ethylene glycol)phthalate]diol—(bishydroxyester 1)
n=2–4
Bishydroxyether:
Poly(ethylene glycol-co-propylene glycol)-polyether 1 M=2 500 g/mol
n=10–80
EXAMPLES
Synthesis of polyhydroxyamides according to the invention (examples 1–9)
Example 1
Polyhydroxyamide 1
10 g (17.7 mmol) of bisaminophenol 1 were dissolved in 100 ml of distilled N-methylpyrrolidone (NMP). A solution of 4.83 g (21.25 mmol) of dicarboxylic acid chloride 1 in 50 ml of distilled γ-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was continued for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 7.08 g (7.08 mmol) of bishydroxycarbonate 1 in 60 ml of distilled NIvIP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 5.4 g (52.3 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 2500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 2000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 19.3 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMIP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 2
Polyhydroxyamide 2
183.13 g (0.5 mol) of bisaminophenol 2 were dissolved in 600 ml of distilled NMP. A solution of 177.07 g (0.6 mol) of dicarboxylic acid chloride 2 in 550 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for 1 hour at 10° C. and then for 1 hour at 20° C. A solution of 115.12 g (0.2 mol) of bishydroxyester I in 250 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 129.4 g (1.6 mol) of pyridine, dissolved in 450 ml of γ-BL, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to a mixture of 3000 ml of demineralized water and 1000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 356.7 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether. The molar mass of the polyhydroxyamide 2 was about 42000 (GPC). This gave the following values for the coefficients of the general formula for this example: a=1; b−k=0; m=70−80 (based on the molar mass distribution); n=0; p=1.
Example 3
Polyhydroxyamide 3
6.14 g (28.37 mmol) of bisaminophenol 3 were dissolved in 100 ml of distilled NMP. A solution of 7.00 g (30.83 mmol) of dicarboxylic acid chloride 1 in 50 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 6.79 g (3.39 mmol) of bishydroxycarbonate 2 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 7.78 g (77.10 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 17.74 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 4
Polyhydroxyamide 4
5.00 g (8.86 mmol) of bisaminophenol 1 were dissolved in 70 ml of distilled N-methylpyrrolidone (NMP). A solution of 2.25 g (11.07 mmol) of dicarboxylic acid chloride 3 in 50 ml of distilled γ-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 2.55 g (4.43 mmol) of bishydroxyester 1 in 40 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 2.78 g (27.5 mmol) of triethylamine, dissolved in 20 ml of γ-BL, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours. In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 8.92 g. The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
FIG. 2 shows a 1H-NMR spectrum of the polyhydroxyamide 4 prepared. The presence of phenolic protons shows that the bishydroxyester 1 did not react with the phenolic protons of the bisaminophenol, i.e. unbranched chains form and not crosslinked products. Crosslinked products would also not have the good solubility like the products according to the invention.
Example 5
Polyhydroxyamide 5
183.12 g (0.5 mol) of bisaminophenol 2 were dissolved in 600 ml of distilled NMP. A solution of 177.07 g (0.6 mol) of dicarboxylic acid chloride 2 in 550 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 400.6 g (0.2 mol) of bishydroxycarbonate 2 in 250 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 129.4 g (1.6 mol) of pyridine, dissolved in 450 ml of γ-BL, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to a mixture of 3000 ml of demineralized water and 1000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 342.3 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 6
Polyhydroxyamide 6
7.89 g (36.49 mmol) of bisaminophenol 3 were dissolved in 100 ml of distilled NMP. A solution of 8.00 g (39.40 mmol) of dicarboxylic acid chloride 4 in 50 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 7.50 g (13.02 mmol) of bishydroxyester 1 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 9.97 g (98.70 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 21.52 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 7
Polyhydroxyamide 7
7.00 g (32.40 mmol) of bisaminophenol 4 were dissolved in 100 ml of distilled NMP. A solution of 8.22 g (40.50 mmol) of dicarboxylic acid chloride 4 in 50 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 9.40 g (16.20 mmol) of bishydroxyester 1 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 10.20 g (101.0 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 13.5 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 8
Polyhydroxyamide 8
10 g (26.28 mmol) of bisaminophenol 4 were dissolved in 100 ml of distilled N-methylpyrrolidone (NMP). A solution of 9.56 g (31.54 mmol) of dicarboxylic acid chloride 1 in 50 ml of distilled g-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 10.51 g (10.51 mmol) of bishydroxycarbonate 1 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 7.96 g (78.5 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 2500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 2000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 18.8 g. The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 9
Polyhydroxyamide 9
12.00 g (21.25 mmol) of bisaminophenol 1 were dissolved in 130 ml of distilled N-methylpyrrolidone (NMP). A solution of 3.55 g (15.66 mmol) of dicarboxylic acid chloride 1 and 1.70 g (6.71 mmol) of dicarboxylic acid chloride 8 (70:30) in 50 ml of distilled g-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 11.50 g (5.75 mmol) of bishydroxycarbonate 2 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 5.65 g (55.93 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 2000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 2000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 15.56 g. The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Thermal, mechanical and adhesion properties (examples 10–30)
Example 10
Determination of the Thermal Stabilities
The polyhydroxyamides described have thermal stabilities of >450° C. according to TGA investigations (thermogravimetry, apparatus: STA 1500 from Rheometric Scientific, heating rate: 5 K/min, inert gas:argon). The isothermal mass loss per hour at 400° C. for 10 hours is:
Example 1: 0.4% Example 2: 0.2% Example 3: 0.3% Example 4: 0.3% Example 5: 0.2% Example 6: 0.3% Example 7: 0.2% Example 8: 0.3% Example 9: 0.3%
The polyhydroxyamides 1–9 described thus meet the requirements for the intended applications.
Example 11
Preparation of a Polymer Solution of Polyhydroxyamide 1 and Investigation of the Properties
5 g of the polyhydroxyamide 1 described in example 1 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 1 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 mm at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 1 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.1 kg/mm 2 (20.60 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 1 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 5a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 1 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 11a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.1 kg/mm2 (20.60 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 1 after Thermal Loading Tests
The same test specimens as in examples 11a–11c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 11a: 1.9 kg/mm 2 (18.64 N/mm 2 ) Example 11b: 1.8 kg/mm 2 (17.66 N/mm 2 ) Example 11c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 12
Preparation of a Polymer Solution of Polyhydroxyamide 2 and Investigation of the Properties
5 g of the polyhydroxyamide 2 described in example 2 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 2 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3 500 rpm. After a short softbake of 1 mm at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 2 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.2 kg/mm 2 (21.58 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 2 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 12a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 2.0 kg/mm 2 (19.62 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 2 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 12a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.3 kg/mm 2 (22.56 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 2 after Thermal Loading Tests
The same test specimens as in examples 12a to 12c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 12a: 2.1 kg/mm 2 (20.60 N/mm 2 ) Example 12b: 1.9 kg/mm 2 (18.64 N/mm 2 ) Example 12c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 13
Preparation of a Polymer Solution of Polyhydroxyamide 3 and Investigation of the Properties
5 g of the polyhydroxyamide 3 described in example 3 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 3 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3 500 rpm. After a short softbake of 1 mm at 120° C. on a hotplate, 10 silicon chips measuring 4×4mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 3 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 3 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 13a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.8 kg/mm 2 (17.66 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 3 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 13a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.0 kg/mm 2 (19.62 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 3 after Thermal Loading Tests
The same test specimens as in examples 13a to 13c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 13a: 1.7 kg/mm 2 (16.67 N/mm 2 ) Example 13b: 1.7 kg/mm 2 (16.67 N/mm 2 ) Example 13c: 1.8 kg/mm 2 (17.66 N/mm 2 )
Example 14
Preparation of a Polymer Solution of Polyhydroxyamide 4 and Investigation of the Properties
5 g of the polyhydroxyamide 4 described in example 4 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 4 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 mm at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 4 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.0 kg/mm 2 (19.62 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 4 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 14a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 4 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 14a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.1 kg/mm 2 (20.60 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 4 after Thermal Loading Tests
The same test specimens as in examples 14a to 14c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 14a: 1.8 kg/mm 2 (17.66 N/mm 2 ) Example 14b: 1.75 kg/mm 2 (17.17 N/mm 2 ) Example 14c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 15
Preparation of a Polymer Solution of Polyhydroxyamide 5 and Investigation of the Properties
5 g of the polyhydroxyamide 5 described in example 5 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 5 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 min at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 5 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.2 kg/mm 2 (21.58 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 5 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 15a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 2.0 kg/mm 2 (19.62 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 5 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 15a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.3 kg/mm 2 (22.56 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 5 after Thermal Loading Tests
The same test specimens as in examples 15a to 15c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 15a: 2.1 kg/mm 2 (20.60 N/mm 2 ) Example 15b: 1.9 kg/mm 2 (18.64 N/mm 2 ) Example 15c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 16
Preparation of a Polymer Solution of Polyhydroxyamide 6 and Investigation of the Properties
15 g of the polyhydroxyamide 6 described in example 6 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 6 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 min at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 6 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 6 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 16a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 6 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 16a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 1.8 kg/mm 2 (17.66 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 6 after Thermal Loading Tests
The same test specimens as in examples 16a to 16c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 16a: 1.8 kg/mm 2 (17.66 N/mm 2 ) Example 16b: 1.7 kg/mm 2 (16.67 N/mm 2 ) Example 16c: 1.6 kg/mm 2 (15.69 N/mm 2 )
Example 17
Preparation of a Polymer Solution of Polyhydroxyamide 7 and Investigation of the Properties
5 g of the polyhydroxyamide 7 described in example 7 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 7 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 min at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 4 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.2 kg/mm 2 (21.58 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 7 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 17a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 2.2 kg/mm 2 (21.58 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 7 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 17a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.1 kg/mm 2 (20.60 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 7 after Thermal Loading Tests
The same test specimens as in examples 17a to 17c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 17a: 2.1 kg/mm 2 (20.60 N/mm 2 ) Example 17b: 2.15 kg/mm 2 (21.09 N/mm 2 ) Example 17c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 18
Preparation of a Polymer Solution of Polyhydroxyamide 8 and Investigation of the Properties
5 g of the polyhydroxyamide 8 described in example 8 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 8 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 min at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 5 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 2.2 kg/mm 2 (21.58 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 8 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 18a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 8 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 18a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 2.3 kg/mm 2 (22.56 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 8 after Thermal Loading Tests
The same test specimens as in examples 18a to 18c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 18a: 2.1 kg/mm 2 (20.60 N/mm 2 ) Example 18b: 1.8 kg/mm 2 (17.66 N/mm 2 ) Example 18c: 2.0 kg/mm 2 (19.62 N/mm 2 )
Example 19
Preparation of a Polymer Solution of Polyhydroxyamide 9 and Investigation of the Properties
5 g of the polyhydroxyamide 9 described in example 9 were dissolved in 20 g of NMP (VLSI-Selectipur®). The dissolution process was expediently effected on a shaking apparatus. The solution was then filtered under pressure through a 0.2 μm filter into a cleaned, particle-free sample tube.
a) Determination of the Adhesion of Polyhydroxyamide 9 to a Titanium Nitride Layer
A 4″ (10.16 cm) silicon wafer was provided with a 50 nm thick titanium nitride layer by sputtering. The abovementioned solution was applied to this wafer by spin coating, for 5 s at 500 rpm and for 25 s at 3500 rpm. After a short softbake of 1 min at 120° C. on a hotplate, 10 silicon chips measuring 4×4 mm 2 , which were likewise provided on the surface with 50 nm titanium nitride by sputtering, were pressed onto the polyhydroxyamide 6 film with a force of 2 N. This stack was then heated for 1 h at 300° C. in a nitrogen atmosphere in an oven. After cooling to room temperature, an adhesion test was carried out by means of a shear tester, Dage Series 400. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
b) Determination of the Adhesion of Polyhydroxyamide 9 to a Tantalum Nitride Layer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 19a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of tantalum nitride. The mean value of the force which was required for shearing off the Si chips was 1.9 kg/mm 2 (18.64 N/mm 2 ).
c) Determination of the Adhesion of Polyhydroxyamide 9 to a Silicon Wafer
The experiment was carried out in exactly the same way as with titanium nitride (cf. example 19a), except that in this case the surface of the wafer and of the chips consisted not of titanium nitride but of silicon. The mean value of the force which was required for shearing off the Si chips was 1.8 kg/mm 2 (17.66 N/mm 2 ).
d) Determination of the Adhesion of Polyhydroxyamide 9 after Thermal Loading Tests
The same test specimens as in examples 19a to 19c were produced again. After heating at 300° C., this stack was subjected 50 times to a thermal load in a conditioned cabinet, Vötsch VT7004, between −50° C. and 150° C. After this treatment, a shear test was carried out. Here, the forces were:
Example 19a: 1.8 kg/mm 2 (17.66 N/mm 2 ) Example 19b: 1.7 kg/mm 2 (16.67 N/mm 2 ) Example 19c: 1.7 kg/mm 2 (16.67 N/mm 2 )
Example 20
Comparative Example for Adhesion
A polyhydroxyamide prepared analogously to example 1 of U.S. Pat. No. 5,077,378 and in the same solution in NMP as in example 11 and the same experiments as in 11a to 11c gave the following mean values:
Titanium surface:
1.5 kg/mm 2 (14.71 N/mm 2 )
Tantalum nitride surface:
1.6 kg/mm 2 (15.69 N/mm 2 )
Silicon surface:
1.55 kg/mm 2 (15.21 N/mm 2 )
Example 21
Determination of the Resilience of Polyhydroxyamide 1
For the polyhydroxyamide 1 described under example 1, substantially higher resiliences were determined compared with the material in example 1 of U.S. Pat. No. 5,077,378. Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 82%. After the load was removed, the material contracted completely.
Example 22
Determination of the Resilience of Polyhydroxyamide 2
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 62%. After the load was removed, the material contracted completely.
Example 23
Determination of the Resilience of Polyhydroxyamide 3
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 78%. After the load was removed, the material contracted completely.
Example 24
Determination of the Resilience of Polyhydroxyamide 4
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 80%. After the load was removed, the material contracted completely.
Example 25
Determination of the Resilience of Polyhydroxyamide 5
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 62%. After the load was removed, the material contracted completely.
Example 26
Determination of the Resilience of Polyhydroxyamide 6
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 76%. After the load was removed, the material contracted completely.
Example 27
Determination of the Resilience of Polyhydroxyamide 7
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 83%. After the load was removed, the material contracted completely.
Example 28
Determination of the Resilience of Polyhydroxyamide 8
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 75%. After the load was removed, the material contracted completely.
Example 29
Determination of the Resilience of Polyhydroxyamide 9
Tensile tests were carried out using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 70%. After the load was removed, the material contracted completely.
Example 30
Comparative Example for Resilience
A polyhydroxyamide prepared analogously to example 1 of U.S. Pat. No. 5,077,378 was subjected to a tensile test using the apparatus MTS 858 from MTS System Corp. on films. The elongation was 9%.
Further Synthesis Examples
Example 31
Polyhydroxyamide 10
7.78 g (21.25 mmol) of bisaminophenol 2 were dissolved in 130 ml of distilled N-methylpyrrolidone (NMP). A solution of 4.62 g (15.66 mmol) of dicarboxylic acid chloride 2 and 2.03 g (6.71 mmol) of dicarboxylic acid chloride 5 (70:30) in 50 ml of distilled γ-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 5.75 g (5.75 mmol) of bishydroxycarbonate 1 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 5.65 g (55.93 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours. In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 2000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 2000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 14.86 g. The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 32
Polyhydroxyamide 11
7.78 g (17 mmol) of bisaminophenol 1 and 1.55 g (4.24 mmol) of bisaminophenol 2 were dissolved in 140 ml of distilled N-methylpyrrolidone (NMP). A solution of 5.08 g (22.37 mmol) of dicarboxylic acid chloride 1 in 70 ml of distilled γ-butyrolactone (γ-BL) was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 11.50 g (5.75 mmol) of bishydroxycarbonate 2 in 60 ml of distilled NMP was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C. 5.65 g (55.93 mmol) of triethylamine, dissolved in 20 ml of NMP, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours. In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to 2000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 1000 ml portions of cold demineralized water and once in 2000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 16.19 g. The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 33
Polyhydroxyamide 12
172.14 g (0.47 mol) of bisaminophenol 2 were dissolved in 600 ml of distilled NMP. A solution of 97.45 g (0.48 mol) of dicarboxylic acid chloride 3 in 550 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 240 g (0.12 mol) of bishydroxycarbonate 2 in 500 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. A solution of 19.7 g (0.12 mol) of endcap 1 in 150 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 129.4 g (1.6 mol) of pyridine, dissolved in 450 ml of γ-BL, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to a mixture of 3500 ml of demineralized water and 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 459.3 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether. It has terminal groups introduced by endcap 1. The product can be completely cyclized to give the corresponding polybenzoxazole.
Example 34
Polyhydroxyamide 13
135.51 g (0.24 mol) of bisaminophenol 1 and 51.89 g (0.24 mol) of bisaminophenol 3 were dissolved in 600 ml of distilled NMP. A solution of 56.76 g (0.25 mol) of dicarboxylic acid chloride 1 and 50.75 g (0.25 mol) of dicarboxylic acid chloride 3 in 550 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 120 g (0.12 mol) of bishydroxycarbonate 1 in 400 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. A solution of 12.54 g (0.12 mol) of endcap 2 in 120 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 129.4 g (1.6 mol) of pyridine, dissolved in 450 ml of γ-BL, are added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to a mixture of 3000 ml of demineralized water and 1000 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 393.7 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether.
Example 35
Polyhydroxyamide 14
172.14 g (0.47 mol) of bisaminophenol 2 were dissolved in 600 ml of distilled NMP. A solution of 97.45 g (0.48 mol) of dicarboxylic acid chloride 3 in 550 ml of distilled γ-BL was added dropwise to this solution at 10° C. while stirring. Stirring was effected for a further hour at 10° C. and then for 1 hour at 20° C. A solution of 300 g (0.12 mol) of polyether 1 in 500 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. A solution of 19.7 g (0.12 mol) of endcap 1 in 150 ml of distilled γ-BL was then added dropwise at 10° C. The reaction solution was stirred for a further 1.5 hours at 10° C. and then for 12 hours at 20° C. After cooling again to 10° C., 129.4 g (1.6 mol) of pyridine, dissolved in 450 ml of γ-BL, were added to the reaction mixture, which was warmed up to room temperature and stirred for 2 hours.
In order to isolate the polymer, the reaction mixture was filtered and the filtrate was added dropwise to a mixture of 3500 ml of demineralized water and 1500 ml of 2-propanol. The precipitated polymer was filtered off with suction and washed twice in 2000 ml portions of cold demineralized water and once in 1000 ml of demineralized water at 80° C., filtered off, and dried for 72 hours at 50° C./10 mbar. The yield was 463.5 g.
The polyhydroxyamide prepared in this manner was readily soluble in solvents such as NMP, γ-BL, tetrahydrofuran, cyclohexanone, cyclopentanone and diethylene glycol monomethyl ether. Thermal load capacity and resilience and adhesion on various substrates were outstanding.
Thermal load capacity, resilience and adhesion on various substrates were also outstanding for the polyhydroxyamides 10 to 13.
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The invention relates to novel polyhydroxyamide compounds that, in the form of their oxazoles, ane suited as a coating material, particularly for electronic components. The invention also relates to a method for producing these novel compounds and to the use thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims priority to PCT application No. PCT/US20131/047869 filed Aug. 16, 2011, which claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/374,838 filed Aug. 18, 2010, the disclosures of which applications are hereby incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to the field of orthopedic bone implants made of artificial materials. More particularly, it relates to bone implants made of pyrocarbon-coated substrates having a modulus similar to that of human bone which, when implanted, have a pyrocarbon articular region and have another region that interfaces with the recipient bone and that is formed so as to promote attachment to such bone without the need for ancillary cement or the like.
BACKGROUND OF THE INVENTION
Orthopedic implants for repair of fractured and/or diseased bones presently constitute a major industrial development because of their ability to rehabilitate patient's joints and load-bearing bone members. Many present-day bone implants utilize biologically compatible metal substrates, typically stainless steel, cobalt-chrome alloys or titanium alloys, and others use ceramic substrates which are nonmetallic inorganic materials often in the form of oxides, nitrides, borides, carbide or sulfides. However, such metal and ceramic implants have a modulus far different from that of human bone. It has now been found that there are long-term advantages to the implantation of prostheses having a modulus of elasticity, i.e. Young's modulus, that is closely similar to that of human cortical bone, particularly where an articular surface is involved at a bone joint. The Young's modulus of cortical bone is measured at between about 20 and 27 GigaPascals. Over the past decade or so, there has been increased interest in producing bone implants of pyrocarbon-coated graphite in order to more closely mimic the mechanical properties of human bone. Cortical bone is a dense, solid mass with only microscopic channels; it forms the outer wall of all bones and is largely responsible for the supportive and protective function of the skeleton. Cortical bone has a Young's modulus of about 20 to 30 Giga Pascal (GPa); such can be closely matched by pyrocarbon that has been coated upon graphite substrates. It has been found that in such instances, long-term compatibility is significantly aided by essentially matching the Young's modulus of a bone implant to that of the cortical bone in which it will be implanted and with which it will interface. As such, artificial isotropic graphite coated with dense isotropic unalloyed pyrocarbon has been found to provide an excellent material for the manufacture of such bone prostheses from the standpoint of its biocompatibility and strength and because it can be deposited with a Young's modulus close to that of cortical bone.
A dense surface layer of pyrocarbon can be deposited by a fluidized bed deposition process so as to exhibit wear-resistant, biocompatible, non-thrombogenic properties and a desired Young's modulus. Such pyrocarbon, upon polishing, provides an excellent articular surface for an implant at a bone joint or the like where there will be articulation with native bone and cartilage. Favorable chemical properties of such pyrocarbon, in addition to its matching mechanical properties, creates an excellent articular surface when included as a part of an implant for a bone that is being repaired. However, in those locations on the implant where it juxtaposes with native bone, the inherent characteristics of the pyrocarbon that render it a desirable articular surface may not result in strong joinder to living bone into which it is being implanted.
Orthopedic manufacturers have searched for biocompatible coatings that will improve long-term attachment of metal and ceramic prostheses and have often coated with ceramics, such as hydroxylapatite, and/or with more biocompatible metals, achieving some improvements but less than total satisfaction. However, the unique nature of such pyrocarbon, an essentially organic material, i.e. organic chemistry being the chemistry of carbon, is such that techniques applicable to coating such hard and/or brittle surface do not translate to the coating of a pyrocarbon surface having this desired Young's modulus. Thus, the search has continued for improved coating procedures that can be used to securely anchor and create a coating upon a particular region of a bone implant that has an overall dense pyrocarbon outer surface in order to significantly enhance its secure attachment to living cortical bone at the locations where there will be interfacial contact.
SUMMARY OF THE INVENTION
A substrate formed of a structurally strong material, such as dense isotropic graphite, is coated overall with a layer of dense microporous isotropic pyrocarbon that has a Young's modulus close to that of human bone in order to create a bone implant or prosthesis that is well-suited for repair of a fractured or diseased bone at a joint where an articular surface is involved. Designated portions of such a pyrocarbon-coated substrate that will interface with the recipient cortical bone into which implantation will occur are then coated (while masking at least the articular surface portion) to provide those designated locations with surface characteristics that will enhance strong, long-term joinder to abutting bone surfaces.
Initially, a thin first or anchor layer of a metal is deposited by physical vapor deposition (PVD) under vacuum conditions onto at least the region or regions of the implant that will interface with human cortical bone. This anchor layer is deposited in such a manner that it penetrates into the interstices of the microporous pyrocarbon and anchors itself thereto while also smoothing the surface of that underlying pyrocarbon in the region or regions upon which such PVD coating is directed and restricted. This thin metal layer, as a result of the penetration into the microporous pyrocarbon creates a strong anchor, and its restricted thickness contributes to the secure, subsequent attachment thereto of a second biocompatible metal layer that is thermal-sprayed so as to have a textured or structured surface. Either the same metal is applied in this plasma-spraying step, or a different biocompatible metal is used having a melting point such that fusion of the two layers will occur. Because the first metal layer is thin, it will locally melt during the subsequent plasma-spraying step, and there will be fusion of it together with globules of plasma-melted metal particles that impact the designated surface as a part of a plasma-spray or other thermal-spray step in an inert gas atmosphere, assuring that a strong bond is created between the two layers. Plasma-spraying is preferably carried out under conditions which create a surface texture having such a defined character and roughness that, upon implantation, a strong, long-term durable, interconnection will result at the interface with living cortical bone being repaired.
In one particular aspect, there is provided a method of making a bone implant, which method comprises the steps of: creating a substrate of structurally strong isotropic graphite of the shape desired for a bone implant, coating the substrate with a surface layer of microporous isotropic pyrocarbon of a density between about 1.7 and 2.1 g/cm 3 and a hardness of at least about 200 DPH, which layer has an average thickness of at least about 100 microns and has an average surface roughness (R a ) of at least 2 microns, said surface being formed of aggregate carbon particles having an average size of about 0.15 to 0.5 micron and adjacent void regions of an average size of about 0.05 to 0.10 micron, which void regions are present in an amount to create an overall surface porosity of about 2 to 10%, using physical vapor deposition (PVD) to coat a first metal layer at least about 2 microns and not greater than about 10 microns thick atop a designated portion of said isotropic pyrocarbon layer while leaving a portion of said pyrocarbon layer uncoated, said coating being applied by PVD from a vapor atmosphere so that such first metal layer penetrates into said microporous pyrocarbon to create a secure bond and presents an exterior surface smoother than said underlying pyrocarbon surface, and thermal-spraying a second layer of a biocompatible metal onto at least a designated portion of said first metal layer using a device that melts fine metal particles to produce minute molten globules at least having liquefied outer surfaces to thereby provide an outermost, textured, second metal layer having an average thickness of at least about 25 microns and a texture that enhances attachment of said outermost metal surface to cortical bone, said metal of said first layer and said metal of said second layer having melting points within about 200° C. of each other so that said thermal-sprayed particles fuse to said first metal layer.
In another particular aspect, there is provided a bone implant, which comprises: a substrate of structurally strong isotropic graphite, an overall uniform microporous layer of isotropic pyrocarbon having an average thickness of at least about 100 microns which envelops said substrate, which pyrocarbon has a density between about 1.7 and 2.1 g/cm 3 , a surface roughness not greater than about 3.5 microns, and a Young's modulus of about 20 to 27 GPa, a first layer of metal between about 2 microns and 10 microns thick disposed atop at least a designated portion of said isotropic pyrocarbon layer, which portion will interface with cortical bone into which implantation will be made, such first metal layer penetrating into the interstices of said microporous pyrocarbon as a result of its deposition from a vapor atmosphere, and an outermost second layer of a biocompatible metal disposed atop said vapor-deposited first metal layer and fused thereto, said outermost, textured, second metal layer having an average thickness of at least about 25 microns and a texture that enhances attachment of said outermost metal surface to cortical bone, said metal of said first layer having a melting point not more than about 200° C. greater than that of said biocompatible metal of said second layer so that said second outermost metal layer is fused to said first metal layer with no apparent interface therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear view of an implant for resurfacing the humerus.
FIG. 2 is an enlarged cross section view of FIG. 1 , taken along the line A-A.
FIG. 3 is a perspective view of an MP prosthetic joint showing the metacarpal element and the phalangeal element in full extension.
FIG. 3A is a side elevation view of the MP joint of FIG. 3 as viewed from the opposite side.
FIG. 4 is a perspective view of the phalangeal element of FIG. 3 .
FIG. 5 is a perspective view of a proximal phalangeal element for inclusion as half of a total implant for a prosthetic PIP joint.
FIG. 5A is a rear view of the proximal phalangeal element of FIG. 5 .
FIG. 6 is a side elevation view, with portions shown in cross section, of a prosthetic PIP joint which includes the proximal phalangeal element of FIG. 5 .
FIG. 7 is a perspective view of the middle phalangeal element shown in FIG. 6 .
FIG. 8 is a rear view of the element of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the construction of a bone implant having such mechanical properties that mimic the characteristics of cortical bone with which it will interface and with which portions of it will articulate, a graphite substrate is chosen in the form of a dense, isotropic fine grain graphite. A preferred graphite is that commercially marketed as Poco AXF-5Q Biomedical Grade Graphite having a density greater than about 1.75 g/cm 3 . Such isotropic graphite can be precisely machined to form substrates of desired dimension within close tolerances. As a result, by taking into consideration the thickness of the coating layers that will be subsequently applied, machining is carried out so that the ultimate product will be an implant of desired shape and form requiring only minimal processing, such as polishing of the articular surface.
The carefully machined graphite substrate is encased in an overall pyrocarbon layer or jacket by coating of the graphite substrate in a fluidized bed under conditions that create an external pyrocarbon surface that, when polished, provides an excellent articular surface. It is known that pyrocarbon exhibits many attributes deemed very desirable for a bone implant, including high strength, wear resistance, resistance to cyclic fatigue, biocompatibility, and a modulus of elasticity similar to cortical bone. When polished, the articular surface region provides a low friction surface interface. Pyrocarbon such as that sold under the trademark PYROLITE can be produced with such properties; however, pyrocarbon that is made in accordance with the teaching of U.S. Pat. No. 5,677,061 is particularly preferred. Such unalloyed, dense, substantially pure pyrocarbon is available as On-X™ pyrocarbon.
The machined substrate is coated overall with a substantially uniform layer of microporous isotropic pyrocarbon using a fluidized bed coating apparatus such as that described in U.S. Pat. No. 6,410,087. A mixture of an inert gas, such as nitrogen, argon or helium, and a hydrocarbon such as propane, propylene, methane or the like are caused to undergo pyrolysis in a fluidized bed of small particles wherein the substrate is being levitated. The temperature is generally maintained between about 1300° C. and 1500° C., and coating conditions are monitored so as to produce an isotropic pyrocarbon having a density between about 1.7 and 2.1 g/cm 3 and preferably between about 1.8 and about 2.0 g/cm 3 . The hardness should be at least about 200 DPH, and preferably, the isotrophy is such that the BAF is between about 1.0 and 1.1. The layer deposited should have an average thickness of at least about 100 microns, and the thickness will not normally exceed about 1500 microns. Usually a thickness of about 100-500 microns of isotropic pyrocarbon is deposited.
Coating in such a fluidized bed apparatus produces a coating that can be fairly described as being substantially uniform, it being understood that there are minor increases in thickness at regions where edges of the substrate meet, or where there is a significant change in the geometry of the substrate. The coating conditions are controlled so that the layer has an average surface roughness (R a ) of at least about 2 microns and will generally fall within the range of about 2-5 microns. The pyrocarbon deposited is in the form of aggregate carbon particles having an average size of between about 0.15 to 0.5 micron and wherein the adjacent void regions to the these aggregate particles have an average size between about 0.05 and about 0.1 micron. The distribution is such that the void regions are present in an amount such as to create an overall surface porosity of about 2-10%.
The pyrocarbon layer having these characteristics has been found to be particularly suitable for accomplishing dual objectives. This hard carbon can be polished in the region of the articular surface of the bone implant, and when polished to a mirror finish in the presence of a lubricating medium, such as synovial fluid, the surface exhibits very low friction during articulation with human bone or cartilage or with another such polished pyrocarbon surface. At the same time, it has been found that this surface allows designated regions of the substrate, which will include at least those that will interface with cortical bone, to be coated in two stages with a metal coating of a character that promotes strong bone ingrowth so as to ultimately secure the implant excellently to the bone into which it is implanted.
This two-layer exterior coating is created through an initial physical vapor deposition (PVD) step followed by a thermal spraying step. To accomplish such coating, the articular surface is masked to avoid vapor deposition in this region, and then at least a designated region of the bone implant that will be in contact with cortical bone is metal-coated. Optionally, the entire remainder of the substrate, except for the articular surface, can be coated; however, regions that will not be in contact with bone, and portions or all of the stem of such a bone implant, may also be masked if desired.
The first layer is produced by physical vapor deposition of a suitable metal or metal alloy onto the pyrocarbon so as to securely anchor it thereto and provide a surface that has less overall roughness than the pyrocarbon surface. Examples of metals that may be used, either in elemental or alloy form, include titanium, niobium, tungsten, tantalum, zirconium and molybdenum. Preferably, a single metal is used and is chosen for its compatibility with the layer that will be subsequently applied thereatop. The PVD process chosen can be selected from known processes including ion plating, cathodic arc deposition, electron beam deposition, sputtering or the like where vacuum conditions are employed, as well known in this art. Temperatures are generally in the range of about 250 to 450° C. The application of this first metal layer by such a high vacuum PVD process results in the intrusion of the metal atoms into the 2-10% microporous surface in a manner so as to essentially fill the void spaces in the surface regions and thus at least partially envelop the aggregate carbon particles in the surface region, while overcoating the designated pyrocarbon surface to a desired thickness of between about 2 and 10 microns. The result is one of creation of an extremely secure anchor to a pyrocarbon surface; this anchor layer is in turn used to secure an exterior second layer of a highly biocompatible metal which is formed with surface characteristics that induce appositional bone growth at the regions of cortical bone with which the surface will interface upon implantation in the bone being repaired.
The second biocompatible metal layer is created by a thermal spraying process using a metal which preferably has a melting point (MP) within about 200° C. of the MP of the metal used for the first metal layer. More preferably, the MP of the second metal is not greater than about 200° C. above that of the first. Titanium or an alloy thereof that is at least 88% titanium, e.g. about 88-90% Ti, about 6% Al and about 4% V, is the preferred biocompatible metal for the second outermost layer; titanium has a melting point of about 1460° C. Generally, for purposes of this application, reference to coating with titanium should be understood to refer to substantially pure titanium as well as an alloy containing at least about 88% Ti. Another biocompatible metal that might be used as the second metal is zirconium. Preferably, both the first and second layers are formed of the same metal or metal alloy so that the melting point criterion is inherently met; for example, both may be titanium or both may be zirconium. However, when titanium is chosen to be the second layer, then palladium, platinum, zirconium and chromium, which have melting points within about 200° C. of that of titanium, would be candidates for the first metal layer in a two-layer bone growth-inducing surface for this bone implant.
The thermal spraying process generally uses particles of the chosen metal between about 1 and 100 microns, preferably about 5 to 80 microns, and more preferably about 10 to 50 microns in size; the particles are likely graded within such range. During the coating process, the particles are partially melted and accelerated to high velocities as they are passed through a flame or an arc, preferably creating a plasma. These particles splatter onto the underlying relatively thin surface of the first metal layer; because of the generally similar melting points and the relative thinness of the first metal layer, fusion results creating a strong integral bond between the two surface coatings. Preferably, an arc or plasma spray process is employed that may generate a temperatures about 30,000° F. (16,600° C.) in an oxygen-free atmosphere, for example an inert gas atmosphere of nitrogen, helium or argon, such as to create at least partial melting of the particles and the consequent, resultant fusion. This thermal-sprayed second layer of biocompatible metal, which is deposited upon the designated portion of the first metal layer that will be in contact with cortical bone, is preferably created so as to have an average thickness of at least about 25 microns and a texture that will enhance the subsequent growth of cortical bone onto this surface. The dual-metal coated surface thus assures strong ultimate attachment of the pyrocarbon-coated graphite implant to the bone being repaired.
A plasma spraying process is preferably selected and controlled to produce globular particles of titanium atop the PVD first metal layer, having particle sizes between about 5 and 15 microns, which globular particles generally agglomerate to create aggregate particles between about 15 and 30 microns in size. These porous metal structures have only random pore interconnections. Pore sizes average in the range of about 5-12 microns, with some being large enough to provide for actual cortical bone ingrowth. It is felt that the thermal-sprayed layer should be at least about 10 microns thick; however, it is preferably at least about 15 microns thick and more preferably has a thickness of at least about 25 microns. Most preferably, the outer or second layer has an average thickness of about 50 microns to 100 microns. When such a relatively thick, thermal-sprayed layer is deposited at a high temperature, fusion will result at the interface between the layers because of the relative thinness of the vapor-deposited layer, which is chosen to have a lower MP or one not more than 200° C. thereabove. Fusion occurs to such an extent that, even when the same two metals are employed, there is no apparent interface ultimately remaining.
Overall, the pyrocarbon surface is smoothed in those designated regions wherein the vapor-deposited first metal coating is applied, as this metal coating intimately fills the topographic interstices that are present in the isotropic, microporous pyrocarbon layer; however, the important result is that there is an intimate and strong anchor of this first metal layer to the underlying hard pyrocarbon surface. The subsequent plasma-sprayed titanium second layer coating is of greater thickness, and as a result of the melting points of the two metals and the relative thinness of the PVD metal layer, fusion creates an integral structure having no apparent interface. The plasma spray process significantly roughens the surface of the first metal layer, producing a layer of randomly connected pores of, for example, about 10 microns in average diameter, and peaks and valleys on the surface so as to constitute an average surface roughness of about 5 to 10 microns. This surface promotes the appositional growth of cortical bone along with some ingrowth, and the result is a strong attachment between the implant and the bone being repaired. Preferably the average roughness is about 8-10 microns; however, it could be somewhat greater for a thicker second metal coating.
FIGS. 1 and 2 show one example of a bone implant that might be made using the method of manufacture set forth hereinbefore in the form of a humeral resurfacing arthroplasty (HRA) 1 . The HRA implant 1 comprises a head 2 and a stem 3 . The head 2 is generally in the shape of a shell, and the stem 3 is cruciform in shape, comprising four flanges 5 arranged at 90° angles to one another. The head 2 has a convex spherical articular surface 6 , which extends to an annular rim 7 that bridges the distance between the spherical outer surface 6 and a concave undersurface 8 . Small arcuate junctions 9 interconnect each of the flanges 5 of the stem 3 to the undersurface 8 of the spherical head.
To construct the HRA implant 1 , a substrate having a precise desired shape is carefully machined from Poco AXF-5Q biomedical grade graphite. The dimensions are such to allow for the thickness of the coatings to be applied so that the resultant structure requires little or no machining, except for polishing the spherical surface 6 that would constitute the articular region, i.e. where there will be an articulating interface with the patient's glenoid or glenoid replacement. After coating with a substantially uniform layer of chemically pure On-X carbon in a fluidized bed process, as described generally in the '061 patent, the convex spherical surface 6 of the head would be masked. The remainder of the pyrocarbon-coated substrate, which would include the designated area that would interface with cortical bone, is then coated with the first metal layer. In such an instance, the entire undersurface extending from Point 1 of FIG. 2 down to the proximal tip of the stem, i.e. Point 3 , would then receive such a coating. Alternatively, because it is within the region from about Point 1 to the inner edge of the annular junctions 9 (Point 2 ) that will interface with cortical bone, if desired, all or a major portion of the stem 3 might also be masked.
If it is desired to use a titanium first or anchoring layer and a titanium second exterior layer, the masked, pyrocarbon-coated substrate might be subjected to, for example, PVD where it would be exposed to a vapor atmosphere of titanium created by cathodic arc deposition under vacuum conditions. During such a vapor deposition process, metallic titanium atoms would be deposited throughout the interstices of the unmasked, microporous, pyrocarbon coated surface, first filling these irregular microporous surface regions, and then forming an outer surface coating having an average thickness of about 5 microns and a surface roughness (R a ) of about 3 microns (which is less than that of the pyrocarbon layer upon which the coating is being deposited). Typical coating times would range between 3 and 6 hours.
Upon completion of the vapor-deposited first anchoring layer of titanium, the still-masked substrate is subjected to plasma-spraying using a chamber filled with an inert atmosphere, e.g. argon, and a plasma spray gun fed with titanium particles of a size between about 10 microns and about 50 microns in an argon stream. The temperature in the region of the arc plasma generator through which the particles are fed would be in the neighborhood of 16,000° C. and would cause the particles to at least partially melt. Plasma spraying is directed against the designated undersurface region of the substrate and results in a porous, globular-like surface across the designated region having pores which are between about 5 and 15 microns in diameter that are randomly interconnected with one another. Multiple passes through the plasma coater may be used, if required, to provide the second, biocompatible, metal coating having an average thickness of about 60 microns.
Following polishing of the convex spherical surface 6 to a mirror finish, testing of the HRA implant shows that the surface 6 exhibits low friction during articulating movement with the glenoid upon implantation. Over a few months time, the two-layer coating strongly remains adhered to the underlying pyrocarbon surface, while significant appositional growth of cortical bone occurs at the locations where there is interfacial contact therewith and effects secure attachment of the implant to the humerus that is being repaired.
As another example of bone implants that may be made using the aforedescribed process, shown in FIGS. 3 , 3 A and 4 are elements of a metacarpal phalangeal (MP) replacement joint 11 . For this joint prosthesis, a metacarpal element 13 and a phalangeal element 14 are manufactured which have articulating surfaces that form the replacement joint. The metacarpal element 13 has a stem 15 and a head 17 , whereas the phalangeal element 14 has a stem 16 and a head 18 . The metacarpal element 13 has a convex, generally spherical articular surface 21 and a generally flat rear or undersurface 19 ( FIG. 3A ) which encircles the stem 15 where it meets the head 17 . The head 18 of the phalangeal element 14 has a concave articular surface 22 and a generally flat rear surface 24 which encircles the stem 16 where it meets the head.
To construct this MP joint replacement, substrates having the desired shape are again machined from isotropic graphite and are similarly coated with a layer of pyrocarbon having the aforementioned characteristics having an average thickness of about 150 microns thick. The metacarpal element 13 is then masked so as to cover the convex spherical articular surface of the head 17 ; from the standpoint of convenience, a pair of flat reliefs 25 formed in the sides of the head 17 would likely also be masked. The designated region for coating of the metacarpal element 13 would be the flat rear surface 19 , for it is this surface which will interface with the resected surface of the metacarpus that is being repaired. The stem 15 will be in contact with cancellous bone in the medullary canal region of the metacarpus. The stem is optionally also coated with the two-layer titanium coating, or all or a portion of it may be masked. For example, the end region of the stem 15 distal from the head 17 may be masked if desired. With respect to the phalangeal element 14 , at least the concave articular surface 22 would be masked. However, it may be expedient to mask substantially the entire head 18 including the peripheral surface 23 and the rim 23 a , except for the designated rear surface 24 where the interface with cortical bone will occur. Likewise, the entire stem 16 may be coated with the two-layer titanium metal coating; however, alternatively, all or a portion of the stem 16 distal from the head 18 may be masked. Once so masked, the phalangeal element 14 and the metacarpal element 13 would be coated as described hereinbefore, and then their concave and convex articular regions would be polished to a mirror finish.
Depicted in FIGS. 5-8 is a prosthesis for replacement of a PIP joint, such as the proximal interphalangeal joint between the proximal phalanx and the middle phalanx. The prosthesis 26 consists of a proximal phalanx implant 27 which has a stem 28 and head 29 and a middle phalanx implant 30 . The implant 27 is designed to be implanted in the proximal phalanx for which it would replace the distal end thereof. The middle phalanx implant 30 has a head 31 and a stem 33 , and it is designed to replace the proximal end of the middle phalanx. The head 31 has a distal or rear surface 35 that is essentially planar, and the region that surrounds the stem 33 is blended smoothly into the rear surface with billets of small radii. The head 31 is generally formed with a pair of projections 39 which flank a broad central notch 41 (see FIG. 7 ). The proximal surface 43 of the head is the articular surface, and it is formed with a chamfer 45 in the central region between a pair of concave depressions 43 which receive the proportionally shaped head of the proximal phalanx implant 27 . The peripheral surface 37 of the head circumscribes the entire head.
The proximal phalanx implant 27 has a head 29 in the form of a pair of condyles 51 that are separated by a central valley 53 . The condyles 51 form the articular surface of which the pair of depressions 43 in the head 31 are portions of mirror images. The rear of the head 29 is in the form of a pair of planar surfaces 55 a and 55 b which are designed to interface with the resected surface of the proximal phalanx.
In making a PIP joint prosthesis using the method described hereinbefore, graphite substrates are again carefully machined to the desired shape and dimensions taking into consideration the thickness that will be added as a result of the coating operation. For the proximal phalanx implant 27 , after coating overall with a layer of pyrocarbon having an average thickness of about 125 microns, the articular surface of the head comprising both condyles 51 and the notch 53 would be masked. The two flat rear surfaces 55 a and 55 b , which essentially surround the stem 28 where it meets the head 29 , would be the primary designated areas for application of the two-metal coating. The stem 28 might optionally also be coated with the two-metal coating. However, the end of the stem distal from the head 29 might be masked, and only the remainder of the stem adjacent the surfaces 55 a and 55 b may be coated with the two-layer metal coating.
With reference to the middle phalanx implant 30 , the two concave depressions which receive the condyles would be masked; however, it might be expedient to mask the entire head including the peripheral surface 37 extending through the notch 41 . The designated surface which will primarily interface with cortical bone is the flat rear surface 35 , which would be coated with the two-layer metal coating, but all of the stem 33 might also be so coated. Optionally, none of the stem might be coated, or only that region of the stem where it blends smoothly outward to the rear surface might be coated, i.e., with that portion of the stem distal from the head being masked.
Coating of the two isotropic pyrocarbon coated substrates with the two-layer titanium coating, followed by polishing of the articular surfaces to a mirror finish, provides pair of articulating bone implants for a replacement PIP joint which result in a low-friction articular region and which result in strong bonds to the proximal phalanx and the middle phalanx as a result of bony cortical appositional growth into the surface regions. The ability to produce implants having a Young's modulus close to that of human cortical bone and having surfaces which interface with cortical bone and enhance bony appositional growth results in a superior PIP joint that is wear-resistant and well-received in the patient's finger.
Although the invention has been described in such detail as to provide the best mode of construction as presently envisioned by the inventors, it should be understood that various modifications and changes as would be obvious to one having ordinary skill in this art may be made without departing from the scope of the invention which is defined in the claims appended hereto. Although the invention has been illustrated with regard to the production of certain exemplary bone implants, it should be understood that the use of the invention is not so restricted. A wide variety of bone implants where there will be an articular surface on the head of the implant which is held in place by a protruding stem of an appropriate form and shape may advantageously be produced using this method.
Particular features of the invention are emphasized in the claims which follow.
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Methods for forming bone implants for the repair of the ends of bones at orthopedic joints, which implants have a Young's modulus close to that of human cortical bone. Substrates of dense isotropic graphite are coated overall with hard, microporous, isotropic pyrocarbon of specific character such that it can be polished to serve as an articular surface and can also securely receive an anchoring first metal layer through PVD. The first layer has a character such that, by thermal spraying a second biocompatible metal layer thereupon, fusion occurs and thereby anchors an outermost layer that is formed with a network of randomly interconnected pores and a surface character of peaks and valleys designed to promote enhanced appositional growth of cortical bone at the interface therewith.
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TECHNICAL FIELD
[0001] The present invention relates to an information processing apparatus including a plurality of graphics chips having different graphics performances, and to an information processing method and a program for an information processing apparatus.
BACKGROUND ART
[0002] In related art, there is an information processing apparatus on which two graphics chips having different graphics performances are mounted and which implements reduction in power consumption and improvement in graphics performance by switching the operations of the chips (see, for example, Patent Literature 1)).
[0003] In the information processing apparatus disclosed in Patent Literature 1, the switching of the two graphics chips is performed with a mechanical switch that is manually operable by a user.
[Citation List]
[Patent Literature]
[PTL 1]
[0004] Japanese Patent Application Laid-open No. 2007-179225
SUMMARY OF INVENTION
[0005] However, in the case where a user manually switches the graphics chips as in the information processing apparatus disclosed in Patent Literature 1, a safety problem may arise. Specifically, for example, if a user switches the graphics chips during execution of a specific application in the information processing apparatus, a trouble may be caused in the operation of the application.
[0006] Further, it takes time and effort for a user to judge which graphics chip is proper as occasion demands in consideration of a trouble that may be caused in the operation of the application and manually switch the graphics chips. Further, this may prevent the effective utilization of the two graphics chips having different graphics performances.
[0007] In view of the above-mentioned circumstances, it is desirable to provide an information processing apparatus, an information processing method, and a program capable of safely and easily switching two graphics chips having different graphics performances in accordance with a use purpose of a user.
[0008] According to one embodiment, the present invention is directed to an information processing apparatus, comprising: a first graphic processing module having a first level of graphic performance; a second graphic processing module having a second level of graphic performance, which is greater than the first level of graphic performance; a controller configured to select one of the first graphic processing module or the second graphic processing module by determining whether the information processing apparatus is capable of outputting data with the first level of graphic performance or the second level of graphic performance, and detecting whether the information processing apparatus is provided with power via a battery or via an external power source.
[0009] The information processing apparatus may include an interface compatible with the second level of graphic performance.
[0010] The controller of the information processing apparatus may be configured to determine that the information processing apparatus is capable of outputting data with the second level of graphic performance by detecting that a connection is provided to the interface.
[0011] The controller of the information processing apparatus may also be configured to determine that the information processing apparatus is capable of outputting data with the second level of graphic performance by determining that an application executed by the information processing apparatus is compatible with the second level of graphic performance.
[0012] The controller of the information processing apparatus may also be configured to detect that the information processing apparatus is provided with power via the external power source by detecting that power is being supplied via an external connection.
[0013] The controller of the information processing apparatus may also be configured to select the second graphic processing module when it is determined that the information processing apparatus is capable of outputting data with the second level of graphic performance.
[0014] The controller of the information processing apparatus may also be configured to select the second graphic processing module when it is detected that the information processing apparatus is provided with power via the external power source.
[0015] The controller of the information processing apparatus may also be configured to select the first graphic processing module when it is determined that the information processing apparatus is not capable of outputting data with the second level of graphic performance.
[0016] The controller of the information processing apparatus may also be configured to select the first graphic processing module when it is detected that the information processing apparatus is provided with power via the battery.
[0017] The controller of the information processing apparatus may also be configured to display a notification when the controller switches between the first and second graphic processing modules.
[0018] The controller of the information processing apparatus may also be configured to display a notification when the controller selects either the first graphic processing module or the second graphic processing module.
[0019] The controller of the information processing apparatus may also be configured to display a power consumption value upon selecting the first graphic processing module or the second graphic processing module.
[0020] The notification may include a button configured to receive a user input indicating whether the selection is accepted.
[0021] The controller of the information processing apparatus may also be configured to determine whether an application executed at the information processing apparatus is affected by the selecting, and the displayed notification indicates that the application is affected.
[0022] The notification may include a button configured to receive a user input indicating whether the selection is accepted.
[0023] The controller of the information processing apparatus may also be configured to switch between the first and second graphic processing modules when the application affected by the selecting is terminated.
[0024] The first graphic processing module may be configured to consume a first amount of power during operation, and the second graphic processing module may be configured to consume a second amount of power, which is greater that the first amount of power, during operation.
[0025] The controller of the information processing apparatus may also be configured to control the information processing apparatus to be in each of a first mode in which the controller automatically selects one of the first and second graphic processing modules, a second mode, in which the first graphic processing module is selected, and a user input is required to switch to the second graphic processing module, and a third mode, in which the second graphic processing module is selected, and a user input is required to switch to the first graphic processing module.
[0026] The information processing apparatus may also include s a switch having a movable portion configured to be moved between three positions, each corresponding to one of the first, second and third modes.
[0027] The switch may be a triangular shaped switch, and the movable portion may be configured to be moved between each corner of the triangle, and each corner of the triangle corresponds to one of the first, second and third modes.
[0028] When the information processing apparatus is in the second mode and the controller determines that the information processing apparatus is capable of outputting data with the second level of graphic performance, the controller may be configured to control a display of the information processing apparatus to display a notification.
[0029] When the information processing apparatus is in the third mode and the controller detects that the information processing apparatus is provided with power via the battery, the controller may be configured to control a display of the information processing apparatus to display a notification.
[0030] According to another embodiment, the invention is directed to a method performed by an information processing apparatus including a first graphic processing module having a first level of graphic performance and a second graphic processing module having a second level of graphic performance, which is greater than the first level of graphic performance, the method comprising: determining, by a controller of the information processing apparatus, whether the information processing apparatus is capable of outputting data with the first level of graphic performance or the second level of graphic performance; detecting, by the controller of the information processing apparatus, whether the information processing apparatus is provided with power via a battery or via an external power source; and selecting, by the controller of the information processing apparatus, one of the first graphic processing module or the second graphic processing module based on the determining and detecting.
[0031] According to another embodiment, the invention is directed to a non-transitory computer readable medium including computer program instructions, which when executed by an information processing apparatus including a first graphic processing module having a first level of graphic performance and a second graphic processing module having a second level of graphic performance, which is greater than the first level of graphic performance, cause the information processing apparatus to perform a method comprising: determining whether the information processing apparatus is capable of outputting data with the first level of graphic performance or the second level of graphic performance; detecting whether the information processing apparatus is provided with power via a battery or via an external power source; and selecting one of the first graphic processing module or the second graphic processing module based on the determining and the detecting.
BRIEF DESCRIPTION OF DRAWINGS
[0032] FIG. 1 is a perspective view showing a PC according to an embodiment of the present invention in the state of being opened.
[0033] FIG. 2 is a left side view of the PC according to the embodiment of the present invention.
[0034] FIG. 3 is a block diagram showing the hardware structure of the PC according to the embodiment of the present invention.
[0035] FIG. 4 is a diagram showing a lighted state of an LED display in accordance with a switch position of a mode selection switch according to the embodiment of the present invention.
[0036] FIG. 5 is a flowchart showing the operation flow of the PC in the case where an AUTO mode is selected with the mode selection switch in the embodiment of the present invention.
[0037] FIG. 6 is a flowchart showing the operation flow of the PC in the case where the AUTO mode is selected with the mode selection switch in the embodiment of the present invention.
[0038] FIG. 7 is a flowchart showing the operation flow of the PC in the case where a STAMINA mode is selected with the mode selection switch in the embodiment of the present invention.
[0039] FIG. 8 is a flowchart showing the operation flow of the PC in the case where a SPEED mode is selected with the mode selection switch in the embodiment of the present invention.
[0040] FIG. 9 is a flowchart showing the operation flow of the PC in the case where both an HDMI connection and a DVI connection are released in the AUTO mode in the embodiment of the present invention.
[0041] FIG. 10 is a flowchart showing the operation flow of the PC in the case where the external monitor is connected to the HDMI connector or the DVI connector in the AUTO mode in the embodiment of the present invention.
[0042] FIG. 11 is a flowchart showing the operation flow of the PC in the case where the external monitor is connected to the HDMI connector or the DVI connector in the STAMINA mode in the embodiment of the present invention.
[0043] FIG. 12 is a flowchart showing the operation flow of the PC in the case where the AC adapter connected in the AUTO mode is removed in the embodiment of the present invention.
[0044] FIG. 13 is a flowchart showing the operation flow of the PC in the case where the AC adapter that is not connected in the AUTO mode is connected in the embodiment of the present invention.
[0045] FIG. 14 is a flowchart showing the switching operation flow of the PC to the STAMINA mode in the embodiment of the present invention.
[0046] FIG. 15 is a flowchart showing the switching operation flow of the PC to the SPEED mode in the embodiment of the present invention.
[0047] FIG. 16 is a diagram showing the process flow of blocks in a detection process of the switching with the mode selection switch in the embodiment of the present invention.
[0048] FIG. 17 is a diagram showing the process flow of blocks in a detection process of a current switch position for the mode selection switch in the embodiment of the present invention.
[0049] FIG. 18 is a diagram showing the process flow of blocks in a detection process of the connection between the external monitor and the HDMI connector or the DVI connector in the embodiment of the present invention.
[0050] FIG. 19 is a diagram showing the process flow of blocks at the time when the graphics chips are switched in the embodiment of the present invention.
[0051] FIG. 20 is a diagram showing an example of a message that indicates a completion of a power supply setting for the AUTO mode and the STAMINA mode in the embodiment of the present invention.
[0052] FIG. 21 is a diagram showing an example of a message that indicates the completion of the power supply setting for the AUTO mode and the SPEED mode in the embodiment of the present invention.
[0053] FIG. 22 is a diagram showing an example of a dialog for confirming with a user whether it is possible to perform switching to the AUTO and STAMINA modes by the
[0054] PC in the embodiment of the present invention.
[0055] FIG. 23 is a diagram showing an example of a dialog for confirming with the user whether it is possible to perform switching to the AUTO and SPEED modes by the PC in the embodiment of the present invention.
[0056] FIG. 24 is a diagram showing an example of a message that indicates a completion of a power supply setting for the STAMINA mode in the embodiment of the present invention.
[0057] FIG. 25 is a diagram showing an example of a dialog for confirming with the user whether it is possible to perform switching to the STAMINA mode by the PC in the embodiment of the present invention.
[0058] FIG. 26 is a diagram showing an example of a message that indicates a completion of a power supply setting for the SPEED mode in the embodiment of the present invention.
[0059] FIG. 27 is a diagram showing an example of a dialog for confirming with the user whether it is possible to perform switching to the SPEED mode by the PC in the embodiment of the present invention.
[0060] FIG. 28 is a diagram showing an example of a dialog for urging the user to perform the switching to the SPEED mode by the PC in the embodiment of the present invention.
[0061] FIG. 29 is a diagram showing an example of a dialog for urging the user to perform the switching to the STAMINA mode by the PC in the case where the application is run that may cause a trouble due to a mode switching in the embodiment of the present invention.
[0062] FIG. 30 is a diagram showing an example of a dialog for urging the user to perform the switching to the SPEED mode by the PC in the case where the application is run that may cause the trouble due to the mode switching in the embodiment of the present invention.
[0063] FIG. 31 is a diagram showing an example of a dialog for indicating, by the PC, a name of the application that may cause the trouble due to the mode switching in the embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0064] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
(External Structure of PC)
[0065] FIG. 1 is a perspective view showing a PC according to an embodiment of the present invention in the state of being opened. FIG. 2 is a left side view of the PC.
[0066] As shown in FIGS. 1 and 2 , a PC 100 is a notebook PC, and includes a main body unit 2 and a display 3 . The main body unit 2 and the display 3 are relatively rotatably connected with each other with hinges 4 . The display 3 includes an LCD (liquid crystal display) 3 a in a region where the display 3 is caused to face the main body unit 2 when being closed to the main body unit 2 .
[0067] The main body 2 includes, in a region where the main body 2 faces the display 3 when the display 3 is closed thereto, an operation input unit 2 a such as a keyboard and a touch pad, a palm rest member 2 b, a non-contact IC (integrated circuit) card antenna 2 c, and a slide mode selection switch 7 . On the palm rest member 2 b, a user puts the wrist when performing an input operation. The main body unit 2 further includes, on a side surface thereof, a power supply switch 2 d, an external display connector 2 e, a USB (universal serial bus) connector 2 f, a disk insertion and removal opening 2 g for a disk drive (not shown), a microphone input terminal 2 h, a headphone connector 2 i, and an HDMI connector 2 j. To the HDMI connector 2 j, an external monitor such as a TV is connected through an HDMI cable, and an image signal generated by the PC 100 is output in conformity with an HDMI standard. To the main body 2 , a DVI connector (not shown) is also provided that is used for outputting an image signal to an external monitor through a DVI cable in conformity with a DVI standard.
[0068] The main body 2 further includes a casing 30 that is constituted of a top case 32 and a bottom case 10 . To the top case 32 , the operation input unit 2 a and the like are provided.
[0069] The mode selection switch 7 is used to switch three modes (described later) of the PC 100 , and is formed so that a movable portion can be moved among three switching positions corresponding to the three modes along a triangular shape of a guide unit.
[0070] In the vicinity of each of three corners of the mode selection switch 7 , three LED (light emitting diode) displays 8 are provided that notify the user of a mode in execution out of the three modes in accordance with a switch position of the mode selection switch 7 . The LED displays 8 will be described later in detail.
(Hardware Structure of PC)
[0071] FIG. 3 is a block diagram showing the hardware structure of the PC 100 . As shown in FIG. 3 , in addition to the structures shown in FIGS. 1 and 2 , the PC 100 includes a CPU (central processing unit) 11 , a chip set 12 , an embedded graphics chip 15 , an external graphics chip 20 , an EC (embedded controller) 16 , a switching circuit 22 , a selector 23 , a DVI connector 2 k , an HDD (hard disk drive) 21 , a nonvolatile memory 25 , a power supply circuit 26 , a battery 27 , a DC jack 28 , and a wattmeter 29 .
[0072] The chip set 12 manages the transmission and reception of data between devices in the PC 100 , and is constituted of a north bridge 13 and a south bridge 14 .
[0073] In the north bridge 13 , the embedded graphics chip 15 , a memory controller (not shown), and the like are embedded. The north bridge 13 is connected with the CPU 11 and the external graphics chip 20 . The south bridge 14 has a connection interface with peripheral devices such as the HDD 21 , the nonvolatile memory 25 , and the EC 16 .
[0074] The embedded graphics chip 15 and the external graphics chip 20 each perform a drawing process based on data received from the CPU 11 , and output a generated image signal to the switching circuit 22 to display an image on the LCD 3 a and the external monitor. In this embodiment, the external graphics chip 20 has a higher graphics performance than the embedded graphics chip 15 .
[0075] The embedded graphics chip 15 has a lower graphics performance than the external graphics chip 20 . However, the power consumption of the embedded graphics chip 15 is smaller than that of the external graphics chip 20 . On the other hand, the external graphics chip 20 has the higher graphics performance in terms of a 3-D process, a high-resolution drawing process, and the like, but involves high power consumption to drive the external graphics chip 20 itself and the peripheral devices thereof, with the result that an electrical load with respect to the entire system of the PC 100 is increased.
[0076] In accordance with the switching of the modes with the mode selection switch 7 , the PC 100 manually or automatically selects one of the embedded graphics chip 15 and the external graphics chip 20 that have the different graphics performances and thus can perform the drawing process (this will be described later in detail).
[0077] The HDD 21 stores, in a built-in hard disk, data or various programs such as utility software for executing the mode switching process in this embodiment, a graphics driver necessary for the operation for various graphics chips, and FEP.sys. Here, the PC 100 may be provided with a flash memory instead of the HDD 21 .
[0078] The nonvolatile memory 25 is a ROM (read only memory), an EEPROM (electrically erasable and programmable read only memory), a flash memory, or the like, and stores data or programs such as BIOS and firmware.
[0079] The EC 16 has functions such as a KBC (keyboard controller), an ACPI/EC, and a PIC (programmable IO controller). The KBC controls a keyboard as the operation input unit 2 a. The ACPI/EC manages the power supply in accordance with an ACPI (advanced configuration and power interface), which is a standard that relates to electrical control. The PIC provides an interface with the utility software.
[0080] With the KBC, the EC 16 can detect the operation of the operation input unit 2 a by the user, and can notify a high-order system such as an OS (operating system) of information called scan code. In addition, the EC 16 includes an interface for performing communication with a system such as the BIOS and the OS (described later) with the PIC, and can transmit and receive a command or data. Further, the EC 16 is connected with the mode selection switch 7 and the LED display 8 .
[0081] The switching circuit 22 switches an image signal outputted from one of the embedded graphics chip 15 and the external graphics chip 20 , and outputs the signal to the LDC 3 a, the HDMI connector 2 j, and the DVI connector 2 k. In accordance with the selection of the graphics chip in each of the modes, the EC 16 outputs an image switching signal to the switching circuit 22 , and controls the switching of the image signal outputted from the graphics chips. The image signal outputted to the HDMI connector 2 j and the DVI connector 2 k is then outputted to the external monitor through the HDMI cable and the DVI cable, respectively.
[0082] The power supply circuit 26 is connected with one of the battery 27 , such as a lithium ion battery, and the DC jack 28 for inputting commercial power through an AC adapter 5 , and supplies the power to the respective units of the PC 100 therethrough.
[0083] The wattmeter 22 is connected to the battery 27 and the DC jack 28 , measures an electric power value (current value) of electric power supplied therefrom, and transmits the measurement value to the CPU 11 . The measurement value is used in a display process of the power consumption before and after the mode switching, which will be described later in detail.
(Details of Mode Selection Switch and LED Display)
[0084] Next, the mode selection switch 7 and the LED display 8 will be described in detail. FIG. 4 is a diagram showing a lighted state of the LED display 8 in accordance with the switch position of the mode selection switch 7 .
[0085] In this embodiment, the PC 100 has three operation modes of a STAMINA mode, a SPEED mode, and an AUTO mode. In the STAMINA mode, the drawing process is performed all the time by the embedded graphics chip 15 in consideration of electric power saving, that is, in consideration of lasting driving of the battery 27 as long as possible. In the SPEED mode, the drawing process is performed all the time by the external graphics chip 20 . Importance is placed on a drawing process performance. In the AUTO mode, an appropriate graphics chip is determined based on a use condition of the PC 100 , and the graphics chip determined performs the drawing process.
[0086] In other words, in the AUTO mode, switching is performed between the STAMINA mode and the SPEED mode when necessary. The PC 100 executes one of those three modes by switching. Thus, one of the embedded graphics chip 15 and the external graphics chip 20 performs the drawing process.
[0087] As shown in FIG. 4 , in the AUTO mode, a movable portion 7 a of the mode selection switch 7 is disposed at the upper right portion, and an LED display 8 c of “AUTO” is lighted. Further, in the AUTO mode, depending on the graphics chip currently selected by the PC 100 , that is, depending on a mode in execution, SPEED mode or STAMINA mode, one of LED displays 8 a and 8 b is lighted too. The color of a light source of the LED displays 8 a and 8 b is set to be different from the color of a light source of the LED display 8 c.
[0088] In addition, in the case where the manual switching (not the AUTO mode) is selected, and the SPEED mode is selected, the movable portion 7 a is disposed on the upper left portion. In the case where the STAMINA mode is selected, the movable portion 7 a is disposed on the lower left. Further, one of the LED displays 8 a and 8 b corresponding to the SPEED mode and the STAMINA mode, respectively, is lighted.
(PC Operation)
[0089] Subsequently, a description will be given on mode switching operations in the PC structured as described above. In the following, the CPU 11 will be described as a main operation subject, but the operations are performed in cooperation with various kinds of hardware and software as described later.
(Operation at Time of Changing Switch)
[0090] First, a description will be given on an operation of the PC 100 in the case where the user selects a position corresponding to each of the modes with the mode selection switch 7 .
[0091] FIGS. 5 and 6 are flowcharts showing the operations of the PC 100 in the case where the AUTO mode is selected with the mode selection switch 7 .
[0092] As shown in FIG. 5 , when the AUTO mode is selected with the mode selection switch 7 (Step 51 ), the CPU 11 judges whether the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Step 52 ).
[0093] Here, in this embodiment, in the case where the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k, the PC 100 is capable of operating only in the SPEED mode in the hardware design.
[0094] In Step 52 , when judging that the external monitor is connected (Yes), the CPU 11 judges whether a current mode is the STAMINA mode or not (Step 53 ). When judging that the current mode is the STAMINA mode (Yes), the CPU 11 performs the subsequent switching process of (B) of FIG. 6 (Step 54 ).
[0095] In Step 53 , when judging that the current mode is not the STAMINA mode (No), the CPU 11 changes only a setting of a power supply option (Step 55 ), because the current mode is the SPEED mode, and it is unnecessary to switch the graphics chips. Then, the CPU 11 displays a message (message ( 2 )) indicating a setting completion and terminates the process (Step 56 ).
[0096] Here, the power supply option is held by the OS of the PC 100 for each mode, and is used to perform an appropriate power supply setting in accordance with the selection of the graphic chip, that is, depending on whether the drawing process performance or the electric power saving is emphasized. Therefore, in Step 55 , the power supply option is the setting in which the drawing process performance is emphasized. FIG. 21 is a diagram showing an example of the message ( 2 ) that indicates the completion of the power supply setting for the AUTO mode and the SPEED mode.
[0097] In Step 53 , when judging that the current mode is the STAMINA mode, as shown in (B) of FIG. 6 , the CPU 11 indicates a dialog (message ( 4 )) for confirming with the user whether the STAMINA mode can be switched to the SPEED mode (Step 70 ).
[0098] FIG. 23 is a diagram showing an example of the dialog (message ( 4 )). As shown in FIG. 23 , on the dialog, an OK button 231 for permitting the switching to the SPEED mode is displayed.
[0099] Then, the CPU 11 judges whether the mode selection switch 7 is returned to the state prior to the switching to the AUTO mode (Step 71 ). When judging that the mode selection switch 7 is returned (Yes), the CPU 11 deletes the dialog and terminates the process (Step 72 ). That is, by returning the mode selection switch 7 , the mode switching process is canceled.
[0100] When the mode selection switch 7 is not returned (No), the CPU 11 judges whether the OK button 231 in the dialog is clicked or not (Step 73 ). When judging that the OK button 231 is clicked (Yes), the CPU 11 performs a switching operation to the SPEED mode (Step 74 ). The switching operation to the SPEED mode will be described later in detail.
[0101] Returning to FIG. 5 , in Step 52 , when the CPU 11 judges that the external monitor is not connected (No), the CPU 11 judges whether the AC adapter 5 is connected to the DC jack 28 (Step 57 ). When judging that the AC adapter 5 is connected (Yes), the CPU 11 performs the same processes as the processes of Steps 53 to 56 (Steps 58 to 60 ). That is, even if the external monitor is not connected to the HDMI connector 2 j or the DVI connector 2 k, in the case where the AC adapter 5 is connected to the DC jack 28 , and it is unnecessary to take into consideration the drive time period of the battery 27 , the CPU 11 performs the SPEED mode to emphasize the drawing process performance.
[0102] In Step 57 , when judging that the AC adapter 5 is not connected (No), the CPU 11 judges whether the current mode is the SPEED mode or not (Step 61 ). When judging that the current mode is the SPEED mode (Yes), the CPU 11 subsequently performs a switching process of (A) of FIG. 6 (Step 62 ).
[0103] In Step 61 , when judging that the current mode is not the SPEED mode (No), that is, judging that the current mode is the STAMINA mode, the CPU 11 changes only a setting of a power supply option (Step 63 ), because it is unnecessary to switch the modes. Then, the CPU 11 displays a message (message ( 1 )) indicating a setting completion and terminates the process (Step 64 ).
[0104] That is, in this case, the CPU 11 sets an appropriate power supply option to maintain the operation by the battery 27 as much as possible with the low power consumption. FIG. 20 is a diagram showing an example of the message ( 1 ) that indicates the completion of the power supply option setting for the AUTO mode and the STAMINA mode.
[0105] In Step 61 , when judging that the current mode is the SPEED mode, as shown in (A) of FIG. 6 , the CPU 11 indicates a dialog (message ( 3 )) for confirming with the user whether the SPEED mode can be switched to the STAMINA mode (Step 65 ). FIG. 22 is a diagram showing an example of the dialog (message ( 3 )). As shown in FIG. 22 , on the dialog, an OK button 221 for permitting the switching to the STAMINA mode is indicated.
[0106] The subsequent operations are the same as the processes of Steps 71 to 74 in (B) of FIG. 6 except that the STAMINA mode and the SPEED mode are reversed (Steps 66 to 69 ). That is, when the switching with the mode selection switch 7 is not canceled, and the OK button 221 on the dialog is clicked, the CPU 11 performs the switching operation to the STAMINA mode. The switching operation to the STAMINA mode will be described later in detail.
[0107] FIG. 7 is a flowchart showing the operation flow of the PC 100 in the case where the switching to the STAMINA mode is performed with the mode selection switch 7 .
[0108] As shown in FIG. 7 , in the case where the STAMINA mode is selected with the mode selection switch 7 (Step 81 ), the CPU 11 judges whether the current mode is the AUTO mode and the STAMINA mode (Step 82 ). When judging that the current mode is the AUTO mode and the STAMINA mode (Yes), the CPU 11 just changes the setting of the power supply option because the mode switching is unnecessary (Step 83 ), and displays a message indicating a setting completion (message ( 5 )), to terminate the operation (Step 84 ). FIG. 24 is a diagram showing an example of the message ( 5 ) that indicates the setting completion of the power supply option for the STAMINA mode. In this case, the electric power saving is emphasized.
[0109] In Step 82 , when judging that the current mode is not the AUTO mode and the STAMINA mode (No), the CPU 11 displays a dialog (message ( 6 )) for confirming with the user whether the current mode may be switched to the STAMINA mode (Step 85 ). FIG. 25 is a diagram showing an example of the dialog (message ( 6 )). As shown in FIG. 25 , on the dialog, an OK button 251 for permitting the switching to the STAMINA mode is displayed.
[0110] The subsequent operation is the same as the processes of Steps 66 to 69 of (A) of FIG. 6 (Steps 86 to 89 ). That is, in the case where the switching with the mode selection switch 7 is not canceled, and the OK button 251 on the dialog is clicked, the CPU 11 switches the current mode to the STAMINA mode.
[0111] FIG. 8 is a flowchart showing the operation flow of the PC 100 in the case where the switching to SPEED mode is performed with the mode selection switch 7 . The operation flow of this case is different from that shown in FIG. 7 only in the mode. That is, the SPEED mode is involved in the operation shown in FIG. 8 , while the STAMINA mode is involved in the operation shown in FIG. 7 . FIG. 26 is a diagram showing an example of a message ( 7 ) that indicates the setting completion of the power supply option for the SPEED mode. In this case, the drawing process performance is emphasized. FIG. 27 is a diagram showing an example of a dialog (message ( 8 )) for confirming with the user whether the switching to the SPEED mode may be performed. As shown in FIG. 27 , on the dialog, an OK button 271 for permitting the switching to the SPEED mode is displayed.
(Operation at Time When Various Events Occur in Respective Modes)
[0112] Subsequently, in the aforementioned modes, the operations of the PC 100 in the case where events occur that require the switching of the modes will be described.
[0113] FIG. 9 is a flowchart showing the operation flow of the PC 100 in the case where both the HDMI connection and the DVI connection are released (the cables are removed from both the HDMI connector 2 j and the DVI connector 2 k ) in the AUTO mode.
[0114] As shown in FIG. 9 , when both the HDMI connection and the DVI connection are released (Step 101 ), the CPU 11 judges whether the AC adapter 5 is connected to the DC jack 28 (Step 102 ).
[0115] When judging that the AC adapter 5 is connected (Yes), the CPU 11 terminates the process because the mode switching is unnecessary (Step 103 ).
[0116] When judging that the AC adapter 5 is not connected (No), the CPU 11 displays a dialog (message ( 3 )) for confirming with the user whether the switching to the STAMINA mode may be performed as shown in FIG. 22 because the current mode is the AUTO and SPEED modes (Step 104 ).
[0117] Subsequently, the CPU 11 judges whether the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k again (Step 105 ). In the case where the connection to the HDMI connector 2 j or the DVI connector 2 k is performed (Yes), the CPU 11 deletes the dialog and terminates the process (Step 106 ). That is, the user can cancel the mode switching process by inserting the HDMI cable or the DVI cable to the HDMI connector 2 j or the DVI connector 2 k again.
[0118] In the case where the external monitor is not connected to the HDMI connector 2 j or the DVI connector 2 k again (No), the CPU 11 judges whether the OK button 221 on the dialog is clicked or not (Step 107 ). When judging that the OK button 221 is clicked (Yes), the CPU 11 switches the current mode to the STAMINA mode (Step 108 ).
[0119] FIG. 10 is a flowchart showing the operation flow of the PC in the case where the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k in the AUTO mode.
[0120] As shown in FIG. 10 , when the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Step 111 ), the CPU 11 judges whether another external monitor is already connected to the remaining connector (Step 112 ). When judging that another external monitor is connected to the remaining connector (Yes), the CPU 11 terminates the process, because the current mode is the AUTO and SPEED modes, and the mode switching is unnecessary (Step 113 ).
[0121] When judging that another external monitor is not connected to the remaining connector (No), the CPU 11 judges whether the AC adapter 5 is connected to the DC jack 28 or not (Step 114 ). When the CPU 11 judges that the AC adapter 5 is connected (Yes), the CPU 11 terminates the process, because the current mode is the AUTO and SPEED modes, and the mode switching is unnecessary (Step 115 ).
[0122] When judging that the AC adapter 5 is not connected (No), as shown in FIG. 23 , the CPU 11 displays the dialog (message ( 4 )) for confirming with the user whether the switching to the SPEED mode may be performed or not (Step 116 ).
[0123] Then, the CPU 11 judges whether the HDMI cable or the DVI cable that is connected to the HDMI connector 2 j or the DVI connector 2 k in Step 111 is removed or not (whether the connection with the external monitor is released or not) (Step 117 ). When judging that the cable is removed (Yes), the CPU 11 deletes the dialog and terminates the process (Step 118 ). That is, the user can cancel the mode switching process by removing the HDMI cable or the DVI cable that is once inserted.
[0124] When judging that the cable is not removed from the HDMI connector 2 j or the DVI connector 2 k (No), the CPU 11 judges whether the OK button 231 is clicked or not on the dialog (Step 119 ). When judging that the OK button 231 is clicked (Yes), the CPU 11 switches the current mode to the SPEED mode (Step 120 ).
[0125] FIG. 11 is a flowchart showing the operation flow of the PC in the case where the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k in the STAMINA mode manually set.
[0126] As shown in FIG. 11 , when the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k in the STAMINA mode, the CPU 11 displays a dialog (message ( 9 )) for urging the switching to the SPEED mode (Step 122 ). FIG. 28 is a diagram showing an example of the dialog (message ( 9 )). As shown in FIG. 28 , in the dialog, a “close” button 281 is displayed along with a message that urges the user to switch the current mode to the SPEED mode with the mode selection switch 7 .
[0127] Subsequently, the CPU 11 judges whether the “close” button 281 is clicked or not on the dialog (Step 123 ). In the case where the “close” button 281 is clicked (Yes), the CPU 11 deletes the dialog and terminates the process (Step 124 ).
[0128] Then, the CPU 11 judges whether the user performs the switching to the SPEED mode or the AUTO mode with the mode selection switch 7 (Step 125 ). When the switching is performed with the mode selection switch 7 (Yes), the CPU 11 operates to switch the current mode to the SPEED mode (Step 126 ).
[0129] FIG. 12 is a flowchart showing the operation flow of the PC in the case where the AC adapter 5 connected in the AUTO mode is removed.
[0130] As shown in FIG. 12 , when the AC adapter 5 is removed (Step 131 ), the CPU 11 judges whether the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Step 132 ). When judging that the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Yes), the CPU 11 terminates the process, because the current mode is the SPEED mode, and the mode switching is unnecessary (Step 133 ).
[0131] When judging that the external monitor is not connected to the HDMI connector 2 j or the DVI connector 2 k (No), as shown in FIG. 22 , the CPU 11 displays the dialog (message ( 3 )) for confirming with the user whether the switching to the STAMINA mode may be performed or not (Step 134 ).
[0132] Subsequently, the CPU 11 judges whether the AC adapter is connected again (Step 135 ). In the case where the AC adapter is connected again (Yes), the CPU 11 deletes the dialog and terminates the process (Step 136 ).
[0133] In the case where the AC adapter 5 is not connected (No), the CPU 11 judges whether the OK button 221 is clicked on the dialog (Step 137 ). When judging that the OK button 221 is clicked (Yes), the CPU 11 operates to switch the current mode to the STAMINA mode (Step 138 ).
[0134] FIG. 13 is a flowchart showing the operation flow of the PC in the case where the AC adapter 5 that is not connected in the AUTO mode is connected.
[0135] As shown in FIG. 13 , when the AC adapter 5 is connected (Step 141 ), the CPU 11 judges whether the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Step 142 ). When judging that the external monitor is connected to the HDMI connector 2 j or the DVI connector 2 k (Yes), the CPU terminates the process, because the current mode is the SPEED mode, and the mode switching is unnecessary (Step 143 ).
[0136] When judging that the external monitor is not connected to the HDMI connector 2 j or the DVI connector 2 k (No), the CPU 11 displays the dialog (message ( 4 )) for confirming with the user whether the switching to the SPEED mode may be performed as shown in FIG. 23 (Step 144 ).
[0137] Subsequently, the CPU 11 judges whether the AC adapter 5 that has been connected once is removed or not (Step 145 ). In the case where the AC adapter 5 is removed (Yes), the CPU 11 deletes the dialog and terminates the process (Step 146 ).
[0138] In the case where the AC adapter 5 is not removed (No), the CPU 11 judges whether the OK button 231 is clicked on the dialog (Step 147 ). When judging that the OK button 231 is clicked (Yes), the CPU 11 operates to switch the current mode to the SPEED mode (Step 148 ).
(Details of Switching Operation to STAMINA Mode)
[0139] Next, the details of the switching operation to the STAMINA mode will be described. FIG. 14 is a flowchart showing the switching operation flow to the STAMINA mode. The operation of FIG. 14 includes an operation during the AUTO mode and an operation during the SPEED mode manually selected.
[0140] As shown in FIG. 14 , when a switching process to the STAMINA mode is generated (Step 151 ), the CPU 11 judges whether an application that may cause a trouble in the switching is run or not (Step 152 ). Here, the application that may cause a trouble in the switching refers to a reproduction application for a movie, a DVD, or the like, a game application, or the like, in particular, an application that uses the external graphics chip 20 . For example, a mailer, a document creation application, a table creation application, or the like does not cause a trouble, even if the switching is performed during the execution of the application.
[0141] When judging that the application that may cause a trouble in the switching is run (Yes), the CPU 11 judges whether the current mode is the AUTO mode or not (Step 153 ). When judging that the current mode is the AUTO mode (Yes), the CPU 11 displays a message (message ( 10 )) that urges the switching to the STAMINA mode (Step 154 ).
[0142] FIG. 29 is a diagram showing an example of the message ( 10 ) that urges the switching. As shown in FIG. 29 , the message indicates that the drive time period of the battery 27 is shortened in the current mode and indicates that the message concerned only has to be clicked to perform switching to the STAMINA mode.
[0143] Subsequently, the CPU 11 judges whether the message concerned is clicked (Step 155 ). When judging that the message is clicked (Yes), the CPU 11 displays the name of the application that may cause a trouble in the switching (Step 157 ). In the case where there is a plurality of applications that may cause a trouble in the switching, the names of those applications are displayed.
[0144] FIG. 31 is a diagram showing an example of a dialog that shows the name of the application. As shown in FIG. 31 , in addition to the name of the application that may cause a trouble in the switching, a message that urges the termination of the application, a forced switching button 311 , and a cancel button 312 are displayed on the dialog. The forced switching button 311 is used to give an instruction that the mode switching is forced to be performed with knowledge of a trouble. The cancel button 312 is used to cancel the switching.
[0145] Subsequently, the CPU 11 judges whether the forced switching button 311 is clicked on the dialog (Step 158 ). When judging that the forced switching button 311 is clicked (Yes), the CPU 11 obtains a power consumption value at that time by using the wattmeter 29 (Step 160 ).
[0146] Then, the CPU 11 performs the switching process to the
[0147] STAMINA mode, that is, a switching process from the external graphics chip 20 to the embedded graphics chip 15 (Step 161 ), and changes the setting of the power supply option (Step 162 ).
[0148] Then, the CPU 11 obtains the power consumption value after the switching of the mode by using the wattmeter 29 (Step 163 ).
[0149] Subsequently, the CPU 11 displays the message ( 1 ) that indicates the completion of the mode switching, and displays the obtained power consumption values before and after the switching (Step 164 ).
[0150] In Step 153 , when judging that the current mode is not the AUTO mode (No), that is, the SPEED mode manually selected, the CPU 11 subsequently performs a process of Step 157 . In this case, the message displayed at the time of the final completion of the switching is the message ( 5 ).
[0151] In addition, in the case where the message is not clicked in Step 155 (No), and in the case where the forced switching button 311 is not clicked in Step 158 (No), the CPU 11 judges whether the applications that may cause a trouble in the switching are entirely terminated (Steps 156 and 159 ). When judging that the applications are terminated, the CPU 11 then performs the process of Step 160 .
[0152] As described above, the CPU 11 displays the name of the application that may cause a trouble in the mode switching to thereby alert the user, with the result that the data of the application in execution can be prevented from being damaged or erased, and the mode switching can be performed safely. Further, in the AUTO mode, the CPU 11 displays the message for urging the switching before displaying the name of the application that may cause a trouble, which can give the user an opportunity to terminate the application by him/herself.
[0153] When the CPU 11 displays the obtained power consumption values according one embodiment of the present invention, the CPU 11 may display the obtained power consumption values at least before or after the switching. Further, the CPU 11 may display a difference between the obtained power consumption values before the switching and after the switching. Also, the CPU 11 may continuously display the obtained power consumption values before, during and after the switching.
(Details of Switching Operation to SPEED Mode)
[0154] FIG. 15 is a flowchart showing the switching operation to the SPEED mode. The process shown in FIG. 15 is different, only in the mode, from the switching process to the STAMINA mode that is shown in FIG. 14 . That is, the SPEED mode is involved in the process shown in FIG. 15 , while the STAMINA mode is involved in the process shown in FIG. 14 , so a description thereof will be omitted. FIG. 30 is a diagram showing an example of a message (message ( 11 )) that urges the switching that is displayed during the AUTO mode in the switching process to the SPEED mode. As shown in FIG. 30 , the message indicates that it may be impossible to use the HDMI connector 2 j or the DVI connector 2 k in the current mode and indicates that the message only has to be clicked to perform switching to the SPEED mode. In addition, in FIG. 15 , the message that is finally displayed in the case where the mode is switched in execution of the AUTO mode is the message ( 2 ), and the message that is finally displayed in the case where the mode is switched during the execution of the STAMINA mode manually selected is the message ( 6 ).
(Process of Blocks at Time When Various Operations are Performed)
[0155] Next, a description will be given on the flow of a signal among blocks of the software and the hardware of the PC 100 in the processes described above.
[0156] FIG. 16 is a diagram showing the process flow of blocks in a detection process of the switching with the mode selection switch 7 . FIGS. 16 to 19 show, as common blocks, utility software 201 , an FEP.sys 202 , a system BIOS 203 , the EC 16 , the mode selection switch 7 , the switching circuit 22 , the LED display 8 , a graphics driver 204 , the embedded graphics chip 15 , the external graphics chip 20 , the HDMI connector 2 j, and the DVI connector 2 k.
[0157] As shown in FIG. 16 , in the case where the switching is performed with the mode selection switch 7 , the switching is transmitted from the mode selection switch 7 to the EC 16 (( 1 ) in FIG. 16 ), and then transmitted to the utility software 201 through the system BIOS 203 and the FEP.sys 202 (( 2 ) to ( 4 ) in FIG. 16 ). Thus, the utility software 201 can display the various dialogs (messages) described above.
[0158] FIG. 17 is a diagram showing the process flow of blocks in a detection process of a current switch position for the mode selection switch 7 .
[0159] As shown in FIG. 17 , the utility software 201 inquires of the EC 16 through the FEP.sys 202 and the system BIOS 203 as to the current switch position in the mode selection switch 7 (( 1 ) to ( 3 ) in FIG. 17 ). In response to the inquiry, the EC 16 detects the current switch position from the mode selection switch 7 (( 4 ) in FIG. 17 ), and transmits a result of the detection to the utility software 201 through the system BIOS 203 and the FEP.sys 202 (( 5 ) to ( 7 ) in FIG. 17 ).
[0160] FIG. 18 is a diagram showing the process flow of blocks in a detection process of the connection between the external monitor and the HDMI connector 2 j or the DVI connector 2 k.
[0161] As shown in FIG. 18 , in the case where the connection to the HDMI connector 2 j or the DVI connector 2 k is conducted, the fact is transmitted to the embedded graphics chip 15 or the external graphics chip 20 (( 1 ) in FIG. 18 ), and further transmitted to the graphics driver 204 (( 2 ) in FIG. 18 ). The graphics driver 204 transmits the connection to the system BIOS 203 (( 3 ) in
[0162] FIG. 18 ), and the system BIOS 203 transmits the connection to the utility software 201 through the FEP.sys 202 (( 4 ) and ( 5 ) in FIG. 18 ).
[0163] FIG. 19 is a diagram showing the process flow of blocks at the time when the graphics chips are switched.
[0164] As shown in FIG. 19 , for example, when an event of clicking the OK button on the dialog is generated, the utility software 201 transmits an instruction for switching the graphic chips to the graphics driver through the FEP.sys 202 and the system BIOS 203 (( 1 ) to ( 3 ) in FIG. 19 ).
[0165] The graphics driver 204 performs initialization of the embedded graphics chip 15 or the external graphics chip 20 or turns on and off of the power thereof (( 4 ) in FIG. 19 ), for example, and transmits an instruction for switching the graphics chips to the EC 16 through the system BIOS 203 (( 4 ) and ( 5 ) in FIG. 19 ). Based on the instruction, the EC 16 causes the switching circuit 22 to switch the graphics chips (( 6 ) in FIG. 19 ).
[0166] Then, the graphics driver 204 transmits the completion of the switching process of the graphics chips to the system BIOS 203 (( 7 ) in FIG. 19 ). The system BIOS 203 notifies the utility software 201 of the completion through the FEP.sys 202 (( 8 ) and ( 9 ) in FIG. 19 ). Thus, the utility software 201 displays the message that indicates the setting completion of the power supply option.
[0167] On the other hand, the system BIOS 203 also notifies the EC 16 of the completion. Based on the notification, the EC 16 causes the LED display 8 in accordance with the switched mode to light up.
(Conclusion)
[0168] As described above, according to this embodiment, the PC 100 prepares the AUTO mode in addition to the STAMINA and SPEED modes, and therefore can automatically switch the embedded graphics chip 15 and the external graphics chip 20 in accordance with the connection condition to the external monitor with the HDMI or the DVI or a connection condition of the AC adapter 5 . Thus, the PC 100 can switch the two graphics chips safely and easily in accordance with the use purpose of the user. Further, if the switching of the modes may cause a trouble in the operation of the application, the PC 100 displays the name of the application and urges the termination of the application. Therefore, the PC 100 can further assure the user of the safety.
MODIFIED EXAMPLE
[0169] The present invention is not limited to the above embodiment, and can be variously modified without departing from the gist of the present invention.
[0170] In the above embodiment, the PC 100 can perform the forced switching even after the name of the application that may cause a trouble due to the mode switching is displayed, but such a forced switching may be completely inhibited.
[0171] Further, in the case where the application that may cause a trouble due to the mode switching is present, the PC 100 may display a screen for urging an immediate termination of the application, or automatically store the task of the application and automatically terminate the application.
[0172] The present application contains subject matter related to that disclosed in Japanese Priority Patent Application JP 2010-007606 filed in the Japan Patent Office on Jan. 7, 2010, the entire content of which is hereby incorporated by reference.
REFERENCE SIGNS LIST
[0173] 2 a operation input unit
2 j HDMI connector
2 k DVI connector
3 display
3 a LCD
[0174] 5 AC adapter
7 mode selection switch
8 ( 8 a, 8 b, 8 c ) LED display
11 CPU
[0175] 15 embedded graphics chip
16 EC
[0176] 20 external graphics chip
21 HDD
[0177] 22 switching circuit
26 power supply circuit
27 battery
28 DC jack
100 PC
[0178] 201 utility software
204 graphics driver
221 , 231 , 251 , 271 OK button
311 forced switching button
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An information processing apparatus that includes a first graphic processing module having a first level of graphic performance and a second graphic processing module having a second level of graphic performance, which is greater than the first level of graphic performance. The information processing apparatus also includes a controller that selects one of the first graphic processing module or the second graphic processing module by determining whether the information processing apparatus is capable of outputting data with the first level of graphic performance or the second level of graphic performance, and detects whether the information processing apparatus is provided with power via a battery or via an external power source.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of casting, and more particularly to a pattern for lost-pattern casting, and also to methods of fabricating shell molds, and to methods of casting using such a pattern.
So-called “lost-wax” or “lost-pattern” casting methods have been known since antiquity. They are particularly suitable for producing metal parts that are complex in shape. Thus, lost-pattern casting is used in particular for producing turbine engine blades.
In lost-pattern casting, the first step normally comprises making a pattern out of a material having a melting temperature that is comparatively low, such as for example out of wax or resin, and then overmolding the mold onto the pattern. After removing the material of the pattern from the inside of the mold, whence the name of such methods, molten metal is cast into the mold in order to fill the cavity that the pattern has formed inside the mold by being removed therefrom. Once the metal has cooled and solidified, the mold may be opened or destroyed in order to recover a metal part having the shape of the pattern. In the present context, the term “metal” should be understood to cover not only pure metals but also, and above all, metal alloys.
In order to be able to make a plurality of parts simultaneously, it is possible to unite a plurality of patterns in a single assembly in which they are connected together by a tree that forms casting channels in the mold for the molten metal.
Among the various types of mold that can be used in lost-pattern casting, so-called “shell” molds are known that are formed by dipping the pattern or the assembly of patterns into a slip, and then dusting refractory sand onto the pattern or the assembly of patterns coated in the slip in order to form a shell around the pattern or the assembly, and then baking the shell in order to solidify the slip and thus consolidate the slip and the sand. Several successive operations of dipping and dusting may be envisaged in order to obtain a shell of sufficient thickness prior to baking it. The term “refractory sand” is used in the present context to designate any granular material of grain size that is sufficiently small to satisfy the desired production tolerances, that is capable, while in the solid state, of withstanding the temperature of the molten metal, and that is capable of being consolidated into a single solid piece by the slip during baking of the shell.
In order to obtain particularly advantageous thermomechanical properties in the part produced by casting, it may be desirable to ensure that the metal undergoes directional solidification in the mold. The term “directional solidification” is used in the present context to mean that control is exerted over the nucleation and the growth of solid crystals in the molten metal as it passes from the liquid state to the solid state. The purpose of such directional solidification is to avoid the negative effects of grain boundaries within the part. Thus, the directional solidification may be columnar or monocrystalline. Columnar directional solidification consists in orienting all of the grain boundaries in the same direction so that they cannot contribute to propagating cracks. Monocrystalline directivity solidification consists in ensuring that the part solidifies as a single crystal, so as to eliminate all grain boundaries.
Directional solidification is particularly desirable when producing parts that are to be subjected to high levels of thermomechanical stress, such as turbine engine blades. Nevertheless, the complex shapes of such blades can interfere with directional solidification, giving rise to unwanted grains, in particular in the proximity of sharp corners in the blade. In particular, in a turbine engine blade with a root and a body on either side of a platform extending substantially perpendicularly to a main axis of the blade, said body presenting a pressure side, a suction side, a leading edge, and a trailing edge, the sudden transition between the body of the blade and the platform can cause such unwanted grains to form, in particular in the vicinity of the trailing edge.
In order to reduce the weight of turbine engine blades, and above all in order to enable them to be cooled, it is common practice to embed refractory cores in the non-permanent pattern. Such a refractory core remains inside the shell mold after the material of the pattern has been removed, and after the metal has been cast and allowed to cool, thereby forming a hollow volume in the metal part. In particular, in order to provide good cooling of the trailing edge, given that its small thickness makes it particularly vulnerable to high temperatures, it is common practice for such a core to be flush with the surface of the pattern at the trailing edge so as to form a cooling slot for the trailing edge. Nevertheless, the small thickness of the core in this location makes it fragile. In addition, in order to keep the core in the correct position inside the shell mold during casting and cooling of the metal, it is desirable to guide its thermal expansion. For this purpose, the pattern may include a guide strip adjacent to the trailing edge and having a varnished surface of the refractory core flush with each side of the pattern between the trailing edge and the expansion strip. The varnish on these surfaces, which may be removed from the shell mold together with the material of the pattern, ensures that there is a small amount of clearance (of the order of a few hundredths of a millimeter) between the refractory core and the shell mold, so as to guide the expansion of the core at this location in a direction perpendicular to its thickness. Inside the expansion strip, the core can be of greater thickness, thereby making it more robust.
Nevertheless, the complexity between the shape of the mold cavity at the intersections of the trailing edge or the expansion strip with the blade platform significantly increases the risk of grains being generated.
OBJECT AND SUMMARY OF THE INVENTION
The present invention seeks in particular to remedy these drawbacks. In particular, the invention seeks to provide a pattern that makes it possible to avoid unwanted grains forming in the proximity of intersections between the trailing edge or the expansion strip with the platform of a turbine engine blade as produced from the pattern in a lost-pattern casting method.
In at least one embodiment of the present invention, this object is achieved by the fact that the pattern also includes a web extending between the platform and said expansion strip and presenting a free edge between them. The term “web” is used in the present context to designate a wall that is very fine, i.e. of thickness that is substantially less than its other dimensions. The thickness of the web is nevertheless not necessarily less than the thickness of the expansion strip.
By means of these provisions, it is possible to ensure a transition between the trailing edge and the platform that is more gradual, avoiding sharp corners that might be at the origin of unwanted grains. Since the raw casting that results from the casting method using such a pattern must in any event be machined subsequently in order to eliminate the expansion strip, this web can be eliminated in the same machining step without giving rise to additional operations.
Advantageously, the free edge of the web may extend from one edge of the platform to the expansion strip, so as to avoid unwanted grains nucleating not only between the platform and the trailing edge, but also at the edge of the platform.
For better avoidance of unwanted grains forming, the pattern may present a progressive transition between a free edge of the expansion strip and the free edge of the web. In addition, the web may be of thickness that is less than or equal to a thickness of the expansion strip, and the free edge of the web may be rounded in a transverse plane.
The pattern may also include an out-of-part segment extending the body from an end remote from the blade root, in particular in order to provide a smooth transition between a selector channel and the body of the blade. Under such circumstances, the web may present height that is no greater than half the height of the body together with the out-of-part segment.
In order to limit the number of corners that might generate unwanted grains, a junction between the web and the platform may extend a junction between the pressure side and the platform.
In order to facilitate directional solidification, this casting pattern may also have a selector channel pattern that is connected to an end of the blade body that is opposite from the blade root. In a casting method using a mold formed around this casting pattern, it is possible, by progressively cooling the molten metal inside the mold from a starter cavity connected to the blade-shaped cavity via a selector channel, e.g. a baffle-shaped channel, to ensure that only one of the grains that has nucleated in the starter cavity propagates into the blade-shaping cavity.
The invention also provides an assembly comprising a plurality of said casting patterns connected together by a tree so as to be capable of producing a plurality of blades simultaneously.
The invention also provides a method of fabricating a shell mold, the method comprising the steps of dipping at least one such casting pattern in a slip, powdering the at least one slip-coated pattern with refractory sand in order to form a shell around at least one pattern, removing the at least one pattern, and baking the shell. In addition, the invention also provides a casting method in which such fabrication of a shell mold is followed by casting molten metal into the shell mold, cooling the metal with directional solidification thereof, knocking out in order to recover the raw metal casting, and finishing the raw casting. This finishing step may in particular include machining away the out-of-part elements from the raw casting.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be well understood and its advantages appear better on reading the following detailed description of an embodiment given by way of non-limiting example. The description refers to the accompanying drawings, in which:
FIG. 1 is a diagram showing the implementation of a directional solidification casting method;
FIG. 2 is a diagram showing an assembly of casting patterns;
FIG. 3 is a side view of a casting pattern in an embodiment;
FIG. 4 is a view of an opposite side of the FIG. 3 pattern;
FIG. 5 is a cross-section of the pattern of FIGS. 3 and 4 on line V-V;
FIG. 6 is a cross-section of the pattern of FIGS. 3 to 5 on line VI-VI; and
FIG. 7 is a longitudinal section view on line VII-VII of the portion of the pattern shown in FIGS. 3 to 6 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows how progressive cooling of the molten metal in order to obtain directional solidification can typically be performed in a casting method.
The shell mold 1 used in this method comprises a central descender 4 extending along the main axis X between a casting cup 5 and a plate-shaped base 6 . While the shell mold 1 is being extracted from the heater chamber 3 , the base 6 is directly in contact with a soleplate 2 . The shell mold 1 also has a plurality of molding cavities 7 arranged as an assembly around the central descender 4 . Each molding cavity 7 is connected to the casting cup 5 by a feed channel 8 through which the molten metal is inserted while it is being cast. Each molding cavity 7 is also connected at the bottom via a baffle-selector channel 9 to a starter 10 formed by a smaller cavity adjacent to the base 6 .
The shell mold 1 may be produced by the so-called “lost-wax” or “lost-pattern” method. A first step of such a method is creating a non-permanent assembly 11 comprising a plurality of patterns 12 connected together by a tree 13 , as shown in FIG. 2 . Both the patterns 12 and the tree 13 are for forming hollow volumes in the shell mold 1 and so they are made of a material having a low melting temperature, such as a patterning resin or wax. When it is intended to produce large numbers of parts, it is possible in particular to produce these elements by injecting the patterning resin or wax into a permanent mold.
In this implementation, in order to produce the shell mold 1 from the non-permanent assembly 11 , the assembly 11 is dipped in a slip, and then dusted with refractory sand. These dipping and dusting steps may be repeated several times, until a shell of slip-impregnated sand of desired thickness has been formed around the assembly 11 .
The assembly 11 covered in this shell can then be heated so as to melt the low melting-temperature material of the assembly 11 and remove it from the inside of the shell. Thereafter, in a higher temperature baking step, the slip is solidified so as to consolidate the refractory sand and form the shell mold 1 .
The metal or metal alloy used in this casting method is cast while molten into the shell mold 1 via the casting cup 5 , and it fills the molding cavities via the feed channels 8 . During this casting, the shell mold 1 is kept in a heater chamber 3 , as shown in FIG. 1 . Thereafter, in order to cause the molten metal to cool progressively, the shell mold 1 supported by a cooled and movable support 2 is extracted from the heater chamber 3 downwards along the main axis X. Since the shell mold 1 is cooled via its base 6 by the support 2 , the solidification of the molten metal is triggered in the starters 10 and it propagates upwards during the progressive downward extraction of the shell mold 1 from the heater chamber 3 . The constriction formed by each selector 9 , and also its baffle shape, nevertheless serve to ensure that only one of the grains that nucleates initially in each of the starters 10 is capable of continuing so as to extend to the corresponding mold cavity 7 .
Among the metal alloys that are suitable for use in this method, there are to be found in particular monocrystalline nickel alloys such as in particular AM1 and AM3 from Snecma, and also other alloys such as CMSX-2®, CMSX-4®, CMSX-6®, and CMSX-10® from C-M Group, Rene® N5 and N6 from General Electric, RR2000 and SRR99 from Rolls-Royce, and PWA 1480, 1484, and 1487 from Pratt & Whitney, amongst others. Table 1 summarizes the compositions of these alloys:
TABLE 1
Monocrystalline nickel alloys in weight percentages
Alloy
Cr
Co
Mo
W
Al
Ti
Ta
Nb
Re
Hf
C
B
Ni
CMSX-2
8.0
5.0
0.6
8.0
5.6
1.0
6.0
—
—
—
—
—
Bal
CMSX-4
6.5
9.6
0.6
6.4
5.6
1.0
6.5
—
3.0
0.1
—
—
Bal
CMSX-6
10.0
5.0
3.0
—
4.8
4.7
6.0
—
—
0.1
—
—
Bal
CMSX-10
2.0
3.0
0.4
5.0
5.7
0.2
8.0
—
6.0
0.03
—
—
Bal
René N5
7.0
8.0
2.0
5.0
6.2
—
7.0
—
3.0
0.2
—
—
Bal
René N6
4.2
12.5
1.4
6.0
5.75
—
7.2
—
5.4
0.15
0.05
0.004
Bal
RR2000
10.0
15.0
3.0
—
5.5
4.0
—
—
—
—
—
—
Bal
SRR99
8.0
5.0
—
10.0
5.5
2.2
12.0
—
—
—
—
—
Bal
PWA1480
10.0
5.0
—
4.0
5.0
1.5
12.0
—
—
—
0.07
—
Bal
PWA1484
5.0
10.0
2.0
6.0
5.6
—
9.0
—
3.0
0.1
—
—
Bal
PWA1487
5.0
10.0
1.9
5.9
5.6
—
8.4
—
3.0
0.25
—
—
Bal
AM1
7.0
8.0
2.0
5.0
5.0
1.8
8.0
1.0
—
—
—
—
Bal
AM3
8.0
5.5
2.25
5.0
6.0
2.0
3.5
—
—
—
—
—
Bal
After the metal has cooled and solidified in the shell mold, the mold can be knocked out so as to release the metal parts, which can then be finished by machining and/or surface treatment methods.
When the parts for molding are of complex shapes, they can nevertheless make the directional solidification of the metal in each mold cavity 7 more complicated. In particular, the sharp corners in the cavity 7 can lead to unwanted grains that weaken the part. In order to avoid such unwanted grains forming, the patterns 12 in this embodiment receive added elements that smooth certain sharp angles in the mold cavities 7 . One such casting pattern 12 for producing a turbine engine blade is shown in FIGS. 3 and 4 . This casting pattern 12 is thus in the shape of a turbine engine blade with a blade body 14 and a blade root 15 for fastening the blade to a turbine engine rotor. The blade body 14 has a suction side 16 and a pressure side 17 that meet along a leading edge 18 and a trailing edge 19 . A platform 20 lies between the blade body 14 and the blade root 15 . The pattern 12 also has out-of-part elements, and in particular an expansion strip 21 adjacent to the trailing edge 19 and an out-of-part segment 22 extending the blade body 14 at an end opposite from the blade root 15 . This out-of-part segment 22 is for connection to the selector channel 9 , and the blade root 15 is for connection to the feed channel 8 so that in the mold cavity 7 formed by the pattern 12 in the shell mold 1 , the molten metal flows from the root of the blade 15 towards the blade body 14 during casting, and subsequently solidifies in the opposite direction during its directional solidification.
The pattern 12 also has, a refractory solid core 23 for the purpose of forming a cavity in the turbine engine blade. On each side of the pattern 12 , a varnished surface 31 of the core 23 is flush with the surface of the pattern 12 between the trailing edge 19 and the strip 21 , as shown in FIGS. 5 and 6 . During the steps of dipping and dusting the pattern 12 , the slip-impregnated sand shell forms on the exposed surfaces of the pattern 12 , including on these varnished surfaces 31 of the core 23 . During removal of the pattern and/or baking of the shell, the varnish covering these surfaces 31 is also eliminated, thereby leaving a small amount of clearance, typically lying in the range two to three hundredths of a millimeter, between these surfaces 31 of the core and the corresponding inside surfaces of the shell mold 1 . At this location, this small clearance allows the core 23 to move perpendicularly to its thickness relative to the shell mold 1 , thereby guiding the thermal expansion of the core 23 during casting and cooling of the metal. Nevertheless, the small size of this clearance prevents the molten metal from running between the core 23 and the shell mold 1 at this location. Thus, in the raw casting, the trailing edge and the strip are separated by a gap that facilitates subsequent machining of the strip while finishing the raw casting.
A particularly critical location for the formation of unwanted grains is in the proximity of the intersection between the trailing edge 19 and the platform 20 . A plurality of sharp corners can meet at this location, thereby increasing the danger of unwanted grains forming. To avoid that, in the embodiment shown, the pattern 12 also has a fine web 24 between the strip 21 and the platform 20 . This web 24 presents a free edge 25 extending between the strip 21 and an end 26 a of an edge 26 of the platform 20 . The web 24 is of thickness e 1 equal to or less than the thickness e 2 of the adjacent strip 21 . The height h 1 of the web 24 is approximately half the raw height h 2 of the blade body 14 including the out-of-part segment 22 . So long as the free edge 25 of the web 24 and the outside edge 27 of the strip 21 are rounded, as shown in FIGS. 5 and 6 , the transition 28 between them is very progressive. The strip 21 and the web 24 both follow the curvature, if any, of the trailing edge 19 . The transition 29 between the web 24 and the platform 20 is rounded in the longitudinal plane, as shown in FIG. 7 , and runs on from the line of transition 30 between the suction side 17 and the platform 20 .
In the casting method used for producing at least one turbine engine blade from such a pattern, the web and the strip in the raw casting can easily be eliminated simultaneously by machining while finishing the raw casting. This makes it possible to obtain a clean part without it being necessary to perform more machining operations than would be required with a pattern that does not have the web 24 .
Although the present invention is described with reference to a specific embodiment, it is clear that various modifications and changes may be made thereto without going beyond the general ambit of the invention as defined by the claims. In addition, individual characteristics of the various embodiments mentioned may be combined in additional embodiments. Consequently, the description and the drawings should be considered in an illustrative sense rather than in a restrictive sense.
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A casting pattern for a lost-pattern casting, the pattern being in a shape of a turbine engine blade with a root and a body on either side of a platform that is substantially perpendicular to a main axis of the blade, and a method of producing a shell mold from the pattern, and a casting method using the shell mold. The blade body presents a pressure side, a suction side, a leading edge, and a trailing edge. The pattern also includes an expansion strip adjacent to the trailing edge, and a refractory core embedded in the pattern but presenting, both on the pressure side and on the suction side, a respective flush varnished surface between the trailing edge and the expansion strip. A web extends between the platform and the expansion strip and presents a free edge between them.
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FIELD OF THE INVENTION
The present invention relates to the field of charge pumps and, more particularly, to methods and circuits for regulating charge pumps.
BACKGROUND OF THE INVENTION
In many electronic devices, it is desirable to generate a voltage having a magnitude that is greater than a magnitude of a supply voltage providing power to the device. In other applications, it is desirable to generate a polarity that is different from the polarity of the supply voltage providing power to a device. Charge pumps may be used for both of these purposes. Although a wide variety of charge pumps have been developed, many charge pumps use capacitors to obtain a boosted voltage or a voltage having a different polarity.
Typically, a supply voltage is sampled on a first terminal of a capacitor (by charging the capacitor to the supply voltage) during a first phase of a cycle. During a second phase of the cycle, one of the terminals is coupled to a load. If the first terminal of the capacitor is coupled to the load and the second terminal is held at ground, a boosted voltage may be generated. Because the capacitor was charged to the supply voltage during the first phase when the second terminal was connected to ground, the voltage on the first terminal is approximately twice the supply voltage during the second phase. If, during the second phase, the second terminal of the capacitor is coupled to the load and the first terminal is held at ground, a voltage with a reverse polarity may be generated. Because the capacitor was charged to the supply voltage during the first phase when the second terminal was connected to ground, the voltage on the second terminal is approximately a negative supply voltage during the second phase. The charge pump repeatedly alternates between the first and second phases, each cycle generating an output voltage that is approximately twice the supply voltage V AA or of a reversed polarity.
Charge pumps are presently used in a wide variety of applications. For example, charge pumps are typically used in memory devices to provide a negative substrate voltage or to provide a boosted voltage that may be applied to the gate of an NMOS transistor to allow the transistor to couple the supply voltage to an output node. Charge pumps are also used in CMOS imagers to generate voltages of different polarities and magnitudes during various operations carried out by the imagers. For example, charge pumps are commonly used to supply power having a polarity that is different from that of the supply voltage to the imaging array of CMOS imagers.
The time required for a charge pump to output a target voltage is sometimes referred to as a time constant of the charge pump. In general, the time constant of a charge pump driving a resistance load is very short as long as the current demands of the load do not exceed the current that may be supplied by the charge pump. The time constant, however, of a charge pump driving a capacitive load may be very long because the voltage applied to a load incrementally increases through a charge sharing process each cycle. The time constant of the charge pump may affect the magnitude of capacitance relative to the load capacitance, as well as the difference between the supply voltage and the load voltage to which the capacitive load has been charged. The charge pump, thus, may be slow to reach the target voltage because the charge pump may not produce more charge than the combination of the pump capacitance, supply voltage and the load voltage. In addition, charge pumps typically do not compensate for charge lost when the charge pump is inactive.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be understood from the following detailed description when read in connection with the accompanied drawing. Included in the drawing are the following figures:
FIG. 1 is a schematic diagram of a charge pump according to one example of the invention;
FIG. 2 is a schematic diagram of a charge pump according to another example of the invention including two voltage boosters arranged in counter-phase;
FIG. 3 is a timing diagram of control signals and generated output voltage for the circuit shown in FIG. 1 ;
FIG. 4 is a schematic diagram of a charge pump according to a further example of the invention;
FIG. 5 is a timing diagram of generated output voltage and clock signals for the circuit shown in FIG. 4 ;
FIG. 6 is a timing diagram of a voltage step signal generated by the charge pump shown in FIG. 4 when pumping charge from a load; and
FIG. 7 is a block diagram of a CMOS imager using one or more of the charge pumps shown in FIG. 1 , 2 or 4 or a charge pump according to another example of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a charge pump, designated generally as 100 , according one example of the invention. Charge pump 100 includes voltage booster circuit 102 , voltage regulator circuit 104 and clock generator 106 . Clock generator circuit 106 provides a set of nonoverlapping clock signals (φ 1 , φ 2 ) to control voltage booster circuit 102 and voltage regulator circuit 104 . Clock signals (φ 1 , φ 2 ) represent a first phase (φ 1 ) and second phase (φ 2 ) of a cycle.
Voltage booster circuit 102 includes capacitance C p , two switches 110 , 112 that are closed during the first phase of each cycle and two switches 114 , 116 that are closed during the second phase of cycle. Voltage booster circuit 102 may be used to supply a negative voltage when powered by a positive supply voltage 118 of voltage V AA . A load L is connected to output node 126 of charge pump 100 . Switches 110 , 112 that are closed during the first phase of each cycle are open during the second phase, and switches 114 , 116 that are closed during the second phase are open during the first phase. The load L is assumed to be the array of a CMOS imager, which may be highly capacitance, with a capacitance of C L . The voltage across the capacitance load C L is designated as V L . Voltage booster circuit 102 is coupled to voltage regulator circuit 104 via node 128 and switch 114 . Voltage booster circuit 102 provides voltage V IN to voltage regulator circuit 104 via node 128 and receives regulator voltage V REG from voltage regulator circuit 104 via switch 114 .
Although a capacitive load C L is illustrated in FIG. 1 , load L may not be entirely capacitive. According to one embodiment, load L may include both capacitor and diode components, where the diode may introduce some charge leakage. For example, load L may correspond to transfer (TX) gates of active pixels (not shown) of a CMOS imager. In this example, voltage booster circuit 102 may be coupled to the TX gates via respective source diffusion regions of a number of driver transistors (not shown), for example, about 480-2500 driver transistors. Accordingly, there may be a significant load from respective forward-biased diffusion diodes of the corresponding pixels. For example, the area of the diodes may be large enough to produce a detectable amount of charge leakage, even for driving voltages (i.e. V L ) for example, of about 250 mV below a threshold voltage of the diode.
Voltage regulator circuit 104 includes supply voltage 120 of voltage V AA , capacitor C FB , switches 122 , 124 and differential amplifier 108 . Switch 122 is closed during the first phase of each cycle and switch 124 is closed during the second phase of each cycle. Switch 122 that is closed during first phase of each cycle is open during the second phase, and switch 124 that is closed during the second phase is open during the first phase. Switch 122 operates together with switch 110 , 112 and switch 124 operates in together with switches 114 , 116 .
Capacitor C FB , switches 122 , 124 and supply voltage 120 form level shift circuit 130 that receives voltage V IN from voltage booster circuit 102 generates level shifted voltage V SHIFT . Differential amplifier 108 receives a reference voltage V REF at the non-inverting input terminal and level shifted voltage V SHIFT at the inverting input terminal and produces regulation voltage V REG . Reference voltage V REF represents a target voltage corresponding to a desired negative pumping voltage. Accordingly, to reach an output level of −m volts (where m is an integer), reference voltage V REF can be set at (V AA −m). Capacitor C FB is a feedback capacitor which is used by differential amplifier 108 to detect load voltage V L . In general, capacitor C L is large, for example, 100 times larger, compared to capacitor C P .
As discussed above, in one embodiment, load L may include a diode component, which may introduce a charge leakage to load L. It may be appreciated that the charge leakage may increase exponentially with increasing voltage V L . Accordingly, a threshold voltage for the target voltage (and thus a suitable maxiumum reference voltage V REF ) may be determined such that charge pump 100 may compensate for the charge leakage. Charge pump 100 , thus, may produce a regulated load voltage V L that may substantially reduce noise due to charge leakage.
During the first phase of each cycle, supply voltage 122 is connected to an upper terminal of capacitor C P by switch 110 while switch 112 connects the lower terminal of capacitor C P to ground. Capacitor C P is therefore charged to −V AA during the first phase. In addition, supply voltage source 120 of voltage regulator circuit 104 is connected to one terminal of capacitor C FB , while switch 112 connects the other terminal of capacitor C FB to ground (i.e., such that V IN is at ground). During the first phase, differential amplifier 108 is disconnected from voltage booster circuit 102 and level shift circuit 102 , and capacitors C P and C FB are each charged to V AA .
During the second phase of each cycle, switch 114 is closed to connect the upper terminal of capacitor C P to receive regulation voltage V REG and the other switch 116 is closed to connect the other terminal of capacitor C P to load L. In addition, switch 124 is closed to connect one terminal of capacitor C FB to the inverting input terminal of differential amplifier 108 and the other terminal of C FB is connected to load L and thus to load voltage V L . Thus, a voltage difference of (V AA −V L ) is generated across level shift circuit 130 .
It may be appreciated that, during the second phase, a feedback circuit is provided by differential amplifier 108 and capacitances C P , C FB . It may also be appreciated that voltage V SHIFT at the inverting input of differential amplifier 108 is at a voltage V AA higher than V L (i.e., it is level shifted). Differential amplifier 108 provides unity gain feedback from V REG to V L . Because of the feedback configuration, differential amplifier 108 adjusts V REG to compensate for any lost charge and to maintain output node 126 at a voltage of V REF −V AA .
In operation, when voltage regulator circuit 104 determines that load voltage V L is outside of a target voltage range, differential amplifier 108 slews to ground (for example, acting as a current sink), such that all charge across C P is pushed into load C L . Accordingly, both output node 126 and level shifted voltage V SHIFT are reduced by ±(C P /C L )·V AA . Thus, the entire supply voltage V AA range is used. When the load voltage V L is within the target voltage range, differential amplifier 108 , acting as a voltage buffer, generates regulation voltage V REG to provide sufficient charge into capacitor C P such that the inverting and non-inverting input terminals of differential amplifier 108 are maintained at a substantially same voltage.
By repeating the sequence of first and second phases using a clock, for example, of a few tens of MHz, a large amount of charge may be efficiently moved into capacitor C P while maintaining a smooth settling for the boosted voltage, when the load voltage V L is within the target voltage range. Namely, voltage regulator circuit 104 may 1) rapidly pump load L to within a target voltage range (where differential amplifer 108 acts as a current sink) and 2) apply differential amplifier 108 , acting as a voltage buffer, to reach the target voltage. As described further below, a size of capacitor C P , used in charge pump 100 , may be reduced. Because the size of capacitor C P may be reduced, a size of an output stage of differential amplifier 108 may also be reduced, thus generating a smaller output current. Accordingly, it may be appreciated that, even with the smaller output current differential amplifier 108 may still be capable of slewing from V AA to ground within a clock phase.
In addition, if differential amplifier 108 has a gain that is fairly high, for example, a gain of greater than 100, voltage booster 102 may keep pumping within the full range (i.e., V AA ) until the load voltage V L is within the target voltage range. Because capacitor C P may be charged to supply voltage V AA , a size of capacitor C P may be reduced. Because the output voltage V IN of voltage booster circuit 102 is level shifted by a higher predetermined value (e.g., V AA ), voltage booster circuit 102 may be operated using a regulation voltage V REG , which generally produces for a larger voltage (compared to a target voltage) that may be used across capacitor C P . Because a larger voltage may be used in voltage booster circuit 102 , a capacitor size needed to reach a target voltage within the time constant may be reduced.
The devices for implementing switches 110 , 112 , 114 , 116 , 122 , 124 are conventional as are circuitry for controlling them during the first and second phases of each cycle. Therefore, a more detailed explanation of these devices and control circuits have been omitted.
FIG. 2 illustrates a charge pump, designated generally as 200 , according to another example of the invention. Charge pump 200 is the same as charge pump 100 ( FIG. 1 ) with an exception. In addition to containing voltage booster circuit 102 - 1 (including switches 110 - 1 , 112 - 1 , 114 - 1 , 116 - 1 , capacitor C P and supply voltage force 118 - 1 ), charge pump 200 also includes a second voltage booster circuit 102 - 2 . Voltage booster circuits 102 - 1 , 102 - 2 are each connected to voltage regulator circuit 104 . Voltage booster circuit 102 - 2 includes switches 110 - 2 , 112 - 2 , 114 - 2 , 116 - 2 , capacitance C P and voltage source 118 - 2 . Switches 110 - 2 , 112 - 2 , 114 - 2 , 116 - 2 are operated out of phase with correspondingly numbered switches 110 - 1 , 112 - 1 , 114 - 1 , 116 - 1 . As a result, capacitor C P of voltage booster circuit 102 - 1 applies a voltage to load L during the second phase of each cycle and capacitor C P of voltage booster circuit 102 - 2 applies a voltage to load L during the first phase of each cycle.
According to another embodiment, charge pumps 100 , 200 ( FIGS. 1 and 2 ) may include a gate (not shown) as part of clock generator 106 or separate from clock generator 106 . The gate may be used to inactivate voltage booster circuit 102 and/or voltage regulator circuit 104 at particular times. In this manner charge pump 100 , 200 ( FIGS. 1 and 2 ) may stop pumping, for example, during sampling of a pixel output of imager array to minimize the introduction of switch noise into sampled pixels.
Referring to FIG. 3 , a timing diagram of generated output voltage and control signals as a function of time are shown. In particular, FIG. 3 shows input clock signal 302 , pump clock signal 304 (i.e. φ 1 , φ 2 ), stop clock signal 306 , capacitive voltage signal 308 , load voltage signal 310 (i.e. V L ) and output voltage signal 312 . Input clock signal 302 is provided to clock generator 106 ( FIG. 1 ). Pump clock signal 304 is used to control charge pump 100 ( FIG. 1 ). Stop clock signal 306 is used to inactivate charge pump 100 ( FIG. 1 ), as described above. Capacitive voltage signal 308 represents a voltage capacitively coupled to load L that cycles during sampling. Load voltage signal 310 is the load voltage V L provided by charge pump 100 ( FIG. 1 ). Output voltage signal 312 represents a voltage of a single metal line across a CMOS imager array.
As shown in FIG. 3 , load voltage signal 310 is pulled down rapidly after initialization. Load voltage signal 310 is shown to recover quickly after a hold period when a substantial amount of charge is pulled from the imager array. It may be seen that some of the coupling of the load to load voltage 310 during sampling (when stop clock signal 306 is asserted) may be accounted for by capacitive voltage signal 308 . When capacitive voltage signal 308 is pulled down, it also pulls down load voltage signal 310 , such that an amount of charge is leaked from output voltage signal 310 . When capacitive voltage signal 308 is released, load voltage signal 310 is initially less negative than prior to stop clock signal 306 being asserted. It may be appreciated that load voltage signal 310 is then reduced, thus, compensated by charge pump 100 ( FIG. 1 ). It may also be appreciated that charge lost to output voltage signal 312 , during the assertion of stop clock signal 306 , is also quickly compensated by charge pump 100 ( FIG. 1 ).
FIG. 4 is a schematic diagram of a charge pump, designated generally as 400 , according to another example of the invention. Charge pump 400 includes voltage booster circuit 402 and regulator circuit 404 . Voltage booster circuit 402 supplies a negative voltage to output node 434 . Regulator circuit 404 generates a set of pump clock signals (φ 1 ′, φ 2 ′) to control voltage booster circuit 402 . A capacitive load C L is connected to output node 434 of charge pump 400 and the voltage across capacitance load C L is designated as V L .
As described further below, pump clock signals (φ 1 ′, φ 2 ′) are generated to activate and control operation of voltage booster circuit 402 when the load voltage V L at node 434 is less than a reference voltage V REF . When load voltage V L is greater than or equal to reference voltage V REF , pump clock signals (φ 1 ′, φ 2 ′) are set to a low value (i.e. 0) and voltage booster circuit 402 is inactive. Pump clock signals (φ 1 ′, φ 2 ′) represent a first phase (φ 1 ′) and second phase (φ 2 ′) of an active pump cycle.
Voltage booster circuit 402 includes supply voltage 432 of voltage V AA , capacitor C P , two switches 424 , 426 that are closed during the first phase (φ 1 ′) of the pump cycle and two switches 428 , 430 that are closed during the second phase (® 2 ′) of the pump cycle. Switches 424 , 426 that are closed during the first phase of each cycle are open during the second phase. Switches 428 , 430 that are closed during the second phase are open during the first phase.
Regulator circuit 404 includes voltage detector circuit 406 and clock generator circuit 408 . Voltage detector circuit 406 receives and samples load voltage V L from node 434 and provides a detected voltage V SENSE to clock generator circuit 408 . Clock generator circuit 408 generates a set of clock signals (φ 1 , φ 2 ) to control voltage detector circuit 408 and the set of pump clock signals (φ 1 ′, φ 2 ′) to control voltage booster circuit 402 . Clock signals (φ 1 , φ 2 ) represent a first phase (φ 1 ) and second phase (φ 2 ) of a clock cycle. As described further below, clock signals (φ 1 , φ 2 ) are generated each clock cycle. Clock signals (φ 1 ′, φ 2 ′), however, are activated when V L is less than reference voltage V REF . Accordingly, regulator circuit 404 detects the load voltage V L and determines whether to activate or deactivate voltage booster circuit 402 .
Voltage detector circuit 406 includes capacitor C s , first set of switches 416 , 418 and second set of switches 420 , 422 . Voltage detector circuit 406 receives and samples load voltage V L on capacitor C s according to the set of clock signals (φ 1 , φ 2 ). Switches 416 , 418 that are closed during the first phase of each cycle are open during the second phase. Switches 420 , 422 that are closed during the second phase of each cycle are open during the first phase. During the second phase, capacitor C s samples load voltage V L when switches 420 , 422 are closed. During the first phase, switches 416 , 418 are closed and the detected voltage sampled by capacitor C s is inverted and provided to clock generator circuit 408 as detected voltage V SENSE .
Clock generator circuit 408 includes comparator 410 , clock generator 412 and AND gates 414 - 1 , 414 - 2 . Comparator 410 compares detected voltage V SENSE with reference voltage V REF and generates a pump signal (pump). Comparator 410 generates a high pump signal (i.e., 1 ) when V SENSE is less than V REF . Comparator 410 generates a low pump signal (i.e., 0 ) when V SENSE is greater than or equal to V REF . Clock generator 412 generates the set of clock signals φ 1 , φ 2 which is provided to voltage detector circuit 406 , regardless of the state of the pump signal. Clock signals φ 1 , φ 2 are gated with the pump signal by AND 414 - 1 , 414 - 2 , respectively, to produce the set of pump clock signals φ 1 ′, φ 2 ′ used to control operation of voltage booster circuit 402 . Clock generator circuit 408 sets the set of pump clock signals φ 1 ′, φ 2 ′ to zero when the pump signal is low, thus causing pumping of voltage booster circuit 402 to cease.
Reference voltage V REF represents a target voltage for the load voltage V L at output node 434 . Although in one embodiment, V REF is a positive value of 400 mV, it is understood that any suitable reference voltage may be used, based on the load voltage. As described above, load L may also include a diode component that may generate a charge leakage. Accordingly, a suitable V REF may also be based on the charge leakage from the diode component.
In operation, the set of clock signals φ 1 , φ 2 for clock generation circuit 406 continues for each cycle such that voltage detector circuit 406 continually detects load voltage V L . Voltage booster circuit 402 , however, is activated when the pump signal is high.
When the pump signal is high and during the second phase of the pump cycle, supply voltage 432 is connected to capacitor C P by switch 430 , while switch 428 connects the other terminal of capacitor C P to ground. Capacitor C P is therefore charged to −V AA during the second phase of the pump cycle. During the first phase of the pump cycle, switch 426 is closed to connect the lower terminal of capacitor C P to ground and switch 424 is closed to connect the other terminal of capacitor C P to load L.
In another embodiment, charge pump 400 may include first and second voltage booster circuits 402 (not shown), each connected to regulator circuit 404 . The first and second voltage booster circuits 402 are similar to each other except that they are operated out of phase. Accordingly, first and second voltage booster circuits 402 may apply a voltage to load L, as described above, during the first and second phases of each cycle, respectively.
According to one embodiment, when charge pump 400 is used with an imager array, clock generator circuit 408 may be configured with a gate (not shown) to inactivate voltage booster circuit 402 at particular times. In this manner, charge pump 400 may stop pumping, for example, during sampling of a pixel output of imager array to minimize the introduction of switch noise into sampled pixels.
Referring to FIG. 5 , a timing diagram of a charge pump output voltage and clock sequences are shown for charge pump 400 . In particular, FIG. 5 shows input clock signal 502 , sense clock signal 504 (i.e., φ 1 , φ 2 ), pump clock signal 506 (i.e. φ 1 ′, φ 2 ), stop clock signal 508 , pump signal 510 , load voltage signal 512 (i.e. V L ) and output voltage signal 514 . Input clock signal 502 is provided to clock generator 412 ( FIG. 4 ). Sense clock signal 504 is used to control voltage detector circuit 406 ( FIG. 4 ). Pump clock signal 506 is used to control voltage booster circuit 402 ( FIG. 5 ). Stop clock signal 508 is used to inactivate charge pump 400 ( FIG. 4 ), as described above. Pump signal 510 is used in clock generator cirucit 408 ( FIG. 4 ) that is used to produce pump clock signal 506 . Load voltage signal 512 is the load voltage V L provided by charge pump 400 ( FIG. 4 ). Output voltage signal 514 represents a voltage of a single metal line across a CMOS imager array.
To produce the timing diagram shown in FIG. 5 , voltage booster circuit 402 has a capacitance C P of 20 pF and a capacitive load C L of 5 nF. As shown in FIG. 5 , voltage booster circuit 402 is capable of pulling down capacitive load C L to −0.5 V in less than 1.75 microseconds (load voltage signal 512 ). After load voltage signal 512 has reached the reference voltage, pump signal 510 is inactivated. When switching a load of 2 pF, voltage booster 402 ( FIG. 4 ) may compensate for lost charge within about 2 cycles. In contrast, conventional charge pumps typically have a start up time of about 30 microsecond with a 140 pF capacitor C P .
As described above, although a capacitive load C L is shown in FIG. 4 , load L may include a diode component that may contribute charge leakage. As shown in FIG. 5 , pump signal 510 may be activated at some interval to compensate for the charge leakage. FIG. 5 also illustrates that pump signal 510 may be triggered after release of stop clock signal 508 , in order to compensate for any charge leakage during inactivation of charge pump 400 ( FIG. 4 ). Furthermore, cycling of output voltage signal 514 may cause some charge leakage by the metal lines across the CMOS array. Accordingly, pump signal 510 is activated in order to compensate for the charge leakage during cycling of output voltage signal 514 .
Referring to FIG. 6 , a timing diagram illustrating a voltage step when pumping charge from a load is shown, for charge pump 400 ( FIG. 4 ). In particular, FIG. 6 shows input clock signal 602 , sense clock signal 604 (i.e., φ 1 , φ 2 ), pump clock signal 606 (i.e. φ 1 ′, φ 2 ′), stop clock signal 608 , pump signal 610 , load voltage signal 612 (i.e. V L ) and output voltage signal 614 . Signals 602 - 614 are similar to signals 502 - 514 , except that a different capacitive load is used. To produce the timing diagram shown in FIG. 6 , voltage booster 402 has a capacitance C P of 20 pF and a capacitive load C L of 4 nF.
As shown in FIG. 6 , load voltage signal 612 slowly drifts upwards due to charge leakage (due to a diode component of load L) before it is pumped down (by activating pump signal 610 ) at about 3.08 microseconds. A small difference is illustrated between the transient responses (for example, between about 3.08 microseconds and about 3.1 microseconds) of load voltage signal 612 and output voltage signal 614 . The difference in the transient responses may be due to a resistance, capacitance (RC) delay between charge pump 400 ( FIG. 4 ) and output voltage 614 . The RC delay may reduce an amount of overshoot in output voltage 614 as compared with load voltage signal 612 .
Although not specifically shown in the drawings, it will be understood that charge pumps 100 , 200 , 400 or a charge pump according to another example of the invention may be adapted to provide a positive rather than negative load voltage V L . Further, by adding additional switches and a capacitor, charge pumps 100 , 200 , 400 or a charge pump according to the other example of the invention may generate both positive and negative voltages.
Charge pumps 100 , 200 , 400 or a charge pump according to some other example of the invention can be used in a wide variety of applications. They are particularly suitable for use in a CMOS imager because the imaging arrays of such devices are highly capacitive (as well as typically including a diode component that may generate a charge leakage). For example, CMOS imager 700 shown in FIG. 7 include CMOS imaging array 706 that responds to a received image to generate corresponding signals. Array 706 is coupled to control and addressing circuit 702 , which interrogates imaging array 706 to output signal S i corresponding to the image received by imaging array 706 . CMOS imager 700 also includes charge pump 704 connected to imaging array 706 to supply imaging array 706 with a negative voltage. Charge pump 704 may be one of charge pumps 100 , 200 , 400 shown in respective FIG. 1 , 2 or 4 or a charge pump according to some other example of the invention.
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
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Charge pumps and methods for regulating charge pumps. The charge pump includes a voltage booster circuit and a voltage regulator circuit. The voltage booster circuit includes first and second input terminals that respectively receive a regulation voltage and an input voltage. The voltage booster circuit generates an output voltage having a polarity that is different from the input voltage. The output voltage is adjusted by the regulation voltage and provided to an output terminal. The voltage regulator circuit is coupled between the first input terminal and the output terminal of the voltage booster circuit. The voltage regulator circuit shifts the output voltage to a level shifted voltage and generates the regulation voltage responsive to the level shifted voltage.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a spring element comprising at least one spring tongue for spring-loading a separately implemented arresting part of a steering column of a motor vehicle and at least one securement part for securing the spring element on a bolt of the steering column.
[0002] Generic spring elements are utilized in the prior art, for example in adjustable steering columns, for the purpose of connecting with one another a first structural part of the steering column, such as a vehicle-stationary bracket unit, with a second structural part of the steering column, such as a steering spindle bearing unit, in which a steering spindle is rotatably bearing-supported. Thus, an arresting part secured on one of the two structural parts is arrested by the spring tongue of the spring element in at least one operating state in or on an engagement element secured on the other structural part. In a second operating state of the steering column, however, this arrester is to be released, for example in order to displace the two structural parts of the steering column into a different position relative to one another. For this purpose it must be possible to release the arresting part from the engagement element. Generic spring elements provided herefor, are disclosed, for example, in WO 2009/121 386 A1. In the first embodiment of WO 2009/121 386 A1, the spring tongue is guided fixedly in a groove of the hook-like arresting part. During a swiveling of the spring element therefore the arresting part is entrained in all directions by the spring tongue. In a second embodiment of WO 2009/121 386 A1, the spring tongue rests only on the arresting part. During a corresponding swivel movement of the bolt, on which the spring element is seated, the spring tongue is raised from the arresting part. In order for the arresting part to be released from the engagement element during a corresponding rotational movement of the bolt, in this second embodiment a pin is provided on the bolt of the steering column, which is guided in an elongated hole of the arresting part and entrains the arresting part as soon as the pin abuts one end of the elongated hole.
SUMMARY OF THE INVENTION
[0003] The invention addresses the problem of providing an alternative disposition whose structure is implemented as simply as possible and is simple in production.
[0004] This is achieved through a spring body according to the present invention.
[0005] The invention thus provides that the spring element comprises additionally at least one entrainer arm, preferably at least two opposingly disposed entrainer arms, for entraining the arresting part during a movement of the spring element. The arresting action of the arresting part is preferably effected through the engagement of the arresting part into an engagement element and can be designated for different purposes of the steering column. Depending on requirements, by switching or by actuation it is feasible to switch on and off the arresting action. The arresting action is effected through the movement of the arresting part between the switched-on and switched-off arresting action. Depending on requirements, the arresting part can, in particular, arrest the position of an adjustable steering column and/or enable a connection of an energy absorption means with a portion of the steering column. For the improvement of the function, it can advantageously be provided that the movement of the arresting part is under spring pre-loading at least in the direction of an end position, preferably in the direction of the switched-on arresting state. The arresting part is implemented as a separate structural part whereby a realization especially well suited for the purpose of arresting is enabled, and the choice of the material can be adapted to the requirements while the spring element can be realized to be especially appropriate for satisfying the spring action and the entrainment effect. In terms of the invention, by entrainment operation or entrainment is to be understood a transmission of the movement between two elements, in particular between the spring element and the arresting part.
[0006] Through the realization according to the invention, the spring element is enabled to fulfill a double function. Thus, the spring tongue can preload or load the arresting part in one direction, for example in order to arrest the arresting part on the engagement element. The at least one entrainer arm, which is also a part of the spring element, can be utilized for the purpose of releasing, with the corresponding movement or swiveling of the spring element, the arresting part from the engagement element. Thereby that the spring element fulfills both functions overall a very simple structure results. By using the spring element, in addition, tolerance differences in the several parts are well compensated.
[0007] Especially preferred physical forms provide in these terms that the spring element is implemented in one piece, preferably as a reformed sheet metal part. The spring tongue can be a leaf spring. The entrainer arm or arms can also be resilient in order to facilitate assembly in preferred physical forms. The entrainer arms can be disposed opposingly such that between them the arresting part can be disposed. Further preferred physical forms of the invention provide that the spring element comprises a receptor cavity, partially encompassed by walls of the spring element, for receiving at least a portion of the arresting part. The arresting part can in this case at least partially be disposed in the receptor cavity partially encompassed by walls of the spring element.
[0008] Apart from the spring element per se, the invention also relates to a configuration with at least one such spring element and with at least one arresting part. In such a configuration, it is in particular provided that the arresting part comprises at least one stop region for the abutment of the entrainer arm or arms on the stop region. The stop region can be a portion of a delimitation of an elongated hole. The spring tongue and the entrainer arm or the spring tongue and the entrainer arms can engage on it at different sides of the arresting part.
[0009] Especially preferred physical forms of the invention provide that the spring tongue spring loads the arresting part in all operating positions. Consequently, in such physical forms, a continuous action of the spring tongue onto the arresting part is provided. When the arresting part is in engagement with the engagement element, the spring tongue presses the arresting part securely on or into the engagement element. If, on the other hand, the arresting part is located with its stop region on the entrainer arm or arms, the spring tongue presses the arresting part against the entrainer arm or arms. The arresting part is preloaded in both cases such that an undesirable clattering of the arresting part cannot occur.
[0010] To dampen vibrations and/or noises, it can be provided to form the spring element such that it is realized completely or at certain surface regions with a cushioning cover or to dispose cushioning on the spring element.
[0011] The configuration according to the invention advantageously comprises in addition at least one bolt. This can be, for example, a clamp bolt known per se of a securement device or energy absorption device of a steering column. Advantageous physical forms provide that the spring element is secured on the bolt, preferably under form closure, by means of the securement part such that it is nonturnable relative to the bolt. The bolt can be guided through a bolt receptor opening of the arresting part. In terms of simple assembly of the spring element and the arresting part on the bolt, preferred physical forms provide that the securement part of the spring element and/or the bolt receptor opening comprise an outwardly open plug-in opening. By means of the particular plug-in opening, the spring element and arresting part can optionally jointly be slid, preferably snapped, onto the bolt in a direction orthogonally to the bolt longitudinal axis.
[0012] The bolt receptor opening in the arresting part is advantageously implemented such that the bolt can be rotated, preferably over 360° and more, stop-free in the bolt receptor opening of the arresting part. To this end, the bolt receptor opening, optionally except for the plug-in opening, can have, for example, a circular cross section. Especially preferred physical forms of the invention provide that a rotational movement of the bolt into a first direction is transmittable exclusively by means of the spring tongue onto the arresting part, and a rotational movement of the bolt into a second direction opposite to the first direction is exclusively transmittable by means of the entrainer arm or arms onto the arresting part. The rotational movement herein does not need to be transmitted completely from the spring element onto the arresting part. It is frequently preferred that during a turning of the bolt from its one end position into its other end position of the arresting part comes out of engagement with the engagement element only shortly before reaching the one end position. It can also be desirable to bring about the engagement of the arresting part into the engagement part only shortly before reaching the other end position of the bolt. It is further conceivable and feasible that the bolt, for example in the realization as a clamp bolt, for opening and closing the fixing system of a steering column must be turned about another angular range than is required or desired for the turning of the arresting part between the arresting and the non-arresting position.
[0013] The invention also relates to a steering column for a motor vehicle, which comprises at least one first structural part and at least one second structural part. The structural parts are movable relative to one another at least in one operating state of the steering column, and the structural parts are secured or are securable on one another via a securement device and/or an energy absorption device. The steering column is characterized thereby that the securement device and/or the energy absorption device comprise or comprises at least a spring element according to the invention or at least one configuration according to the invention.
[0014] One of these structural parts of the steering column can be, for example, a steering spindle bearing unit in which the steering spindle, on which the steering wheel is secured, is rotatably supported. The other of the structural parts of the steering column can be, for example, a so-called bracket unit which is fixed on the motor vehicle itself. Steering columns with two structural parts movable, preferably displaceable, relative to one another are known per se as adjustable steering columns in numerous physical forms within prior art. By displacing the two structural parts, thus for example steering spindle bearing unit and bracket unit relative to one another, the position of the steering wheel can be adapted to the driver. A securement device of the steering column herein comprises at least one position in which the two structural parts can be moved relative to one another for the displacement. The securement device comprises further at least one second position in which the structural parts are fixed relative to one another in their position under form and/or friction closure. It is further known in prior art to provide in steering columns so-called energy absorption devices. These serve the purpose of avoiding in the event of a crash as much as possible an injury of the driver through the impact of the driver onto the steering wheel if the motor vehicle impacts onto an obstacle. Generic energy absorption devices known per se serve for the purpose of the two structural parts of the steering column to be shifted relative to one another under defined conditions in order to absorb the energies occurring during the impact of the driver onto the steering wheel in a manner noninjurious to the driver. The securement devices and energy absorption devices can be integrated as one device. However, they can also be realized as devices separate from one another. The concept according to the invention now comprises equipping such securement devices and/or energy absorption devices of a steering column with a spring element according to the invention or a configuration according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the following description of the Figures, the embodiments selected as examples are described, wherein preferred physical forms and characteristics of the invention are evident.
[0016] FIG. 1 shows a first embodiment according to the invention of a steering column for a motor vehicle, in which a corresponding configuration of spring element, arresting part and bolt are employed;
[0017] FIG. 2 shows a detail depiction from FIG. 1 in the region of the configuration of the spring element, arresting part and bolt;
[0018] FIGS. 3-5 show select structural parts of this first embodiment, detached from the remainder of the steering column;
[0019] FIG. 6 shows a depiction analogous to FIGS. 3-5 with an alternative embodiment form of the spring element;
[0020] FIGS. 7 and 8 show partially cut depictions related to the first embodiment;
[0021] FIGS. 9-11 show depictions of parts of a second embodiment according to the invention;
[0022] FIG. 12 shows a detail of a third embodiment according to the invention;
[0023] FIGS. 13 and 14 show alternative physical forms of an arresting part;
[0024] FIG. 14 a shows an alternative variant of the spring element, such as can be employed, for example, in an arresting part according to FIG. 14 ;
[0025] FIGS. 15 and 16 show the arresting part from FIG. 13 with superjacent spring element;
[0026] FIG. 17 shows a further embodiment according to the invention;
[0027] FIGS. 18-21 show several physical forms of suitable bending and tearing tabs;
[0028] FIGS. 22 and 23 shows examples of alternative implementations of the bending or tearing tabs in cooperation with the arresting part and the spring element;
[0029] FIGS. 24 and 25 shows examples of the form of the recess and of an arresting tooth; and
[0030] FIGS. 26 and 27 shows examples of a spring element with cushioning.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Similar or identically acting elements are denoted in the Figures by the same reference numbers.
[0032] The steering column 4 depicted in FIG. 1 is equipped with a configuration realized according to the invention comprising a spring element 1 , an arresting part 3 and a bolt 6 . Before discussing these details essential to the invention, first, the structure known per se of the steering column 4 will be briefly described. The steering column 4 comprises as a second structural part 15 a bracket unit provided for securing the steering column 4 on the motor vehicle. The second structural part 15 comprises for this purpose securement plates 17 . The first structural part 14 of the depicted steering column 4 is a steering spindle bearing unit in which the steering spindle 16 is rotatably bearing supported. In this embodiment, between the first structural part 14 and the second structural part 15 is disposed an intermediate part 25 as is known per se. The second structural part 15 realized as a bracket unit comprises two side jaws 26 , between which the steering spindle bearing unit 14 in the form of the first structural part 14 is fixed, together with the intermediate part 25 , in its position when the securement device 20 is in its closed position. In the opened position of the securement device 20 the position of the first structural part 14 , in the form of the steering spindle bearing unit, can be displaced relative to the second structural part 15 , thus to the bracket unit. As is known per se, the securement device 20 comprises a bolt 6 realized as a clamp bolt. On this bolt a cam disk 18 and a cam follower disk 19 are located. The cam follower disk 19 is secured on the side jaw 26 such that it is torsion-tight. The cam disk 18 is fixed on bolt 6 such that it is perforce turned simultaneously with it. Through the turning of the bolt 6 the securement device 20 can be brought into the opened position as well as also into the closed position. This is known per se and does not require further explanation. To turn the bolt 6 about its longitudinal axis, a motor or the like can be provided. In simple physical forms, for this purpose on bolt 6 , (while not shown in FIG. 1 , but shown in FIGS. 7 and 8 ), a manually actuatable lever 33 can be provided. If the securement device 20 is in its opened position, the first structural part 14 can be shifted relative to the second structural part 15 , whereby the bolt 6 is simultaneously also shifted in the elongated holes 38 of the side jaws 26 . In the depicted embodiment, by means of the securement device 20 in its closed position for the arresting of the height adjustment a form closure is established between the toothings visible on the side jaw. The length adjustment is arrested by means of a friction or force closure between the side jaws. However, the securement device 20 can equally well also be realized such that it acts exclusively under friction or force closure or exclusively under form closure or it can combine friction and form closure. The steering column can also be adjustable in one direction only.
[0033] In order to be able to absorb specifically the energy introduced into the steering column 4 in the event of a crash through the impact of the driver onto the steering wheel or the steering spindle 16 , the present first embodiment comprises, in addition to the securement device 20 , also an energy absorption device 21 . In the depicted embodiment, this provides a tear-bend tab 22 , which is fixed on the first structural part 14 . Alternatively, a pure bending tab or a pure tearing tab can also be provided. This fixing can be attained via the most diverse measures known within prior art. In the depicted physical form, the tear-bend tab 22 , however, comprises openings 32 , through which hooks 23 fixed on the first structural part 14 are guided. The cooperation of hooks 23 and openings 32 leads to the desired securement of the tear-bend tab 22 on the first structural part 14 . The tear-bend tab 22 comprises in the depicted embodiment a tab section 27 in which a sequence of recesses 28 is depicted. Into these recesses 28 the arresting part 3 can engage with its at least one arresting tooth 10 . The arresting part 3 can be realized as a catch, as a hook or the like. As is also realized in the depicted embodiment, the arresting part 3 is preferably disposed on the bolt 6 such that it is swivellable.
[0034] In the depicted embodiment the tab section 27 with its recesses 28 serves as an engagement element into which the arresting part 3 can engage with its arresting tooth 10 . The engagement element or the tab section 27 is herein fixed on the first structural part 14 in the described manner. Due to its bearing, the arresting part 3 is swivellably, but otherwise fixedly, secured on the bolt 6 on the second structural part, thus on the vehicle-stationary bracket unit. If, in the event of a crash, there occurs an impact of the driver on the steering wheel, not depicted here and to be attached on the mounting neck 41 of the steering spindle 16 , and therewith on the steering spindle 16 , the latter, together with the spindle bearing unit in the form of the first structural part 14 , is shifted in the longitudinal direction of the steering spindle 16 into the bracket unit in the form of the second structural part 15 . With corresponding energy introduction, the bending-over and tearing-open of the tear-bend tab 22 occurs at the attenuations 24 , since the tear-bend tab 22 , as already described, is secured, on the one hand, on the first structural part 14 and, on the other hand, via the arresting part 3 also on the second structural part 15 . A stop 42 can herein be provided which delimits the displacement in the longitudinal axis and which breaks away after a predefined force has been exceeded, and therewith enables further dislocation during which the energy absorption takes place via the tear-bend tab 22 .
[0035] Regarding the physical form of the tear-bend tab 22 it should be noted that through a realization of the tab in which the tab is torn open along the attenuation 24 the tear-bend tab 22 is converted in simple manner into a pure bending tab 22 a while maintaining the same formation. It is in any event also advantageous for a connection region to remain between the tab section and the holding region in which the openings 32 are located for receiving the hooks 23 .
[0036] The fundamental structure is known per se and disclosed, for example, in WO 2009/121 386 A1 and can be realized in many diverse physical forms. With respect to the configuration realized according to the invention of spring element 1 , arresting part 3 and bolt 6 of the first embodiment, reference is now made to FIGS. 3 to 6 . The configuration can be better visualized here since other structural parts of the steering column 1 are not shown in FIGS. 3 and 4 , and in FIGS. 5 and 6 additionally only the tear-bend tab 22 is depicted. The spring element 1 comprises the securement part 5 , the spring tongue 2 and, additionally in the depicted embodiment, two entrainer arms 7 . In the proximity of the securement part 5 between walls of the spring element 1 or securement part 5 a receptor cavity 8 is formed in which a portion of the arresting part 3 is disposed in the assembled state according to the Figures. The spring tongue 2 advantageously comprises, as is also realized in the embodiment depicted here, a rounded press-on section 40 . This ensures in every position an optimal force introduction from the spring tongue 2 into the arresting part 3 . The securement part 5 of the spring element 1 comprises recesses realized such that after the securement part is placed on the bolt 6 , this element is held via form closures 29 nonturnably on the bolt 6 . This means that every rotational movement of the bolt 6 about its longitudinal axis is perforce also simultaneously carried out by the spring element 1 . The form closure 29 is advantageously realized such that the spring element 1 can be placed onto the bolt 6 from a direction orthogonal to the longitudinal direction of bolt 6 . For this purpose the securement part 5 comprises, for one, the plug-in opening 35 . For another, the walls of spring element 1 forming the form closure on the side of the securement part are advantageously realized such that, with respect to one another, they extend parallel or in the shape of a U or V. It is understood that a corresponding form closure can also be realized through other physical forms. The spring tongue 2 , which in the depicted embodiment is realized as a leaf spring, advantageously presses continuously onto the arresting part 3 . In the position depicted in FIGS. 5 , 6 , and 8 this leads to the arresting tooth 10 of the arresting part 3 being pressed against the engagement element or the tab section 27 . If the tear-bend tab 22 and the arresting tooth 10 are oriented appropriately with respect to one another, this leads to the arresting tooth 10 being pressed into one of the recesses 28 . However, it may also occur that the arresting tooth 10 comes to lie on an intermediate web between two adjacent recesses 28 . If this is the case, the arresting tooth 10 in the event of a crash initially slides over this intermediate web and subsequently, due to its spring loading by means of the spring tongue 2 , snaps into the next recess 28 . In the final analysis, in both cases the arresting of the tab section 27 occurs via the arresting part 3 on bolt 6 and therewith on the second structural part 15 . If a displacement of the two structural parts 14 and 15 is to be carried out, then in the first embodiment the manually actuated lever 33 is swiveled into the position according to FIG. 7 . The securement device 20 hereby comes into the opened position. During this swivel or rotational movement of the bolt 6 about its longitudinal axis, it also entrains spring element 1 via the form closure 29 . Starting at a certain swivel angle, the abutment of the entrainer arms 7 on the stop region 9 of the arresting part 3 occurs, which raises the arresting tooth 10 from the tab section 27 . In preferred physical forms in this position according to FIG. 7 it is still provided that the spring tongue 2 spring-loads the arresting part 3 and presses it against the entrainer arms 7 . This prevents clattering of the arresting part 3 on the bolt from occurring. In the first embodiment the stop region 9 is realized as a delimitation of an elongated hole 31 in the arresting part 3 . However, such does not need to be the case, as the following embodiments will show.
[0037] For the sake of completeness, reference is made to the fact that on the arresting part 3 and engagement element, instead of the arresting tooth 10 and the recesses 28 , other projections, structural parts or other elements can also be disposed with which the arresting part 3 and the engagement element, here the tab section 27 , come into engagement with one another.
[0038] In the first embodiment, as can be seen in FIG. 4 , the bolt receptor opening 11 in the arresting part 3 is realized as a completely circular hole. As a consequence the arresting part 3 , if no spring element 1 is emplaced, can be freely rotated over more than 360° on the bolt 6 . For another, the consequence is that the arresting part 3 of this first embodiment must be slid onto the bolt 6 in its longitudinal direction. Assembling the spring element 1 can take place by emplacing it from a direction orthogonal to the longitudinal direction of the bolt. For this purpose the entrainer arms 7 are advantageously implemented such that they are resilient such that when they are placed onto the arresting part 3 with their hook-shaped extensions 30 they are initially flexed apart and subsequently snap resiliently into the elongated hole 31 in the arresting part 3 . It would alternatively also be feasible to bend the entrainer arms 7 initially appropriately far apart and subsequently bend them toward one another such that they or their hook-shaped extensions 30 engage into the elongated hole 31 .
[0039] Through the described physical form of spring element 1 and arresting part 3 it is in any event ensured in the first as well as also in the other embodiments that a rotational movement of the bolt 6 into a first direction 12 is exclusively transmittable by the spring tongue 2 onto the arresting part 3 , and a rotational movement of the bolt 6 into a second direction 13 opposite the first direction is transmittable exclusively by means of the entrainer arms 7 onto the arresting part 3 .
[0040] In FIG. 6 an alternative embodiment form of the spring element 1 is exemplified, in which the rounded press-on section 40 of the spring tongue 2 is oriented in the direction of the bolt 6 . Thereby a prestress in the direction of bolt 6 is effected which can fulfill additional functions.
[0041] In FIGS. 26 and 27 a spring element with a cushioning is exemplified. In FIG. 26 on the hook-shaped extension is disposed a cushioning element 47 for cushioning the contact with the stop region 9 of the arresting part 3 . The cushion is preferably formed of rubber or a synthetic material. In FIG. 27 the hook-shaped region is coated with a cushioning layer 48 which, again, is preferably comprised of synthetic material or rubber. The cushioning layer 48 can be applied onto the desired regions of the spring element 1 in simple manner by immersion. The cushioning can alternatively also be disposed on the arresting part 3 in the stop region 9 or on another suitable site.
[0042] With reference to FIGS. 9 to 11 , a second embodiment according to the invention will be described. The structural parts of the steering column 4 not depicted in these Figures can be realized, for example, as in the first embodiment. The essential difference of this second embodiment is to be seen in the implementation of the arresting part 3 . The arresting part 3 does not comprise an elongated hole 31 here, but rather only a single web-like projecting stop region 9 , on which the entrainer arms 7 or their hook-shaped extensions 30 can abut in order to raise the arresting part 3 from the tab section 27 . The arresting tooth 10 of the arresting part 3 is here also realized as in the first embodiment in the form of a bar. The longitudinal extent of the bar-shaped implementation form extends parallel to the swivel axis through the bolt receptor opening 11 .
[0043] In the first embodiments according to FIGS. 1 to 11 the configuration of spring element 1 , arresting part 3 and bolt 6 forms a portion of the energy absorption device 21 . FIG. 12 shows a steering column 4 realized according to the invention in which the energy absorption device 21 was omitted. Here, the configuration of spring element 1 , arresting part 3 and bolt 6 forms a portion of the securement device 20 . This is attained in the depicted embodiment thereby that the tab section 27 ′ is fixedly secured on the first structural part 14 . This can be achieved through welding or other securement measures. In the depicted embodiment the securement of the tab section 27 ′ on structural part 14 takes place inter alia by means of a rivet 34 . It is alternatively also conceivable and feasible to integrate the recesses 28 directly into the first structural part 14 . The recesses can also be replaced by projections which cooperate with the arresting tooth 10 for the formation of the form closure. In such embodiments the arresting part 3 can be employed, for example, for the purpose of ensuring at opened securement device 20 that the structural part 14 can be displaced orthogonally to its longitudinal direction, not however in its longitudinal direction relative to the second structural part 15 . However, this should only be considered an example.
[0044] FIG. 13 shows a further embodiment of an arresting part 3 . The bolt receptor opening 11 of the arresting part 3 comprises an outwardly open plug-in opening 35 . This permits emplacing the configuration of spring element 1 and arresting part 3 jointly from a direction orthogonal to the longitudinal axis of the bolt onto the latter which enables an especially simple assembly. The FIGS. 15 and 16 show a configuration of spring element 1 and arresting part 3 according to FIG. 13 in views from different directions. In the view from behind according to FIG. 16 the two centering jaws 39 disposed on the spring element 1 can be seen which ensure that the arresting part 3 cannot become canted in the receptor cavity 8 . Corresponding centering jaws 39 can be realized in every physical form of a spring element 1 shown.
[0045] In FIG. 14 is shown an embodiment of an arresting part which illustrates that the arresting part can comprise at least two arresting teeth which are spaced at different distances from the securement device of the spring element and preferably, as also realized here, are implemented in the shape of a bar. In the example according to FIG. 14 the arresting part 3 comprises precisely three arresting teeth 10 . All three arresting teeth 10 are realized in the form of a bar, the longitudinal extent of the bar-shaped realizations each extending parallel to the swivel axis. The utilization of several arresting teeth 10 enables the same arresting part 3 to be applied for differently thick tab sections 27 or engagement elements. It is also feasible to provide several arresting teeth 10 in order to effect redundancy of the form-closure connection if, for example in the event of a crash, an intermediate web of the tap section 27 or an arresting tooth 10 is so deformed that it no longer holds. The embodiment according to FIG. 14 also comprises a bolt receptor opening 11 with an outwardly open plug-in opening 35 such that this arresting part 3 can be plugged onto the bolt 6 from a direction orthogonal to the longitudinal axis of same.
[0046] FIG. 14 a shows a spring element 1 in particular suitable for the arresting part 3 according to FIG. 14 . This spring element 1 differs in terms of realization of the rounded press-on section 40 of the spring tongue 2 from the previously described spring element 1 . In FIG. 14 a , this rounded press-on section 40 is realized in a region of the spring tongue 2 bent away at an angle in the direction toward the securement part 5 . This results in the formation of a force component onto the arresting part 3 which presses the arresting part 3 onto the bolt 6 disposed in the bolt receptor opening 11 .
[0047] In particular through this realization, the arresting part 3 is able to shift with its bolt receptor opening 11 with respect to the bolt 6 such that bolt 6 is positioned shifted with respect to the arresting part 3 in the direction of, with respect to the arresting part 3 , the plug-in opening 35 . Due to the prestress, the spring tongue 2 ensures with the press-on section 40 the secure engagement of the arresting tooth or teeth into the recesses 28 . Such a shift can be expedient in order to effect a “deeper incarving” of the arresting tooth or teeth when moving the steering spindle 16 with respect to the bracket, the second structural part 15 . Through the “deeper incarving” or the cut-back, the form closure can be improved or maintained even at incipient deformation of the recesses 28 in the tab section. The shifting can also serve for a tolerance compensation and enable employing tabs 27 of different thicknesses at otherwise identical structural parts, as can be expedient for different motor vehicle constructions.
[0048] Further improvement of the form closure between the arresting part 3 and the engagement element can be attained through the improved form of that region of the energy absorption device 21 in which the recesses 28 for the engagement of the arresting part 3 are located. Examples thereof are illustrated in FIGS. 22 and 23 . It is conceivable and feasible to crimp over the tab 27 and herein to return it as tab 43 approximately congruently with tab 27 . In this tab section 43 are also introduced recesses approximately correspondingly or approximately congruently to the recesses 28 . The one arresting tooth 10 or the several arresting teeth 10 on arresting part 3 are preferably longer in order to be able to engage into corresponding recesses 28 of tab 27 and the tab 43 . In this manner it becomes feasible to increase the force of resistance against the deformation of the recesses.
[0049] Alternatively to an integral, one-piece embodiment, the tab section 27 can be reinforced through a second separately implemented tab 44 . The tab 44 is disposed approximately congruently with the tab section 27 and comprises corresponding recesses disposed approximately congruently with recesses 28 . Here also arresting teeth 10 are preferably correspondingly longer. The connection between the two tabs 27 , 44 can be established by welding, riveting, adhesion or other means. The rivet can even be guided through one of the recesses 28 in both tabs 27 , 44 in order to effect the connection. The rivet can be implemented of a synthetic material.
[0050] For increasing the force of resistance against a deformation of the recesses 28 , it is further conceivable and feasible to implement these with a special cross sectional form. In FIG. 24 a top view onto the tab section 27 with the recesses 28 is shown. The recesses 28 have a rectangular basic form which have in the proximity of the center axis 45 of the tab section 27 an arcuate narrowing. This means one or several corners of the rectangular cross section are not connected with one another by a straight line but rather by an arcuate line, the distance of the arcuate line from the imaginary straight line between the particular corners increases toward the center axis line 45 . The webs 46 between the recesses 28 are thereby reinforced and offer a greater force of resistance against deformation. It suffices correspondingly to reinforce (=provision with corresponding arcuate form) only that side of the recess in the direction of which the resistance force against a dislocation in the arrested state must be absorbed. The arcuate form is mathematically preferably describable through a quadratic polynomial. The recesses are further preferably rounded in the corners in order to decrease stress concentration.
[0051] It is further conceivable and feasible to adapt the tooth form of the one arresting tooth 10 or the several arresting teeth 10 to the form of the recess 28 . The tooth can in particular have an outer form corresponding (quasi identical) to the inner form of the recess, as is depicted in FIG. 25 .
[0052] In all of the embodiments depicted here the spring element 1 is implemented integrally in one piece as a reformed metal sheet part.
[0053] FIG. 17 shows a detail from a further steering column 4 implemented according to the invention. The configuration of spring element 1 and arresting part 3 as well as bolt 6 corresponds to the first embodiment and does not need to be discussed again. The same applies to numerous further components of the steering column 4 . The difference from the previously depicted embodiments lies essentially in the type of energy absorption. Thus, the engagement element in the form of the tab section 27 in the embodiment according to FIG. 17 is not a part of a tear-bend tab. The tab section 27 , rather, comprises a deformation bolt 36 which penetrates an elongated hole 37 disposed in the spindle bearing unit or in the first structural part 14 . The gap between the side walls delimiting the elongated hole 37 , into which the deformation bolt 36 engages, is so narrow that a dislocation of the tab section 27 against the first structural part 14 or the steering spindle bearing unit is only possible by the deformation bolt 36 widening the elongated hole 37 . In the event of a crash, energy is hereby absorbed in the desired manner. The form of the elongated hole 37 or the thickness of the delimiting walls can be varied in order to attain a desired energy absorption profile.
[0054] FIGS. 18 to 21 show additionally different physical forms of bending or tear-bend tabs, as these can be utilized alternatively in the previously depicted physical forms of steering columns 4 . In FIG. 18 this is a pure bending tab 22 a . In FIGS. 19 and 20 these are tear-bend tabs 22 in which the tab is initially only bent over until subsequently tearing along the attenuations 24 occurs with the simultaneous recurving. In FIG. 21 the tearing of the attenuations 24 starts after a relatively short path of pure recurving.
[0055] Using two tabs disposed next to each other as examples, FIG. 20 illustrates that it is feasible to dispose several tabs, such as bending tabs, tearing tabs and/or tear-bend tabs, etc., next to one another as energy absorption element.
[0056] To the extent applicable or implementable, all of the diverse individual features of the several examples can be interchanged and/or combined among one another without leaving the scope of the invention.
LEGEND TO THE REFERENCE NUMBERS
[0000]
1 Spring element
2 Spring tongue
3 Arresting part
4 Steering column
5 Securement part
6 Bolt
7 Entrainer arm
8 Receptor cavity
9 Stop region
10 Arresting tooth
11 Bolt receptor opening
12 First direction
13 Second direction
14 First structural part
15 Second structural part
16 Steering spindle
17 Securement plate
18 Cam disk
19 Cam follower disk
20 Securement device
21 Energy absorption device
22 Tear-bend tab
22 a Bending tab
23 Hook
24 Attenuation
25 Intermediate part
26 Side jaw
27 , 27 ′ Tab section
28 Recess
29 Form closure
30 Hook-shaped extension
31 Elongated hole
32 Opening
33 Lever
34 Rivet
35 Plug-in opening
36 Deformation bolt
37 Elongated hole
38 Elongated hole
39 Centering jaws
40 Rounded press-on section
41 Mounting neck
42 Stop
43 Tab section
44 Strip
45 Center line
46 Web
47 Cushioning element
48 Coating
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The invention relates to a spring element including at least one spring tongue for spring-loading a separate locking part of a steering column of a motor vehicle and at least one fastening part for fastening the spring element to a pin of the steering column. The spring element also has at least one carrier arm, preferably at least two carrier arms, arranged opposite each other for carrying along the locking part when the spring element moves.
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FIELD OF THE INVENTION
[0001] This invention relates to a new and improved linear hydraulic drive system for use with a Stirling engine.
BACKGROUND PRIOR ART
[0002] Resonant free piston Stirling engine systems are known in the art wherein the load apparatus is hydraulically driven from the periodic pressure wave of the engine. In such known systems the load apparatus is typically disposed within an incompressible fluid-filled space between a pair of flexible diaphragms which seal in and isolate the incompressible fluid, referred to herein as “hydraulic fluid”, from the Stirling Engine. One of the diaphragms is arranged to be acted on by the resulting pressure wave produced in the hydraulic oil and the other diaphragm is arranged as part of a gas spring. The pressure waves produced in the hydraulic oil are operative to reciprocally drive the movable member of the load apparatus in a direction along the same axis as that of the Stirling Engine. Such prior art engine-driven system assemblies were arranged in a stacked, coaxial relationship. While generally satisfactory, the diaphragms employed dramatically limited the useful life of such a device before maintenance was required. Other prior art arrangements had the load components immersed in the hydraulic oil making maintenance, service and repair difficult and expensive.
SUMMARY OF THE INVENTION
[0003] The hydraulic drive system of the instant invention is arranged and constructed to operate from the periodic pressure wave of the Stirling engine to pump the hydraulic fluid through a loop wherein a piston or motor drive is deployed to covert the hydraulic fluid flow to linear or rotary motion. In one embodiment, the hydraulic fluid is acted upon directly by the periodic pressure wave produced by the Stirling Engine. Alternately, the heat engine or Stirling engine may produce mechanical or electrical power that is used to power the hydraulic output system.
[0004] While the new and improved hydraulic power output and pump system of this invention is capable of use with a Stirling engine, it can be equally well applied in systems wherein fuel explosions or other periodic pressure pulses are available to provide the motive force. Also, while the invention will generally be described in connection with a hydraulic motor, it is understood that the invention could also be applied to compressors, pumps, pistons, linear alternators, and other like load apparatus.
[0005] In accordance with the instant invention, there is provided a new and improved hydraulic drive system for use with a Stirling engine which reduces the length of the engine-drive assembly.
[0006] In accordance with the instant invention, there is also provided a hydraulic drive system for use with a Stirling engine wherein the hydraulic oil is positively displaced so as to provide compact, light-weight drive means consisting of few components which can directly provide power to conventional pistons, hydraulic motors, or other like loads.
[0007] In accordance with the instant invention, there is also provided a hydraulic drive system for use with a Stirling engine which can be readily pressurized to 100 atm for use with a Stirling engine similarly pressurized so as to provide a very high specific power per unit weight and per unit volume in a compact, light-weight drive means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] These and other advantages of the instant invention will be more fully and particularly understood in connection with the following description of the preferred embodiments of the invention in which:
[0009] FIG. 1 is a cross section of a heat engine and a hydraulic drive system according to the instant invention;
[0010] FIG. 2 is a three dimension sketch of a hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the pump employs a tangential inflow and a tangential outflow design;
[0011] FIG. 3 is a three dimension sketch of a hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the pump employs a tangential inflow and bottom outflow design;
[0012] FIG. 4 is a three dimension sketch of a hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the pump employs a bottom inlet through a three dimension elbow and a tangential outflow design; and,
[0013] FIG. 5 is a schematic drawing of an alternate embosiment of a heat engine and a hydraulic drive system according to the instant invention
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The preferred embodiment of the invention is shown in FIG. 1 . A shroud 11 covers a series of louvred fins 1 which transfer heat from the hot combustion gasses 2 to the heat engine wall 5 and into the louvred fins 6 within the engine which in turn transfer the heat to the working fluid 7 . In addition, the hot combustion gasses 2 transfer heat to the upper end-cap 8 which in turn transfers this heat to the working fluid 7 within the engine. The hot combustion gasses are produced by the flame 3 which is fed by the gas ring burner 4 . The hot combustion gasses exit the system through the chimney 9 . In addition, radiation transfers heat from the flame 3 to the louvred fins 1 . The shroud 11 is supported by a series of louvred fins 12 which are in turn supported by an outer cover 13 . The louvred fins 12 act as a pre-heater for the combustion gasses thereby improving the burner efficiency and also act to support the heated section of the heat engine wall 5 which is weakened due to its heating. The outer cover 13 is substantially colder than the heat engine wall 5 and the louvred fins 12 and 1 serve to mechanically translate the support offered by the outer cover 13 to the heat engine wall 5 . Thus, a cooler metal serves to support the hotter wall. The louvred fins 14 serve as the regenerator section of the heat engine while the louvred fins 15 serve to remove heat from the working fluid and transfer it through the cold section of the heat engine wall 16 and into the hydraulic fluid 40 . It will be appreciated that other construction for a heat engine may be used with the hydraulic drive described hereafter.
[0015] The displacer 19 is supported by a shaft 20 which is supported by member 21 and is attached to an eccentric drive 18 which is mounted on an electric motor 37 which is immersed in the hydraulic fluid 40 within the main pump chamber 34 whereby eliminating the need for a pressure seal within the displacer drive system.
[0016] When the engine is hot and the displacer 19 moves to its bottom dead centre position the working fluid 7 expands thereby exerting pressure on the hydraulic fluid 40 within the main pump chamber 34 . The hydraulic fluid 40 begins to flow in response to this pressure. The hydraulic fluid 40 flows through the pipe 38 through the one way check valve 39 through pipe 22 through the heat exchanger 23 through pipe 24 into accumulator 25 through pipe 26 and through the motor 27 (which provides useful work—i.e. the output to a load) through pipe 28 into accumulator 29 through pipe 30 through check valve 31 through pipe 32 through the cooling section 17 and through pipe 33 back into the main pump chamber 34 .
[0017] The accumulator 29 maintains a pressure greater than the engine buffer pressure so that when the displacer travels to the top dead centre and the pressure within the engine is reduced to the buffer pressure, the hydraulic fluid 20 can flow through pipe 30 through check valve 31 through pipe 32 through the cooling section 17 and through pipe 33 back into the main pump chamber 34 to refill the main pump chamber 34 in preparation for the next cycle. The size of the reservoirs 25 and 29 and of the entire hydraulic piping must be sufficient to allow the rate of flow required to deliver the power output from the engine to the motor 27 . One major advantage of this system is that the accumulators 25 and 29 and the working fluid 7 can all be pre-pressurized to a high pressure thereby yielding a very high specific power output for a small engine. The hydraulic fluid may be an oil or an aqueous fluid. If the hydraulic fluid is an oil, then the preferred hydraulic oil is silicone oil. If the hydraulic fluid is aqueous, then the preferred hydraulic fluid comprises water, an antifreeze and a corrosion inhibitor. In some applications, the aqueous hydraulic fluid may be buffered.
[0018] Optional floating splash guard 35 minimizes splash within the engine. The member 21 also serves to trap a small amount of gas in a head space above the hydraulic fluid thereby ensuring that the fluid level can never rise above member 21 . Alternatively, a float mechanism may be employed to limit the amount of hydraulic fluid which will flow in during the refilling cycle although the buffer pressure should control this as well.
[0019] An embodiment for the hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the hydraulic pump employs a tangential inflow and a tangential outflow design is shown in FIG. 2 . In this embodiment the fluid to be pumped 40 enters the pump housing 45 through tangential inlet 41 and follows a spiral path 42 to the tangential outlet 43 where the fluid 44 exits the pump. A check valve (not shown) may be used at one or both of the inlet 41 and the outlet 44 to maintain unidirectional flow within the pump.
[0020] An embodiment for the hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the hydraulic pump employs a tangential inflow and an axial outflow design is shown in FIG. 3 . In this embodiment the fluid to be pumped 46 enters the pump housing 51 through tangential inlet 47 and follows a spiral path 48 to the bottom outlet 49 where the fluid 50 exits the pump. A check valve (not shown) may be used at one or both of the inlet 47 and the outlet 49 to maintain unidirectional flow within the pump.
[0021] An embodiment for the hydraulic pump to be driven by a periodic pressure pulse source such as a Stirling engine wherein the hydraulic pump employs an axial inflow and a tangential outflow design is shown in FIG. 4 . In this embodiment the fluid to be pumped 52 enters the pump housing 58 through a bottom inlet 53 and through a three dimensional elbow 54 which sets the flow onto a spiral path 55 to the tangential outlet 56 where the fluid 57 exits the pump. A check valve (not shown) may be used at one or both of the inlet 53 and the outlet 56 to maintain unidirectional flow within the pump.
[0022] In the alternate embodiment of FIG. 5 , a hydraulic power deliver system utilizes mechanical energy output from a heat engine. As shown therein, a heat engine 60 , which may the same or different to the heat engine shown in FIG. 1 , has a linear to rotary converter. Linear to a rotary converter may be provided integrally with heat engine 60 . For example, as shown in FIG. 5 , linear to rotary converter is designated by reference numeral 62 and is enclosed in container 64 which may be the outer shell of heat engine 60 . Mechanical energy from linear to rotary converter 62 is supplied by output shaft 66 which is drivingly connected to pump 68 . Output shaft may be directly drivingly coupled to pump 68 or, alternately, it may be indirectly coupled such as through a transmission or other power regulation means. In a further alternate embodiment, heat engine 60 may include a linear generator (e.g. the power piston of heat engine 60 may comprise a portion of a linear generator). In such a case, heat engine 60 would produce electricity which could be used to power pump 68 .
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A heat engine has a region within which a working fluid travels and an hydraulic fluid provided in a reservoir and the output from the heat engine drives the movement of the hydraulic fluid.
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TECHNICAL FIELD
[0001] The invention relates to an electro-hydraulic control system for a transmission; specifically, an electro-hydraulic control system having multiplexed trim valves that is preferably for a countershaft transmission.
BACKGROUND OF THE INVENTION
[0002] Multi-speed power transmissions, particularly those using planetary gear arrangements, require a hydraulic system to provide controlled engagement and disengagement, on a desired schedule, of the clutches and brakes or torque-transmitting mechanisms that operate to establish the ratios within the planetary gear arrangement.
[0003] These control systems have evolved from substantially pure hydraulic control systems, wherein all of the control signals are produced by hydraulic devices, to electro-hydraulic control systems, wherein a number of the control signals are produced by an electronic controller. The electronic controller emits electrical control signals to solenoid valves, which then issue controlled hydraulic signals to the various operating valves within the transmission control.
[0004] With many of the early pure hydraulic and first generation electro-hydraulic control systems, the power transmission utilized a number of freewheel or one-way devices which smooth the shifting or ratio interchange of the transmission during both upshifting and downshifting of the transmission. This relieves the hydraulic control system from providing for the control of overlap between the torque-transmitting mechanism that was coming on and the torque-transmitting mechanism that was going off. If this overlap is excessive, the driver feels a shudder in the drivetrain, and if the overlap is too little, the driver experiences engine flare or a sense of coasting. The freewheel device prevents this feeling by quickly engaging when the torque imposed thereon is reversed from a freewheeling state to a transmitting state
[0005] The advent of electro-hydraulic devices gave rise to what is known as clutch-to-clutch shift arrangements to reduce the complexity of the transmission and the control. These electro-hydraulic control mechanisms are generally perceived to reduce cost and reduce the space required for the control mechanism.
[0006] In addition, with the advent of more sophisticated control mechanisms, the power transmissions have advanced from two-speed or three-speed transmissions to five-speed and six-speed transmissions. In at least one presently available six-speed transmission, just five friction devices are employed to provide six forward speeds, neutral condition, and a reverse speed.
[0007] Countershaft transmissions are often a desirable design option as they typically have low spin losses and offer wide ratio coverage. The relatively large number of clutches sometimes associated with countershaft transmissions may require double transition shifts. To reduce the number of components to the extent possible, clutches are sometimes reused in different speed ratio ranges.
[0008] It is desirable to provide drive-home capabilities within the transmission in the event that the electronic system undergoes a malfunction or discontinuance of operation. The drive-home feature of a power transmission is an important factor in that it permits the vehicle operator to return home with the vehicle so that the proper repairs can be undertaken at a repair station rather than in the field where the vehicle underwent the malfunction.
SUMMARY OF THE INVENTION
[0009] An electro-hydraulic control system is provided that uses logic valves to multiplex trim systems to more than one torque-transmitting mechanism, thereby minimizing the number of required components. Additionally, the electro-hydraulic control system preferably has more than one failure mode so that the transmission operates at a respective predetermined speed ratio in the event of an interruption in electrical power.
[0010] The electro-hydraulic control system controls the selective engagement of a plurality of torque-transmitting mechanisms in a transmission that provides multiple speed ratios. The electro-hydraulic control system has a trim valve and a logic valve that is selectively movable between a first position and a second position. The trim valve selectively communicates pressurized fluid to the logic valve. The logic valve multiplexes the trim valve by directing the pressurized fluid to a first toque-transmitting mechanism for engagement thereof when in the first position and to a second torque-transmitting mechanism for engagement thereof when in the second position. As used herein, a valve is “multiplexed” when it has more than one function, such as when it is able to at least partially control engagement of more than one torque-transmitting mechanism. Preferably, the electro-hydraulic control system has multiple logic valves each multiplexing a different trim valve to control engagement of different pairs of the torque-transmitting mechanisms.
[0011] The electro-hydraulic control system preferably includes a three position dog clutch actuator valve that controls the position of a dog clutch in the transmission. The position of two of the logic valves along with a solenoid valve may control the position of the dog clutch actuator valve, which in turn determines the position of a third of the logic valves.
[0012] Preferably, the trim valves are each part of a different trim system that also includes a solenoid valve energizable by the controller to move the trim valve, thereby permitting the flow of pressurized fluid therethrough. Some of the solenoids are normally open-type valves while others are normally closed-type valves such that the trim valves, the logic valves and the dog clutch actuator valve are positioned to establish different preferred “failure modes” in the event of an electrical power failure. The electro-hydraulic control system establishes one “failure mode” that is a speed ratio included in a first set of the speed ratios attainable by the transmission if there is an electrical power failure when the transmission is operating in any of the speed ratios in the first set, and establishes another “failure mode” that is a different speed ratio included in a second set of speed ratios attainable by the transmission if there is an electrical power failure when the transmission is operating in any of the speed ratios of the second set.
[0013] When system established the failure mode that is a speed ratio in the second set, the dog clutch actuator valve is in a neutral position which latches two of the logic valves to prevent movement thereof. Another logic valve is energizable to selectively break the latch and allow movement of these two logic valves. The latching of the logic valves X and Y provides the ability to achieve the high speed, power-off failure mode.
[0014] Preferably, the transmission is a countershaft transmission with seven torque-transmitting mechanisms, including the dog clutch, as well as a torque-converter clutch to lockup a torque converter. The electro-hydraulic control system described above controls engagement and disengagement of these torque-transmitting mechanisms to attain nine forward and at least two reverse speed ratios. (A speed ratio is also referred to herein as a speed ratio range.)
[0015] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic representation of a countershaft transmission having torque-transmitting mechanisms engaged and disengaged via an electro-hydraulic control system within the scope of the invention;
[0017] FIGS. 2A and 2B are a schematic representation of a hydraulic control portion of the electro-hydraulic control system of FIG. 1 having valves to control engagement and disengagement of the torque-transmitting mechanisms of the transmission of FIG. 1 ; and
[0018] FIG. 3 is a table indicating the state of many of the valves shown in FIGS. 2A and 2B for each speed ratio achievable by the transmission of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to the drawings, wherein like reference numbers represent the same or corresponding parts throughout the several views, there is shown in FIG. 1 a powertrain 10 . The powertrain 10 includes a power source or engine 12 , a torque converter 14 and a countershaft transmission 16 . The torque converter 14 is connected with the engine 12 and with a transmission input member 18 via a turbine 20 . Selective engagement of a torque converter clutch TCC allows the engine 12 to be directly connected with the input shaft 18 , bypassing the torque converter 14 . The input member 18 is typically a shaft, and may be referred to as an input shaft herein. The torque converter 14 includes the turbine 20 , a pump 24 and a stator 26 . The converter stator 26 is grounded to a casing 30 through a typical one-way clutch that is not shown. A damper 28 is operatively connected to the engaged torque converter clutch TCC for absorbing vibration.
[0020] The transmission 16 includes a plurality of intermeshing gears, a first countershaft 32 , a second countershaft 34 , an intermediate shaft 36 and an output member 38 , which may be a shaft. The transmission 16 further includes a plurality of torque-transmitting mechanisms, including the torque converter clutch TCC, six rotating clutches: C 1 , C 2 , C 3 , C 4 , C 5 and C 7 ; and one stationary clutch C 6 . Torque is transferred from the input member 18 to the output member 38 along various powerflow paths through the transmission 16 depending on which of the plurality of selectively engagable torque-transmitting mechanisms are engaged.
[0021] Clutch C 4 is selectively engagable to connect the input member 18 for rotation with the intermediate shaft 36 . Gear 40 rotates with the input member 18 and continuously intermeshes with gear 42 , which rotates with the second countershaft 34 . Gear 44 rotates with input member 18 and continuously intermeshes with gear 46 , which rotates with the first countershaft 32 . Gear 48 rotates with sleeve shaft 51 which is concentric with first countershaft 32 and is selectively connectable with the first countershaft 32 by engagement of clutch C 3 . Gear 48 continuously intermeshes with gear 50 , which rotates with intermediate shaft 36 . Gear 50 also continuously intermeshes with gear 52 , which rotates with sleeve shaft 53 , which is concentric with second countershaft 34 and is selectively connectable for rotation with second countershaft 34 by engagement of clutch C 5 . Gear 54 rotates with sleeve shaft 55 which is concentric with and selectively connectable for rotation with first countershaft 32 by engagement of clutch C 1 . Gear 54 continuously intermeshes with gear 56 (in a different plane than the two-dimensional schematic, as indicated by the dashed lines therebetween). Gear 56 rotates about and is selectively connectable for rotation with a sleeve shaft 57 by the positioning of a dog clutch DOG in a reverse position indicated as R. The sleeve shaft 57 is selectively connectable for rotation with the second countershaft 34 by engagement of clutch C 2 . Gear 58 rotates with the sleeve shaft 55 and continuously intermeshes with gear 60 , which rotates with the intermediate shaft 36 . Gear 60 continuously intermeshes with the gear 62 , which is selectively connectable for rotation with the sleeve shaft 57 by positioning of the dog clutch DOG in a forward position indicated by F in the FIG. 1 .
[0022] The transmission 16 further includes a planetary gear set 64 with a sun gear member 66 connected for rotation with the intermediate shaft 36 , a ring gear member 68 selectively connectable for rotation with the intermediate shaft 36 by engagement of clutch C 7 , a carrier member 70 connected for rotation with the output member 38 and rotatably supporting planet gears 72 that intermesh with both the sun gear member 66 and the ring gear member 68 . A clutch C 6 is selectively engagable to ground the ring gear member 68 to the stationary member 30 .
[0023] In a preferred embodiment, the following gear tooth counts are used: gear 40 has 39 teeth; gear 42 has 37 teeth; gear 46 has 40 teeth; gear 44 has 31 teeth; gear 48 has 34 teeth; gear 50 has 31 teeth; gear 52 has 34 teeth; gear 54 has 62 teeth; gear 56 has 46 teeth; gear 58 has 26 teeth; gear 60 has 44 teeth; gear 62 has 26 teeth; ring gear member 68 has 85 teeth and sun gear member 66 has 35 teeth. By the selective engagement of the torque-transmitting mechanisms TCC, C 1 , C 2 , C 3 , C 4 , C 5 , C 6 , C 7 and DOG according to the table of FIG. 3 , and assuming the tooth counts listed above, the following sample numerical speed ratios are attained between the input member 12 and the output member 14 for the following speed ratio ranges: second reverse speed ratio range (R 2 ): 2.18; first reverse speed ratio range (R 1 ): 7.42; first forward speed ratio (1st 7.49; second forward speed ratio (2nd): 5.51; third forward speed ratio (3rd): 4.03; fourth forward speed ratio (4th): 2.97; fifth forward speed ratio (5th): 2.18; sixth forward speed ratio (6th): 1.61; seventh forward speed ratio (7th): 1.18; eighth forward speed ratio (8th): 1.00; ninth forward speed ratio (9th): 0.87. Alternate solenoid-energizing schemes are available for the first, third, fifth and seventh speed ratio ranges with one or more of the logic valves in different positions for the same range. For example, three different alternate seventh forward speed ratios (7th′), (7th″) and (7th′″) are available by energizing solenoids associated with different ones of the logic valves X, Y, Z and W, as discussed below and indicated in FIG. 3 .
[0024] The selective engagement and disengagement of the torque-transmitting mechanisms is controlled by an electro-hydraulic control system 74 , which is shown in further detail in FIGS. 2A and 2B . The electro-hydraulic control system 74 includes an electronic controller 76 , which may be one or more control units and is referred to as ECU in FIG. 1 , as well as a hydraulic control portion 100 referred to as HYD in FIG. 1 . The electronic controller 76 is programmable to provide electrical control signals to the hydraulic control portion 100 to establish the fluid pressures that control engagement and disengagement of the torque-transmitting mechanisms TCC, C 1 , C 2 , C 3 , C 4 , C 5 , C 6 , C 7 and DOG. Electrical signals are also sent to the electronic controller 76 based on fluid pressure in the hydraulic control portion 100 to provide feedback information such as information indicative of valve positions. The locations of various pressure switches which provide such feedback are indicated as pressure switches SW 1 , SW 2 , SW 3 , SW 4 , SW 5 , SW 6 , SW 7 and SW 8 in FIGS. 2A and 2B .
[0025] Referring to FIGS. 2A and 2B , the hydraulic control portion 100 includes a main regulator valve 104 , a control regulator valve 106 , an EBF (exhaust back flow) regulator valve 108 , a converter flow valve 110 , and a lube regulator valve 112 . The main regulator valve 104 is in fluid communication with a hydraulic pump 114 , such as a variable volume pump, that draws fluid from a reservoir 116 for delivery to a main passage 118 . The control regulator valve 106 is in fluid communication with the main regulator valve 104 , and establishes a reduced control pressure within passage 117 , which is then communicated to other valves described below, depending upon their position. The EBF regulator valve 108 is operable to vent pressurized fluid within passage 117 to exhaust should an over pressurized condition occur. Pump 119 is an engine-driven pump that also draws fluid from reservoir 116 and that controls the lubrication pressure to a lubrication system 121 and provides cooling fluid to a transmission cooling system 123 .
[0026] The hydraulic control portion 100 includes many solenoid valves, such as variable pressure type solenoid valves PCS 1 , PCS 2 , PCS 3 , PCS 4 , PCS 5 , PCS 6 , and PCS 7 , and shift-type (i.e., on/off type) solenoid valves SS 1 , SS 2 and SS 3 . Each solenoid valve is in electric signal communication with the control unit 76 and is actuated upon receipt of a control signal therefrom. The solenoid valves PCS 1 , PCS 7 and PCS 5 are normally high or normally open-type solenoid valves, while the remaining solenoid valves PCS 2 , PCS 3 , PCS 4 , PCS 6 , SS 1 , SS 2 and SS 3 are normally low or normally closed-type solenoid valves. As is well known, an open solenoid valve will distribute output pressure in the absence of an electrical signal to the solenoid. As used herein, a normally high-type solenoid is energized by a control signal to be placed in and to remain in a closed position, while a normally low-type valve is energized to be placed in and to remain in a closed position.
[0027] The hydraulic control portion 100 also includes a plurality of trim valves 120 , 122 , 124 , 126 , 128 and 130 . Trim valve 120 , solenoid valve PCS 1 and a spring-biased relief valve 132 are a first trim system that, as will be further explained below, is multiplexed to control engagement and disengagement of both clutch C 1 and clutch C 4 . Trim valve 122 , solenoid valve PCS 2 and accumulator valve 134 are a second trim system that is multiplexed to control engagement and disengagement of both clutch C 2 and C 5 . Trim valve 124 , solenoid valve PCS 3 and accumulator valve 136 are a third trim system that is multiplexed to control engagement and disengagement of both clutch C 3 and C 7 (for clutch C 7 , only for some speed ratios). Trim valve 126 , solenoid valve PCS 4 , converter flow valve 110 and accumulator valve 138 are a fourth trim system that controls engagement of the torque-converter clutch TCC. Trim valve 128 , solenoid valve PCS 6 and accumulator valve 140 are a fifth trim system that controls engagement and disengagement of clutch C 6 . Trim valve 130 , solenoid valve PCS 7 and accumulator valve 142 are a sixth trim system that controls engagement of clutch C 7 in those speed ratios for which the third trim system is not controlling. For each trim system, actuation of the associated solenoid valve causes actuation of the respective trim valve and clutch (or one of the respective clutches in the case of multiplexed trim valves). Solenoid valve PCS 5 and the main regulator valve 104 control the main pressure level in main passage 118 from the pump 114 .
[0028] The hydraulic control portion 100 further includes logic valves X, Y, Z and W, and a dog clutch actuator valve 144 . Solenoid SS 1 receives an electrical control signal from the control unit 76 to actuate or shift, thereby shifting logic valve X. The position of logic valve X controls in part the position of dog clutch actuator valve 144 , as the downward shift on the logic valve X (moving from a spring-set position to a pressure-set position) caused by energizing solenoid SS 1 allows pressurized fluid provided from passage 118 in passage 143 to pass through the logic valve X into passage 146 in communication with the dog clutch actuator valve 144 . Solenoid valve SS 2 receives an electrical control signal from the control unit 76 to actuate or shift, thereby shifting logic valve Y, allowing pressurized fluid provided from passage 118 in passage 143 to pass through logic valves X and Y into outlet passage 148 in communication with dog clutch actuator valve 144 . Solenoid valve SS 3 receives an electrical control signal from the control unit 76 to actuate or shift, thereby allowing pressurized fluid from passage 164 to outlet passage 151 in communication with both logic valve W and dog clutch actuator valve 144 . The pressurized fluid in passage 151 causes the logic valve W to shift downward in FIG. 2B , allowing fluid in passage 155 to be exhausted.
[0029] The position of logic valve Z is controlled by the position of the dog clutch actuator valve 144 . (It should be appreciated that the dog clutch actuator valve 144 has two separately movable valve components, a spool valve 157 and a plug valve 159 .) Specifically, when the dog clutch actuator valve 144 is in a reverse position (as depicted in FIG. 2B ) controlled pressure fluid provided to passage 161 from passage 117 is not provided to logic valve Z through passage 163 . However, when the dog clutch actuator valve is in either the neutral position or the forward position, the controlled pressure fluid from passage 161 is provided to passage 163 through restricted passage 165 A to move the logic valve Z from a spring-set position to a pressure-set position. Restricted passage 165 B is in fluid communication with switch SW 8 and restricted passage 165 C is in fluid communication with passage 153 . Two exhaust ports. EX 1 and EX 2 , are in fluid communication with the dog clutch actuator valve 144 and two switches SW 7 and SW 8 are in communication with the valve 144 to monitor its position based on pressure readings. Pressure switch SW 7 exhausts through exhaust port EX 1 , depending on the position of the spool valve 157 . Also depending on the position of the spool valve 157 , Pressure switch SW 8 exhausts through the cavity formed by the portion of the central bore of dog clutch actuator valve 144 (which is attached to a sump), shown just below pressure switch SW 8 .
[0030] Referring to FIG. 3 , a table shows the steady-state conditions of the following valves during available speed ratios (also referred to as ranges): logic valves W, X, Y and Z, dog clutch actuator valve 144 , and pressure control solenoid valves PCS 1 , PCS 2 , PCS 3 , PCS 4 , PCS 5 , PCS 6 and PCS 7 . With respect to the logic valves W, X, Y and Z, an “0” in the chart indicates that the valve is in a spring-set position (“unstroked”) and a “1” indicates that the valve is in a pressure-set position (“stroked”). With respect to the dog clutch actuator valve 144 , an “R” indicates that the dog clutch actuator valve 144 is in a reverse position (with the spool valve 157 and plug valve 159 each in their relatively lowest positions as they appear in FIG. 2B ). Switch SW 7 will indicate a relatively low pressure condition (i.e., a low logic state) and switch SW 8 will indicate a relatively high pressure condition (i.e., a high logic state). Exhaust ports EX 1 and EX 2 will exhaust. An “F” indicates that the dog clutch actuator valve 144 is in a forward position, with the spool valve 157 in its relatively highest position with an uppermost part of the spool valve 157 shown in FIG. 2B experiencing exhaust pressure fluid in passage 146 and a lowest portion of the plug valve 159 experiencing exhaust pressure in passage 148 , and flow of controlled pressure from passage 117 permitted across the valve to passage 163 . Switch SW 7 will indicate a relatively high pressure condition and switch SW 8 will indicate a relatively low pressure condition. Exhaust ports EX 1 and EX 2 will exhaust. An “N” indicates that the dog clutch actuator valve 144 is in a neutral position in which the upper and lower ends of the valve are subjected to main pressure fluid from passages 146 and 148 , respectively, and flow of controlled pressure fluid from passage 117 permitted across the valve 144 to both passages 153 and 163 . Switches SW 7 and SW 8 will both indicate a relatively high pressure condition. Exhaust ports EX 1 and EX 2 will exhaust.
[0031] With respect to the columns in FIG. 3 for the respective pressure control solenoid valves PCS 1 , PCS 2 , PCS 3 , PCS 4 , PCS 6 and PCS 7 , the clutch listed for a particular speed ratio in a column for a particular solenoid valve indicates that the solenoid valve is in fluid communication with that clutch during that speed ratio. If the box listing the clutch is not shaded, then the solenoid is not energized in the case of a normally closed-type solenoid or is energized in the case of a normally open-type solenoid, and the listed clutch is not engaged. If the box is shaded, then the solenoid is energized in the case of a normally closed-type solenoid or is not energized in the case of a normally-open type solenoid, and the listed clutch is thereby engaged. With respect to PCS 5 , “MM” indicates that the pressure control solenoid PCS 5 is being energized as necessary to control an output pressure in passage 149 that controls a pressure bias on the main regulator valve 104 . The pressure control solenoid PCS 5 , by varying the pressure within passage 149 , is operable to vary the operating characteristics of the main regulator valve 104 , thereby modulating the pressure within the passage 118 . The column of FIG. 2 labeled “Exhaust” indicates which of the clutches are being exhausted (emptied of pressurized fluid) during each of the various speed ratios.
[0032] As is apparent from the chart of FIG. 3 , the pressure control solenoid PCS 1 and the first trim system of which it is a part is multiplexed to control the engagement and disengagement of both clutches C 1 and C 4 . The pressure control solenoid PCS 2 and the second trim system of which it is a part is multiplexed to control the engagement and disengagement of both clutches C 2 and C 5 . The pressure control solenoid PCS 3 and the third trim system of which it is a part is multiplexed to control the engagement and disengagement of both clutches C 3 and C 7 (at least for ranges reverse (R 2 ), reverse (R 1 ), startup and neutral conditions, and the first forward speed ratio range (1st). For ranges above the first forward speed ratio range (1st), pressure control solenoid PCS 7 controls the engagement and disengagement of clutch C 7 . Pressure control solenoid PCS 4 controls the engagement of the torque-converter clutch TCC. Pressure control solenoid PCS 6 controls the engagement of clutch C 6 , except in speed ratio ranges (7th″). (7th′″), (8th) and (9th). In these speed ratios, clutch C 6 is not engaged, and is also not affected by the state of the pressure control solenoid PCS 6 . The dashed lines in the chart of FIG. 3 indicate that the respective pressure control solenoid and trim system are decoupled from the respective clutch. The column labeled “Exhaust” indicates, for each speed ratio range, clutches that are being exhausted through the logic valves. The remaining clutches that are not engaged are exhausted through the associated trim valves.
[0033] FIGS. 2A and 2B depict the hydraulic control portion 100 with the positioning of the valves corresponding to the second reverse speed ratio range (R 2 ) of FIG. 3 . When operating in the reverse speed ratio range (R 2 ), the trim valves 122 and 124 are pressure-set and trim valve 120 is spring-set by energizing the solenoids PCS 2 , PCS 3 , and PCS 1 , respectively. The remaining trim valves 126 , 128 and 130 , and the logic valves X, Y, Z and W remain in a spring-set position. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutches C 2 and C 7 , which will engage, while clutches C 3 , C 4 , and C 5 will exhaust. To effect the engagement of clutch C 2 , pressurized fluid from the passage 150 is communicated to the outlet passage 152 of the trim valve 122 . Because it is in the spring-set position, the logic valve Y will communicate the fluid within the passage 152 to the clutch C 2 . To effect the engagement of the clutch C 7 , pressurized fluid within the passage 154 is communicated to the outlet passage 156 of the trim valve 124 . Because it is in the spring-set position, the logic valve Z will communicate the fluid within passage 156 to the clutch C 7 .
[0034] When operating in the first reverse speed ratio range (R 1 ), the trim valves 122 and 128 are pressure-set and trim valve 120 is spring-set by energizing solenoids PCS 2 , PCS 6 and PCS 1 , respectively. The remaining trim valves 124 , 126 and 130 , and the logic valves X, Y, Z and W remain in a spring-set position. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutches C 2 and C 6 , which will engage, while clutches C 3 , C 4 , and C 5 will exhaust. To effect the engagement of clutch C 2 , pressurized fluid from the passage 150 is communicated to the outlet passage 152 of the trim valve 122 . Because it is in the spring-set position the logic valve Y will communicate the fluid within the passage 152 to the clutch C 2 . To effect the engagement of clutch C 6 pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . Because they are in the spring-set position, logic valve X and logic valve Y communicate the fluid within passage 118 to passage 158 .
[0035] When starting the engine 12 of FIG. 1 (indicated in FIG. 3 as “startup”), the logic valve X and the trim valve 128 are pressure-set and trim valve 120 is spring-set by energizing the solenoids SS 1 , PCS 6 , and PCS 1 , respectively. The remaining trim valves 120 , 124 , 126 and 130 , and logic valves Y, Z and W remain in a spring-set position. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutch C 6 , which will engage, while clutches C 1 , C 3 , and C 5 will exhaust. To effect the engagement of clutch C 6 , pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . The pressure-set position of logic valve X and the spring-set position of logic valve Y allow fluid in passage 118 to be communicated to passage 158 .
[0036] When operating in the neutral state, indicated as “N” in FIG. 3 , the trim valve 128 is pressure-set and trim valve 120 spring set by energizing solenoids PCS 6 and PCS 1 , respectively. The remaining trim valves 124 , 126 and 130 , and the logic valves X, Y, Z and W remain in a spring-set position. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutch C 6 , which will engage, while clutches C 3 , C 4 and C 5 will exhaust. To effect the engagement of clutch C 6 , pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . Because they are in the spring-set position, logic valve X and logic valve Y communicate the fluid within passage 118 to passage 158 .
[0037] When operating in the first forward speed ratio range (1st), the trim valves 120 and 128 are pressure-set by not energizing solenoid PCS 1 and energizing PCS 6 , respectively. (Note that, because PCS 1 is normally open, in a steady state condition, no energizing control signal is required in order to pressure-set the trim valve 120 .) The remaining trim valves 122 , 124 , 126 and 130 , and the logic valves X, Y, Z and W remain in a spring-set position. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutches C 1 and C 6 , which will engage, while clutches C 3 . C 4 , and C 5 exhaust. To effect engagement of clutch C 1 , pressurized fluid within passage 150 is communicated to outlet passage 162 of trim valve 120 . To effect the engagement of clutch C 6 , pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . Because they are in the spring-set position, logic valve X and logic valve Y communicate the fluid within passage 118 to passage 158 .
[0038] When operating in the alternate first forward speed ratio range (1st′), in addition to pressure-setting trim valves 120 and 128 as in the first forward speed ratio range (1st), trim valve 126 is also pressure-set by energizing solenoid valve PCS 4 . Solenoid valve SS 3 is also energized to shift the dog clutch actuator valve 144 to a forward position, thus blocking exhaust of controlled pressure fluid from passage 117 in passage 161 provided to passage 163 through restricted passage 165 A, to move the logic valve Z from a spring-set position to a pressure-set position. Solenoid valve SS 3 is no longer energized after the dog clutch actuator valve 144 moves to the forward position, as confirmed by the pressure switches SW 7 and SW 8 shown in communication with the dog clutch actuator valve 144 , and control pressure in passage 151 is exhausted, to eliminate unnecessary loading of the dog clutch DOG. With the above-stated valve configuration, the main pressure in passage 118 is in fluid communication with clutches C 1 and C 6 , which will engage. The main pressure in passage 118 is communicated to the converter flow valve 110 via passage 164 across trim valve 126 to passage 167 . Clutches C 4 , and C 5 exhaust.
[0039] When operating in the second forward speed ratio range (2nd), the trim valves 122 , 126 and 128 are pressure-set and trim valves 120 and 130 are spring-set by energizing solenoids PCS 2 , PCS 4 , PCS 6 , PCS 1 and PCS 7 , respectively. If the second forward speed ratio range is attained in a shift from the first alternate speed ratio range (1st′), then the dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′). The remaining trim valves 120 and 124 remain in a spring-set position. With the above-stated valve configuration, clutches C 2 , TCC and C 6 will be in an engaged position while clutches C 4 and C 5 exhaust. To effect engagement of clutch C 2 , pressurized fluid within passage 150 is communicated to outlet passage 152 of trim valve 122 . To effect the engagement of clutch C 6 , pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . Because they are in the spring-set position, logic valve X and logic valve Y communicate the fluid within passage 118 to passage 158 . To effect engagement of clutch TCC, trim valve 126 is pressure-set by energizing solenoid valve PCS 4 , so that the main pressure in passage 118 is communicated to the converter valve 110 via passage 164 across trim valve 126 to passage 167 .
[0040] When operating in the third forward speed ratio range (3rd), the trim valves 124 , 126 and 128 are pressure-set and trim valves 120 and 130 are spring-set by energizing solenoids PCS 3 , PCS 4 , PCS 6 , PCS 1 and PCS 7 , respectively. The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. The remaining trim valve 122 remains in a spring-set position. With the above-stated valve configuration, clutches C 3 , TCC and C 6 will be in an engaged position while clutches C 4 and C 5 will exhaust. To effect engagement of clutch C 3 , pressurized fluid from passage 118 within passage 154 is communicated to outlet passage 156 of the trim valve 124 and through the pressure-set logic valve Z to clutch C 3 . To effect engagement of clutch TCC, trim valve 126 is pressure-set by energizing solenoid valve PCS 4 . To effect engagement of clutch C 6 , pressurized fluid within passage 158 is communicated to outlet passage 160 of trim valve 128 . Because they are in the spring-set position, logic valve X and logic valve Y communicate the fluid within passage 118 to passage 158 .
[0041] When operating in the alternate third forward speed ratio range (3rd′), the trim valves 124 , 126 and 128 are pressure-set and trim valves 120 and 130 are spring set by energizing solenoids PCS 3 , PCS 4 , PCS 6 , PCS 1 and PCS 7 , respectively, to cause engagement of clutches C 3 , TCC and C 6 , as described above with respect to the third forward speed ratio range (3rd). The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. Additionally, solenoid valve SS 2 is energized to move the logic valve Y to a pressure-set position, thus allowing main pressure from passage 118 in communication with passage 169 to flow across the logic valve Y to outlet passage 148 , moving the plug valve 159 of the dog clutch actuator valve 144 upward. Additionally, the shifting of logic valve Y puts exhaust pressure rather then main pressure into communication with the switches SW 2 and SW 1 at the trim valves 120 and 128 , respectively.
[0042] When operating in the fourth forward speed ratio range (4th), trim valves 122 , 126 and 128 are pressure-set and trim valves 120 and 130 are spring-set by energizing solenoids PCS 2 , PCS 4 , PCS 6 , PCS 1 and PCS 7 , respectively. The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. Solenoid valve SS 2 is energized to place logic valve Y in a pressure-set position. With the above-stated valve configuration, clutches C 5 , TCC and C 6 will be in an engaged position while clutches C 2 and C 4 will exhaust. Engagement of the clutches TCC and C 6 are as described above with respect to the third forward speed ratio range (3rd). To effect engagement of clutch C 5 , solenoid PCS 2 is energized to move trim valve 122 to a pressure-set position. Pressurized fluid from passage 118 in communication with passage 150 is communicated to outlet passage 152 across trim valve 122 and then across the pressure-set logic valve Y into communication with clutch C 5 .
[0043] When operating in the fifth forward speed ratio range (5th), trim valves 120 , 126 and 130 are pressure-set. Solenoid PCS 4 is energized to pressure-set trim valve 126 , but solenoids PCS 1 and PCS 7 are not energized to pressure-set trim valves 120 and 130 , as these are normally open-type solenoid valves. The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. Solenoid valve SS 2 is energized to place logic valve Y in a pressure-set position. With the above-stated valve configuration, clutches C 1 , TCC and C 7 will be in an engaged position while clutches C 2 and C 4 will exhaust. To effect engagement of clutch C 1 , pressurized fluid within passage 150 is communicated to outlet passage 162 of trim valve 120 . With the logic valve X in the spring-set position, fluid in passage 162 communicates with the clutch C 1 across the logic valve X. To effect the engagement of clutch TCC, trim valve 126 is pressure-set by energizing solenoid PCS 4 . To effect the engagement of clutch C 7 , pressurized fluid within passage 154 is communicated to outlet passage 173 and across the pressure-set logic valve Z to the clutch C 7 . With the logic valve Y in a pressure-set position, pressurized fluid in passage 152 can exhaust.
[0044] When operating in the alternate fifth forward speed ratio range (5th′), trim valves 120 , 126 and 130 are pressure-set, by energizing solenoid PCS 4 , but not solenoids PCS 1 or PCS 7 , as described above with respect to the fifth forward speed ratio range (5th). The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. With the above-stated valve configuration, the clutches C 1 , TCC and C 7 are engaged (as described above with respect to the fifth forward speed ratio range (5th)) while the clutches C 4 and C 5 exhaust.
[0045] When operating in the sixth forward speed ratio range (6th), trim valves 122 , 126 and 130 are pressure-set. Solenoids PCS 2 and PCS 4 are energized to pressure-set trim valves C 2 and TCC, respectively, but solenoid valve PCS 7 is not energized, as it is normally open. The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. With the above-stated valve configuration, clutches C 2 , TCC and C 7 will engage while clutches C 4 and C 5 will exhaust. To effect engagement of clutch C 2 , pressurized fluid within passage 150 is communicated to outlet passage 152 of trim valve 122 . The clutches TCC and C 7 are engaged as described above with respect to the fifth forward speed ratio range (5th).
[0046] When operating in the seventh forward speed ratio range (7th), trim valves 124 , 126 and 130 are pressure-set. Solenoids PCS 3 and PCS 4 are energized to pressure-set trim valves 124 and 126 , respectively, but solenoid valve PCS 7 is not energized, as it is normally open. The dog clutch actuator valve 144 remains in the forward position and the logic valve Z in a pressure-set position due to the previous actuation of the dog clutch actuator valve 144 in the first alternate forward speed ratio range (1st′) or in the second forward speed ratio range (2nd), as described above. With the above-stated valve configuration, clutches C 3 , TCC and C 7 will engage while clutches C 4 and C 5 will exhaust. To effect engagement of clutch C 3 , pressurized fluid from passage 118 within passage 154 is communicated to outlet passage 156 of the trim valve 124 and through the pressure-set logic valve Z to clutch C 3 . The clutches TCC and C 7 are engaged as described above with respect to the fifth forward speed ratio range (5th).
[0047] When operating in the seventh alternate forward speed ratio range (7th′), trim valves and solenoids are energized as described with respect to the seventh forward speed ratio range (7th), except that solenoid valve SS 2 is also energized to place the Y valve into a pressure-set position, thus providing pressurized fluid to channel 148 , control pressure to channel 175 , and exhaust fluid to channel 171 , causing the pressure at switch SW 2 in communication with trim valve 120 to be exhaust pressure and pressure at switch SW 1 in communication with trim valve 128 to be control pressure.
[0048] When operating in the seventh alternate forward speed ratio range (7th″), trim valves and solenoids are energized as described with respect to the seventh forward speed ratio range (7th), except that solenoid valves SS 1 and SS 2 are also energized. Energizing solenoid valve SS 1 places logic valve X in a pressure-set position to allow pressurized fluid from passage 143 to passage 146 and shifts the dog actuator clutch valve 144 to a neutral position, while preventing the pressurized fluid in passage 143 from reaching passage 174 , changing the monitored pressures at the switches SW 3 and SW 4 associated with trim valves 122 and 124 from high pressure to low pressure and the monitored pressure at the lower switch SW 8 associated with the dog clutch actuator valve 144 from exhaust pressure to control pressure. With the dog clutch actuator valve 144 in a neutral position, logic valve Z is in a pressure-set position. Solenoid valve SS 2 is also energized to place logic valve Y into a pressure-set position, thus providing pressurized fluid to channel 148 and exhaust fluid to channel 171 , causing the pressure at switch SW 2 associated with trim valve 120 to be at exhaust pressure and pressure at switch SW 1 associated with trim valve 128 to be at control pressure.
[0049] When operating in the seventh alternate forward speed ratio range (7th′″), trim valves and solenoids are energized as described with respect to the seventh forward speed ratio range (7th), except that solenoid valves SS 1 , SS 2 and SS 3 are also energized. Energizing solenoid valves SS 1 and SS 2 has the effects described above with respect to speed ratio range (7th″). Energizing solenoid valve SS 3 as well moves logic valve W to a pressure-set position, thus exhausting fluid in channel 155 .
[0050] When operating in the eighth forward speed ratio range (8th), trim valves 124 , 126 and 130 are pressure-set. Solenoid valve PCS 4 is energized to pressure-set trim valve 126 , but solenoid valves PCS 1 and PCS 7 are not, as these are normally open-type solenoid valves. Solenoid valves SS 1 and SS 2 are also energized to move the logic valves X and Y, respectively, to pressure-set positions, causing the dog clutch actuator valve 144 to be in a neutral position. With logic valve X in a pressure-set position, pressurized fluid from passage 143 is communicated to passage 146 , while preventing the pressurized fluid in passage 143 from reaching passage 174 , causing the monitored pressures at the switch SW 3 associated with trim valve 122 to be at exhaust pressure, that at the switch SW 4 associated with trim valve 124 to be at control pressure, and that at the lower switch SW 8 associated with the dog clutch actuator valve 144 to be at control pressure. With the dog clutch actuator valve 144 in a neutral position, logic valve Z is in a pressure-set position. With the above-stated valve configuration, clutches C 4 , TCC and C 7 will engage while clutches C 1 , C 2 and C 6 will exhaust. To effect engagement of clutch C 4 , pressurized fluid from passage 150 crosses the pressure-set trim valve 120 to outlet passage 162 and across pressure-set logic valve X into communication with clutch C 4 . To effect the engagement of clutch TCC, trim valve 126 is pressure-set by energizing solenoid valve PCS 4 . To effect engagement of clutch C 7 , pressurized fluid from passage 154 crosses pressure-set trim valve 130 to communicate with passage 173 and then crosses pressure-set logic valve Z into communication with clutch C 7 . The pressure-set position of logic valve X allows pressurized fluid to pass from passage 143 across the pressure-set logic valve X to passage 146 , shifting the dog clutch actuator valve 144 to a neutral state or position, allowing control pressure fluid to contact the lower switch SW 8 associated with the dog clutch actuator valve 144 . Furthermore, the pressure-set position of logic valve Y allows some of the pressurized fluid crossing logic valve X to be routed to passage 148 .
[0051] When operating in the ninth forward speed ratio range (9th), trim valves 122 , 126 and 130 are pressure-set. Solenoid valves PCS 2 and PCS 4 are energized to pressure-set trim valves 122 and 126 , but solenoid valve PCS 7 is not energized, as it is normally-open type solenoid valve. Solenoid valves SS 1 and SS 2 are also energized so that logic valves X and Y, respectively, are in pressure-set positions and the dog clutch actuator valve 144 is in a neutral position. With the above-stated valve configuration, clutches TCC and C 7 will engage (as described above with respect to the eighth forward speed ratio range (8th)) as well as clutch C 5 , while clutches C 1 , C 2 and C 6 will exhaust. To effect engagement of clutch C 5 , pressurized fluid from forward 150 communicates with outlet passage 152 across the pressure-set trim valve 122 and then with clutch C 5 through the pressure-set logic valve Y. Because the control system 100 is designed with the dog clutch actuator valve 144 in the neutral position in the higher speed ratio ranges (the alternate seventh forward speed ratio ranges (7th″) and (7th′″)), as well as in the eighth (8th) and ninth (9th) forward speed ratio ranges, spin losses are reduced in the transmission 10 of FIG. 1 .
Multiplexing of Trim Systems
[0052] As is evident from the Figures and from the above description, the first trim system, which includes solenoid valve PCS 1 and trim valve 120 , is multiplexed to control engagement of clutches C 1 and clutch C 4 . Shifting of the logic valve X between a spring-set position and a pressure-set position determines which of the clutches C 1 and C 4 will be engaged via the pressurized fluid fed through the pressure-set trim valve 120 and the logic valve X.
[0053] Furthermore the second trim system, which includes solenoid valve PCS 2 and trim valve 124 is multiplexed to control engagement of clutches C 2 and C 5 . Shifting of logic valve Y between a spring-set position and a pressure-set position determines which of the clutches C 2 and C 5 will be engaged via pressurized fluid fed through the pressure-set trim valve 124 to the logic valve Y.
[0054] Still further, the third trim system, which includes the solenoid valve PCS 3 and the trim valve 124 is multiplexed to control engagement of the C 3 and C 7 clutches, at least in speed ratio ranges (R 2 ), (R 1 ), startup, neutral, and first forward speed ratio range (1st). In speed ratio ranges above the first forward speed ratio range (1 st ), engagement of clutch C 7 is controlled by the sixth trim system, which includes solenoid valve PCS 7 and trim valve 130 . Shifting of logic valve Z between a spring-set position and a pressure-set position determines which of the clutches C 3 and C 7 will be engaged via pressurized fluid fed through the pressure-set trim valve 124 to the logic valve Z. The shifting of logic valve Z is controlled by the position of the dog clutch actuator valve 144 , which in turn is controlled by the positions of the logic valves X and Y and by solenoid valve SS 3 .
Double Transition Shifts and Skip Shifts
[0055] As is evident from FIG. 3 and from the above description, a shift from the fourth forward speed ratio range (4th) to the fifth forward speed ratio range (5th) involves a four clutch, double transition shift. That is, clutches C 5 and C 6 are disengaged while clutches C 1 and C 7 are engaged. Thus, even with the multiplexing of the trim systems, this four clutch shift is achieved by the control system 100 . A four clutch, double transition shift is also realized. As is evident from FIG. 3 , numerous other shifts also involve double transition shifts (i.e., a shift that requires that more than one clutch be engaged or disengaged). The system 100 is also able to accomplish many skip shifts, including a shift from the first reverse speed ratio range (R 1 ) to the first forward speed ratio range (1st); a shift from the second reverse speed ratio range (R 2 ) to the first forward speed ratio range (1st); a shift from the first alternative forward speed ratio range (1st′) to the third forward speed ratio range (3rd); a shift from the third forward speed ratio range (3rd) to the fifth forward speed ratio range (5th); a shift from the fifth forward speed ratio range (5th) to the seventh forward speed ratio range (7th); and a shift from the second alternative seventh forward speed ratio range (7th″) to the ninth forward speed ratio range (9th).
Logic Valves Used to Control Power Off/Drive-Home Modes
[0056] The hydraulic control system 100 is configured to provide a functional “drive-home” system in the event of an interruption or failure in electrical power, which would prevent selective energizing of the solenoid valves. The hydraulic control system 100 is designed to default to two different speed ratio ranges (referred to as failure modes), i.e., there are two different failure modes, depending on which speed ratio range the system 100 is providing when failure occurs. Specifically, if power failure occurs while the transmission 10 is operating in any of the first reverse speed ratio range (R 1 ), the second reverse speed ratio range (R 2 ) or is in neutral (N), the hydraulic control system 100 will automatically operate in a neutral state (i.e., an operating condition which will not allow driving the vehicle in either forward or reverse). This “failure” to a neutral state occurs for several reasons. First, in each of the first reverse speed ratio range (R 1 ), the second reverse speed ratio range (R 2 ) or the neutral (N) speed ratio range, the dog clutch actuator valve 144 is in a reverse position during normal operation (i.e., when electrical energy is available). Additionally, because solenoid valve PCS 1 is a normally open-type valve, trim valve 120 will be pressure-set in the absence of an energizing control signal. This causes the pressurized fluid in passage 150 to communicate with outlet passage 162 and be directed through the logic valve X (which allows flow to clutch C 1 when in the spring-set position) to clutch C 1 . Because the trim valves 122 , 124 , 128 and 130 and the logic valves Z and Y are in spring-set positions during a power failure with the dog clutch actuator valve 144 in a reverse position, trim valve 128 does not allow pressurized fluid flow to clutch C 6 , logic valve Z does not allow pressurized fluid flow to clutches C 3 and C 7 , and logic valve Y does not allow pressurized fluid flow to clutches C 2 and C 5 . With only clutch C 1 engaged, the transmission 10 of FIG. 1 operates in a neutral state.
[0057] If power failure occurs when the transmission 10 is in any of the speed ratio ranges (1st), (1st′), (2nd). (3rd), (3rd′), 4th), (5th), (5th′), (6th). (7th), and (7th′), referred to herein as “low” speed ratio ranges, the hydraulic control system 100 will automatically operate in the fifth forward speed ratio range (5th). This “failure” to the fifth forward speed ratio range (5th) occurs for several reasons. First, in each of the first forward speed ratio range (1st) through the seventh alternate forward speed ratio range (7 th ′), the dog clutch actuator valve 144 is in a forward position during normal operation (i.e., when electrical energy is available), causing logic valve Z to be pressure-set Additionally, because solenoid valve PCS 1 is a normally open-type valve, trim valve 120 will be pressure-set in the absence of an energizing control signal. This causes the pressurized fluid in passage 150 to communicate with outlet passage 162 and be directed through the logic valve X (which allows flow to clutch C 1 when in the spring-set position) to clutch C 1 . Solenoid valve PCS 7 is also a normally-open type solenoid valve, so trim valve 130 will be pressure-set in the absence of an electrical control signal and will provide pressurized fluid from passage 154 to outlet passage 173 and through the pressure-set logic valve Z to clutch C 7 . Because the trim valves 120 , 124 , and 128 and the logic valves X and Y are in spring-set positions during a power failure with the dog clutch actuator valve 144 in a reverse position, trim valve 128 does not allow pressurized fluid flow to clutch C 6 , and logic valve Y does not allow pressurized fluid flow to clutches C 2 and C 5 . With only clutches C 1 and C 75 engaged, the transmission 10 of FIG. 1 operates in the fifth forward speed ratio range, except without engagement of the torque-converter clutch TCC.
[0058] If power failure occurs when the transmission 10 is in any of the speed ratio ranges (7th″), (7th′″), (8th), or (9th), referred to herein as “high” speed ratio ranges, the hydraulic control system 100 will automatically operate in the eighth forward speed ratio range (8th). This “failure” to the eighth forward speed ratio range (8th) occurs for several reasons. First, in each of the alternate seventh forward speed ratio range (7th″) through the ninth forward speed ratio range (9th), the dog clutch actuator valve 144 is in a neutral position during normal operation (i.e., when electrical energy is available), causing logic valve Z to be pressure-set. When power is interrupted, the neutral position of the dog clutch actuator valve 144 causes logic valves X and Y to remain pressure-set (i.e., the dog clutch actuator valve 144 latches the logic valves X and Y), as they are in each of the alternate seventh forward speed ratio range (7th″) through the ninth forward speed ratio range (9th), even though solenoid valves SS 1 and SS 2 are not energized, because there are no exhaust routes open for the pressurized fluid in passages 146 and 148 acting on logic valves X and Y, and for the controlled pressure fluid acting on logic valves X and Y through the spring-set logic valve W which communicates passage 153 with passage 155 . During normal operation, the solenoid SS 3 can be energized to place logic valve W in a pressure-set position (either in steady state, or temporarily) to prevent fluid communication between passages 153 and 155 , thus preventing the dog clutch actuator 144 from having a latching effect on logic valves X and Y.
[0059] The logic valves X and Y also function to “lock out” clutch C 6 during forward ratio ranges (7th″), (7th′″), (8th) and (9th). This occurs because, in these operating ranges, the logic valves X and Y are both in pressure-set positions. Thus, logic valve X and logic valve Y prevent pressurized fluid from passage 118 from reaching passage 158 , while logic valve Y allows control pressure fluid from passage 117 to passage 179 , preventing trim valve 128 from being placed in a pressure-set position by solenoid valve PCS 6 .
[0060] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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An electro-hydraulic control system is provided, preferably for a countershaft transmission, that uses logic valves to multiplex trim systems to more than one torque-transmitting mechanism, thereby minimizing the number of required components. Additionally, the electro-hydraulic control system preferably has more than one failure mode so that the transmission operates at a respective predetermined speed ratio in the event of an interruption in electrical power.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved device for monitoring the yarn travel in the shuttle of a loom, the shuttle being provided with a threader, said device comprising an assembly which includes a piezoelectric transducer element, a yarn feeler member mechanically coupled with the piezoelectric transducer element, an induction coil operatively connected with said transducer element and elastic supporting means. Generally, such a device is intended for stopping the loom when the yarn breaks or ceases to travel on its predetermined path in the shuttle.
U.S. Pat. No. 3,467,149 and Swiss Pat. No. 44l 172 disclose electronic devices for surveying the presence of weft thread in a shuttle loom which comprise a piezoelectric signal generator including a coil and arranged in the shuttle, and a detection circuit including a further coil arranged along the path of the shuttle movement. As shown in said United States patent, the shuttle is formed with a hollow central chamber, within which is mounted a weft bobbin. The weft thread to be supplied by the shuttle is wound about the bobbin and is played out from the front end of the bobbin. The thread passes over the signal generator near the front of the shuttle; and then it leaves the shuttle via an output guide. The bobbin is supported at the rear thereof by means of a bobbin support within the hollow chamber.
The signal generator is mounted within the hollow chamber toward the front thereof by means of rubber bearings which serve to isolate the signal generator from vibratory effects within the shuttle. The signal generator itself includes a base member mounted between the rubber bearings. A wire-like thread feeler element is mounted on the base member and extends to a position such that the weft thread must rub across the feeler element as it is drawn off from the bobbin and moves toward the output guide.
The wire-like thread feeler element is mounted in cantilever fashion at one end to extend upwardly from the base member. The thread feeler element then bends over to extend transversely across and above the base member. The base member, the weft bobbin, and the output guide are all positionally related such that the weft thread presses slightly downwardly upon the thread feeler element toward its free end and rubs across the element during its movement from the bobbin toward the output guide. An elongated piezoelectric crystal is supported at each end thereof by means of mounting elements to extend horizontally above the base member just under the thread feeler element. A vibration coupling member interconnects the thread feeler element and the piezoelectric crystal at a point midway between the two mounting elements.
A signal generator coil is wound about the periphery of the base member. This coil acts as an antenna for controlling electromagnetic field interaction between the moving signal generator and the stationary signal receiver as the shuttle passes closely over the signal receiver. Various other electrical components are embedded within the base member and are electrically connected with the signal generator coil and the piezoelectric crystal.
In said United States and Swiss patents no details are disclosed about the disturbances influencing the piezoelectric signal generator from outside the shuttle, and the enormous accelerations the shuttle undergoes when the loom is working and which imply very serious problems. This refers particularly to the impacts acting upon the shuttle when driven or stroken by the picker, further to the intense noise existing in weaving sheds, and to the vibrations generated by the operating loom which may be transferred to the shuttle. By such influences the signal generator may be damaged or even rendered inoperative, or wrong electrical signals may be generated in the sensitive signal generator or other components of the monitoring equipment which cause unwanted stops of the loom.
A further problem results from spurious electrical signals from the surroundings of the loom or the electric supply which may cause trouble by inductive effects on the induction coils of the signal generator and detecting circuit arranged at the loom.
A further rather difficult problem is the arrangement and accommodation of the signal generator in the front end of a conventional weaving shuttle without adding to the dimensions of the shuttle. Any enlargement of the width, height and/or length of the shuttle might necessitate structural changes on the loom and thus would be impracticable.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide a piezoelectric yarn travel monitoring or sensing assembly which is rugged and insensitive to undesired interferences of any kind, and particularly an assembly mounted in the shuttle of a loom of such construction and arrangement as to avoid the problems mentioned in the foregoing context.
It is a further object of the invention to provide a piezoelectric yarn travel monitoring unit which is of improved design and function relative to prior units of similar destination, in such a manner as to be suitable for permanent practical use in weaving mills.
Another more specific object of the invention is the provision of a piezoelectric yarn travel sensing unit which can be easily mounted in the shuttle of a weaving loom and which can be easily replaced by another similar sensing unit.
In order to implement the aforementioned objectives and others which will become more readily apparent as the description proceeds, the piezoelectric yarn travel monitoring device of the invention is generally characterized by the improvement that
the induction coil is disposed in an area beneath the threader in a cutout of the shuttle;
that the yarn feeler member and the piezoelectric transducer element are directly connected with one another; and
that the yarn feeler member is arranged as a unilaterally clamped flexural vibratory member having a free end which is in contact with the traveling yarn.
The notation -- directly connected with one another -- is to be understood such that the yarn feeler member which preferably has the shape of a sheet of metal is connected fixedly and without using an intermediate or coupling member with the piezoelectric transducer element. Such coupling members which normally consist of elastic material, as rubber, usually imply damping losses to the vibrating system and thus attenuation of the signal indicating the yarn travel.
In the aforementioned prior electronic weft thread surveying device, a damping coupling member is provided between feeler member and transducer element, and, moreover, the traveling weft thread does not act upon the feeler member at a well defined location and with well defined power arm since the weft thread traverses along the feeler member over a length section thereof. Thus, the leverage changes permanently with the traveling weft so that excitation of a well defined vibratory mode is questionable.
Omitting the coupling member and shaping the inventive yarn feeler member as a clamped-free flexural member provides for a mechanical vibratory system having a well defined resonant frequency and high Q. Moreover, guiding the yarn over the free end or a defined location near the free end of the yarn feeler member ensures the latter to be excited by the traveling yarn with well defined leverage and thus with high efficiency in its resonant mode. The inventive monitoring assembly or unit may be arranged in the shuttle such that the yarn feeler member is located in the area of the threading slot of the threader and immediately in front of the latter. Preferably the yarn feeler member is provided with an aperture or recess at its free end which serves as a yarn guide. Another embodiment of the invention consists in arranging the induction coil on a bolt protruding from the threader in downward direction and through a central hole of the coil and securing it to said bolt by means of a locking member. Preferably elastic means, as rubber washers, are placed between coil and adjacent parts of the shuttle and coil fixing means.
A further advantageous embodiment consists in a ring or receptacle of elastic material, as rubber, receiving the induction coil and engaging at its circumference a peripheral groove in the shuttle body. In the free space of the shuttle a transverse wall may be provided connecting the inner walls of the shuttle and arranged near the induction coil such as to protect the latter and the transducer element from damage when the weft bobbin is changed in a faulty manner. Another inventive improvement consists in providing the threader at its end facing the weft bobbin and the yarn feeler member with at least one projection protruding over said feeler member and protecting it from damage.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will be apparent upon consideration of the following detailed description thereof which makes reference to the annexed drawings wherein:
FIG. 1 shows a vertical longitudinal section of one end of a shuttle provided with a threader and a sensing insert,
FIG. 2 is a plan view of the shuttle end shown in FIG. 1,
FIG. 3 is a cross section taken along the line III--III in FIG. 1,
FIGS. 4 and 5 show two alternative embodiments of the means for supporting the sensing insert in the shuttle, and
FIGS. 6 and 7 are front views of two modified embodiments of the yarn feeler member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 and 2, a weft bobbin 2 and a threader 3 having a threading slot 10 are located in the front end 1' of a shuttle 1 which may be of conventional design. A sensing assembly or insert 4 comprises a yarn feeler member 5, a piezoelectric transducer element 8 and an induction coil 9, which components are interconnected rigidly, i.e. without using intermediate members of elastic material. As shown particularly in FIGS. 1 and 3, induction coil 9 is placed in a cutout 13 of shuttle 1 underneath threader 3. Induction coil 9 is provided with a central hole (not shown) which receives a bolt 14 protruding downwards from threader 3, and a releasable locking ring 12 is provided at bolt 14 to fix induction coil 9 thereto. Shock and vibration absorbing washers 15 and 16 of elastic material, as rubber, are provided adjacent the two major parallel faces i.e. the top and bottom faces, respectively, of induction coil 9 and the thereto parallel adjacent faces of cutout 13 and locking ring 12, respectively. Thus, the flat major faces of induction coil 9 are arranged in parallel relationship to the bottom face of shuttle 1 and to the top face of the not shown sley beam. In order to suppress still more completely impacts and vibrations which might be transferred to sensing assembly 4, a bushing of elastic material (not shown) can be placed on bolt 14 within the central hole of induction coil 9, so that the latter is mounted in shuttle 1 by means of elastic material interposed at all its supported faces.
As shown in FIG. 1, the top face of induction coil 9 is covered to some extent by the body of shuttle 1 below threader 3. On the exposed top face of induction coil 9 piezoelectric transducer element 8 which may be plate-shaped is mounted with one of its plane surfaces connected directly, i.e. without using an intermediate member of elastic material, to said top face. Yarn feeler member 5 which may be a metal sheet or strip bent to an L-shaped configuration is also connected directly to the top face of transducer element 8. The components 5, 8 and 9 may be bonded together, e.g. by means of an epoxy resin adhesive. The lower clamped or fixed arm 7 of yarn feeler element 5 is parallel to the top face of induction coil 9, whereas the free arm 6 which is intended to contact and sense the weft thread is perpendicular to said top face and extends in a direction at right angles to the mean path of the weft thread which extends between the tip of weft bobbin 2 and threading slot 10.
Transducer element 8 is provided at its top and bottom surfaces with metal electrodes (not shown) which are connected with the winding of induction coil 9 by leads (not shown). As may be seen from FIGS. 1 and 3, induction coil 9, transducer element 8 and yarn feeler member 5 are joined to a structural unit or assembly which may be easily removed from cutout 13 and bolt 14 after detaching locking ring 12, and replaced with another similar unit.
Specific measures may be taken for protecting the sensing insert 4 from undesired physical contact with other parts. Thus, in the inner space of shuttle 1 a transverse wall 11 may be provided which extends in a vertical direction from the bottom face of shuttle 1 to a level above the top face of transducer element 8. Transverse wall 11 protects transducer element 8 and induction coil 9 from being hit by the tip of weft bobbin 2 when changing the latter. Additionally, along the upper edge of threader 3 facing weft bobbin 2 a projection 17 protruding over the free end 6 of yarn feeler member 5 is arranged for shielding this member from mechanical actions from the upper side of the shuttle. Moreover, yarn feeler element 5 is located immediately at the thread inlet 3' of threader 3 so that its free part 6 is placed safely in a recess formed by threader 3 and the adjacent walls of shuttle 1.
FIG. 3 shows the flat free part 6 of yarn feeler member 5 as seen from the side of weft bobbin 2. At the upper end of said free part 6 a thread guide 18 is provided. This thread guide is formed as an aperture or eye, with an open threading slit 18'. When the loom is working, the traveling weft thread guide 18 continuously so that the edges thereof are worn only slightly and at a uniform rate.
With reference to FIGS. 4 and 5 two modified embodiments of the means for supporting sensing insert or assembly 4 in shuttle 1 are shown wherein induction coil 9 is arranged in a similar position as in FIGS. 1 and 3, however, in a circular cutout of the shuttle. In FIG. 4, induction coil 9 is fittingly received in an open circular receptacle 19 consisting of elastic material. Receptacle 19 is provided with a peripheral flange 20 engaging a circumferential groove in the front end 1' of shuttle 1. Thus, induction coil 9 and the whole of sensing assembly 4 are supported elastically and shockproof, and, moreover such as to be easily replaceable. In FIG. 5, induction coil 9 is fitted tightly in a peripheral bearing ring 21 of elastic material, as rubber, engaging a circumferential groove 22 in shuttle 1 such as to support sensing insert 9 elastically in shuttle 1.
In FIG. 6, yarn feeler member 5 is provided with a stright upper edge 23 at its free part 6, whereas the embodiment shown in FIG. 7 has a thread guide shaped as an open recess 24 in its upper edge. As for the components of sensing insert 4 not shown in FIGS. 4 through 7, they may be shaped and arranged in a similar manner as illustrated and described with reference to FIGS. 1 through 3.
Other embodiments and modifications of the inventive monitoring devices are also comprised by the scope of the claims. By way of example, the front face of threader 3 adjacent yarn feeler member 5 may be recessed such as to receive the free part 6 of said feeler member 5 and to protect same from damage at the upper and lateral edges thereof. Induction coil 9 may be supported elastically at its periphery as in FIGS. 4 and 5, and, additionally, by means of a bolt 14 and locking ring 12, as illustrated in FIGS. 1 and 3, or mounted by other elastic members in shuttle 1.
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A device for monitoring the travel of a yarn, particularly weft yarn in the shuttle of a loom, which device is designed as an assembly or unit comprising a piezoelectric transducer element, a yarn feeler member fixedly bonded with the transducer elements and arranged as a unilaterally clamped flexural vibratory member, and an induction coil operatively connected with the piezoelectric transducer element, and wherein a yarn guide means is provided at or near the free end of the vibratory yarn feeler member such that the yarn when traveling acts upon said feeler member in a restricted area thereof.
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The present invention relates to a gas-cooled electric machine, particularly to an air-cooled turbo-generator with a closed coolant circulation system, having a rotor shaft on which there is at least one axial fan inside a generator housing.
BACKGROUND
As is generally known, turbo-generators for generating three-phase current are powered by steam or gas turbines. As a rule, the rotor of a turbo-generator consists of a solid cylindrical forged body made of steel in which the excitation winding is distributed over individual slots. The rotor turns in the bore of the stator of a generator. The stator consists of a sheet metal body which, in turn, has slots to accommodate the armature winding. The decisive factor in the configuration and construction of such turbo-generators is the cooling technology, since this makes it possible to substantially raise the output. Today's turbo-generators often work with a gaseous coolant and with fans that are arranged on the rotor and that circulate the coolant inside the generator.
European patent application EP 1209802 A2 describes the arrangement of a fan in a turbo-generator with a closed cooling-gas circulation system. The cooling gas enters the axial fan from the end of the machine, undergoes a pressure increase in said fan and is thereby conveyed into the machine parts that are to be cooled. Before the cooling gas flows back into the fan, it is passed through heat exchangers.
Moreover, a few cases of air-cooled generators are known from the state of the art with which the air pressure in the generator interior is markedly raised by means of external compressors that are supplied by an external power system. Swiss patent specification CH 541 890 describes boosting the pressure of a generator in order to raise the generator output, whereby compressed air from the compressor of a gas turbine is fed into the generator housing. The low stationary replenishment volume is determined by the leakage rate of the air in the generator, essentially by the leakage volume at the place where the rotor shaft enters the housing. As a result, the volume output flow brought about by the generator ventilation remains practically unchanged. The higher air density achieved in the generator interior leads to an improvement of the cooling properties and can result in an increase in output while the temperature of the generator components remains constant. As a rule, interfaces to the power plant process-control technology are provided. The disadvantages here are the relatively high complexity and the high costs incurred for the external auxiliary devices, for the power and for the process-control technology. Moreover, such an approach is somewhat malfunction-prone.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide an improved gas-cooled electric machine that avoids that above-mentioned drawbacks of the state of the art. Moreover, a marked pressure increase is to be achieved in the generator housing so as to attain improved heat dissipation and thus more effective cooling of the generator. In this context, there should be no need for additional external devices to raise the pressure or for external control devices, but rather, a simple and inexpensive solution is to be provided that is also well-suited for easily retrofitting existing generators.
The gas-cooled electric machine according to the invention, particularly a turbo-generator having a rotor shaft on which there is at least one axial fan inside a generator housing, is characterized in that a pressure boosting means is arranged on the axial fan in order to raise the absolute pressure in the generator interior, said means having one or more flow channels between the hub interior that is delimited by the hub of the axial fan and the generator interior, whereby the flow inlet and the flow outlet are radially at a distance from each other.
This approach is particularly advantageous since this results in an improved gas-cooled electric machine that avoids the above-mentioned drawbacks of the state of the art. A marked increase in the absolute pressure in the generator housing is achieved which, due to the higher density of the cooling medium, brings about improved heat dissipation and thus more effective cooling of the generator. Moreover, the pressure boosting automatically equalizes the unavoidable leakage losses. No additional external devices to raise the pressure or external control devices are needed for this purpose, but rather, only modifications to the already existing fan module, which are also suitable for easily retrofitting existing generators.
The present invention modifies the already existing axial fan with a pressure boosting means that makes use of the fact that one side of the fan hub delimits the hub interior and, via this interior, is connected to the housing exterior and thus to the ambient pressure. The pressure is then increased via the radius differential between the inlet opening of the flow channel located in the hub interior and the outlet opening located in the generator interior. The generator interior is sealed off from the ambient atmosphere and is suitable for the pressures being generated by the pressure boosting. In this context, the outlet opening lies on a radius which, measured from the shaft axis, is larger than the radius on which the inlet opening lies. The static pressure boosting can be calculated according to the known formula
Δ p=ρ/ 2( v co 2 −v ci 2 )
Here, Δp stands for the pressure differential between the ambient atmosphere and the generator interior. ρ stands for the density of the cooling gas. Moreover, v co stands for the circumferential speed at the outlet opening and v ci stands for the circumferential speed at the inlet opening. In turbo-generators, as a rule, the stationary rotational speed of the rotor shaft should be considered as given, which is why a desired pressure differential Δp can be set by selecting the appropriate radii on which the inlet opening and the outlet opening of the flow channel are arranged. Furthermore, the number of flow channels provided on the axial fan for the pressure boosting means can vary, but as a rule, it will match or be a fraction of the number of compressor blades.
In an advantageous embodiment of the present invention, there are radial bores in the hub of the axial fan that serve as flow channels. This embodiment is a particularly simple and inexpensive variant of the present invention.
In an advantageous embodiment of the present invention, the flow at the flow outlet is deflected in the axial direction downstream from the main flow of the axial fan. In advantageous refinements of this embodiment, there are diagonal or L-shaped or Z-shaped or double-L-shaped bores in the hub of the axial fan that serve as flow channels. As a result, the flow is deflected so that the flow of the absolute pressure increase does not affect the main flow of the axial fan.
In an especially advantageous embodiment of the present invention, there is a tubular sleeve for lengthening the flow channel. Here, the flow channel can be advantageously lengthened at least to the blade height of the axial fan. The tubular sleeve can be arranged downstream as well as upstream from the blade of the axial fan. This depends, for instance, on the design of the fan hub, on the arrangement of the fan blades and on the flow conditions in each individual case.
In another advantageous embodiment of the present invention, the tubular sleeve has a streamlined jacket. The jacketed tubular sleeve can also be referred to as a streamlined additional blade, by means of which the outlet radius can be defined over the entire blade height of the axial fan through the parallel outlet with the main flow. As a result, the function of the axial fan is not impaired and it might even be improved. Depending on the embodiment, the streamlined jacketed tubular sleeve can also be configured as a streamlined body or as a radial bore made in an additional blade.
According to another particularly advantageous embodiment of the present invention, a blade bore made in the fan blade and configured as a radial channel serves as the flow channel, whereby said blade bore has a corresponding outlet opening. As a result, the influence on the main flow of the axial fan is kept to a minimum and pressure losses caused by other add-on parts are avoided. Here, depending on the construction of the fan blades, the radial bores can either be made subsequently or else they are already formed when the new fan blades are manufactured, for example, as a hollow core in the case of blades that are cast around a bolt core. In an advantageous refinement, there is at least one lateral outlet opening on the fan blade that allows a free flow out of the radial channel. The outlet opening can be configured, for example, as a recess shaped like a segment of a circle or as a semi-circular recess or else as a spherical recess. There can be several recesses on one side or on both sides of the fan blades. In the case of outlet openings on both sides, they can be arranged, for instance, alternatingly. If the outlet opening is located at the tip of the blade, the radial channel is adequately limited towards the top by the inlet opening of the axial fan, so that the flow here is deflected in the direction parallel to the axis.
In another advantageous embodiment of the present invention, there are several connecting channels leading towards the trailing edge of the blade. As a result, the main flow of the fan is minimally affected and in some cases, the flow is even enhanced.
In an advantageous embodiment of the two latter embodiments, the radial channel arranged in the fan blade is closed at the tip of the blade by means of a plug. This facilitates the production and allows the deflection of the boosting flow, even in those cases where the outlet opening is not located at the tip of the blade.
In another advantageous embodiment of the present invention, there is an axial fan with a pressure boosting means arranged at each end of the electric machine. As a result, the conveyed mass flow can be increased by the pressure boosting means if necessary.
In yet another advantageous embodiment of the present invention, the pressure boosting means is dimensioned so as to achieve a pressure differential Δp ranging from 0.1 bar to 0.5 bar, preferably from 0.2 bar to 0.3 bar. Experiments have proven that such an increase in the absolute pressure is sufficient for a marked improvement in the output of a turbo-generator.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantageous embodiments of the invention are described below with reference to the accompanying drawings, which show the following:
FIG. 1 —a schematic partially cutaway view of a first advantageous embodiment of an axial generator with pressure boosting means according to the present invention;
FIGS. 2 a and 2 b —a schematic partially cutaway view of a second and third advantageous embodiments of a pressure boosting means according to the present invention;
FIG. 3 —a fourth advantageous embodiment of a pressure boosting means according to the present invention;
FIGS. 4 a - 4 d —fifth and sixth embodiments of a pressure boosting means according to the present invention;
FIGS. 5 a - 5 b —a seventh advantageous embodiment of a pressure boosting means according to the present invention;
FIG. 6 —an eighth advantageous embodiment of a pressure boosting means according to the present invention;
FIG. 7 —a schematic sectional view of a fan blade in the arrow direction VII-VII from FIG. 6 ;
FIG. 8 —a ninth advantageous embodiment of a pressure boosting means according to the present invention;
FIG. 9 —a schematic sectional view of an axial fan blade in the arrow direction IX-IX from FIG. 8 .
Only the elements that are essential for understanding the invention are shown. In the descriptions to follow, parts that are identical or similar have been provided with the same reference numerals. As a rule, the depictions are not to scale. The directional indications “axial” and “radial” generally refer to the axis of the rotor shaft.
DETAILED DESCRIPTION
FIG. 1 shows a first advantageous embodiment of a pressure boosting means arranged on an axial fan of a gas-cooled turbo-generator, whereby FIG. 1 schematically depicts only the components that are important for the pressure boosting means.
The turbo-generator has a closed cooling circulation system. Preferably, air is employed as the cooling medium. The direction of flow of the circulated cooling medium is indicated in the figure by flow lines with directional arrows and runs in the drawing plane essentially from the right-hand side to the left-hand side. The turbo-generator has a partially depicted generator housing 1 made of sheet steel that completely accommodates the generator itself (not shown here) and the axial fan 4 provided for circulating the coolant.
Here, the axial fan 4 is arranged on a rotor shaft 2 that is mounted on shaft bearings 3 located outside of the generator housing 1 . The shaft exit is sealed off from the ambient atmosphere by means of a shaft gasket 9 . The axial fan 4 essentially has an encircling fan hub 8 that widens in an anvil-like manner in the radial direction and that is arranged on the rotor shaft 2 , whereby several fan blades 7 that project from the fan hub 8 in the radial direction and that are arranged next to each other in the circumferential direction on the outer circumference of the fan hub are anchored by means of a blade foot 32 configured as a threaded bolt and with a spacing sleeve 29 and a screwed connection 28 . Moreover, in the area of the tips of the fan blades 7 , there is an annular inlet opening 10 that, in the radial direction, delimits the blade grid formed by the fan blades 7 . In this context, the axial fan 4 rotates at the same rotational speed as the rotor shaft 2 , that is to say, there is no separate regulation of the rotational speed of the axial fan 4 here.
Moreover, a cover ring 31 that is rigidly connected to the generator housing 1 is arranged concentrically with respect to the rotor shaft 2 , whereby the side of the cover ring facing away from the generator housing 1 overlaps with part of the outer circumference of the fan hub 8 . As a result, an annular space designated as the hub interior 5 is created between the cover ring 31 and the rotor shaft 2 as well as between the generator housing 1 and the fan hub 8 , in which space the ambient pressure P Amb prevails. The generator interior 34 is sealed from the hub interior 5 during operation since the cover ring 31 forms a sealing gap with the fan hub 8 .
Recesses 33 are provided on the generator housing 1 in the area of the hub interior 5 , said recesses connecting the hub interior 5 to the ambient atmosphere. Moreover, there is a filter on the outside of the housing in the area of the bores 33 , in the present embodiment, it is a filter fiber mat 6 , which serves to prevent the penetration of dust or other dirt particles.
In FIG. 1 , two additional blind holes 11 , 12 are provided as the flow channel in the area of the fan hub 8 , whose cross section widens in an anvil-like manner radially outwards, said blind holes connecting the hub interior 5 to the generator interior 34 . Here, the first blind hole 11 that is made essentially parallel to the axial direction of the rotor shaft 2 is open towards the hub interior 5 . The second blind hole 12 runs radially outwards towards the top of the fan hub 8 and it intersects with the blind hole 11 that is parallel to the axis. As a result, an L-shaped connection is established between the hub interior 5 and the generator interior 34 .
These blind holes 11 , 12 are distributed along the circumference of the fan hub 8 , preferably in a number that matches the number of fan blades 7 . In the present embodiment according to FIG. 1 , the pressure boosting means is formed by the L-shaped arrangement of the two blind holes 11 , 12 .
During operation, due to the rotational speed of the rotor shaft 2 , air in the hub interior 5 is drawn from the blind hole 11 that is open towards the annular space and this air is then conveyed into the generator interior 34 through the second blind hole 12 . Since the inlet of the drawn-in ambient air, that is to say, the inlet into the blind hole 11 , lies on a smaller radius of the rotor shaft axis than the outlet of the drawn-in air from the blind hole 12 on the hub top, the pressure increases here according to the known formula
Δp=ρ/ 2( v co 2 −v ci 2 ).
As a result, the pressure P Gen in the generator interior 34 is greater by Δp than the ambient pressure P Amb that prevails in the hub interior 5 . Due to this rise in the absolute pressure in the generator interior 34 , for example, by 0.2 bar, an increase in the cooling output and thus an overall output improvement can be achieved for air-cooled generators in a known manner. Here, the magnitude of the pressure differential between the ambient pressure and the inner pressure in the generator can be varied by appropriately selecting the radius on which the inlet bore lies as well as the radius on which the outlet bore lies. The stationary rotor speed of the generator can be assumed to be given. The mass flow can be varied as a function of the size of the diameter of the bore.
Alternative embodiments to the advantageous embodiment shown in FIG. 1 will be described below. In this context, the details that are not important for the embodiment in question have not been depicted, so that a general reference is hereby made to the depiction in FIG. 1 .
FIG. 2 a shows a second advantageous embodiment of a pressure boosting means according to the invention, in which a diagonal passage bore 13 is made in the fan hub 8 . As a result, the cooling air conveyed by the pressure boosting means into the generator interior 34 can flow out more favorably, which does not have negative impact on the flow coming off the fan blades 7 . The same applies to the third embodiment depicted in FIG. 2 b , in which there is a Z-shaped or double-L-shaped passage channel 14 . Here, too, the flow is deflected, so that negative effects on the flow coming off the fan blades 7 are reduced. Here, the inlet side in the hub interior 5 lies on a smaller radius than the outlet side in the generator interior 34 .
FIG. 3 shows a fourth embodiment in which the radius differential over the hub height is lengthened by means of a tubular sleeve 17 that is anchored in the fan hub 8 by means of a threaded bore 16 and that is connected to the hub interior 5 via a diagonal bore 15 . In the embodiment according to FIG. 3 , the tubular sleeve 17 is arranged on the trailing edge of the fan blades 7 and its height approximately matches the height of the fan blades 7 . This likewise prevents disturbances on the flow coming off the fan blades 7 , although the height of the tubular sleeve 17 can be varied here in such a way that the desired increase in the absolute pressure in the generator interior 34 can be achieved.
FIG. 4 a shows a fifth advantageous embodiment of the present invention and FIG. 4 b shows a sectional view in the arrow direction along an intersection line IV-IV in FIG. 4 a . Here, on the trailing edge of the fan blade 7 , there is a tubular sleeve 21 with a streamlined jacket 18 or an additional blade with a radial bore. The tubular sleeve 21 has a radial channel 35 that is closed at its upper radial end by a plug 20 . An outlet opening 19 is provided on the downstream side of the streamlined jacket 18 . In the present embodiment, the streamlined jacket 18 is precisely as high as the fan blades 7 and is anchored in the fan hub 8 precisely like the fan blades 7 (not shown here). Here, the approach flow comes from the hub interior (not shown here) via a bore 22 . The desired increase in the absolute pressure in the interior of the generator can be set by appropriately selecting the radius on which the outlet opening 19 —which is essentially configured as a bore that is parallel to the axis—is arranged. On the one hand, the arrangement selected for the embodiment according to FIGS. 4 a and 4 b provides a solution that has more favorable flow properties than the embodiment shown in FIG. 3 . On the other hand, the distance of the outlet opening 19 from the rotor shaft, that is to say, the radius on which the outlet opening 19 is arranged, can be freely varied over the entire blade height without having a negative impact on the flow coming off the fan blades 7 . A contributing factor here is the deflection of the direction of the flow coming off the streamlined jacket 18 into a flow that is parallel to the rotor axis. The fan blades 7 and the tubular sleeve 21 with the streamlined jacket 18 or the additional blades can be advantageously arranged in such a way that they enhance the main flow of the fan. This can be achieved, for instance, by an axial overlapping of the blades.
FIG. 4 c shows a sixth advantageous embodiment of the present invention in which a pressure boosting means similar to the one depicted in FIG. 4 a is arranged on the fan hub 8 . FIG. 4 d shows a sectional view along the intersection line IV-IV in FIG. 4 c . In the advantageous embodiment according to FIGS. 4 c and 4 d , however, the tubular sleeve 21 with the streamlined jacket 18 or the additional blade with the radial bore is arranged in the flow direction upstream from the actual fan blade 7 . Here, too, the approach flow comes via the hub interior 5 . The tubular sleeve 21 with the streamlined jacket 18 or the additional blade is anchored on the fan hub 8 analogously to the fan blades 7 , that is to say, by means of a screw thread 23 . A sleeve 24 extends into the hub interior 5 , as a result of which the radial differential between the cooling air inlet and the cooling air outlet is additionally increased. Moreover, here, the outlet opening 19 is also arranged on a larger radius than in the embodiment according to FIG. 4 a , which brings about a higher pressure differential. Here, too, in order to optimize the flow, the fan blades 7 and the tubular sleeve 21 with the streamlined jacket 18 or the additional blade can be slightly offset tangentially and arranged so as to overlap axially.
FIGS. 5 a and 5 b show a seventh advantageous embodiment of the present invention in which the pressure boosting means is integrated into the fan blade 7 . FIG. 5 b shows a sectional view along the intersection line V-V in FIG. 5 a . According to this embodiment, ambient air is drawn in via a blade bore 25 configured as a radial channel, said bore being lengthened by an inlet shaft 27 in the hub interior 5 , whereby the ambient air is conveyed into the generator interior 34 via an outlet opening 26 that lies on a larger radius. The inlet shaft 27 is located in the blade foot that affixes the blades 7 to the fan hub 8 by means of a spacing sleeve 29 and a screwed connection 28 . The outlet opening 26 is created on a profile back of the fan blade 7 as a recess shaped like a segment of a circle so that the impact on the main flow of the fan is kept to a minimum.
FIG. 6 and FIG. 7 show an eighth advantageous embodiment of the present invention, whereby FIG. 7 depicts a top view along the intersection line VII-VII from FIG. 6 . In this embodiment, the pressure boosting means is likewise integrated as a blade bore 25 into the fan blade 7 . The outlet opening 26 is created on the profile back of the fan blade 7 as a recess shaped like a segment of a circle at the tip of the blade so that the impact on the main flow of the fan is kept to a minimum.
FIG. 8 and FIG. 9 show a ninth advantageous embodiment of the present invention whereby FIG. 9 depicts a sectional view along the line IX-IX from FIG. 8 . The pressure boosting means is integrated into the fan blade 7 and has a radial blade bore 25 that is closed at the blade tip by a plug 20 , and three outlet openings 26 that are parallel to the axis and arranged above each other. Here, too, the flow coming off the fan blades 7 is only slightly influenced by the pressure boosting means and the desired pressure increase is attained by an appropriate arrangement of the outlet openings 26 . Here, too, the ambient air is drawn in through the hub interior (not shown here) via an inlet shaft 30 arranged in the fan hub 8 .
Generally speaking, the arrangement of the lateral outlet opening in the streamlined jacket 18 of the tubular sleeve 21 or in the additional blade ( FIGS. 4 a , 4 c , 5 a , 5 b , 6 , 7 ) is radially sub-divided or “blurred” in a manner analogous to FIG. 8 , where the radial bore has several circles milled on it above each other.
Preferably, air is generally employed as the cooling medium; the hub interior is filled with air at atmospheric pressure. However, it is also conceivable to employ other gaseous cooling media in the generator interior. Leakage medium that escapes at the gap gasket (shaft gasket 8 , cover ring 31 ) is automatically drawn back into the generator. Therefore, medium loss is greatly reduced.
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A gas-cooled electric machine includes a generator housing, a rotor shaft, at least one axial fan disposed on the rotor shaft inside the generator housing and having a hub, and a pressure boosting apparatus associated with the axial fan and configured to raise an absolute pressure in a generator interior. The pressure boosting apparatus has at least one flow channel between an interior of the hub and the generator interior and is at least partially delimited by the hub. A flow inlet into the flow channel and a flow outlet out of the flow channel are disposed radially at a distance with respect to each other.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a joining structure for fitting parts or articles together, in particular, for use in the process of assembling component parts, such as interior parts of vehicles.
2. Description of the Related Art
In the production line of vehicles, it is repeatedly performed by workers to attach various kinds of interior parts such as console boxes and door linings to vehicle bodies. Those parts have to be infallibly attached in the predetermined positions. In addition, it is desirable to simplify and facilitate the work of attachment of the parts and to shorten the amount of time required for attaching the parts, especially when those parts are attached to mass-produced cars.
Japanese Patent Public Disclosure P2000-118318A discloses a structure for mounting a plate member on linings of a vehicle and a decorative component of a vehicle having the same structure. The plate mounting structure comprises a hook of a generally T-shaped cross section which is attached to a component part such as a door liner pad, a pair of stick-like guides formed on the hook or a substrate plate coalesced into the hook, and a hole formed in a member such as a door trim board. The hook of a T-shaped cross section has a head portion extending horizontally and a leg portion extending vertically. In addition, the pair of stick-like guides extend in parallel with the head portion of the hook. On the door trim board, a pair of protruding portions are formed beside the hole and a recess or slit is formed between the protruding portions to receive the leg portion of the hook therein. When mounting a decorative component such as the door liner pad on the door trim board, the head portion of the hook is inserted into the hole of the door trim board and then the hook is slid toward the protruding portions in order that the leg portion of the hook enter the recess or slit between the protruding portions. Thereby, the head portion of the hook is brought into contact with the upper surfaces of the protruding portions, while the pair of stick-like guides are brought into contact with the lower surfaces of the protruding portions. As a result, the protruding portions are wedged between the head portion and the stick-like guides so that the door liner pad of a decorative component is mounted on the door trim board of a vehicle.
The plate mounting structure disclosed in P2000-118318A has a structure that the head portion of the hook and the pair of protruding portions are interlocked to fix the door liner pad onto the door trim board. In order to enhance rigidity of the coupling arrangement between the door liner pad and the door trim board, it is, therefore, necessary to increase the thickness of the junction between the head and leg portions of the hook. In the event that the hook is molded from a synthetic resin and the thickness of the junction is increased, however, there is the possibility that a recess or so-called sink, a deformation or a crack is produced in the upper surface of the head portion when the junction between the head and leg portions are cooled down. If the sink, deformation and/or crack is formed in the upper surface of the head portion, the head portion has to be covered by another part to prevent the sink, deformation and crack from being exposed to the cabin of a vehicle. The sink, deformation and/or crack may be also formed in one side of the substrate plate, when the hook and the substrate plate was integrally molded from a synthetic resin and the leg portion of the hook coalesced into the other side of the substrate plate. In this case, it is also necessary to cover the defects on the side surface of the substrate plate by another means when the defected surface of the substrate plate is exposed to the interior of a cabin.
In addition, the plate mounting structure disclosed in Japanese Patent Public Disclosure P2000-118318A has a hole put through a member such as a door trim board, into which the head portion of the hook is inserted. The hole is left open after the head portion of the hook and the pair of protruding portions were interlocked to fix the door liner pad onto the door trim board. Therefore, the plate mounting structure cannot be used in the state that the member having the hole appears on the outside.
Furthermore, in order to fix the door liner pad onto the door trim board, the plate mounting structure mentioned above requires the following two steps of: inserting the head portion of the hook into the hole; and sliding the hook toward the protruding portions. The direction of inserting the head portion is at a right angle to the direction of sliding the hook. Consequently, the two steps have to be carried out as a discontinuous action. Therefore, the mounting work required for the plate mounting structure is not always efficient.
SUMMARY OF THE INVENTION
The objective of the present invention is to provide a joining structure of component parts that facilitates the coupling of component parts and simplifies the connecting activities of parts.
Another objective of the present invention is to provide a joining structure of component parts that can fix a component part onto another part quickly.
Further objective of the present invention is to provide a joining structure of component parts that generates a sufficient strength of connecting component parts.
Further objective of the present invention is to provide a joining structure of component parts, wherein the connected parts joined by the joining structure can be used as a product or a part of a product without any further processing of the product.
In order to achieve the aforementioned objects, a joining structure as a first aspect of the present invention comprises:
a first component part having a hollow protruding portion projecting from the side surface of said first component part, a flange portion projecting from the outer periphery of said hollow protruding portion with leaving a space from the side of said first component part, and an abutting surface formed on said flange portion to be opposed to the side surface of said first component part;
a second component part having a connecting groove for receiving said flange portion therein, said connecting groove extending along the side surface of said second component part and comprising a side slot for inserting said flange portion into said connecting groove, an upper slot for receiving said hollow protruding portion therein, and a bearing surface to be engaged with said abutting surface; and
one or more strut portions formed on said first and/or second component parts, wherein said strut portions are compressed between said first and second component parts when said flange portion is inserted into said connecting groove, and whereby said abutting surface and said bearing surface are clamped together by the force exerted by said strut portions.
A joining structure as a second aspect of the present invention comprises:
a first component part having a hollow protruding portion projecting from the side surface of said first component part, a flange portion projecting from the outer periphery of said hollow protruding portion with leaving a space from the side of said first component part, an abutting surface formed on said flange portion to be opposed to the side surface of said first component part, and one or more latch portions formed on the side edges of said flange portion;
a second component part having a connecting groove ( 23 ) for receiving said flange portion therein, said connecting groove extending along the side surface of said second component part and comprising a side slot for inserting said flange portion into said connecting groove, an upper slot for receiving said hollow protruding portion therein, a bearing surface to be engaged with said abutting surface, and one or more intermediate slots for receiving said latch portions; and
one or more strut portions formed on said first and/or second component parts, wherein said strut portions are compressed between said first and second component parts when said flange portion is inserted into said connecting groove, and whereby said abutting surface and said bearing surface are clamped together by the force exerted by said strut portions.
In the specification, the term of “hollow” means that the interior of an item, part or member is not filled with a material which makes up the item, and it does not matter whether an interior space of the item is closed or not. Similarly, the terms of “a hollow body” used in the specification means an item whose interior is not filled with a material which makes up the item, and it does not matter whether an interior space of the item is closed or not.
In the joining structure of the present invention, the protruding portion formed on the side of a first component part takes the form of a hollow body that prevents bringing about sinking, deforming and cracking of the side surface of the first component part, even in the event that the protruding portion is enlarged in order to increase the strength for connecting the first component part and a second component part. In addition, the connecting groove formed on the side of the second component part is also defined by a hollow body that comprises a pair of supporting ribs and a supporting plate bridging the pair of supporting ribs. Consequently, the hollow body can prevent generating the defects of sinking, deforming and cracking in the side surface of the second component part, even in the event that the supporting ribs and the supporting plate are increased in thickness in order to enhance the rigidity of the coupling arrangement between the first and second component parts.
Furthermore, no opening exists on the product surfaces of the first and second component parts to be joined together. Therefore, the joined parts can be used as a product or a part of a product without any further processing of the product.
In addition, the first and second component parts can be joined by inserting a flange portion of the first component part into the connecting groove of the second component part only in one direction. Therefore, the parts can be joined quickly and easily.
These and other advantages or effectiveness of the present invention will be defined from the detailed description of the present invention, which is made with reference to the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an exploded perspective view of an automotive console assembly having a joining structure of a type in which joining is effected in a horizontal direction;
FIG. 1B is an exploded perspective view of an automotive console assembly having a joining structure of a type in which joining is effected in a vertical direction;
FIG. 2 is a fragmentary, perspective view showing left and right side panels of the console assembly shown in FIG. 1A ;
FIG. 3 is a fragmentary, perspective view of a console box of the console assembly shown in FIG. 1A ;
FIG. 4A is a plan view of the joining structure shown in FIGS. 2 and 3 ;
FIG. 4B is a sectional view taken along the line A-A in FIG. 3 ;
FIG. 4C is a sectional view taken along the line B-B in FIG. 4A ;
FIG. 5 is a fragmentary, perspective view of a console box shown as a second embodiment of the present invention;
FIG. 6 is a sectional view taken along the line C-C in FIG. 5 ;
FIG. 7 is a fragmentary, perspective view of left and right side panels shown as a second embodiment of the present invention;
FIG. 8 is a fragmentary, perspective view of left and right side panels shown as a third embodiment of the present invention;
FIG. 9 is a fragmentary, perspective view of a console box shown as a third embodiment of the present invention;
FIG. 10 is a plan view of the joining structure shown in FIGS. 8 and 9 ; and
FIG. 11 is a sectional view taken along the line D-D in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of the invention will be described by taking as an example a console assembly, which is to be disposed between a driver's seat and a front passenger's seat of a motor vehicle.
Embodiment 1
FIGS. 1 to 4 shows a first embodiment of the present invention. As is shown in FIG. 1A , a console assembly 1 is made up by connecting a right side panel 3 and a left side panel 4 to a console box 2 which is made to open at a top thereof. The box 2 , the right side panel 3 and the left side panel 4 are integrally molded from a synthetic resin material, respectively. Four supporting portions 5 are formed integrally on each of left and right sides of the box 2 . Four flange portions 6 are formed integrally on each of the left and right side panels 3 , 4 . These flange portions 6 are positioned in such a manner as to correspond to the supporting portions 5 on the box 2 .
FIG. 1B shows a console assembly which is similar to that shown in FIG. 1A , and in FIG. 1B , constituent components given like reference numerals to those in FIG. 1A are constituent components having like designations. However, the console assembly 1 illustrated in FIG. 1B differs from that shown in FIG. 1A in that supporting portions 5 and flange portions 6 thereof are formed in a different direction. The supporting portion 5 in FIG. 1B is made into a form which results by rotating the supporting portion 5 in FIG. 1A through 90 degrees in a clockwise direction, and the flange portion 6 illustrated in FIG. 1B is made into a form which results by rotating the locking portion 6 in FIG. 1A through 90 degrees in a counterclockwise direction.
Due to those differences, the way of assembling the side panels to the box becomes different between the console assemblies shown in FIGS. 1A and 1B . Namely, in the console assembly 1 shown in FIG. 1A , the flange portions 6 are brought into engagement with the corresponding supporting portions 5 by moving the left and right side panels 3 and 4 in a longitudinal direction of each side panel relative to the box 2 , whereas in the console assembly 1 shown in FIG. 1B , the supporting portions 5 and the flange portions 6 are brought into engagement with each other by moving the left and right side panels 3 and 4 in a downward direction in the figure relative to the box 2 . The supporting portions 5 and the flange portions 6 in FIG. 1A and the supporting portions 5 and the flange portions 6 in FIG. 1B have the same configurations.
In both the console assemblies 1 in FIGS. 1A and 1B , interior surfaces RS 2 of the box 2 and exterior surfaces RS 1 , of the left and right side panels 3 , 4 constitute product surfaces. The exterior surfaces RS 1 of the left and right side panels 3 , 4 mean surfaces opposite to surfaces thereof where the flange portions 6 are formed.
As is shown in FIG. 1A or FIG. 1B , the four flange portions 6 are formed integrally on the rear surfaces of the left and right side panels 3 , 4 , respectively. In addition, the eight supporting portions 5 are formed on the exterior surfaces of the box 2 in such a manner as to correspond to the flange portions 6 , respectively. As is shown in FIG. 2 , the portions on the left and right side panels 3 , 4 where the flange portions 6 are formed are made to constitute connecting portions 7 , and as is shown in FIG. 3 , the portions on the box 2 where the supporting portions 5 are formed are made to constitute connecting portions 8 . The numbers of connecting portions 7 and 8 are arbitrary. Hereinafter, embodiments of the present invention will be described by taking as examples one of the connecting portions 7 formed on the left side panel 4 shown in FIG. 1A and one of the connecting portions 8 formed on the box 2 shown in FIG. 3 . Including the modified example shown in FIG. 1B the configurations of the other connecting portions 7 and 8 are the same as the configurations of the connecting portions 7 and 8 which will be described below.
As is shown in FIG. 2 , a hollow protruding portion 9 is formed integrally on the connecting portion 7 on the left side panel 4 , and a plate-shaped locking portion 6 is formed integrally on an end face of the protruding portion 9 in such a manner as to be spaced apart a certain distance from the connecting portion 7 . An opening 10 is formed in a central portion of the flange portion 6 , and the opening 10 communicates with an interior space 11 of the protruding portion 9 . As is shown in FIG. 4A , the hollow protruding portion 9 is formed substantially into the shape of U, which is the twenty-first letter of the alphabet in cross section, and a distal end portion thereof is formed into a smooth curved surface, whereas a rear end portion thereof is closed by a bend portion 13 of the plate-shaped locking portion 6 which is bent downwards. An abutting surface 14 is formed on a surface of surfaces of the plate-shaped locking portion 6 which faces a surface of the connecting portion 7 . As is shown in FIGS. 2 and 4 , the abutting surface 14 is formed on the perimeter of the protruding portion 9 . In addition, the plate-shaped flange portion 6 has a distal bent portion 15 which is bent towards the box 2 , and the bent portion 15 provides a guide surface for connecting the flange portion 6 to the supporting portion 5 .
FIG. 3 shows a connecting portion 8 of the box 2 which is brought into engagement with the flange portion 6 and the protruding portion 9 of the connecting portion 7 on the left side panel 4 . The connecting portion 8 is positioned where four reinforcement ribs 16 , 17 , 18 , 19 intersect each other which are formed on an exterior surface of the box 2 in such a manner as to protrude therefrom. The supporting portion 5 formed at the connecting portion 8 has a pair of supporting ribs 20 , 21 which are formed integrally on the reinforcement ribs 16 , 17 , respectively, and a supporting plate 22 is molded integrally between the supporting ribs 20 , 21 in such a state that the supporting plate 22 bridges the supporting ribs 20 , 21 . A connecting groove 23 is formed between the supporting plate 22 and a surface of the connecting portion 8 of the box 2 , and the connecting groove 23 extends between the supporting ribs 20 , 21 . An opening 24 , into which the flange portion 6 is inserted, is formed at one end of the connecting groove 23 , and an opening 25 , from which the distal bent portion 15 of the flange portion 6 protrudes, is formed at the other end of the connecting groove 23 .
An upper slot 26 is formed in the supporting plate 22 in such a manner as to receive therein the protruding portion 9 formed on the connecting portion 7 on the left side panel 4 . The upper slot 26 is made to open to a side slot 24 on the side of the connecting groove 23 and extends along the connecting groove 23 in a direction in which the protruding portion 9 enters. As is shown in FIG. 4A , a step portion 27 is formed at an intermediate portion along the length of the upper slot 26 in such a manner that the step portion 27 so formed is brought into engagement with a shoulder portion 28 of the protruding portion 9 which has entered the upper slot 26 so as to prevent the dislodgement of the protruding portion 9 from the upper slot 26 . Since the supporting ribs 20 , 21 are formed integrally on the reinforcement ribs 16 , 17 , respectively, they each have a high rigidity, but since the protruding portion 9 is the hollow body having the opening 10 , the protruding portion 9 can deform when entering the upper slot 26 .
A bearing surface 29 is formed on a side of the supporting plate 22 which faces the connecting groove 23 . The bearing surface 29 is situated on the perimeter of the upper slot 26 . The bearing surface 29 is formed in such a position that the bearing surface 29 is allowed to be brought into engagement with the abutting surface 14 of the plate-shaped flange portion 6 when the connecting portion 7 on the left side panel 4 is connected to the connecting portion 8 on the box 2 .
Extension ribs 30 , 31 are formed at distal end portions of the supporting ribs 20 , 21 , respectively, in such a manner as to protrude therefrom. The extension ribs 30 , 31 are brought into press contact with the connecting portion 7 or in the vicinity thereof on the left side panel 4 when the connecting portion 7 of the left side panel 4 is connected to the connecting portion 8 of the box 2 , so as to function as a strut for interlocking the abutting surface 14 of the plate-shaped flange portion 6 to the bearing surface 29 of the supporting plate 22 under pressure. In addition, as is shown in FIG. 4C , the extension ribs 30 , 31 each have a curved surface 32 which is inclined moderately towards the side slot 24 in the connecting groove 23 . The curved surface 32 constitutes a guide surface when the plate-shaped flange portion 6 is inserted into the connecting groove 23 .
In the embodiment shown in FIG. 1A , in order to connect the left side panel 4 to the box 2 , the plate-shaped flange portion 6 formed at the connecting portion 7 on the left side panel 4 as shown in FIG. 2 is inserted into the connecting groove 23 formed at the connecting portion 8 on the box 2 shown in FIG. 3 , and at the same time, the hollow protruding portion shown in FIG. 2 is pushed into a deepest portion of the upper slot 26 shown in FIG. 3 , whereby as is shown in FIG. 4B , since the extension ribs 30 , 31 of the box 2 are brought into press contact with the vicinity of the connecting portion 7 on the left side panel 4 , so as to attempt to forcibly open a space between the left side panel 4 and the box 2 , the abutting surface 14 of the plate-shaped flange portion 6 and the bearing surface 29 of the supporting plate 22 are interlocked with each other under pressure, whereby the position and posture of the panel 4 relative to the box 2 are maintained. In addition, as this occurs, the shoulder portion 28 of the protruding portion 9 is brought into engagement with the step portion 27 of the upper slot 26 , so as to prevent the disengagement of the connection between the panel 4 and the box 2 .
In addition, the connecting portions 7 and 8 , which are provided four each, are connected to each other at the same time that the left side panel 4 is connected to the box 2 . Namely, in the embodiment shown in FIG. 1A , the connection of the panel 4 and the box 2 is established only by performing an operation in which the panel 4 is caused to move in its longitudinal direction so that the four connecting portions 7 on the panel 4 are brought into engagement with the four connecting portions 8 on the box 2 simultaneously. A connection of the right side panel 3 to the box 2 will be effected in a similar manner. In addition, in the modified example shown in FIG. 1B , the left and right side panels 3 , 4 are connected to the box 2 , respectively, through operations in which the left and right side panels 3 , 4 are caused to move downwards relative to the box 2 . In this way, the connection of the left and right side panels 3 , 4 to the box 2 is established, whereby the console assembly 1 is assembled completely.
Interior surfaces RS 2 of the box 2 and exterior surfaces RS 1 of the left and right side panels 3 , 4 of the console assembly 1 can constitute product surfaces of the console assembly 1 as they are. Namely, the supporting portion 5 formed integrally on the connecting portion 8 of the box 2 constitutes a hollow body which is made to open to the outside by virtue of the existence of the connecting groove 23 having the side slot 24 . In addition, the protruding portion 9 formed integrally on the connecting portion 7 of each of the left and right side panels 3 , 4 constitutes a hollow body which is made to open to the outside by virtue of the existence of the interior space 11 having the opening 10 . Due to this, even when the box 2 and the panels 3 , 4 are formed from synthetic resin, an internal stress is made difficult to be produced when the synthetic resin molded bodies are cooled which stress would otherwise be produced at the portions where the hollow bodies are formed in association with the shrinkage of the synthetic resin material. Consequently, it is possible to prevent the generation of defects such as sink mark, deformation, cracking and the like on the interior surfaces RS 2 of the box 2 and the exterior surfaces RS 1 of the left and right side panels 3 , 4 . It is noted that an armrest which can be opened and closed (not shown) is mounted over an opening of the box 2 .
Embodiment 2
FIGS. 5 to 7 show a second embodiment of the invention. In FIGS. 5 to 7 , same reference numerals to those used in FIGS. 1 to 4 denote constituent components having the same designations as those described in FIGS. 1 to 4 . The features of this embodiment resides in a configuration in which in place of the extension ribs 30 , 31 in the first embodiment, a ridge portion 33 is formed in such a manner as to surround an opening 10 in a plate-shaped flange portion 6 formed at a connecting portion 7 of each of left and right side panels 3 , 4 , and distal end portions of the ridge portion 33 are made to continuously contact a rear end bent portion 13 A of the flange portion 6 . Since the rear end bent portion 13 A is connected to the ridge portion 33 , the rear end bent portion 13 A has a portion which protrudes further downwards from an opening 10 side surface of the flange portion 6 than the rear end bent portion 13 of the first embodiment. In addition, a supporting portion 5 formed at a connecting portion 8 of a box 2 has a supporting plate 22 which is formed integrally with reinforcement ribs 16 , 17 in such a state that the supporting plate 22 bridges the reinforcement ribs 16 , 17 . A connecting groove 23 extends between the supporting plate 22 and a surface of the connecting portion 8 . The other configurations are the same as those of the first embodiment.
As is shown in FIG. 6 , when the plate-shaped flange portion 6 is inserted into the connecting groove 23 , the ridge portion 33 is brought into press contact with a surface of the connecting portion of the box 2 so as to function as a strut, and an abutting surface 14 of the plate-shaped flange portion 6 and a bearing surface 29 of the supporting plate 22 are bonded to each other under pressure, whereby the position and posture of the panel 4 relative to the box 2 are maintained, so that the connecting strength between the box 2 and the left and right side panels 3 , 4 can be increased. In addition, since no portion exists at the connecting portion 8 of the box 2 which protrudes further than the reinforcement ribs 16 , 17 , the storability of the box 2 can also be enhanced.
Embodiment 3
FIGS. 8 to 10 show a third embodiment. In FIGS. 8 to 10 , same reference numerals to those used in FIGS. 1 to 4 denote constituent components having the same designations. The features of this embodiment resides in a configuration in which in place of the shoulder portion 28 of the protruding portion 9 and the step portion 27 of the upper slot 26 , a pair of flange projections 6 A, 6 B are formed on a plate-shaped flange portion 6 and intermediate slots 30 A, 31 A are formed in supporting ribs 20 , 21 , respectively, in such a manner as to open to edge portions of extension ribs 30 , 31 , so that, when left and right side panels 3 , 4 are connected to a box 2 , the flange projections 6 A, 6 B are brought into engagement with the intermediate slots 30 A, 31 A, respectively, whereby connecting portions 7 of the left and right side panels 3 , 4 can be prevented from being dislodged from connecting portions 8 of the box 2 in an ensured fashion. The other configurations are similar to those of the first embodiment.
It is noted that, while in the first to third embodiments, the protruding portion 9 is formed substantially into the shape of U, which is the twenty-first letter of the alphabet, in cross section, a projecting portion formed into the shape of an arbitrary alphabet letter, for example, H, M and the like, in cross section can be used in the connecting construction of the invention.
In addition, while in the first to third embodiments, the hollow protruding portions and flange portions are formed on the left and right side panels and the supporting portions are formed on the box, the supporting portions may be formed on the left and right side panels and the hollow protruding portions and flange portions may be formed on the box.
Furthermore, the interlocking structure of the third embodiment of the invention shown in FIGS. 8 to 10 which are made up of the flange projections 6 A, 6 B and the intermediate slots 30 A, 31 A can be formed on the joining structure of the second embodiment of the invention shown in FIGS. 5 to 7 .
The present invention realizes a joining structure of component parts producing the aforementioned features and advantages, without diminishing moldability of the products to be integrally molded from synthetic resin.
It is noted that the joining structure of the present invention can be used not only when joining automotive interior parts but also when connecting other items to each other.
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In a joining structure, a protruding portion on the side of a first component is a hollow body that prevents bringing about sinking, deforming, and cracking of the side surface of the first component part, even in the event that the protruding portion is enlarged in order to increase strength for connecting the first component part and a second component part. In addition, the connecting groove on the side of the second component part is also defined by a hollow body that includes a pair of supporting ribs and a supporting plate bridging the pair of supporting ribs. Consequently, the hollow body can prevent defects of sinking, deforming, and cracking in the side surface of the second component part, even in the event that the supporting ribs and the supporting plate are increased in thickness in order to enhance the rigidity of the coupling arrangement between the first and second component parts.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the implementation of a memory. More specifically, the invention relates to the implementation of a queue, particularly a FIFO-type queue (First In First Out), in a memory. The solution in accordance with the invention is intended for use specifically in connection with functional memories. By a functional memory is understood a memory in which updates, such as additions, are carried out in such a way that first the path from the root of a tree-shaped structure to the point of updating is copied, and thereafter the update is made in the copied data (i.e., the update is not directly made to the existing data). Such an updating procedure is also termed “copy-on-write”.
BACKGROUND OF THE INVENTION
[0002] In overwrite memory environments, in which updates are not made in the copy but directly in the original data (overwrite), a FIFO queue is normally implemented by means of a double-ended list of the kind shown in FIG. 1. The list comprises nodes of three successive elements in a queue, three of such successive nodes being shown in the figure (references N(i−1), Ni and N(i+1)). The element on the first edge of each node has a pointer to the preceding node in the queue, the element on the opposite edge again has a pointer to the next node in the queue, and the middle element in the node has either the actual stored data record or a pointer to a record (the figure shows a pointer).
[0003] However, such a typical way of implementing a FIFO queue is quite ineffective for example in connection with functional memories, since each update would result in copying of the entire queue. If, therefore, the queue has e.g. N nodes, all N nodes must be copied in connection with each update prior to performing the update.
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to accomplish an improvement to the above drawback by providing a novel way of establishing a queue, by means of which the memory can be implemented in such a way that the amount of required copying can be reduced in a functional structure as well. This objective is achieved with a method as defined in the independent claims.
[0005] The idea of the invention is to implement and maintain a queue by means of a tree-shaped structure in which the nodes have a given maximum size and in which (1) additions of data units (to the queue) are directed in the tree-shaped data structure to the first non-full node, seen from below, on the first edge of the data structure and (2) deletions of data units (from the queue) are also directed to a leaf node on the edge of the tree, typically on the opposite edge. Furthermore, the idea is to implement the additions in such a way that the leaf nodes remain at the same hierarchy level of the tree-shaped data structure, which means that when such a non-full node is not present, new nodes are created to keep the leaf nodes at the same hierarchy level. The tree-shaped data structure will also be termed shortly a tree in the following.
[0006] When the solution in accordance with the invention is used, each update to be made in the functional environment requires a time and space that are logarithmically dependent on the length of the queue, since only the path leading from the root to the point of updating must be copied from the structure. The length of this path increases logarithmically in relation to the length of the queue. (When a FIFO queue contains N nodes, log N nodes shall be copied, where the base number of the logarithm is dependent on the maximum size of the node.)
[0007] Furthermore, in the solution in accordance with the invention the node to be updated is easy to access, since the search proceeds by following the edge of the tree until a leaf node is found. This leaf node provides the point of updating.
[0008] In accordance with a preferred embodiment of the invention, the data structure also comprises a separate header node comprising three elements, each of which may be empty or contain a pointer, so that when one element contains a pointer it points to a separate node constituting the end of the queue, when a given second element contains a pointer it points to said tree-shaped structure that is maintained in the above-described manner, and when a given third element contains a pointer it points to a separate node constituting the beginning of the queue. In this structure, additions are made in such a way that the node constituting the end is always filled first, and only thereafter will an addition be made to the tree-shaped structure. Correspondingly, an entire leaf node at a time is always deleted from the tree-shaped structure, and said leaf node is made to be the node constituting the beginning of the queue, wherefrom deletions are made as long as said node has pointers or data units left. Thereafter, a deletion is again made from the tree. On account of such a solution, the tree need not be updated in connection with every addition or deletion. In this way, the updates are made faster than heretofore and require less memory space than previously.
[0009] Since the queue in accordance with the invention is symmetrical, it can be inverted in constant time and constant space irrespective of the length of the queue. In accordance with another preferred additional embodiment of the invention, the header node makes use of an identifier indicating in each case which of said separate nodes constitutes the beginning and which constitutes the end of the queue. The identifier thus indicates which way the queue is interpreted in each case. The queue can be inverted by changing the value of the identifier, and the tree structure will be interpreted as a mirror image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the following the invention and its preferred embodiments will be described in closer detail with reference to examples in accordance with the accompanying drawings, in which
[0011] [0011]FIG. 1 illustrates a typical implementation of a FIFO queue,
[0012] [0012]FIG. 2 a shows a tree-shaped data structure used in the implementation of a FIFO queue and the principle of updates made in a functional memory,
[0013] [0013]FIG. 2 b illustrates the generic structure of a discrete node in the tree-shaped data structure used to implement the FIFO queue,
[0014] [0014]FIGS. 3 a . . . 3 h illustrate making of additions to a FIFO queue when the memory is implemented in accordance with the basic embodiment of the invention,
[0015] [0015]FIGS. 4 a . . . 4 g illustrate making of deletions from a FIFO queue when the memory is implemented in accordance with the basic embodiment of the invention,
[0016] [0016]FIGS. 5 a . . . 5 h illustrate making of additions to a FIFO queue when the memory is implemented in accordance with a first preferred embodiment of the invention,
[0017] [0017]FIGS. 6 a . . . 6 h illustrate making of deletions from a FIFO queue when the memory is implemented in accordance with the first preferred embodiment of the invention,
[0018] [0018]FIG. 7 illustrates a preferred embodiment for a header node used in the structure, and
[0019] [0019]FIG. 8 shows a block diagram of a memory arrangement in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] [0020]FIG. 2 a illustrates a tree-shaped data structure used to implement a FIFO queue in accordance with the invention and the principle of updating used in a functional memory environment. The figure illustrates a FIFO queue in an initial situation in which the queue comprises data records 1 . . . 5 and thereafter in a situation in which a further record 6 has been added to the queue.
[0021] The data structure in accordance with the invention, by means of which the FIFO queue is established, comprises nodes and pointers contained therein. FIG. 2 b illustrates the generic structure of a node. The node comprises a field TF indicating the node type and an element table having one or more elements NE. Each element in the node has a pointer pointing downward in the structure. In accordance with the invention, a given upper limit has been set for the number of elements (i.e., the size of the node). Hence, the nodes are data structures comprising pointers whose number in the node is smaller than or equal to said upper limit. In addition to the pointers and the type field, also other information may be stored in the node, as will be set forth hereinafter. At this stage, however, the other information is not essential to the invention.
[0022] The node at the highest level of the tree is called the root node, and all nodes at equal distance from the root node (measured by the number of pointers in between) are at the same (hierarchy) level. The nodes to which there are pointers from a given node are said to be child nodes of said node, and correspondingly said given node is said to be the parent node of these nodes. The tree-shaped data structure in accordance with the invention can have two kinds of nodes: internal nodes (N 1 , N 2 and N 3 ) and leaf nodes (N 4 , N 5 and N 6 ). Internal nodes are nodes wherefrom there are pointers either to another internal node or to a leaf node. Leaf nodes, on the other hand, are nodes at the lowest level of the tree, wherefrom only records are pointed to. Thus the leaf nodes do not contain pointers to other leaf nodes or internal nodes. Instead of pointers, the leaf nodes can also contain actual records, particularly when all records to be stored in the queue are of equal size. Whilst it was stated above that each element in a node has a pointer pointing downward in the structure, the leaf nodes make an exception to this if the records are stored in the leaf nodes.
[0023] In FIG. 2 a, the rectangle denoted with broken line A illustrates a tree-shaped structure in an initial situation in which the structure comprises nodes N 1 . . . N 6 , in which case records 1 . . . 5 in the FIFO queue are either in leaf nodes N 4 . . . N 6 or leaf nodes N 4 . . . N 6 contain pointers to records 1 . . . 5 . When record 6 is added to this FIFO queue, an addition is made to node N 4 , wherein in the functional structure the path from the root node (N 1 ) to the point of updating (node N 4 ) is first copied. The copied path is denoted with reference P and the copied nodes with references N 1 ′, N 2 ′ and N 4 ′. Thereafter record 6 is added to the copy (node N 4 ′) and pointers are set to point to the previous data. In this case, the pointer (PO) of the second element of node N 1 ′ is set to point to node N 3 . After the updating, the memory thus stores a data structure represented by a polygon denoted by reference B. The nodes that are not pointed to are collected by known garbage collection methods.
[0024] In the invention, a balanced tree structure is used to implement a queue. This tree meets the following two conditions:
[0025] 1. all leaf nodes of the tree are at the same level.
[0026] 2. All internal nodes of the tree are full, except for the nodes on the left or right edge of the tree, which are not necessarily full.
[0027] The first condition is called the balance condition and the second condition the fill condition. In addition, a maximum size is set for the nodes of the tree, the nodes may e.g. be permitted only five child nodes. In the following, the maintenance of the FIFO queue in accordance with the invention will be described in detail.
[0028] [0028]FIGS. 3 a . . . 3 h illustrate a procedure in which records 1 . . . 8 are added to an initially empty tree structure (i.e., a FIFO queue) one record at a time. In this example, as in all the following examples, the following presumptions and simplifications have been made (for straightforwardness and clarity):
[0029] a node may have a maximum of two pointers only,
[0030] the records (i.e., their numbers) are drawn within the leaf nodes, even though each leaf node typically has a pointer to said record. It is presumed in the explication of the example that the leaf nodes have pointers to records, even though the leaf nodes may also contain records.
[0031] the copying to be carried out in the functional structure is not shown in order to more clearly highlight the principle of the invention. Thus, the same reference is used for the copy of a node and the corresponding original node.
[0032] In the initial situation, the queue is empty, and when an addition is made to the queue, single-pointer internal node (N 1 ) pointing to the added record is formed (FIG. 3 a ). When another record is added to the queue, the node is made into a two-pointer node containing pointers to both the first and the second record (FIG. 3 b ). When a third record is added, a new two-pointer internal node (N 2 ) is created, the right-hand pointer of which points to the old internal node and the left-hand pointer of which points to a new leaf node (N 3 ) having as a single child the new added record (FIG. 3 c ). When a fourth record is added, the addition is made (FIG. 3 d ) to the single-child node (N 3 ) on the left-hand edge of the tree. In connection with the addition of a fifth record, a new two-pointer root node (N 4 ) is again created, the right-hand element of which is set to point to the old root node and the left-hand element of which is set to point through two new single-pointer nodes (N 5 and N 6 ) to the added record (FIG. 3 e ). These new nodes are needed in order for the balance condition of the tree to be in force, that is, in order that all leaves of the tree may be at the same level.
[0033] The addition of the next record (record six) is again made to the single-child leaf node N 6 on the left-hand edge of the tree (FIG. 3 f ). Thereafter, in connection with the addition of the next record, the node (N 5 ) on the left-hand edge of the tree next to the leaf node is filled, and the new pointer of said node is set to point to the added record (seven) through a new (single-child) leaf node N 7 . The last record (eight) is added by adding another pointer to this leaf node, pointing to the added record.
[0034] As stated previously, the copying carried out in the structure has not been illustrated at all for simplicity and clarity, but the figures only show the result of each adding step. In practice, however, copying is carried out in each adding step, and the update is made in the copy. Thus, for example record two is added in such a way that a copy is made of leaf node N 1 and the record pointer is added to this copy. Correspondingly, for example in connection with the addition of record five, the content of the two-pointer node (N 2 ) that is the root node is copied into the correct location before the addition and the update is made in the copy (nodes N 4 . . . N 6 with their pointers are added). FIG. 2 a shows what kind of copying takes place for example in connection with the addition of record 6 (cf. FIGS. 3 e and 3 f ). Since such a functional updating policy is known as such and does not relate to the actual inventive idea, it will not be described in detail in this context.
[0035] Deletion from the tree takes place in reverse order, that is, the right-most record is always deleted from the tree. FIGS. 4 a . . . 4 g illustrate a procedure in which all the records referred to above are deleted one at a time from the FIFO queue constituted by the tree structure of FIG. 3 h which contains eight records. In the initial situation, the rightmost record (i.e., record one) of the tree is first searched therefrom, the relevant node is copied in such a way that only record two remains therein, and the path from the point of updating to the root is copied. The result is a tree as shown in FIG. 4 a. Similarly, record two is deleted, which gives the situation shown in FIG. 4 b, and record three, which gives the situation shown in FIG. 4 c. If during deletion an internal node becomes empty, the deletion also proceeds to the parent node of said node. If it is found in that connection that the root node contains only one pointer, the root node is deleted and the new root will become the node which this single pointer points to. When record four is deleted, it is found that internal node N 2 becomes empty, as a result of which the deletion proceeds to the root node (N 4 ). Since the root node contains only one pointer after this, the root node is deleted and node N 5 will be the new root. This gives the situation of FIG. 4 d. Thereafter the deletions shown in the figures proceed in the manner described above, i.e. the rightmost record is always deleted from the tree and the root node is deleted when it contains only one pointer.
[0036] The copying to be carried out has not been described in connection with deletion either. The copying is carried out in the known manner in such a way that from the leaf node wherefrom the deletion is made, only the remaining part is copied, and in addition the path from the root to the point of updating. The pointers of the copied nodes are set to point to the nodes that were not copied.
[0037] As will be seen from the above explication, in a FIFO queue in accordance with the invention
[0038] all leaf nodes in the tree are always at the same level (the lowest level if the records are not taken into account),
[0039] all nodes in the tree are full, except for the nodes on the edges of the tree, and
[0040] nodes are filled upwards. This means that in the first place, a non-full leaf node on the edge of the tree is filled. If such a leaf node is not found, the next step is to attempt to fill a non-full internal node on the edge next to a leaf node.
[0041] The additions and deletions can also be expressed in such a way that when an addition is made to the tree, the new record is made to be a leaf in the tree, which is obtained first in a preorder, and when a deletion is made from the tree the deletion is directed to the record that is obtained first in a postorder.
[0042] The above-stated structure can also be implemented as a mirror image, in which case the node added last is obtained first in a postorder and the one to be deleted next is obtained first in a preorder. This means that the additions are made on the right-hand edge and deletions on the left-hand edge of the tree (i.e., contrary to the above).
[0043] The above is an explanation of the basic embodiment of the invention, in which a FIFO queue is implemented merely by means of a tree-shaped data structure. In accordance with a first preferred embodiment of the invention, a three-element node, which in this context is called a header node, is added to the above-described data structure. One child of this header node forms the leaf node at the end (or pointing to the end) of the FIFO queue, the second child contains a tree of the kind described above, forming the middle part of the FIFO queue, and the third child forms the leaf node at the beginning (or pointing to the beginning) of the queue (provided that such a child exists). The separate nodes of the beginning and the end are called leaf nodes in this connection, since a filled node of the end is added as a leaf node to the tree and a leaf node that is deleted from the tree is made to be the node of the beginning.
[0044] [0044]FIGS. 5 a . . . 5 h illustrate a procedure in which records 1 . . . 8 are added to an initially empty queue one record at a time. The header node is denoted with reference HN, the leftmost element in the header node, which in this case points to a (leaf node at the end of the queue, is denoted with the reference LE, and the rightmost element in the header node., which in this case points to a (leaf) node at the beginning of the queue, is denoted with reference RE.
[0045] When a record is added to the end of the queue, a copy is made of the leaf node of the end and the record pointer is added to the copy (FIGS. 5 a and 5 b ). If, however, the leaf node of the end is already full (FIGS. 5 d and 5 f ), said leaf node is transferred to the tree in the header node (pointed to from the middlemost element in the header node). Thereafter a new leaf node for the end is created, in which said record is stored (FIGS. 5 e and 5 g ). The addition of the leaf node to the tree is made in the above-described manner. The addition thus otherwise follows the above principles, but an entire leaf node is added to the tree, not only one record at a time. Hence, all leaf nodes in the tree are at the same level. The node pointed to from the leftmost element of the header node is thus always filled, whereafter the entire leaf node is added to the tree.
[0046] When a deletion is made from the beginning of the queue, it is first studied whether the beginning of the queue is empty (that is, whether the right-most element in the header node has a pointer). If the beginning is not empty, the rightmost record is deleted from the leaf node of the beginning. If, on the other hand, the beginning is empty, the rightmost leaf node is searched from the tree representing the middle part of the queue. This leaf node is deleted from the tree in the manner described above, except that an entire leaf node is deleted from the tree at a time, not only one record at a time as in the basic embodiment described above. This deleted leaf node is made to be the leaf node of the beginning of the queue, and thus the beginning is no longer empty. If also the tree is empty, the leaf node of the end is made to be the leaf node of the beginning. If also the end is empty, the entire queue is empty. Deletion from the beginning of the queue is made by copying the leaf node of the beginning in such a way that its last record is deleted in connection with the copying.
[0047] [0047]FIGS. 6 a . . . 6 h illustrate a procedure in which the records 1 . . . 8 added above are deleted from the queue one record at a time. The initial situation is shown in FIG. 5 h. In the initial situation, the beginning of the queue is empty, and thus the rightmost leaf node is searched from the tree, said node being deleted from the tree and the deleted leaf node being made into the leaf node of the beginning of the queue. This gives the situation of FIG. 6 a. The next deletion is made from the leaf node of the beginning, as a result of which the beginning becomes empty. Thereafter the rightmost record in the tree (record three) is again deleted. Since in that case only a single pointer remains in the root node of the tree, said root node is deleted. Also the new root node has only one pointer, wherefore it is deleted too. This gives the situation of FIG. 6 c, in which the next record to be deleted is record four. When this record is deleted, the beginning of the queue is again empty (FIG. 6 d ), and thus in connection with the next deletion the leaf node pointing to record six is moved to the beginning of the queue, which makes the tree empty (FIG. 6 e ). When record six has been deleted, also the beginning is empty (FIG. 6 f ), and thus in connection with the next deletion the leaf node of the end is made to be the leaf node of the beginning (FIG. 6 g ). When also the end is empty (in addition to the fact that the beginning and the tree are empty), the entire queue is empty.
[0048] For the header node, the updating policy of the functional structure means that in connection with each addition, the header node and the leaf node of the end of the queue are copied. From this copy, a new pointer is set to the tree and to the old beginning (which thus need not be copied). Correspondingly, in connection with deletions the header node and the remaining portion of the leaf node of the beginning of the queue are copied and a new pointer is set from the copy to the tree and the old end.
[0049] By adding a header node to the memory structure, the updates will be made faster and less space-consuming than heretofore, since for the header node the additions require a (constant) time independent of the length of the queue. For example, if the maximum size of the node is five, only a fifth of the additions is made to the tree, and thus four fifths of the additions require a constant time and a fifth a time logarithmically dependent on the length of the queue.
[0050] In accordance with another preferred embodiment of the invention, a bit is added to the header node, indicating which edge of the header node constitutes the end and which the beginning of the FIFO queue. In other words, the value of the bit indicates whether the queue is inverted or not. If the bit has for example the value one, the leaf node pointed to from the leftmost element LE of the header node is construed as the end of the queue and the leaf node pointed to from the rightmost element RE as the beginning of the queue, respectively. If the value of the bit changes to be reverse, the beginning and end are construed in the reverse order and, furthermore, the tree representing the middle part of the queue is construed as a mirror image in relation to the previous interpretation. FIG. 7 illustrates the generic (logical) structure of the header node. In addition to the inversion bit IB, the node comprises the above-stated type field TF, indicating that a header node is concerned. In addition, the node has the above-stated three elements, each of which may be empty or contain a pointer. The order of these elements can also vary in such a way that the beginning, middle, or end of the queue can be pointed to from any element. Thus, the middle part is not necessarily pointed to from the element in the middle and the beginning or end from an element on the edge.
[0051] Since copying the header node and making an update in the copy and updating the above-stated bit to an inverse value of the original value is sufficient for inversion of the queue, the queue can be inverted in constant time and space. Since the structure is also fully symmetrical, the queue can be used as a double-ended queue, that is, additions can also be made to the beginning and deletions can be made from the end of the queue (FIFO or LIFO principle). For a double-ended queue, the shorter term deque is also used.
[0052] The bit indicating the direction of the queue can also be used in the basic embodiment of the invention in which there is no header node. In such a case, the bit can be added to the individual nodes, and thus the bit indicates which edge of the tree is the beginning of the queue and which the end in that part of the tree which is beneath said node.
[0053] [0053]FIG. 8 illustrates a block diagram of a memory arrangement in accordance with the invention, implementing a memory provided with a header node. The memory arrangement comprises an actual memory MEM, in which the above-described tree structure with its records is stored, a first intermediate register IR_A in which the leaf node of the end (or beginning) of the queue is stored, a second intermediate register IR_B in which the leaf node of the beginning (or end) of the queue is stored, and control logic CL maintaining the queue (making additions of records to the queue and deletions of records from the queue).
[0054] For the control logic, the memory arrangement further comprises a flag register FR in which the value of the inversion bit is maintained. Furthermore, the memory arrangement comprises an input register IR through which the input of the record pointers takes place and an output register OR through which the record pointers are read out.
[0055] As normally in systems of this kind, the records are stored in advance in the memory (MEM), and in this record set a queue is maintained by means of pointers pointing to the records.
[0056] When a record pointer is supplied to the input register, the control logic adds it to the leaf node in the first intermediate register IR_A. If the first intermediate register is full, however, the control logic first stores the content of the register in the tree stored in the memory MEM. This takes place in such a way that the control logic follows the edge of the tree and copies the path from the root to the point of updating and makes the update in the copy. Thereafter the control logic adds a pointer to the intermediate register IR_A.
[0057] When records are deleted from the queue, the control logic reads the content of the second intermediate register IR_B and deletes the record closest to the edge therefrom, if the intermediate register is not empty. If the intermediate register is empty, the control logic retrieves from memory, following the edge of the tree, a leaf node and transfers its remaining part to the second intermediate register. At the same time, the control logic updates the tree in the manner described above.
[0058] Even though the invention has been explained in the above with reference to examples in accordance with the accompanying drawings, it is obvious that the invention is not to be so restricted, but it can be modified within the scope of the inventive idea disclosed in the appended claims. For example, the maximum size of the nodes is not necessarily fixed, but it can e.g. follow a pattern, for example so that at each level of the tree the nodes have their level-specific maximum size. Since the actual records can be stored separately and the tree only serves for forming a queue therefrom and maintaining the queue, the records can be located in a memory area or memory block separate from the tree.
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The invention relates to a method for implementing a queue, particularly a FIFO queue, in a memory (MEM) and to a memory arrangement. In order to enable reducing the amount of copying particularly in a functional environment, at least part of the queue is formed with a tree-shaped data structure (A, B) known per se, having nodes at several different hierarchy levels, wherein an individual node can be (i) an internal node (N 1 -N 3 ) containing at least one pointer pointing to a node lower in the tree-shaped hierarchy or (ii) a leaf node (N 4 -N 6 ) containing at least one pointer to data unit ( 1 . . . 6 ) stored in the memory or at least one data unit. A given maximum number of pointers that an individual node can contain is defined for the nodes. The additions to be made to said part are directed in the tree-shaped data structure to the first non-full node (N 4 ), seen from below, on a predetermined first edge of the data structure and they are further implemented in such a way that the leaf nodes remain at the same hierarchy level of the tree-shaped data structure, wherein when a non-full node is not present, new nodes are created to maintain the leaf nodes at the same hierarchy level. The deletions to be made from said part are typically directed to the leaf node on the opposite edge of the tree.
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BACKGROUND OF THE INVENTION
This invention relates to folding cartons, and more particularly to a folding carton having a bucket-like shape, a locking bottom, and a separate lid including an integral handle.
In the fast food industry, minimizing the cost of containers for take-home or carry-out foods is becoming increasingly important. In the particular case of pre-cooked fried chicken, for example, the container should be strong and easily carryable, and at the same time it is desirable that it be collapsible for shipment and storage prior to use.
The prior art discloses many cartons of a hexagonal or multisided bucket-like shape. However, when a substantial weight is placed in the prior art containers, many of them have a tendency to gap open at the bottom. On the other hand, without weight in the container, as is the case just prior to filling, the bottom has a tendency to buckle, thus making filling the container difficult.
Most prior art containers, which are acceptable for the above-mentioned purpose, do not have a handle for carrying and must be carried in the arms, a relative inconvenience.
Accordingly, it is the object of the present invention to provide a bucket-shaped folding carton having a carrying handle.
Another object is to provide a carton having a separate lid.
A further object is to provide a carton having a locking bottom.
A still further object is to provide a locking bottom cover which seals gaps in the container bottom.
Other objects of this invention will be made apparent in the following specification and claims.
BRIEF SUMMARY OF THE INVENTION
The present invention is a bucket-shaped folding carton having holes around its top rim and a separate lid engageable in the holes. The lid includes panels substantially covering the open top and a central upstanding rib forming a handle. The carton body includes a locking flap engageable to hold the bottom of the carton in position.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, areas having adhesive applied thereon are indicated by stippled shading. A dot-dash line indicates a hinge line formed by scoring or creasing the material.
FIG. 1 is a top perspective view of the lid.
FIG. 2 is a top perspective view of the carton showing the lid engaged.
FIG. 3 is a top view of the lid in its unfolded or blank form.
FIG. 4 is a top plan view of the carton body in its unfolded or blank form.
FIG. 5 is a top perspective view of the carton body showing the locking flap in its unlocked position.
FIG. 6 is a fragmentary top perspective view similar to FIG. 5 showing the locking flap in its locked position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, lid 10 is shown generally, engaged with carton body 12. Preferably the lid and carton body are hexagonal, however, the carton body may be square or polygonal, and the periphery of the lid may be square, polygonal or substantially round.
FIG. 1 shows the lid comprised of cover panels 14 and handle panels 16 and 16' which are hinged together and hinged to the cover panels to upstand therefrom forming a central rib 18. Tabs 20 extend from the periphery of the cover panels. Extensions, preferably in the form of hooks 22 are formed integrally with the central rib and extend outwardly from both ends thereof, preferably below the plane of the cover panels, to engage with the carton body.
A hand hole 24 is formed through the central rib 18, and a hand hole flap 26 is hinged to the upper edge of handle panel 16. It is rotatable 180° through the hand hole to serve as a finger guard when carrying the carton.
Now referring to FIG. 3, the lid is shown in its unfolded or blank condition. It is preferably die cut out of medium thickness paperboard and either or both sides may be coated or printed on as desired. The hinge lines are scored to allow the two handle panels 16 and 16' to form the central rib 18, and to allow the hand hole flap 26 to be rotatable through the handhole 24. An inward cut 28 at the ends of each handle flap allow the extensions of the central rib to be positioned below the plane of the cover panels 14. The cover panels include ventilation holes 30.
The carton body is shown in FIG. 4 in its unfolded condition. The blank is die-cut, similarly to the lid, from medium thickness paperboard and may be coated or printed as desired.
A plurality of articulate side panels 32, 34, 36, 38, 40 and 42 forming the sides of the carton are each shaped similarly with a trapezoidal configuration. As a group they have a top edge 44, a bottom edge 46, and ends 48 and 50. They are jointed at the hinge lines which are formed by creasing or scoring the blank. At one end 50 a glue flap 52 is hinged to side panel 42 and is adhesively attachable to the other end 48 of the side panels. Preferably, the reverse side of the glue flap is attachable to the obverse side of panel 32 forming a tubular body with the glue flap on the interior.
Attached to the bottom edges of selected side panels 32, 34, 38, 40 and 42 are a plurality of bottom support flaps 54, 56, 58, 60, 62, 64, 66 and 68 which are foldable perpendicular to the side panels. Flap 56 is adhesively attachable to the reverse side of flap 58, and likewise flap 64 is attachable to flap 60.
A bottom cover panel 70 is hinged to the bottom edge of one of the side panels 36 and is foldable perpendicular to the side panels to cover the segmented bottom formed by the support flaps. Flap 68 is adhesively attachable to the reverse side of the bottom cover panel adjacent to its hinge line.
As shown in FIGS. 4, 5 and 6, a locking flap 72 is hinged to bottom cover panel 70. The locking flap is configured to engage the edge of glue flap 52 in wedging abutment, holding the bottom cover panel in position at the bottom of the carton. Preferably, the glue flap is configured to leave a space between the bottom edge of the glue flap, in the plane thereof, and the bottom of the carton, and the locking flap is configured to fill that space, its top edge abutting the bottom edge of the glue flap.
Adjacent to the top edge 44 of the carton body, the side panels include a plurality of holes 74. Preferably the holes are located on the hinge lines which are the angles of the carton. The shape of the holes is preferably that of a "T" with a distended stem.
Tabs 20 on the lid are engageable with the upper part of the holes (FIG. 2) and the hooks 22 are engageable with the stem part of the holes.
For ease in determining the orientation of the lid, all of the holes are configured similarly. In addition, added ventilation is provided around the periphery of the top of the carton by holes of the present configuration. At the end 48 of the side panels a half hole shape 76 is provided to match with the hole on the other end 50 when the carton is assembled.
OPERATION
The manner of use of the folding carton of the preferred embodiment can be conveniently described in two phases, namely: pre-assembly normally done at the factory, and the final use by the end user.
In the factory, after the blank for the carton body 12 is die-cut and scored, the adhesive attachments are made. Glue flap 52 is attached to the opposite end panel 32 forming a tubular body with the glue flap on the interior. Bottom cover panel 70 is folded into the tubular body, and bottom support flap 68 is adhesively attached to the section of panel 70 adjacent to its hinge line.
Flap 56 and flap 58 are adhesively attached, and flap 64 and flap 60 are likewise attached. The carton body may now be folded flat, with the bottom cover panel and the support flaps inside the flattened carton.
The end user thus receives the carton in a semi-assembled, flattened condition. When the carton body 12 is rounded, the bottom support flaps 54, 56, 58, 60, 62, 64, 66 and 68 and the bottom cover panel 70 make the bottom of the carton. The locking flap, as seen in FIG. 5 is folded up against side panel 32 to come into wedging abutment with glue flap 52.
In FIG. 6 the edge of the locking flap and the edge of the glue flap are shown engaged. This forces the bottom cover panel flat, and maintains the carton in its rounded or expanded position.
The lid 10 is received by the end user in its unfolded or blank condition. It is folded to assume the shape shown in FIG. 1. The hand hole flap 26 is folded 180° through the hand hole 24.
The carton is then filled with fried chicken or other product and the lid 10 engaged with the carton body 12. Tabs 20 are inserted in the corresponding holes 74, and hooks 22 are engaged in two of the opposing holes 74. The lid may assume any of several orientations on the carton body because of the universal design of the holes.
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A folding carton having a bucket-like shape. The bottom of the carton body includes a locking flap which is operable to hold the bottom flat. Around the top of the carton is a plurality of holes. A separate lid includes tabs which are engageable in the holes. The lid further includes an integral handle by which the carton may be carried.
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FIELD OF THE INVENTION
The present invention relates generally to vibration dampening in conjunction with tool usage and, more particularly, to a hand-held rivet bucking tool or "bar " which uses a visco-elastic polymer to dissipate at least a portion of the impact energy received.
BACKGROUND OF THE INVENTION
A vibration-damped hand-held rivet bucking tool currently exists in the art, as evidenced by U.S. Pat. No. 5,269,381. In this design, a vibration exposed inertia member is telescopically received by a cup-shaped grip element so as to allow axial reciprocal movement of the inertia member in relation to the grip element during use of the tool. Between the grip element and the inertia member there is provided a vibration damping system having two springs which are pre-tensioned between the grip element and the inertia member in opposite directions to obtain a balanced neutral position therebetween. When the relative position between these two elements is changed due to vibration forces, the springs act to regain the neutral position. The grip element and the inertia member have circular cross sections and are rotationally interlocked by a key.
This design presents certain drawbacks, however. First, the use of two counteracting springs results in a large number of components which must be manufactured with tight tolerances. Second, a central rod is used to hold the various components together internally, and this central rod is secured to the grip element by means of a screw, precluding straight-forward replacement or swapping of the rivet engaging implement formed on one end of the inertia member. If one or more of the springs could be replaced by an improved energy dissipation system, a simpler design should result and, at the same time, facilitate a quick-change of the rivet engaging implement or "dolly."
SUMMARY OF THE INVENTION
An object of the present invention is to provide a hand-held portable bucking tool having a housing with an interior chamber which receives an impact-receiving shank and a vibration dampening means which includes an energy dissipative polymer to absorb and dissipate at Least a portion of the vibration energy associated with the impact received. In one embodiment, the energy dissipative polymer may simply be compressed by the impact-receiving shank, however, in the preferred embodiment, a portion of the shank internal to the housing narrows to a rod-shaped element smaller in diameter than the shank itself, and the polymer material surrounds the rod at its distal end, and is bonded thereto, enabling the shank and rod to reciprocate axially by a small degree as each impact is received, transferring a portion of the associated energy to the polymer, which converts that energy into heat. Preferably, the outer surface of the polymer surrounding the rod at its distal end is further bonded to a cylindrical casing slidably received within a cylindrical bore associated with the housing, enabling the polymer material so encased to slide within the housing, in addition to enabling the shank and rod to reciprocate within the surrounding polymer. The preferred embodiment further includes a spring disposed between the distal end of the shank rod with the encased polymer and the terminal end of the bore within the housing, resulting in a two-piece piston assembly to convert and dissipate any energy over wider range of impacts.
A second object of the present invention is to provide a readily replaceable impact receiving member or "dolly". The dolly can be readily removed and replaced by rotating and removing the dolly from the housing. The dolly is retained in place by a plurality of ball bearings which engage a plurality of longitudinal grooves formed in the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing in partial cross section of a hand-held rivet bucking tool wherein a dolly shank is configured so as to compress an energy dissipative polymer;
FIG. 2 is an alternative embodiment of a hand-held rivet bucking tool according to the invention, wherein an energy dissipative polymer surrounds a shank movable with respect there;
FIG. 3 is yet a further alternative embodiment of the invention, wherein an energy dissipative polymer surrounds a movable shank portion, and further including a spring configured as part of a two-part piston assembly;
FIG. 4 is a side-view drawing in partial cross section incorporating the embodiment of FIG. 3, but further including a quick-change dolly capability; and
FIG. 5 shows a cross section of the tool of FIG. 4 taken along lines A--A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows generally at 100 a first embodiment of a hand-held rivet bucking tool or "bucking bar" according to the invention. An impact receiving member 102 or "dolly" includes a shank 108 slidably received along an axis 104 within a housing 106. The housing 106 has an interior chamber 110 adapted to receive the dolly shank 108 and a closed rounded outer end 112 opposite the chamber opening 114 adapted to easily fit into the palm of a user's hand. The dolly 102 has an impact receiving end 116 having an impact receiving surface 118 which is shaped according to the type of work being done. The impact receiving surface 118 can further be provided with a coating to inhibit wear.
Within the interior chamber 110, the shank 108 preferably narrows to a rod portion 120 connected to a plate 122. Between this plate 122 and the interior surface 124 opposite the opening 114 there is disposed a slug of an energy dissipative polymer, preferably of the visco-elastic type. Such polymeric material is commercially available, though other sources may alternatively be used or become available. In the configuration of FIG. 1, this polymeric material is disposed within a bellows 130, comprising a thin, outer metallic shell, though plastics and other materials may alternatively be used for this purpose. As the surface 118 experiences vibrational impacts during use, the energy is transmitted through the slidable shank portion 108, through rod 120 and plate 122, causing a compression of the polymeric material. Compression of this polymeric material is such that vibration energy received is at least partially converted into heat, which may be absorbed by the housing 106 and radiated from its outer surfaces. Although the shank portion 108 may be constructed as a solid unit having the plate 122 integrally formed therewith in unitary fashion, the rod 120 is preferably instead utilized so that at least a portion of the heat generated by the material 130 may be contained within chamber 110 as well as radiated from the outer surface of the housing 106.
FIG. 2 is a side-view drawing representative of an alternative embodiment of the invention, wherein, instead of compressing the energy-dissipative polymer, such material is supported around a rod portion 220 enabling a greater movement of the shank 208, and a greater dissipation of the energy through the polymeric medium 230, in this case shown in cross section. In addition to being bonded angularly around the rod 220, an outer cylindrical casing 231 is further bonded around the outer portion of the material 230, not only to contain the material 230, but also to provide some degree of slidability between the casing 231 and the inner wall 211 of the interior volume 210. In the configuration of FIG. 2, an annular step 233 is provided at the distal end of the inner chamber restricting further distally extensive motion of the encased polymeric material 230, thereby enabling the rod 220 to readily assume an axially oriented reciprocating motion, as indicated by the arrow 205 as the surface 218 receives an impact.
FIG. 3 shows yet a further alternative embodiment of the invention, in this case replacing step 233 of FIG. 2 with a spring 335, resulting in a two-part piston-type of assembly within the chamber 310. Now, as surface 318 receives an impact, causing shank portion 308 to slide relative to the housing 306, two stages of energy dissipation occur, the first being the movement of rod 320 relative to the casing 331, as its axial motion is restricted to a certain degree by the spring 335. However, with a sufficiently strong impact, spring 335 compresses in addition to the movement of rod 310 within polymeric material 330, resulting in a two-part energy dissipation system.
FIG. 4 illustrates generally at 400 yet another, further alternative embodiment of the invention, including the two-part piston-type energy dissipation system of FIG. 3, but further including quick-change dolly assembly. In the preferred embodiment, this quick-change assembly is facilitated by splitting the outer housing into two portions, an outer body portion 406, and an inner sleeve portion 407, the two portions being slidable with respect to one another, though with the extent of such motion being constrained and controlled in the following manner. An annular lip 440 is formed as shown on the inner wall of the outer housing member 406, and a corresponding lip 442 is formed as shown on the outer surface of the inner housing portion 407, resulting in two circularly shaped opposing surfaces at either end of a cylindrically shaped chamber 443. Within this chamber 443 there is placed a spring 444 which urges the surfaces 440 and 442 apart, but with the extent of this separation being maintained by an annular ring 446 formed in a groove 447 of the inner housing portion 407, such that as spring 444 forces the surfaces 440 and 442 apart, an outwardly extending portion of this ring 446 is caught by an annular portion of the outer housing 406, thus restricting any further extent of the sliding motion between the two housing bodies. With a sufficiently strong spring 444, these bodies 406 and 407 are biased apart to an extent sufficient to cause the two housing portions to behave as a unitary structure during use for rivet impact bucking.
Making further reference to FIG. 4, an annular groove 454 having a hemispherically shaped inner wall is now included around an inner section of the outer housing body 406, as shown, and one or more longitudinal grooves 450, also preferably including a hemispherically shaped surface, are formed along a portion of the shank 408 the extent of one such longitudinal slot 450 being evident in FIG. 4. In addition, a ball bearing 452 is provided in conjunction with each longitudinal groove 450 formed along the shank portion 408, each ball bearing 452 residing in a cavity formed radially outward from the longitudinal axis of the tool and through the body of the inner housing member 407 as aperture 453. Thus, in FIG. 4, the aperture 453 would be formed through the body of member 407 in a manner projecting outwardly from the drawing sheet. The width W of the wall of the body of the inner housing member 407 is such that with this spring 444 biasing the two housing components apart to their fullest extent as shown, the ball 452 is held in a more or less stationary position, but with tolerances allowing the shank portion 408 to reciprocate axially, at least to the extent of the longitudinal groove 450. Regardless of the impact motion, however, the shank 408 is effectively stopped at the longitudinal extent of the groove 450.
However, should a dolly change be in order, with pressure applied to the externally exposed surface 460 of the inner sleeve portion 407, compressing spring 444, the apertures formed through the body of the inner housing component 407 may, with sufficient pressure, be brought into alignment with the annular groove 454, enabling the balls 452 to move radially outward with respect to the longitudinal axis of the tool, so that, when fully received by the annular groove 454, all portions of each ball "clear" the non-longitudinally grooved sections of the shank 408, enabling the shank 408 to be slid outwardly from the bore of the inner housing component 407, thereby effectuating a change in the dolly portion of the tool.
FIG. 5 is a cross section of the tool of FIG. 4, taken along lines A--A, which would illustrate the situation with the spring 444 being compressed, so that the balls may be received by annular groove 454. FIG. 5 illustrates the preferred embodiment of having three equally spaced apart grooves 450, 450' and 450", each with an associated ball 452, 452' and 452", respectively. Thus, three apertures are formed radially outwardly and through the body of the inner housing component 407, these being 453,453' and 453".
FIG. 5 also shows each ball bearing being in a different stage in terms of leaving its associated longitudinal groove to be received by the annular groove 454. That is, in the case of ball 452, although it could under the circumstances shown roll into the annular groove portion 454 and thus clear the non-grooved portions of the shank 408, in this case it is illustrated as remaining proximate to is respective longitudinal groove. Ball 452', on the other hand, has rolled partially out of its respective longitudinal groove 450', but not yet into the annular groove 454, and its thus straddling a position between the two grooves. Ball 452", however, has rolled entirely out of its respective groove 450", and has been received along its outer surface to the fullest possible extent by the annular groove 454, such that the innermost point of the ball 450" now fully clears all portions of the shank 408, including outer non-longitudinally grooved portions of the shank. Accordingly, if all balls 452, 452' and 452" are configured radially outwardly to their fullest possible extent as in the case of ball 452", all portions of the shank will clear their respective balls and the shank may be pulled out or out of the drawing of FIG. 5 for replacement or maintenance purposes.
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The present invention relates to a hand held rivet bucking tool having a vibration dampening assembly including a visco-elastic polymer. The bucking tool features a dolly disposed within a housing and a vibration dampening assembly disposed therebetween. The visco-elastic polymer portion of the vibration dampening assembly absorbs and dissipates the vibration energy resulting from impacts received and delivered by the dolly. A second embodiment of the invention features a quick change dolly which can readily be removed from the housing so that a particular dolly can be used in conjunction with a particular rivet to be installed.
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FIELD OF THE INVENTION
This disclosure relates to the field of large scale integrated circuit chips which do self-testing and error reporting. Also, this disclosure relates to the implementation of digital circuits placed in large scale integrated chips.
BACKGROUND OF THE INVENTION
In recent years it has been seen that the complexity and density of very large scale integrated circuit designs has increased manyfold. As a result of this, it has become increasingly important to establish the reliability of this type circuitry.
Many of the present day large scale integrated circuit desings have been implemented with error detection circuits, such as parity generation and parity checking circuits. Such types of circuits are often designated as CED (concurrent error detection) circuits. Many of the systems in the prior art do detect errors by the use of conventional error-checking circuits and then will often inform a maintenance processor of the error. To a great extent, however, the error-related information obtained is very limited and sufficient information cannot be obtained unless the entire scan path is analyzed.
The system presented here is applicable to VLSI designs where a scan path is utilized. In a chip, flip-flops are connected to each other to form one or more long shift registers. Those long shift registers are also designated as a shift chain, snake or scan path.
The purpose of implementing snakes in a VLSI design is to minimize the maintenance controller interface signals. All the data, for example, chip initialization data, are shifted (written) into the snakes through an SDI, serial data input, or shifted out (read from) the snakes through an SDO, serial data output, in serial form.
The objective of the present system is to sample the outputs of the concurrent error detection (CED) circuits and to collect sufficient error information for a maintenance controller to analyze the error data under normal operating conditions and not merely under specialized error checking conditions.
Thus, it is an objective of this system to provide circuits in a VLSI device together with an error log and analysis mechanism which can operate without disrupting the normal operation of the system for one set of faults, and further to generate a signal to freeze the VLSI circuit for another type of faults, in order to prevent erroneous data from being propagated into other modules.
Additionally, the system of this disclosure operates to provide circuitry that will provide exhaustive self-test of the concurrent error detection (CED) circuits and to provide a structured and expandable error logging and reporting circuit system for the large scale integrated chip.
SUMMARY OF THE INVENTION
The system of the present disclosure involves a circuit implemented in very large scale integrated format for logging and for reporting errors occurring during normal operations.
The circuitry is provided with two register stages. The first register stage is capable of providing detailed error information and reporting it to a maintenance controller through a serial interface.
A second register stage logs the errors occurring only during the transfer of information from the first register stage to the maintenance controller, and the second register stage can accumulate this error information so that no information is lost on accumulated errors at any time.
The system captures both the permanent and the intermittent faults as they are detected by the concurrent error detecting circuits (CED), hence providing the maintenance controller with a mechanism to alert the field engineer or operator of a potential error by means of counting the intermittent errors.
The VLSI implemented circuitry system provides a "hold" signal to freeze the state of the entire circuit in those cases where the error incurred is a "fatal error", thus providing a mechanism for the maintenance controller to take possible recovery action.
Additionally, with the use of a mask register, the VLSI implemented circuitry system may suspend the reporting of selective errors, under the control of the maintenance controller.
Additionally, in the test mode, the circuitry operates to exhaustively test the CED circuits in order to obtain proper error detection coverage.
In the system, the first stage register (E s , FIG. 3) is made up of an error register, a mask register, an additional information register, and a shadow flag flip-flop. The first stage register is called an error snake, E s , FIG. 3. There are no other fields in this snake and it is shiftable without affecting other parts of the chip, even during normal run time.
The second stage register is called the shadow register, and is part of a chip snake C s , FIG. 3. The chip snake is the shift register formed by all the flip-flops that perform the specified functions of the chip. There may be more than one chip snake in a chip, but one chip snake is assumed here for simplicity.
Every snake has its own serial data input and output.
The purpose of making the error snake shiftable when the chip is in normal operation mode is that error information may be obtained without disturbing the operation of the chip during run time, for non-fatal errors. If the error is fatal, the entire chip is frozen (hold state).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the chip snake and error snake in a VLSI chip;
FIG. 2 shows a block diagram illustrating one bit of the error log system;
FIG. 3 is a block diagram of the error log system;
FIG. 4 is a diagram of the control and fatal error logic circuit;
FIG. 5 is an illustration of the D-type flip-flop used in this system;
FIG. 6 illustrates a chip implemented with multiple function shift registers (MFSRs);
FIGS. 7A and 7B is a diagram of a 16-bit MFSR implementation;
FIG. 8 shows the MFSR function table;
FIG. 9 shows the symbolic representation of the MFSR, multiple function shift register;
FIG. 10 illustrates the various self test phases;
FIGS. 11A, 11B, 11C is a drawing of a high level implementation diagram of the error log system in a chip;
FIG. 12(a) shows an error load logic schematic;
FIG. 12(b) shows an error load logic symbol representation;
FIG. 13(a) shows the control and fatal error logic schematic;
FIG. 13(b) shows a control and fatal error logic symbol representation;
FIG. 14(a) shows a shadow flag flip-flop schematic;
FIG. 14(b) shows a shadow flag flip-flop symbol representation;
FIG. 15 is a diagram showing timing for the error log system when an error is captured and there are no subsequent errors; and
FIG. 16 is a diagram showing timing for the error log system when an error is captured and when subsequent errors occur.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 shows a generalized diagram of a VLSI chip that has snake implementation to provide controllability and observability to its states.
All the flip-flops in the chip may be connected as a shift register that is called a snake. A maintenance controller can access this snake using serial data input and output pins, thus minimizing maintenance interface requirements. This snake is called the chip snake, C s .
The designation "a (chip logic)" indicates the combinatorial circuits that a system may have. System flip-flops in the chip snake, C s , generate signals to the combinatorial circuit "a", and/or may capture the outputs of the combinatorial circuit "a" as shown by lines c and d.
If CED (concurrent error detection circuits b) have been implemented in the design, registers are required which may be formed as a snake to capture the error signals "e". This snake is called the error snake, E s . When an error is captured, a maintenance controller (100, FIG. 2) accesses the error snake to get information on the error.
A shadow register S r , FIG. 3 is required to capture the error signals e when the error snake is being accessed by the maintenance controller. The shadow register S r , FIG. 3, resides in the chip snake C s , and it transfers its information to the error snake, E s , when the maintenance controller's access to the error snake is complete.
With reference to FIG. 2, there is seen a "bit slice" of the error log register, 90 of FIG. 3. In FIG. 2 it is indicated how one bit of the CED (concurrent error detection) information is handled. The concurrent error detection signal 1 is designated as CED(i). It is ORed with the output of one bit of the shadow register 2, thus accumulating the errors involved.
An OR gate 3 receives the concurrent error detection signal CED(i) and also the Q signal from the shadow register 2. The output of the OR gate 3 is ANDed by means of AND gate 4 with the "NAND" 8 of the "HOLD-ERROR-BAR" and the ERROR-BAR.
The HOLD-ERROR-BAR signal (FIG. 2) is designated as 82 while the ERROR-BAR signal is designated as 83.
Thus the signal 1 of the CED(i) will be loaded into the shadow register 2 (one bit) only if the HOLD-ERROR-BAR 82 and/or the ERROR-BAR 83 are in the condition of low (active).
In FIG. 2, the error register 5 is a flip-flop which is a part of the error register E r (FIG. 3) while the mask register 6 is a flip-flop which is part of the mask register M r shown in FIG. 3.
Thus, while FIG. 2 indicates the circuitry for one bit of information, the circuitry of FIG. 3 indicates the circuitry for "n" bits of information. In FIG. 2, the mark "i" indicates one bit while "(i-1)" indicates a shift of the one bit.
There is a one-to-one correspondence between one mask bit and one error register bit.
The Q output of error register 5 is ANDed with the AND gate 7 which also receives the Q output of mask register 6.
The single mask bit in mask register 6 is set to "1" if it is not desired to mask the signal 1, CED(i). Thus the output of the AND gate 7 will be the same as that of the error register flip-flop 5.
The outputs of the AND gate 7 and other AND gates at the outputs of other bits of the error register E r and the mask register 6 form the ERROR signals 71, (i . . . j) FIGS. 2 and 3. The NOR gate 10 (FIGS. 2 and 3) receives all the ERROR signals and generates ERROR-BAR signal 83 which causes, when active, a hold on the error snake E s of FIG. 1, and enables the shadow register 2 through gates 8 and 4 (FIG. 2) to load subsequent ERROR signals, if any.
In the normal or "no error" condition, the input to the bit "i" of the shadow register 2 is always "0", where HOLD-ERROR-BAR is equal to "1 " and the ERROR-BAR is equal to "1". These are the signal lines 82 and line 83, FIGS. 2, 3.
If an error occurs where CED(i) is equal to "1", then the output Q of bit error register 5 goes high and the ERROR-BAR signal 83 goes low if the error is not masked. The signal 83 holds the error-register-bit and at the same time enables the shadow-register-bit of register 2 so that the subsequent errors on CED(i) can be loaded into the flip-flop of the shadow register 2 of FIG. 2.
The ERROR-BAR 83 signal also goes to the maintenance controller (MC) 100 and warns the MC of the error condition.
The bit (FIG. 2) error register 5 and the bit (FIG. 2) in mask register 6 are in the same shift chain called the "error snake", E s of FIG. 1.
The shadow register 2 is connected to another shift chain called the "chip snake", C s of FIG. 1.
The shift chain that contains the error register 5 and the mask register 6 may be shifted when the signal 82 (HOLD-ERROR-BAR) is active and thus equal to "0 ".
The shift chain that the shadow register 2 is part of, may be shifted when the signal 21 (HOLD-CHIP-SNAKE-BAR) is active and thus equal to "0".
As long as the error snake E s is in the "hold mode", then the errors are accumulated in the shadow register 2.
The output of the OR gate 3 (FIG. 2) becomes the signal GCED(i) 31 (FIGS. 2, 3) if the error signal 1 or CED(i) is fatal.
In FIG. 3 there is seen a higher level schematic drawing of the error snake, E s , implementation of an "n" bit error snake. In this case the error snake is any multiple of 16 because the error snake has been implemented using a multiple function shift register (MSFR) which is 16 bits wide.
The error snake circuitry is basically composed of elements S r , S f , E r , M r , and A r , as indicated in FIG. 3.
An MSFR is basically a BILBO or built-in logic block observer which has the functions of--Hold, Load, Shift, Pattern Generation, and Signature Collection.
In the chip testing function, the MSFR can generate patterns or collect signatures to test a combinatorial network.
The error log circuitry 90 of FIG. 3 contains two shift chains. One is called the "error snake" (E s ) and the other is called the "shadow register" (S r ) of FIG. 3 which is part of another chain called the "chip snake" (C s ). In the simplest case, all functional flip-flops on the chip are part of the chip snake (C s ).
In FIG. 3, the shadow flag flip-flop (S f ) is used to tell whether the information contained in the error register (E r ) has been loaded from the shadow register (S r ) or not.
If the shadow flag flip-flop (S f ) of FIG. 3 is set, it implies that the contents of the error register (E r ) have been loaded from the shadow register (S r ) and that more than one error may have been logged.
These errors are logged during the previous hold of the error snake. The "SHIFT-COMPLETE" signal (70 s of FIG. 3) generates a pulse from control logic 70 at the end of the shift operation of the error snake when the HOLD-ERROR-BAR signal 82 is deactivated. This deactivating pulse is called the SHIFT-COMPLETE signal (70 s ).
If the shadow register (S r ) has logged errors, then the shadow flag flip-flop register (S f ) is set to "1" and is held as such.
In FIG. 3, the logic circuit 50 is the error load logic circuitry which is equivalent to OR gate 3 plus an AND gate 4 of FIG. 2 and the OR gate 501 of FIG. 4. The "n" bit circuitry for the load logic 50 is the logic for the shadow register (S r ) of FIG. 3 and is controlled by the CLEAR/LOAD signal 81 from the control logic 70.
The control logic 70 is made up of the NAND gate 8 plus the AND gate 9 of FIG. 2 in addition to the gate 703 of FIG. 4.
As long as there are no errors logged in the error register (E r ), the load logic 50 is disabled. As soon as an error does occur, the error snake is held and the load logic 50 is enabled, so that subsequent errors are then logged in the shadow register (S r ).
The GCED 31 signal is the input to the fatal error circuit 60 in FIG. 3, which is made up of the NAND gate 601 and the flip-flops 602 and 603 of FIG. 4.
Referring to FIG. 4, there is seen a diagram of the control and fatal error logic 60, also seen in block 60 of FIG. 3.
In FIG. 3 there was shown the block designated as the fatal error logic error 60. When this block is shown in more detail it will be seen to be composed of those items in FIG. 4 which are designated as flip-flop latch 603, mask fatal error flip-flop 602, and NAND gate 601.
Referring back to FIG. 2, it was seen that the signal line 31 represented the GCED(i) signals which are considered fatal to the operation of the chip. In FIG. 4, the i . . . j signals 31 (FATAL ERROR signals only) are placed through an ORing function of gate 501 and registered in a flip-flop 603 and thence gate 601 to generate the FATAL-ERROR-BAR signal 60 f .
For circuit debugging purposes, the signal 60 f may be masked on gate 601 by the flip-flop 602.
In case of a "fatal error", the chip operation must be stopped in order not to propagate the error to other modules around the chip. Thus the FATAL-ERROR-BAR signal (60 f ) and the HOLD-BAR signal 22 (from the maintenance controller) are ANDed by the AND gate 703 (FIG. 4) to generate the signal 21 which is the HOLD-CHIP-SNAKE-BAR signal that "freezes" the chip snake.
The chip operation may be frozen by the HOLD BAR signal 22 (FIG. 3) from the maintenance controller 100 or else by the FATAL-ERROR-BAR signal 60 f , when there is a fatal error.
The AND gate 703 (FIG. 4) is located in the control logic 70 of FIG. 3. The fatal-error flip-flop 603 and the mask fatal-error flip-flop 602 are in the chip snake shown as C s of FIG. 3.
Before the exact implementation is delineated, basic components used in the system will be described.
FIG. 5 shows the symbol for a D-type flip-flop that has been used in the design, where
CP=clock input
D=data input when TE=0
TI=data input when TE=1
TE=selects between D and TI
Q=true output
Q/=false output
As was discussed earlier, MSFRs have been used as registers in this system. An MFSR stands for "multiple function shift register" which is basically a linear function shift register (LSFR) described by the polynomial:
P(x)=1+x.sup.4 +x.sup.7 +x.sup.9 x.sup.16
A 16-bit MSFR has been built using 18 flip-flops of the type described in FIG. 5.
The MFSR designed for this system provides the following functions:
(i) Load function: The MFSR functions as a parallel load register. All flip-flops are loaded at the same time. Load function is the normal operation mode.
(ii) Hold function: Present state of the MFSR is frozen if a hold function is being performed. No new data is loaded. An MFSR may be held in both normal operation and maintenance mode.
(iii) Shift function: Eighteen flip-flops form a shift register (snake). State of a flip-flop is shifted to the next flip-flop stage. Shift function is performed in maintenance mode.
(iv) Pattern Generation: An MFSR is used as a pattern generator if its outputs are feeding the inputs of a combinatorial circuit. An MFSR can generate looping (walking) patterns or random patterns (all 16-bit possible combinations except zero). Pattern generation is a maintenance mode function.
(v) Signature Collection: An MFSR can collect signatures if its inputs are being fed by the outputs of a combinatorial circuit. At each clock, the present state of the MFSR is exclusively ORed with the present outputs of the combinatorial circuit and shifted. The compressed data resulting in the MFSR after a specified number of clocks is the signature. Signature collection is a maintenance mode function.
Referring to FIG. 6, to elaborate on the use of MFSRs in a chip for normal functions as well as self-testing, there is seen a chip in which MFSRs are utilized as registers. All MFSRs are connected to each other to form a chip snake (C s ) and an error snake (E s ).
For normal operation, the chip is initialized using the serial path (with CHIP-SDI 101 and CHIP-SDO 102; ERR-SDI 103 and ERR-SDO 104) by the maintenance controller, 100. Then, the chip is returned to normal mode. In normal mode, MFSR 1 (105) and MFSR 2 (106) may capture the inputs 112 from other chips; and process those signals through the combinatorial circuit 109 and register the result in MFSR q (107) and MFSR p (108). The results may be sent out of the chip through the chip outputs 113.
Concurrent error detection (CED) circuits 110 (FIG. 6) are utilized to detect run time errors. If any error occurs, it is captured by the error snake (E s ). Then, the maintenance controller may shift out the error snake to determine the error and analyze the error that occurred.
If the chip is to be tested with a scheme that is called BIST, built-in self test, the maintenance controller initializes the chip, such that MFSR 1 (105) and MFSR 2 (106) will generate patterns; and MFSR q (107) and MFSR p (108) will collect signatures to test the combinatorial circuit 109. At the end of the test, the maintenance controller will shift out the chip snake to analyze the signature. The same method is used to test the CED (110) logic by collecting signatures at the error snake (E s ).
During testing, at each clock, a new pattern is generated by the pattern generating MFSR and the result is compressed as signature by the signature collecting MFSR. If the test is done on a defective circuit, the signature would be different from the expected signature which was obtained from the good circuit with the same patterns.
FIG. 7 is the complete schematic for the MFSR used in this system.
The first two flip-flops (T1, T0) as shown by 214 and 215, are the configuration flip-flops. The sixteen flip-flops numbered as 216, 217 and 218 are the ones that are used as a register for normal operation and as a pattern generator or a signature collector in test mode.
Normal mode is when all maintenance control signals are inactive. SYHBAR (213) is the only signal that performs the normal mode operations: load and hold. The logic in the chip that uses the MFSR asserts or denies the SYHBAR 213 signal. With all the maintenance signals being "1" (inactive), SYHBAR propagates through the circuit group shown by 229 and determines the levels of signals (C0, C1) 232 and 231 which select one of four inputs on the fifteen serial multiplexors designated 219, 220--and 221.
If the MFSR is being selected (addressed), SYHBAR will be a "1" and C0, C1=11 and input 3 on the four-input multiplexors will be selected. Therefore, the data inputs (FIG. 7) D0-D15, shown by 201, will be loaded in parallel to the respective flip-flops through their D inputs.
If the MFSR is not being selected, SYHBAR will be a "0" and C0, C1=00 and input 0 on the four-input multiplexor will be selected. Hence, the present state of the register will be reloaded, or in other words, it is frozen.
Maintenance control signals are SDI (207), serial data input; SDO (234), serial data output; SHIFT-BAR (208), shift control signal; SEL-BAR (209), select signal; TESTMODE-BAR (210), test mode signal; TC (211), test count signal; HOLD-BAR (212), hold bar signal.
Except for the TC (211) signal, these signals are all generated by the maintenance controller, and are all active low signals. TC (211) is a signal generated by a counter in the chip and it is an active high signal. This counter is called "test counter" and it times the duration the self test runs. When TC goes active (=1), the test mode ends.
As long as HOLD-BAR 212 is active (=0), the MFSR is in maintenance mode. If HOLD-BAR 212 is the only active signal, then the MFSR is in hold mode.
Hold Mode
HOLD-BAR is "0"; all other maintenance signals are "1". The level on the HOLD-BAR 212 line will propagate through the circuit shown by 229 (FIG. 7A) and the outputs C0, C1=00 and hence the present state of the MFSR will hold. The (T1 and T0) 214 and 215 flip-flops, have been designed such that if there is no shift operation, they always hold.
Shift Mode
HOLD-BAR=0, SHIFT-BAR=0, SEL-BAR=0. The shift operation overrides the hold mode. The output of the NOR gate 228 (FIG. 7A) puts a "1" on the TE inputs of the (T1) 214 and (T0) 215 flip-flops and the TI data inputs will be selected. SDI 207 supplies the input data in serial form, and the shift path that is selected on the MFSR is through the input 1 of multiplexor 227 (FIG. 7A) and input 2 of the four-input multiplexors 219, 220, 221 (FIG. 7B) and through the D inputs and Q outputs of the flip-flops to the SDO 234 serial data output, FIG. 7B.
The reason for keeping HOLD-BAR 212, FIG. 7A, active during a shift operation is that in case the shift cannot be done continuously (may be done eight bits at a time), between shift operations, the data in the snakes must be held.
Pattern Generation
HOLD-BAR=0, TESTMODE-BAR=0. (FIG. 7) Before TESTMODE-BAR 210 is activated, proper data must be set in T1, T0 (214, 215) and fifteen data registers, through a shift operation. The outputs of the T1, T0 flip-flops determine the type of patterns to be generated. The data in the fifteen data flip-flops (216, 217--218) is called the "seed" for the patterns.
When the TESTMODE-BAR 210 (FIG. 7A) is activated, T1, T0 flip-flops continue to hold, and the input 0 of the multiplexor 227 is selected and the shift path on the fifteen four-input multiplexors and fifteen flip-flops is also selected, that is selected in shift-mode as well. If T1, T0=00, then the Last Q (203) determines the serial input to the shift path. If Q15 is connected to the Last Q (203), 16-bit walking (looping) patterns are generated. In cases where MFSRs are concatenated, the Q15 (FIG. 7B) of the last MFSR is connected to the Last Q input of the first MFSR to generate long walking patterns.
If T1, T0=01, then input 0 of the multiplexor 225 is selected. This signal is the output of an EXOR (exclusive OR) function 205 whose inputs are Q6, Q8, Q11, Q15 shown as 204 (FIG. 7A), feedback lines from the respective flip-flops. This way, 16-bit random patterns are generated. These are all 16-bit possible combinations, except all-zeros, generated randomly rather than binary counter fashion.
Pattern generation starts as soon as TESTMODE-BAR 210 (FIG. 7A) is activated and continues until TC 211 goes active (=1) although TESTMODE-BAR is kept active.
Signature Collection
HOLD-BAR=0, TESTMODE-BAR=0. T1, T0=10, a seed in the fifteen flip-flops must be set up through a shift operation.
The inputs 0 on the multiplexors 225 and 227 are selected as for random pattern generation. Since the output of the NOR gate signal 233 is active (=1), the TI inputs (FIG. 7A, 7B) of the fifteen flip-flops are selected as the data input. TI inputs come from the outputs of the EXOR gates 222, 223 and 224. Parallel data inputs D0-D15 (FIGS. 7, 9) shown as 201 are EXORed with the outputs of the flip-flops in previous stages. D0 is EXORed with the output of the multiplexor 227 which is effectively the output of the EXOR function 205. At each clock, a shift operation also occurs. This way, the data on D0-D15 is compressed on the MFSR to form a signature. Also, D0-D15 may be the outputs of a combinatorial circuit under test. If the signature obtained from the circuit is "different" from the one that was obtained originally on the good circuit (for example, by simulation) with the same patterns, then the circuit under test is defective.
All the description of MFSRs given above is summarized in FIG. 8.
Also, a symbol for the 16-bit MFSR is given in FIG. 9, but all maintenance signals are not shown for simplicity.
Referring to FIG. 10, there is seen all the phases of a "self-test" as well as the maintenance control signals (TESTMODE) being asserted or denied.
Also referring back to FIG. 6, an example may be illustrated. With a shift in operation, MFSR q 107 and MFSR p 108 should be seeded with non-zero data and configured as random pattern generators to test the CED circuit 110. And also, the error snake MFSRs (E s , FIG. 6) should be configured to collect the singature, being seeded with some data (all-zeros seed possible). Since MFSRs are 16 bits long, they can generate 65,536 minus 1 non-zero patterns. Therefore, the test counter TC in the chip should be seeded with 65,536 minus 1. At each clock, the signature will be collected in the error snake (E s , FIG. 6). Test and signature collection will stop when the test counter asserts the TC 211 signal at 65536-1 clocks later. Then, in the second shift phase, the error snake (E s ) is shifted out by the maintenance controller to analyze the signature.
The above illustrates how the "self-test" of the CED circuits is performed with this system.
Implementation of the system in a VLSI chip is seen in FIGS. 11A, B, C which shows the chip snake (C s ) and the error snake (E s ) organization with MFSRs. The shadow register, the error register, mask register, and additional information register, the control and fatal error logic, error load logic, and shadow flag flip-flop are also shown. FIGS. 11A, B, C is analogous to FIG. 1, but provides more detail.
Additionally, to emphasize the expandability of the system, a possible 16-bit expansion is shown by the dotted lines in FIGS. 11A, B, C. The additional blocks are the shadow register, error load logic, error register and the mask register.
In the chip snake (C s ), MFSR k 162 (FIG. 11A) is part of the operational circuit and it represents many MFSRs. Just like MFSR k , MFSR x 167, FIG. 11C, too represents many MFSRs and it is part of the operational circuit. They perform whatever functions the chip is designed for. They may receive inputs from combinatorial logic, say 150, 154; signals from chip inputs, say 157, FIG. 11A, 159, FIG. 11C. They may generate signals to combinatorial logic circuits, say 151, 155; or the signal they generate, say 158, FIG. 11A, 160 FIG. 11C, may leave the chip on the chip output pins.
MFSR l 163, FIG. 11A, is the 16-bit MFSR, shadow register (S r ) in FIG. 3; and its input comes from the error load logic 1 (174), FIG. 11A, whose inputs are the error signals from the CED circuits shown as 152. The signals shown by line 1 in FIG. 11A are the signals (1) in FIG. 2. If there are more than sixteen CED outputs, expansion is required in the error log system. By dotted lines (in FIGS. 11B and 11C), shown are an expansion shadow register 164 (MFSR m ), and an expansion error load logic 175 which captures the error signals from CED logic 153. Each error load logic is equivalent to logic 50 in FIG. 3 and its complete implementation will be discussed hereinafter. Note that the feedback lines 177 (FIG. 11A) and 178 (FIG. 11B) are equivalent to the feedback from the Q output of the flip-flop 2 to the input of the OR gate 3 in FIG. 2. The feedback is for the shadow register to not lose any errors, but to accumulate them. The error load logic 50 sends the error signals to both shadow register 163 and error register 168, FIG. 11A, also generates a GCED signal 31, FIG. 3, for fatal errors. The GCED 1 and GCED 2 (FIG. 11B) shown by bus 51, (also shown by 31 in FIG. 3), are ORed by gate 176, FIG. 11B. The OR gate 176 is required only if expansion is implemented. The output of OR gate 176 is an input to the control and fatal error logic 165 (FIG. 11B) that generates the signal 60 f FATAL-ERR-BAR which is also 60 f in FIGS. 3 and 4. The FATAL-ERR-BAR signal 60 f , FIG. 3, causes the HOLD-CHIP-SNAKE-BAR signal 21 to go active, such that it holds the chip snake (C s ). It may also go to the maintenance controller to inform it of the fatal error.
The control and fatal error logic 165, FIG. 11B, contains an MFSR and its details will be subsequently described. Using the HOLD-BAR 22 and HOLD-ERR-BAR 82 (FIG. 3, FIG. 11A) signals from the maintenance controller 100 and the error signal from the OR gate 176, FIG. 11B, and the ERROR-BAR signal 83 from the error snake MFSR n , FIG. 11B, it generates; HOLD-CHIP-SNAKE-BAR 21 for the MFSRs in the chip snake; HOLD-ERR-SNAKE-BAR 91 for the MFSRs in the error snake and the shadow flag flip-flop; CLEAR/LOAD-SHADOW-REG 81, FIG. 11B, for the shadow registers 163 and 164; SHIFT-COMPLETE signal 70 s for the shadow flag flip-flop (173, FIG. 11A). These signals have the same reference numbers in FIG. 3.
Also note that all MFSRs are connected to each other to form a "shift path" for the chip snake. The maintenance controller signals SHIFT-BAR and TESTMODE-BAR are connected to all MFSRs in the design (but not shown in FIG. 11A, 11B, 11C). All the maintenance signals are shown in the complete implementation diagrams.
The error snake (E s ) in FIG. 11A, 11B, 11C contains: a shadow flag flip-flop 173; the error (first) register 168, which is an MFSR; the error (second) register 169 which is an MFSR; first mask register 170 which is an MFSR; second mask register 171 which is an MFSR; additional information register 172, which may be many MFSRs. The shadow flag flip-flop 173 and MFSRs form a shift path for the error snake.
The error registers 168, 169 (FIGS. 9, 11A, and 11B) are just 16-bit MFSRs. They capture the error signals from the error load logic and causes the ERROR-BAR signal 83, FIG. 11B, to be generated for the unmasked errors. The AND gates 7, FIGS. 11A, 11B, provide the masking function. For each error register and mask register, sixteen such AND gates are required. The gates 7 are analogous to the AND gates 7 and 10 in FIG. 2. The 32-input NOR gate function 10, FIG. 11A generates the ERROR-BAR signal 83 and it is the same NOR gate as 10 in FIG. 2. The ERROR-BAR signal 83 is an input to the control and fatal error logic 165, FIG. 11B. It also connects to the maintenance controller to inform it of error conditions (FIG. 2).
When the maintenance controller 100 receives this signal, it can shift out the error snake and analyze the error register to see which circuit failed. If the shadow flag flip-flop contains a "1", it means the information in the error register was transferred from the shadow register which accumulated the errors that occurred when the error snake was being shifted because of a previous error.
The mask register 170 (FIG. 11B), 171 (FIG. 11C) provides the 16-bit mask information for the two error registers and it is just an MFSR. Note that these are feedback paths from the Q(0-15) outputs to the D(0-15) inputs of the mask register 170 and 171. The mask register MFSRs shift when the SHIFT-BAR signal is active; and will always hold otherwise. Those feedback lines are for the hold function.
The error register 169 (FIG. 11B) and the mask register 171 (FIG. 11C) have been used here for the expansion example.
The additional information register 172, FIG. 11C, may contain as many MFSRs as required by the specific chip design. Its length entirely depends on which information is to be captured corresponding to the errors in the error register. The information in it is frozen when HOLD-ERR-SNAKE-BAR 91 is activated by the ERROR-BAR signal 83. Its inputs may come from chip logic 156, FIG. 11C.
Referring to FIG. 12(a), there is seen the details of the error load block, 50 of FIG. 3.
The OR gates shown by 3 and the AND gates shown by 4 are analogous to these in FIG. 2. The GCED signal 51 generated by the OR gate 501 is as shown in FIG. 4 by the same reference numbers. The signals ERROR-REG D0-D15 (801) are the error signals for the error register. The outputs of the AND gates 4, SHADOW-REG D0-D15 are the error signals for the shadow register. The signals SHADOW-REG Q0-Q15, shown by 802, are the feedback lines from the shadow register outputs. The SHADOW-ENABLE signal 803 is connected to the CLEAR/LOAD-SHADOW-REG signal generated by the control 70 and fatal error logic block, 60 of FIG. 3.
FIG. 12(b) is a symbolic representation for the load logic used in the system.
FIG. 13(a) is the schematic for the control and fatal error logic 70 and 60 of FIG. 3. It contains a 16-bit MFSR. Only D0, D1 inputs and Q0/, Q1 and Q2 are used. The outputs Q(2-15) are fed back to the inputs D(2-15), so the MFSR could be used as a signature collector for the combinatorial circuits feeding its inputs with signals 822 and 823.
The input 822 comes from the OR gate 176 or the GCED signal 51 if expansion is not implemented. The signals HOLD-BAR 824 and HOLD-ERR-BAR 823 are as shown in FIG. 11A by line 82. The ERROR-BAR signal 83 comes from the NOR gate 10 in FIG. 11A.
The output signals FATAL-ERR-BAR 60 f , SHIFT-COMPLETE 70 s , HOLD-ERR-SNAKE-BAR 91, CLEAR/LOAD-SHADOW-REG 81 and HOLD-CHIP-SNAKE-BAR 21 are connected to other blocks in the system as shown in FIGS. 11A, B, C by the same reference numbers.
FIG. 13(b) is the symbolic representation for the control and fatal error logic that is used in the system.
FIG. 14(a) is the schematic for the shadow flag flip-flop. A D-type flip-flop is used. The signal SHIFTB 831 is the SHIFT-BAR and the SELB signal 832 is the SEL-BAR from the maintenance controller. The output of the NOR gate 834 selects SDI as the data input on TI. SDI 833 is the serial data input and SDO 835 is the serial data output. The SHIFT-COMPLETE signal 839 comes from the control and fatal error logic block and loads a "1" to the flip-flop 836 when the shift of the error snake is completed. HOLDB 838, when active, holds the flip-flop 836 and is connected to HOLD-ERR-SNAKE-BAR signal 91 from the control and fatal error logic block 165 in FIG. 11B. CLK line 837 (FIG. 14a) is the clock input.
FIG. 14(b) is the symbol representation for the shadow flag flip-flop that can be used in the system.
In reference to FIG. 15, it is now assumed that during normal operation of the VLSI circuitry chip, an error occurs and this error is registered in the error register E r of FIG. 3. Since the snakes are in normal mode, E r performs a load operation.
The error snake freezes itself and is shifted out by the maintenance controller for error analysis; and it is assumed that no other errors occur during the shift operation. Now it will be seen that the following sequence of activities will occur:
1. For example, one of the concurrent error detector circuits, CEDn, generates an error signal. In FIG. 15 this is shown at the time point T1.
2. In the next clock period, at time T2, the error register bit "n" in the error register is set. If the circuit is not masked, then the ERROR-BAR signal goes "active" which freezes the error snake (E s in FIG. 3) and then enables the shadow register S r of FIG. 3. The ERROR-BAR signal 83 of FIG. 2 and signal line 83 of FIG. 11 goes off the chip and alerts the maintenance controller 100 for error analysis. If the error is fatal, the chip snake (C s of FIG. 11) is also held frozen, (hold function).
3. When the maintenance controller 100 operates to select and make a shift operation to analyze the error, it asserts the HOLD-ERROR-BAR signal 82 of FIG. 3; (and 82 of FIG. 2) which also freezes the error snake (E s of FIG. 3), performing a hold function on the MFSRs.
4. In the next following clock time, at time T4, the control and fatal control logic QO output will go to "0" (in FIG. 13).
5. Then some clocks later, - for example, at time T5, the maintenance controller 100 selects the error snake and asserts the SHIFT-BAR at time T5 as shown in FIG. 15. In the next clock, the shift operation then starts. The SHIFT-BAR signal remains active until after all of the bits in the error snake are shifted out to the maintenance controller 100.
6. The maintenance controller 100 will shift all zeroes into the error register (E r ) and also restore the mask register (M r of FIG. 3) information as it shifts out. As soon as the error data is shifted out, - as, for example, at time T6, the ERROR-BAR signal goes inactive.
7. The maintenance controller 100 then denies the SHIFT-BAR at time, - for example, T7, as soon as the shift is complete.
8. Then, some clocks later, as, - for example, at time T8, the maintenance controller 100 releases the HOLD-ERROR-BAR signal which causes the SHIFT-COMPLETE signal to be asserted for one clock, at time T8.
9. Now, since the SHIFT-COMPLETE signal has been high in the previous clock from T8 to T9, then the shadow flag flip-flop output goes high, as seen in FIG. 15.
Since it has been assumed here that no errors have occurred during the error register shift operation, the shadow register will be cleared at time T9 or the end of clock T8 which, in turn, will clear the shadow flag flip-flop in the next clock at time T10.
Now the error snake (E s of FIG. 3) is ready to receive further error signals.
With reference to FIG. 16, the assumption is made that an error occurs and the error signal is stored in the shadow register S r of FIG. 3 when the error snake E r is being shifted out because of a previous error. The shadow register S r is shown in FIG. 2, FIG. 3 and FIG. 11.
The sequence of events which transpire are shown in FIG. 16 with certain time points designated as T1 through T4 as discussed hereinbelow.
1. At time T1, the CEDn signal indicates that an error has occurred, which is then registered in the shadow registers S r because the CLEAR/LOAD-SHADOW-REG signal is active (that is, in the "high" position). At time T2 in FIG. 16 the shift is completed but the HOLD-ERROR-BAR is still active due to the previous error signal. Therefore, the shift process is still active.
2. Up until this point of clock time T2, the signal activities will be seen to be the same as that shown in FIG. 15 previously. However, after the clock time of T2, since the HOLD-ERROR-BAR is inactive, the contents of the shadow register S r will be transferred to the error register E r causing the ERROR-BAR signal to go active at time T3. This will, in turn, cause a shift operation (assertion of SHIFT-BAR signal) to be initiated from the maintenance controller 100.
3. Since there is an error signal in the shadow register S r , the shadow flag flip-flop 173 of FIG. 11 will hold a "high" level at least until the shift operation has started and thence it will go high and low depending on where the error bits are in the error register E r . The shadow flag flip-flop 173 of FIG. 1 is the first bit that is shifted out.
4. After the shifting operation has been completed, the circuit will behave in the same fashion as was described in connection with FIG. 15.
There has been described herein a specialized VLSI chip which includes means for detecting and logging errors which can be reported to an associated maintenance controller. Both intermittent and permanent errors are reported. Non-fatal errors do not stop the normal operation of the chip but detection of a fatal error (which ruins the chip integrity) will cause the chip to be frozen into a hold mode to prevent any further propagation of errors.
The versatility provided allows each error bit to be masked in order to facilitate debugging and isolation of the problem area. Additional information, such as the address of the problem area of a specific error, may be obtained in an additional register of the error log circuitry without disturbing the normal operation of the chip.
Errors are detected by concurrent error detection circuitry (CED) and the built-in self-testing circuitry (BIST) tests the CED circuitry itself and also the transmission of data to/from the associated maintenance controller.
The chip is tested when the maintenance controller initializes the chip causing a first set of multi-function shift registers to generate test patterns, and a second set of multi-function shift registers to collect signatures which can then be analyzed by the maintenance controller to determine the correct operation of the chip.
While other implementations of the above functions may be designed, it is to be understood that the invention is defined by the following claims.
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A VSLI chip is implemented with registers which log permanent and intermittent errors occurring within the chip as sensed by concurrent error detection circuitry (CED). If a fatal error is detected (one which would destroy the reliability of chip operations), then the chip is immobilized into a hold mode (freeze). Interrupts are signalled to a cooperating maintenance controller which can pass the error information to an external computer for display and for locating a faulty area.
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PRIORITY
This application is a continuation-in-part application of and claims priority to U.S. Non-provisional patent application Ser. No. 12/244,017, filed on Oct. 2, 2008, entitled “Plasma Uniformity Control Using Biased Array.” The entire specification of U.S. Non-provisional patent application Ser. No. 12/244,017, is incorporated herein by reference.
FIELD
The present disclosure is related to semiconductor manufacturing, particularly to semiconductor manufacturing using plasma.
BACKGROUND
Ions are commonly implanted into a substrate in ion implantation processes to produce semiconductor devices. These ion implantations may be achieved in a number of different ways. For example, a beam-line ion implantation system may be used to perform the ion implantation process. In the beam-line ion implantation system, an ion source is used to generate ions, which are manipulated in a beam-like state, and then directed toward the wafer. As the ions strike the wafer, they dope a particular region of the wafer. The configuration of doped regions defines their functionality, and through the use of conductive interconnects, these wafers can be transformed into complex circuits.
In another example, a plasma containing ions may be generated near the substrate. A voltage is then applied to the substrate to attract ions toward the substrate. This technique is known as plasma doping (“PLAD”) or plasma immersion ion implantation (“PIII”) process. FIG. 1 shows an exemplary plasma doping system 100 . The plasma doping system 100 includes a process chamber 102 defining an enclosed volume 103 . Within the volume 103 of the process chamber 102 , a platen 134 and a workpiece 138 , which is supported by the platen 134 , may be positioned.
A gas source 104 provides a dopant gas to the interior volume 103 of the process chamber 102 through the mass flow controller 106 . A gas baffle 170 is positioned in the process chamber 102 to deflect the flow of gas from the gas source 104 .
The process chamber 102 may also have a chamber top 118 having a dielectric section extending in a generally horizontal direction and another dielectric section extending in a generally vertical direction.
The plasma doping system may further include a plasma source 101 configured to generate a plasma 140 within the process chamber 102 . The source 101 may include a RF power source 150 to supply RF power to either one or both of the planar antenna 126 and the helical antenna 146 to generate the plasma 140 . The RF source 150 may be coupled to the antennas 126 , 146 by an impedance matching network 152 that matches the output impedance of the RF source 150 to the impedance of the RF antennas 126 , 146 in order to maximize the power transferred from the RF source 150 to the RF antennas 126 , 146 .
The plasma doping system 100 also may include a bias power supply 148 electrically coupled to the platen 134 . The bias power supply 148 may provide a continuous or a pulsed platen signal having pulse ON and OFF time periods to bias the workpiece 138 . In the process, the ions may be accelerated toward the workpiece 138 . The bias power supply 148 may be a DC or an RF power supply.
In operation, the gas source 104 supplies a dopant gas containing a desired dopant species to the chamber 102 . To generate the plasma 140 , the RF source 150 resonates RF currents in at least one of the RF antennas 126 , 146 to produce an oscillating magnetic field. The oscillating magnetic field induces RF currents into the process chamber 102 . The RF currents in the process chamber 102 excite and ionize the primary dopant gas to generate the plasma 140 .
The bias power supply 148 provides a pulsed platen signal to bias the platen 134 and, hence, the workpiece 138 to accelerate ions from the plasma 140 toward the workpiece 138 . The frequency of the pulsed platen signal and/or the duty cycle of the pulses may be selected to provide a desired dose rate.
The above technique is known to provide high implant throughput. However, the uniformity of the dose is difficult to control. In the beam-line ion implantation system, components such mass analyzer magnets, deceleration electrodes and other beam-line components may be used to manipulate ions into a uniform ion beam, and the workpiece may be uniformly implanted with ions in the uniform ion beam. Such components, however, are not available with a plasma doping system. To uniformly implant the workpiece in the plasma doping system, the plasma generated near the substrate should be uniform, as PLAD implant uniformity is closely related to plasma uniformity.
In a typical plasma based system, the generated plasma is typically non-uniform; the plasma density is typically higher in the center of the plasma than near the chamber walls, as shown in FIG. 4 . As a result, implant profile on the workpiece shows a similar non-uniform profile—higher implant dose in the middle, and lower dose in the edges of the workpiece. Typically, RF power, gas flow and distribution, magnetic confinements, etc. may be adjusted to improve the plasma uniformity. However, such techniques may mitigate the plasma non-uniformity, but cannot change the generic non-uniform density profile shown in FIG. 4 .
As such, systems and methods to improve the uniformity of the plasma in a plasma based system are needed.
SUMMARY
A technique for processing a workpiece is disclosed. In accordance with one exemplary embodiment, the technique may be realized as a method for processing a substrate. The method may comprise: providing the workpiece in the chamber; providing a plurality of electrodes between a wall of the chamber and the workpiece; generating a plasma containing ions between the plurality of electrodes and the workpiece, ion density in an inner portion of the plasma being greater than the ion density in an outer portion of the plasma portion, the outer portion being between the inner portion and the wall of the chamber; and providing a bias voltage to the plurality of electrodes and dispersing at least a portion of the ions in the inner portion until the ion density in the inner portion is substantially equal to the ion density in the periphery plasma portion.
In accordance with other aspects of this particular exemplary embodiment, the method may further comprise attracting ions to the workpiece from the inner and outer portions of the plasma.
In accordance with further aspects of this particular exemplary embodiment, the providing the bias voltage to the plurality of electrodes may comprise independently biasing the plurality of electrodes.
In accordance with additional aspects of this particular exemplary embodiment, the providing the bias voltage to the plurality of electrodes may comprise positively biasing the plurality of electrodes.
In accordance with further aspects of this particular exemplary embodiment, the providing the bias voltage to the plurality of electrodes may comprise negatively biasing the plurality of electrodes.
In accordance with other aspects of this particular exemplary embodiment, the method may further comprise: coupling the plurality of electrodes to one or more power supplies, where the one or more power supplies may provide a pulsed bias voltage having a duty cycle.
In accordance with further aspects of this particular exemplary embodiment, the method may further comprise: adjusting the duty cycle of the pulsed bias voltage provided to the plurality of electrodes.
In accordance with additional aspects of this particular exemplary embodiment, the method may further comprise providing a magnetic field in same direction as an electric field created by the biasing the plurality of electrodes.
In accordance with other aspects of this particular exemplary embodiment, the plurality of electrodes may comprise a first electrode disposed near the inner portion of the plasma and a second electrode disposed near the outer portion of the plasma, and where the first electrode may be applied with a first bias voltage and the second electrode is applied with a second bias voltage.
In accordance with further aspects of this particular exemplary embodiment, the first bias voltages may be more positive than the second bias voltage.
In accordance with additional aspects of this particular exemplary embodiment, the first bias voltage may be less positive than the second bias voltage.
In accordance with another exemplary embodiment, the technique may be realized as a method for processing a workpiece. The method may comprise: providing the workpiece in a plasma chamber; providing first and second electrodes between a wall of the plasma chamber and the workpiece; generating a plasma containing ions between the plurality of electrodes and the workpiece, the plasma may comprise a first plasma portion disposed near the first electrodes and a second plasma portion disposed near the second electrode, where the first plasma portion may have a greater ion density than the second plasma portion; providing a bias voltage to the first and second electrodes and dispersing at least a portion of the ions in the first plasma portion until the ion density in the first plasma portion is substantially equal to the ion density in the second plasma portion; and biasing the workpiece and attracting ions to the workpiece from the first and second portions of the plasma having substantially equal ion density.
In accordance with other aspects of this particular exemplary embodiment, the first plasma portion may be disposed near a middle of the plasma and the second plasma portion may be disposed near a periphery of the plasma next to the first plasma portion.
In accordance with further aspects of this particular exemplary embodiment, the second plasma portion may be disposed near a middle of the plasma and the first plasma portion is disposed near a periphery of the plasma next to the second plasma portion.
In accordance with additional aspects of this particular exemplary embodiment, the providing the bias voltage to the first and second electrodes comprises independently biasing at least one of the plurality of electrodes.
In accordance with further aspects of this particular exemplary embodiment, the providing the bias voltage to the first and second electrodes may comprise positively biasing at least one of the plurality of electrodes.
In accordance with additional aspects of this particular exemplary embodiment, the providing the bias voltage to the first and second electrodes may comprise negatively biasing at least one of the plurality of electrodes.
In accordance with further aspects of this particular exemplary embodiment, the providing the bias voltage to the first and second electrodes may comprise biasing the first electrodes with a first bias voltage and the second electrodes with a second bias voltage.
In accordance with other aspects of this particular exemplary embodiment, the first bias voltage may be more positive than the second bias voltage.
In accordance with additional aspects of this particular exemplary embodiment, the first bias voltage is less positive than the second bias voltage.
In accordance with another exemplary embodiment, the technique may be realized as a method for processing a workpiece. The method may comprise: providing the workpiece in a plasma chamber; providing first and second electrodes between a top of the plasma chamber and the workpiece; generating a plasma between the plurality of electrodes and the workpiece, where the plasma may comprise first and second portions having different plasma density; independently applying bias voltage first and second electrodes until the difference in the plasma density of the first and second portion of the plasma is reduced.
In accordance with additional aspects of this particular exemplary embodiment, more positive bias voltage is applied to one of the first and second electrodes near first and second portions the bias voltage applied to one of the first and second electrodes near one of the first and second portions of the plasma with greater plasma density to improve uniformity of the plasma density between the first and second portions.
The present disclosure will now be described in more detail with reference to exemplary embodiments thereof as shown in the accompanying drawings. While the present disclosure is described below with reference to exemplary embodiments, it should be understood that the present disclosure is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments, as well as other fields of use, which are within the scope of the present disclosure as described herein, and with respect to which the present disclosure may be of significant utility.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to facilitate a fuller understanding of the present disclosure, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings should not be construed as limiting the present disclosure, but are intended to be exemplary only.
FIG. 1 represents a traditional plasma doping system;
FIG. 2 represents a first embodiment of the apparatus of the present disclosure;
FIG. 3 represents a top view of the apparatus shown in FIG. 2 ;
FIG. 4 represents a graph illustrating typical ion density profile in a plasma tool;
FIG. 5 represents a top view of a second embodiment of the apparatus of the present disclosure;
FIG. 6 represents the apparatus of FIG. 2 with an added magnetic field; and
FIG. 7 represents a further embodiment of the apparatus of FIG. 2 .
FIG. 8A illustrates another exemplary apparatus according to another embodiment of the present disclosure.
FIG. 8B illustrates a plurality of exemplary electrodes incorporated in the apparatus shown in FIG. 8A .
FIG. 8C illustrates an exemplary operation of the apparatus shown in FIG. 8A .
FIGS. 9A and 9B illustrate several exemplary operations of the apparatus shown in FIG. 8A .
FIG. 10A illustrates another exemplary apparatus according to another embodiment of the present disclosure.
FIG. 10B illustrates a plurality of another exemplary electrodes incorporated in the apparatus shown in FIG. 10A .
DETAILED DESCRIPTION
Herein, several embodiments of an apparatus and method for achieving uniform plasma density are disclosed with reference to accompanying drawings. The detailed disclosure contained herein is intended for illustration, for better understanding the disclosure, and not a limitation thereto. For example, the disclosure may be made with reference to a plasma doping or a plasma immersion ion implantation system. However, the present disclosure may be equally applicable to other plasma based systems including plasma based etching and deposition systems.
As described above, a plasma doping system is used to create a plasma in close proximity to the workpiece. The workpiece may be then biased to a certain electrical potential. However, the plasma density or the ion concentration within the generated plasma may be non-uniform. Typically, the concentration of ions is the highest near the center and lower near the chamber wall, as shown in FIG. 4 .
In a plasma based system that is radially symmetric, the ion diffusion pattern may also be radially symmetric along the horizontal direction. As such, the plasma generated in a radially symmetric plasma based system may have approximately concentric density profile. Ion concentration at a point removed from the center of the plasma may be approximately the same as another point equidistanced from the center. Such a characteristic in symmetric plasma based system may result in a dome shaped plasma density profile.
Plasma is a quasi-neutral state where positively and negative charged particles show collective behaviors. Charged particles in the plasma are responsive to both electrical and magnetic fields. By using these fields to manipulate the local distribution of the charged particles within the plasma, the implant uniformity can be improved. FIG. 2 represents a first embodiment of the apparatus. In this figure, many of the components in the plasma doping system of FIG. 1 have not been included in FIG. 2 for purpose of clarity and simplicity. However, it should be understood that the components shown in FIG. 1 may also be in the plasma doping system.
Referring to both FIGS. 1 and 2 , the plasma 140 may be positioned between the workpiece 138 and the baffle 170 . The baffle 170 can be a stationary baffle 170 and/or adjustable baffle 170 . The adjustable baffle 170 can move in a vertical direction (up and down) relative to the wafer or the chamber ceiling. This movement may occur prior to and/or during wafer processing. Periodic pulses of bias voltage at the workpiece may be applied to accelerate ions toward the workpiece. However, as seen in FIGS. 1 and 2 , there are no mechanisms to confine the plasma or control its uniformity. In one embodiment, a set of electrical conductors 200 is preferably located on the underside of the baffle 170 such that the conductors 200 may be positioned above the plasma. These conductors may preferably be electrically insulated from one another and from the baffle. For example, an insulating material (not shown) may separate the conductors 200 from one another and from the baffle 170 . In another embodiment, the electrical conductors 200 may be disposed around the plasma (e.g. the side of the plasma). Yet in another embodiment, a set of electrical conductors 200 may be disposed above the plasma and another set of electrical conductors 200 may be disposed around the plasma.
In the present embodiment, the electrical conductors 200 may be pins 200 . However, those or ordinary skill in the art will recognize that the electrical conductors 200 may be other types of conductor 200 . In addition, the electrical conductors may have diameters of other values. In the present embodiment, the pins 200 may preferably be arranged in a two-dimensional array, as shown in FIG. 3 .
In a plasma doping system, the plasma may have a cylindrical shaped volume, having a diameter of about 50 cm and a height of about 10-20 cm. Thus, if the two-dimensional array is to extend over the plasma region, and the distance between adjacent pins is about 1.0 cm, then the array may contain about 304 pins. However, those of ordinary skill in the art will recognize that the number of the pins in the array may be more or less. For example, if the array of the pins covers the 300 mm wafer region with the distance between adjacent pins of 2.54 cm, then the array would contain only about 110 pins.
Additionally, the electrical conductors can be various shapes including rectangular, square, round or other shapes. The most preferred shapes include (1) a flat cylindrical shape (0.1-1.0 cm in diameter) and (2) a pointed-tip cylindrical shape (0.05 cm or less in diameter for pointed tip, 0.1-1.0 cm in diameter for the pin body). For the latter case, the total angle of the pointed-tip may be less than 90 degrees.
Each of these pins may be independently controlled. For example, each pin may be biased to a voltage independent of other pins. Furthermore, each pin may be biased either positively or negatively. Finally, these bias voltages may be constant, or pulsed. In addition, the bias voltages may vary between conductors. Furthermore, the magnitude of the bias voltage at a particular conductor may vary over time. Thus, the two-dimensional array may be used to create any desired electrical field, and that field can be static or may vary.
By creating an electrical field potential above the plasma, the ion concentration within the plasma can be altered. For example, the use of a positive bias voltage will draw the electrons within the plasma toward those positively biased pins. The magnitude of that bias voltage may determine the size of the affected field. By drawing the electrons toward the upper portion of the plasma, the positive ions may disperse due to space charge effects. Such a dispersion of the positive ions may change the positive ion distribution within the plasma. Therefore, the dispersion may locally lower the concentration of implanted ions when the substrate bias voltage is applied. Negative bias voltages on the pins may have different effect. The negative voltage may repel the electrons and thereby cause the plasma to be locally compressed. This compression increases the local concentration of positive ions near the workpiece.
FIG. 4 shows a typical graph of the ion concentration as compared to the distance from the center of the system along one axis. Although this shows ion concentration versus distance in one dimension, similarly shaped graphs exist in all dimensions. Thus, by applying positive bias voltage near the center of the system, the ion concentration can be lowered, thereby improving uniformity. Additionally, applying negative bias voltage near the outer portions of the plasma compresses the plasma, and therefore effectively increases its concentration, further improving uniformity.
Furthermore, electrical conductors 230 may be placed vertically around the sides of the plasma, as shown in FIG. 7 . Side baffles 235 are positioned about the sides of the plasma. A set of electrical conductors 230 is preferably located on the side of the side baffle 235 . These conductors 230 are electrically insulated from one another and from the side baffle 235 . Such a configuration may serve to better confine the plasma.
As noted above, the bias voltage applied to one or more pins may be constant (DC) or intermittent, such as pulsed. Additionally, the pulsed bias voltage may be positive or negative. Alternatively, the one or more pins may be floated or grounded, as desired. Applying the pulsed bias voltages to the pins has certain advantages over DC bias. Since the plasma electrons are sensitive to the positive bias voltages, DC bias may cause too much perturbation to the plasmas, such as causing plasma instability or redistribution of the plasma in some applications. In such cases, pulsed bias with small duty cycle (50% or less) can minimize the plasma perturbation while providing controllability of the plasma uniformity. The duration of each pulse may preferably be between microseconds and milliseconds in the order of magnitude.
As noted above, the bias voltage applied to one or more electrical conductors 200 may be positive or negative. Alternatively, one or more electrical conductors may be grounded or floated. If biased, the bias voltage may be a constant voltage, or varying. In certain embodiments, the bias voltage is a periodic waveform having a duty cycle. This duty cycle can be between microseconds and milliseconds in order of magnitude. Furthermore, the duty cycle can vary, such that the duration of the pulses can change based on the plasma density and the desired density. Thus, bias voltage waveform may change in duration, frequency, magnitude, duty cycle or polarity over time.
Although each pin maybe independently controlled, groups of pins can be grouped together in one or more groups, and different groups may be controlled independently of other groups. For example, pins removed from the center by the same distance may be controlled together if the density profile of the non-uniform plasma is radially symmetric. However, if the plasma density is asymmetric, each pin or each group of pins may be controlled independently.
While the disclosure describes an array of pins as shown in FIG. 3 , other embodiments are possible and within the scope of the disclosure. For example, another embodiment of the electrical biased elements is shown in FIG. 5 . In this Figure, it is assumed that the plasma is symmetrical and therefore, the ion concentrations at a same distance from the center are all identical. Each concentric ring represents a set of electrically conductive elements 210 , which can be biased independently of the adjacent rings. Thus, the same effect is desired, and therefore the same bias voltage can be applied. Other embodiments are also within the scope of the disclosure.
In addition to electrical fields, magnetic fields can be added to further improve the plasma uniformity and therefore implant uniformity. In the above embodiment, there was no magnetic field, thus charged particles are free to move in all directions. By introducing a magnetic field parallel to the electrical field, charged particles will be limited in their freedom of motion. Referring to FIG. 6 , a magnetic field is added to the apparatus shown in FIG. 2 and is created parallel to the electrical field. In this embodiment, charged particles are more restricted in their movement, in that the charged particles are confined along the magnetic field lines. Thus the effect of the bias voltages described above is more contained. In other words, each electrically conductive element controls the ion concentration of the plasma in the volume located directly below the element. Thus, the bias voltages applied at one element do not affect the ion concentrations in other areas of the plasma.
The magnetic field can be created in a variety of ways, as are known by those skilled in the art.
Apparatus and method for improving plasma uniformity in a plasma based system are disclosed. Although the present disclosure has been described herein in the context of particular systems and particular implementations in particular environments for a particular purpose, the present disclosure is not limited thereto. Those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure can be beneficially implemented in any number of environments for any number of purposes. For example, one or more electrical conductors near a portion of the plasma with greater ion or plasma density may be applied with a first bias voltage. The portion of the plasma with greater density may not necessarily be positioned in the inner or middle portion of the plasma. In some embodiments, the portion with greater density may be located at the outer or periphery portion of the plasma, the portion located between the inner portion and the chamber wall.
This first bias voltage, which applied to one or more electrical conductors near the portion of the plasma with greater density, may be a positive bias voltage. With this bias voltage, the positively charged ions near the electrical conductors may be dispersed away from the portion of the plasma with greater ion or plasma density. In the process, there may be a local decrease in plasma density in the portion. As a result, plasma with increased uniformity may be achieved.
Alternatively, one or more electrical conductors near another portion of the plasma with less ion or plasma density may be applied with a second bias voltage. The second bias voltage may be less positive than what the first bias voltage would have been. In one example, the second bias voltage may be a negative bias voltage. In another example, the second bias voltage may be a positive bias voltage, but less than what the first bias voltage would have been had the first bias voltage been applied to other conductors. With the application of negative bias voltage, the plasma may be compressed. In the process, the density of the less dense portion of the plasma may increase, and the uniformity of the plasma may be enhanced.
In another embodiment, one or more electrical conductors near a portion of the plasma with greater ion or plasma density may be applied with a first bias voltage. Meanwhile, one or more electrical conductors near another portion of the plasma with less ion or plasma density may be applied with a second bias voltage, less positive than the first bias voltage.
By independently applying one or more bias voltages to one or more electrical conductors, plasma with greater uniform density may be achieved.
Referring to FIG. 8A , there is shown another exemplary plasma processing apparatus 800 according to another embodiment of the present disclosure. In FIG. 8B , there is shown a plurality of electrical conductors 810 that may be included in the plasma processing apparatus 800 shown in FIG. 8A . Much like the earlier embodiment shown in FIG. 2 , the plasma processing apparatus 800 contains a plasma source 101 for generating the plasma 140 in the chamber 102 . In addition, the plasma processing apparatus 800 comprises a platen 134 for supporting a substrate 138 . Those skilled in the art will recognize that several components in the plasma processing apparatus shown in FIGS. 1 and 2 are also contained in the plasma processing apparatus 800 of FIG. 8A . Such components in FIG. 8A should be understood in relation to the same components in the plasma processing apparatus shown in FIGS. 1 and 2 .
As illustrated in FIG. 8A the plasma processing apparatus 800 may comprise a plurality of electrical conductors 810 disposed at various positions within the plasma chamber 102 . The electrical conductors 810 may be a part of or attached to the baffle 170 , as shown in FIG. 2 . In other embodiments, the electrical conductors 810 may be spaced apart from the baffle. For example, the electrical conductors 810 may be located below the baffle and closer to the plasma 140 . Yet in another embodiment, the plasma processing system 800 may be without the baffle. In this embodiment, only the electrical conductors 810 are illustrated for clarity and simplicity.
The plurality of electrical conductors 810 may comprise at least one first or inner electrical conductor 810 a disposed near the center of the chamber 102 or the inner portion of the plasma 140 . The plurality of electrical conductors 810 may also comprise one or more second or outer electrical conductor 810 b disposed near the outer portion of the plasma 140 , the portion between the inner portion of the plasma and the chamber wall. In other embodiments, there may be one or more intermediate electrical conductors disposed between the inner and outer electrical conductors 810 a and 810 b . If included, the intermediate electrical conductors may comprise one or more third and fourth electrical conductors 810 c and 810 d positioned between the inner and outer conductors 810 a and 810 b.
Much like the prior embodiments, the first and second conductors 810 a and 810 b may be electrically isolated from each other. Moreover, each of the first conductors 810 a , if two or more are provided, may be electrically isolated from each other. If two or more are provided, each of the second conductors 810 b may also be electrically isolated from each other. Likewise, each of the third and fourth conductors 810 c and 810 d may also be electrically isolated from each other and from each of the first and second conductors 810 a and 810 b . Further, if two or more are included, each of the third conductors 810 c and each of the fourth conductors 810 d may be electrically isolated from each other.
Each of the first and second conductors 810 a and 810 b may be independently biased. If included, the third and fourth conductors 810 c and 810 d may also be independently biased. The bias voltage applied to the conductors 810 a - 810 d may be a continuous or pulsed bias. Moreover, the bias voltage applied may be positive or negative bias voltage. In some embodiments, at least one of the first and second 810 a and 810 b , and the third and fourth conductors 810 c and 810 d if included, may remain floating or grounded.
In operation, a plasma source 101 in the plasma doping system 800 may generate a plasma 140 between the workpiece 138 and the electrical conductors 810 . However, the present disclosure does not preclude generating a plasma above the first and second conductors 810 a and 810 b . The plasma 140 generated in the chamber 102 may have a density profile similar to the profile shown in FIG. 8C . For example, the plasma 140 may have higher ion density near its inner portion and less ion density near its outer portion.
To improve the uniformity, a bias voltage may be provided to one of more of the first and second electrical conductors 810 a and 810 b . In the present embodiment, a first bias voltage may be applied to the first conductor 810 a . This first bias voltage may be a positive bias voltage. If applied with a positive bias voltage, the first electrical conductor 810 a may locally disperse the positively charged ions away from the inner portion of the plasma 140 . As a result, the difference in the plasma density between the inner portion of the plasma 140 and the outer portion of the plasma 140 may decrease, and the uniformity of the plasma 140 may improve.
Alternatively, the second conductor 810 b may also be applied with the bias voltage. In the present embodiment, the bias voltage applied to the second electrical conductor 810 b may be a second, less positive voltage. For example, the second electrical conductor 810 b may be biased with negative bias voltage. By applying a negative bias voltage to the second conductor 810 b , the outer portion of the plasma 140 with less plasma density may be compressed. As such, further improvement to the uniformity of the plasma 140 may be achieved.
In another embodiment, both the first and second conductors 810 a and 810 b may be independently biased with the first and second bias voltages. In this embodiment, the dispersion of ions from the portion of the plasma with greater density and the compression of the portion of the plasma with less density may occur. When both bias voltages are applied, they may be applied simultaneously or at different times.
If included, the third and fourth electrodes 810 c and 810 d may also be biased. If biased, the third electrode 810 c may be biased with less positive bias than the first electrode 810 a , but more positive bias than the second electrode 810 b . Meanwhile, the fourth electrode 810 d , if biased, may be biased with less positive bias than the third electrode 810 c , but more positive than the bias voltage applied to the second electrode 810 b . By applying the most positive bias voltage to the electrical conductor near the portion of the plasma with greatest ion density, the uniformity of the plasma, as a whole, may be improved. To enhance the improvement in the uniformity, less positive voltage may be applied to one or more electrical conductors near the portion of the plasma with less plasma density.
Those of ordinary skill in the art will recognize that the plasma processing apparatus 800 may also be used for improving the uniformity of plasma having different density profiles. In one example, the density profile of the plasma is such that the outer portion has a greater density and the inner portion of the plasma has less density, as shown in FIG. 9A . In such an embodiment, the second electrical conductor 810 b near the outer portion of the plasma may be biased with a positive bias voltage. Alternatively or in addition, the first electrical conductor 810 a may be biased with less positive bias voltage. In another example, the density profile of the plasma is such that the inner portion and the outer portion of the plasma have less ion density than a portion of the plasma therebetween, as shown in FIG. 9B . In such an example, the electrical conductors near the portion of the plasma with greater ion density may be biased with more positive bias voltage. Meanwhile, the electrical conductors near the portion of the plasma with less ion density may be applied with less positive bias voltage. In the process, the plasma with non-uniform ion density may be made more uniform. By independently applying the bias voltage and controlling the applied bias voltage, the electrical conductors of the present disclosure may locally control the plasma density and improve the plasma uniformity.
Referring to FIG. 10A , there is shown a plasma processing system 1000 according to another embodiment of the present disclosure. In FIG. 10B , there is shown a plurality of electrical conductors 1010 that may be included in the plasma processing system shown in FIG. 10A . As shown in FIG. 10B , the electrical conductors 1010 may comprise a first electrical conductor 1010 a disposed near the inner portion of the plasma 140 , and a second electrical conductor 1010 b disposed near the outer portion of the plasma 140 . Optionally, there may be one or more intermediate electrical conductors. In the present embodiment, the intermediate electrical conductors may comprise a third electrical conductor 1010 c and a fourth electrical conductor 1010 d , disposed between the first and second electrical conductor 1010 a and 101 b.
As shown in FIG. 10A , the first conductor 1010 a may be disposed near the inner portion of the plasma 140 , whereas the second conductor 1010 b may be disposed near the outer portion of the plasma 140 . In addition, the second electrical conductor 1010 b may be configured to surround the first conductor 1010 a . Although not necessary, the first and second conductors 1010 a and 1010 b of the present embodiment may be concentric. In some other embodiments, the first and second conductors 1010 a and 1010 b may have shapes other than circular shape as shown in FIG. 10A .
Much like the prior embodiments, the first and second conductors 1010 a and 1010 b may be electrically isolated from each other. If included, each of the third and fourth conductors 1010 c and 1010 d may also be electrically isolated from each other and from each of the first and second conductors 1010 a and 1010 b . In addition, each of the first and second conductors 1010 a and 1010 b may be independently biased. If included, the third and fourth conductors 1010 c and 1010 d may also be independently biased. Each conductor 1010 a - 1010 d may be independently biased with a continuous or pulsed with bias voltage. The bias voltage applied may be positive or negative. Or, at least one of the first and second conductors 1010 a and 1010 b , and the third and fourth conductors 1010 c and 1010 d , if included, may remain floating or grounded.
In an exemplary operation, a plasma source 101 in a plasma doping system shown in FIGS. 1 and 2 may generate a plasma 140 with non-uniform density shown in FIG. 4 . To improve the uniformity, a bias voltage may be provided to one of more of the first and second electrical conductors 1010 a and 1010 b . For example, if the plasma 140 has higher ion density near its inner portion, as shown in FIG. 4 , a first positive bias voltage may be provided to the first conductor 1010 a . With the positive bias voltage, the first electrical conductors 1010 a near the inner portion of the plasma 140 may disperse the positively charged ions away from the inner portion of the plasma 140 , toward the outer portion of the plasma 140 . As a result, the uniformity of the plasma 140 may improve.
Alternatively, the second conductor 1010 b may be applied with a bias voltage that is less positive than what the first bias voltage would have been had the first bias voltage been also applied to the first conductor 1010 a . For example, the second conductor 1010 b may be applied with negative bias voltage. With the application of negative bias voltage, the plasma may be compressed, and the density of the less dense portion of the plasma may increase. In the process, the uniformity of the plasma may be enhanced.
In some embodiments, both the first and second conductors 1010 a and 1010 b may be independently biased. In this embodiment, the first conductor 1010 a may be applied with a first, positive bias voltage, and the second conductor 1010 b may be applied with a second, less positive (e.g. negative) bias voltage.
If included, the third and fourth electrical conductors 1010 c and 1010 d may also be applied with bias voltage. To increase the uniformity of the plasma such as the plasma shown in FIG. 4 , the third and fourth electrical conductors 1010 c and 1010 d may be biased with less positive bias voltage than the first electrical conductor 1010 a , but more positive bias voltage than the second electrical conductor 1010 b . In addition, the third electrical conductor 1010 c may be biased with more positive bias voltage than the fourth electrical conductor 1010 d . In the process, a plasma with more uniform ion density, as shown in FIG. 8 , may be achieved.
Although the present disclosure has been described herein in the context of particular systems and particular implementations in particular environments for a particular purpose, the present disclosure is not limited thereto. Those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure can be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.
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A technique for processing a workpiece is disclosed. In accordance with one exemplary embodiment, the technique is realized as a method for processing a substrate, where the method comprises: providing the workpiece in the chamber; providing a plurality of electrodes between a wall of the chamber and the workpiece; generating a plasma containing ions between the plurality of electrodes and the workpiece, ion density in an inner portion of the plasma being greater than the ion density in an outer portion of the plasma portion, the outer portion being between the inner portion and the wall of the chamber; and providing a bias voltage to the plurality of electrodes and dispersing at least a portion of the ions in the inner portion until the ion density in the inner portion is substantially equal to the ion density in the periphery plasma portion.
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PRIORITY CLAIM
[0001] This applications claims the priority date of provisional application No. 62/343,813 filed on May 31, 2016, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] The present disclosure relates generally to an illuminated liquid vessel, and more particularly, illuminating a liquid filled vessel, such as a water bottle, through the use of sturdy, compact, and customized snap-in and pressure fit lighting features.
[0003] Illuminated containers are often used as a novelty item for various entertainment purposes, such as concerts, parties, sporting events, and other social or themed events. However, the durability, versatility, and longevity of the illuminated containers are often diminished by sub-par lighting and bottle components as well as ineffective methods of manufacture and connectivity of said lighting and bottle components. An apparatus is needed to improve the durability, longevity and effectiveness of illuminating liquids within various drinking vessels and other containers for liquids.
SUMMARY
[0004] An illuminable container device, comprising a housing for containing a liquid; a recess configured within a base area of said housing, with said recess extending upwardly into said housing and in a substantial dome shape; wherein said recess comprises a plurality of sub-recesses situated around a circumference area of said recess and that are concave in shape and extend laterally into said housing; a light device, comprising a light housing that is substantially cylindrical in shape with a miniature dome situated at a center of a top area of said light device; said light housing comprising a plurality of ribs situated around a circumference of said light housing; and said plurality of ribs are convex in shape and configured to fit within said plurality of sub-recesses of said recess.
[0005] An illuminable container device, comprising a housing for containing a liquid; a recess configured within a base area of said housing, with said recess extending upwardly into said housing and in a substantially cylindrical shape; a light device, comprising a light housing with a substantially cylindrical shape, said light housing comprising a plurality of ridges, which are positioned vertically around a circumference of said light housing; said light device configured to fit into and substantially fill said recess being held therein by a pressurized fit.
[0006] A wearable illuminable container device, comprising a housing for containing a liquid; a recess configured within a base area of said housing, with said recess extending upwardly into said housing and in a substantially cylindrical shape;
[0007] a light device, comprising a light housing with a substantially cylindrical shape, said light housing comprising a plurality of ridges, which are positioned vertically around a circumference of said light housing, said plurality of ridges being curved in nature; and a lanyard configured to couple around said device by an adjustable multi-prong securing element.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 illustrates a perspective view of an example illuminated liquid vessel, with a lighting element configured within an umbrella cavity of the vessel, in accordance with one embodiment;
[0009] FIG. 2 depicts a cross-section view of an example illuminated liquid vessel, with a lighting element configured therein, in accordance with one embodiment;
[0010] FIG. 3 depicts a bottom plan view of an example illuminated liquid vessel, with a lighting element configured therein, in accordance with one embodiment;
[0011] FIG. 4 depicts a bottom plan view of an example illuminated liquid vessel, without a lighting element configured therein, in accordance with one embodiment;
[0012] FIG. 5A depicts a perspective view of an example lighting element for an illuminated liquid vessel, in accordance with one embodiment;
[0013] FIG. 5B depicts a side view of an example lighting element for an illuminated liquid vessel, in accordance with one embodiment;
[0014] FIG. 5C depicts a top view of an example lighting element for an illuminated liquid vessel, in accordance with one embodiment;
[0015] FIG. 5D depicts a bottom view of an example lighting element for an illuminated liquid vessel, in accordance with one embodiment;
[0016] FIG. 6 depicts a side cross-section view of a lighting element for an illuminated liquid vessel, in accordance with one embodiment;
[0017] FIGS. 7A-F depict a lighting element for an illuminated liquid vessel, in accordance with another embodiment;
[0018] FIG. 8 depicts a top cross-sectional view of an example illuminated liquid vessel, with a lighting element configured therein;
[0019] FIG. 9 depicts a top cross-sectional close-up view of an example illuminated liquid vessel, without a lighting element configured therein;
[0020] FIG. 10 depicts a side cross-sectional close-up view of an example illuminated liquid vessel, without a lighting element configured therein;
[0021] FIG. 11 depicts a perspective view of an example lanyard element for use with an example illuminated liquid vessel, in accordance with one embodiment;
[0022] FIG. 12 depicts a close-up view of a safety element an example lanyard for use with an example illuminated liquid vessel, in accordance with one embodiment;
[0023] FIG. 13 illustrates a perspective view of another embodiment of an illuminated liquid vessel, with a lighting element configured within a pressure-fit cavity of the vessel, in accordance with one embodiment;
[0024] FIG. 14 illustrates a perspective view of the illuminated liquid vessel embodiment of FIG. 13 , without a lighting element configured within a pressure-fit cavity of the vessel, in accordance with one embodiment.
[0025] FIG. 15A-F illustrates perspective, side, top, bottom, and cross-section views of a lighting element in accordance with another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The detailed descriptions set forth below in connection with the appended drawings are intended as a description of embodiments of the invention, and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The descriptions set forth the structure and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent structures and steps may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0027] FIG. 1 illustrates a perspective view of an example illuminated liquid vessel ( 100 ), with a lighting element ( 200 ) configured within a recess, or cavity ( 105 ) of the illuminated liquid vessel, in accordance with one embodiment. The illuminated liquid vessel ( 100 ) is intended to represent various forms of drinking vessels and beverage containers, such as water bottles, alcoholic beverage containers, beverage dispensers, multi-gallon containers, and other similar liquid containing vessels. Such liquid vessels may be configured to hold carbonated or non-carbonated liquids, and liquids of varying levels of alcohol content. In an example embodiment, liquid vessel ( 100 ) may have an approximate height of 9.021 inches and the capability to hold approximately 16.9 ounces of liquid. Other heights, sizes, and ounce capacity may be used in connection with vessel ( 100 ) in accordance with the scope of the present disclosure.
[0028] In an example embodiment, liquid vessel ( 100 ) may be made of a clear plastic composition commonly known in the art, and comprising an approximate total mass composition of approximately 28 mL for purposes such as durability and strength, and that may be uniform in thickness of composition. The plastic composition for liquid vessel ( 100 ) may also be comprised of polyethylene terephthalate, or also known as “PET,” for purposes such as reuse or recycling of the liquid vessel, and are known to a person of ordinary skill in the art. Liquid vessel ( 100 ) may also be composed of other plastic composition types, such as translucent materials, and may also contain differing total mass compositions of plastic without deviating from the scope of the present invention. Yet further, liquid vessel ( 100 ) may be composed of other known bottle and container materials, such as aluminum, recycled materials, as well as combinations of different materials, such as plastic and aluminum.
[0029] In the exemplary embodiment, illuminated liquid vessel ( 100 ) may be comprised of a generally cylindrical body portion ( 101 ), a shoulder portion ( 102 ), a neck portion ( 102 a ), base portion ( 103 ), and a mouth ( 104 ). The body ( 101 ) may further be comprised of an indented panel segment ( 101 a ) that is situated around the circumference of the body ( 101 ) and may be used for such purposes including enhanced light projection as well as for labels (not shown), marketing, branding, and decorative aspects that may be applied or used in connection with the illuminated liquid vessel ( 100 ). For example, indented panel segment ( 101 a ) may contain a label wrapped around it with branding, sponsorship, and content information. In another example, the label for indented panel segment ( 101 a ) may contain a hologram imprint that may reflect outside vessel ( 100 ) when light element ( 200 ) is activated.
[0030] Segment ( 101 a ) may further be comprised of a top and a bottom slanted ridge (( 101 b ) and ( 101 c ), respectively), which are also situated around the circumference of the body ( 101 ), and contiguous with segment ( 101 a ). Top ridge ( 101 b ) may be configured to slant inward in angular direction from the shoulder ( 102 ) and toward segment ( 101 a ), whereas bottom ridge ( 101 c ) may be configured to slant away in angled from base ( 103 ), and toward the segment ( 101 a ). In one embodiment, ridges ( 101 b ) and ( 101 c ) may be angled at approximately 45 degrees.
[0031] Situated above body ( 101 ) is the shoulder portion ( 102 ), which is slightly curved upward toward neck portion ( 102 a ). Neck portion ( 102 a ) is situated above shoulder ( 102 ) and is generally narrower is width and circumference that the other portions of vessel ( 100 ). In the exemplary embodiment, neck portion ( 102 a ) is elongated in height for such purposes as, and including, but not limited to, enhancing the lighting effect for vessel ( 100 ). Situated at the top area of neck ( 102 a ) is the mouth ( 104 ). Mouth ( 104 ) may comprise a narrow cylindrical shape with an opening at its top end to allow a user of the vessel ( 100 ) to drink or otherwise utilize the contents of vessel ( 100 ). When vessel ( 100 ) is not in used, mouth ( 104 ) may be covered by a cap piece containing internal threading (not shown) that may be coupled to threading that is proximate mouth ( 104 ) (as shown in FIG. 1 ).
[0032] Situated below body ( 101 ) is base portion ( 103 ) containing a plurality of curved indentations there within ( 103 a, b, c, d , and e , respectively) (See FIG. 3 for additional detail and illustration) situated adjacent to each other in a generally equidistance manner around the circumference of the base ( 103 ). Also situated within base ( 103 ) is a cavity ( 105 ), which may be dome shaped in an example embodiment, and configured to hold light element ( 200 ) via a snap-in mechanisms (explained in further detail with respect to FIGS. 4-10 ).
[0033] FIG. 2 illustrates a cross-section view of an example illuminated liquid vessel ( 100 ) showing light element ( 200 ) configured therein, in accordance with one embodiment. In this view, the outline of light element ( 200 ) is shown when it is placed and situated within cavity ( 105 ). Light element ( 200 ) may further comprise a light housing ( 201 ), which encloses and contains the internal lighting components (not shown) of light element ( 200 ) (See FIGS. 5A-D for additional details). Also shown in this view, a base portion ( 203 ) of light element ( 200 ) may sit flush with and level with a center base area ( 106 ) (not shown) of liquid vessel ( 100 ), which is generally surrounded by indentations ( 103 a ), ( 103 b ), ( 103 c ), ( 103 d ), and ( 103 e ). Base portion ( 203 ) may be situated at a height elevated above feet ( 103 a - e ), or generally at the same level as feet ( 103 a - e ), so as not to interfere with the stability and placement of liquid vessel ( 100 ) when placed upon a flat or other similar surface.
[0034] FIG. 3 illustrates a bottom plan view of an example illuminated liquid vessel ( 100 ) with light element ( 200 ) configured therein, in accordance with one embodiment. In this view, the base ( 203 ) of light element ( 200 ) is shown as it may be enclosed and placed within cavity ( 105 ). As mentioned earlier, surrounding center base area ( 106 ) are indentations ( 103 a, b, c, d , and e) positioned adjacent to each other in a substantially equidistance manner around the circumference of base ( 103 ). The positioning of indentations ( 103 a, b, c, d , and e) may generally provide support for bottling conditions for certain types of liquids, such as carbonated liquids. Center base area ( 106 ) may provide central support for the remaining portion of base ( 103 ), and may contain an opening or entry area to configure light element's ( 200 ) placement into cavity ( 105 ). Also shown in this figure is a tooling gap ( 107 ), which in this view is positioned between the middle area of ( 103 a ) and ( 103 b ), but which may be positioned between any of ( 103 a, b, c, d , or e ) in accordance with the scope of the present disclosure.
[0035] Tooling gap ( 107 ) may be comprised of a small, narrow passage way that may be generally rectangular in shape without detracting from the overall style and aesthetic of vessel ( 100 ). The narrow passage way of tooling gap ( 107 ) may provide a sufficient amount of space within base ( 103 ) for a tool, such as a screwdriver, elongated pin, or other similar tool to be inserted there within for purposes of engaging with the base ( 203 ) and removing light element ( 200 ) from liquid vessel ( 100 ) when needed or desired. In certain instances, tooling gap ( 107 ) may be utilized to remove light element ( 200 ) for such purposes, including, but not limited to, replacing light element ( 200 ) with a new or alternate light, or before liquid vessel ( 100 ) is sent for recycling.
[0036] FIG. 4 depicts a bottom plan view of an embodiment of an illuminated liquid vessel ( 100 ) without a light element ( 200 ) configured therein, in accordance with one embodiment. Similar to FIG. 3 , the view in FIG. 4 depicts the additional components of base ( 103 ), such as indentations ( 103 a, b, c, d , and e), base center area ( 106 ), and tooling gap ( 107 ). In this view, cavity ( 105 ) and the circular opening of base center area ( 106 ) are depicted from below and further illustrate the inner dome shape of cavity ( 105 ) from another view.
[0037] FIG. 5A depicts a perspective view of a light element ( 200 ) for use with liquid vessel ( 100 ), in accordance with one embodiment. As previously mentioned, light element ( 200 ) may be comprised of housing ( 201 ), which may encapsulate and contain all of the internal components of light element ( 200 ). In the present embodiment, housing ( 201 ) may be formed of a rigid plastic material to provide, among other aspects, enhanced protection to the internal components of light element ( 200 ).
[0038] Situated at the uppermost area of housing ( 201 ) is a light dome ( 205 ) where the bulb or lighting element of the internal components of light element ( 200 ) may be positioned within housing ( 201 ). In the exemplary embodiment, light dome's ( 205 ) shape allows for light to be reflected into liquid vessel ( 100 ) at an enhanced or a maximum level of dispersion therein. The material used to form housing ( 201 ) may also be employed to provide other protective qualities to light element ( 201 ), such as waterproof qualities, and to withstand handling, vibrations, and other impacts that may be caused by a user or other handling. Additionally, other comparable materials may be employed as the material used to form housing ( 201 ) without deviating from the scope of the present disclosure. In an exemplary embodiment, housing ( 201 ) may be formed from a single injection molding process, and which may enhance the creation of housing ( 201 ) as a uniform component with a smooth curved surface.
[0039] Situated around the horizontal circumference of housing ( 201 ) are ribs ( 202 a ), ( 202 b ), and ( 202 c ). In the present embodiment, the overall body of ribs ( 202 a - c ) are generally rounded and convex in shape, and in one embodiment, may have approximate dimensions of 2.1 millimeters in thickness along substantially all of the curvature of the body portion of each of ribs ( 202 a - c ), and are the same dimensions in size with each rib ( 202 a - c ) wrapping around approximately one-third (⅓) of the circumference of housing ( 201 ). Each end of ribs ( 202 a ), ( 202 b ), and ( 202 c ) may be generally rounded or curved and tapered off in shape. Ribs ( 202 a - c ) may also provide additional reinforcement and support to housing ( 201 ). The overall shape of each of ribs ( 202 a - c ) are configured to fit securely within the cavity ( 105 ) of liquid vessel ( 100 ) via a plurality of complementary shaped spaces within cavity ( 105 ) (not shown in this figure). As will be discussed in detail below, cavity ( 105 ) may be further comprised of a plurality of sub-recesses, or rib enclosures ( 105 a - c ), which are generally concave in shape and pre-formed to fit around or complement each of ribs ( 202 a - c ).
[0040] FIG. 5B depicts a side view of an exemplary light element ( 200 ) for liquid vessel ( 100 ), in accordance with one embodiment. In this view, two of the ribs, ( 202 a ) and ( 202 b ), may be positioned centrally between a base area ( 203 ) and a top area ( 204 ) of housing ( 201 ). In an exemplary embodiment, the dimension of light element ( 200 ) may be as follows: approximately 15 millimeters in height from base ( 203 ) to top ( 204 ), or approximately 23 millimeters in height from base ( 203 ) to the top height of light dome ( 205 ) of light element ( 200 ); the diameter of light element ( 200 ) measuring at the base ( 203 ) only may be approximately 29.9 millimeters, while the length of light element ( 200 ), including the width of ribs ( 202 a - c ) may measure approximately 33.8 millimeters in total length. In one embodiment, base ( 203 ) of light element ( 200 ) may be sonic welded to housing ( 201 ) to prevent the entry of water and other elements into light element ( 200 ).
[0041] FIG. 5C depicts a top view of an example light element ( 200 ) for liquid vessel ( 100 ), in accordance with one embodiment. In this view, the curvature, length, width, and positioning of ribs ( 202 a ), ( 202 b ), and ( 202 c ) can be seen, including a small gap of space separating each of ribs ( 202 a - c ). In one embodiment, the small gap between each of ribs ( 202 a - c ) may be approximately 1.1 millimeters. As mentioned earlier, each of ribs ( 202 a - c ) cover substantially all of the circumference of light element ( 200 ). Also shown in this view is light dome ( 205 ), and as indicated above, the shape of light dome ( 205 ) allows for light to be reflected into liquid vessel ( 100 ) via cavity ( 105 ) at an enhanced level with a maximum level of dispersion. The shape of light dome ( 205 ) may resemble in shape a conical or curved bullet head, or other similar shape, without deviating from the scope of the present disclosure, and for purposes of enhancing the lighting effect of light element ( 200 ) in liquid vessel ( 100 ).
[0042] FIG. 5D depicts a bottom view of an example light element ( 200 ) for liquid vessel ( 100 ) in accordance with one embodiment. In this view, button ( 206 ) is shown, which may be utilized by a user of liquid vessel ( 100 ) to turn on or activate the internal components of light element ( 200 ) in order to illuminate liquid vessel ( 100 ). In the example embodiment, button ( 206 ) may have approximate dimensions of 7.5 millimeters in diameter and 4 millimeters in height, and may sit flush with base ( 103 ) of liquid vessel ( 100 ) or may be positioned at a height slightly higher than indentations ( 103 a, b, c, d , and e). Button ( 206 ) may be large enough in size or diameter to easily accommodate when a user engages button ( 206 ) to activate light element ( 200 ), providing user friendly access as well as to prevent the loss or damage to button ( 206 ).
[0043] FIG. 6 depicts a side cross-section view of a light element ( 200 ) for a liquid vessel ( 100 ), in accordance with one embodiment. In this view, the placement of internal components ( 207 ) (details not shown) of light element ( 100 ) are positioned upon base ( 203 ) and generally filling the area within housing ( 201 ) and light dome ( 205 ), which may be comprised of a LED light piece ( 207 a ) and related lighting components that are known in the art. LED light piece ( 207 a ) of light element ( 200 ) may include lighting capabilities to produce lighting effects in a plurality of settings. Some of such settings may include, but are not limited to continuous lighting, flashing lighting, and lighting that is responsive to and produces lighting effects concurrent with the vibrations from sounds, such as music. LED light piece ( 207 a ) may also include lighting capabilities to produce different colors of light, including single lighting and red, green, blue (“RGB”) lighting. In an exemplary embodiment, LED light piece ( 207 a ) may have three (3) different arrangement settings, and seven (7) different light colors to be activated in one or more of the three (3) arrangement settings depending upon a user's preference. In yet another embodiment, LED light piece ( 207 a ) or light element ( 200 ) may contain a wireless interface that is capable of receiving wireless signals from, for example, a venue or stadium control center for purposes of controlling the lighting effects of light element ( 200 ), including in synchronization with other vessels ( 100 ) in the proximity. Such lighting effect control or synchronization may be desired, for example, during a theme show, movie, concert, or other entertainment event.
[0044] FIGS. 7A-G illustrate various representative views of another light element ( 200 ) for illuminating liquid vessel ( 100 ), in accordance with another embodiment, namely, a side perspective view of light element ( 200 ) ( FIG. 7A ); a bottom perspective view showing the inner portion of light element ( 200 ) ( FIG. 7B ); a top perspective view of light element ( 200 ) ( FIG. 7C ); a side perspective view of light element ( 200 ) ( FIG. 7D ); another side view of light element ( 200 ) ( FIG. 7E ); and a bottom view of light element ( 200 ) ( FIG. 7F ). In this embodiment, light dome ( 205 ) may be larger in size with a diameter that runs the length of a substantial portion of the diameter of top area ( 204 ).
[0045] FIG. 8 illustrates a top cross-sectional view of an exemplary liquid vessel ( 100 ) with a light element ( 200 ) configured therein. Cavity ( 105 ) is shown from above, with an exemplary light element ( 200 ) positioned within to illuminated liquid vessel ( 100 ) and its contents. As explained earlier, light element ( 200 ) may snap into cavity ( 105 ) via rib enclosures ( 105 a - c ), which are concave in shape in order to fit around the convex shape of ribs ( 202 a - c ). By snapping in or otherwise popping light element ( 200 ) into cavity ( 105 ) and its rib enclosures ( 105 a - c ), allows light element to be securely attached within liquid vessel ( 100 ), with rib enclosures ( 105 a - c ) providing light element ( 200 ) with a high level of reinforcement and stability once placed within.
[0046] Similar to FIG. 8 , FIG. 9 depicts a top cross-sectional close-up view of an example liquid vessel ( 100 ), but without a light element ( 200 ) configured therein. In this view, the shape of cavity ( 105 ) and its rib enclosures ( 105 a - c ) are shown in an empty state, and further illustrates cavity's ( 105 ) reinforced features, including with a thicker layer of plastic material (or other material used to make vessel ( 100 )) for placing light element ( 200 ) thereupon. In another embodiment, cavity ( 105 ) may contain a uniform concave shaped space around the circumference of cavity ( 105 ) instead of a plurality of rib enclosures ( 105 a - c ) to accommodate ribs ( 202 a - c ), or other variations in shape that may be implemented to form ribs ( 202 a - c ), including as a singular uniform rib around the circumference of housing ( 201 ).
[0047] In following with FIGS. 8 and 9 , FIG. 10 depicts a side cross-sectional close-up view of an example liquid vessel ( 100 ), and without a light element ( 200 ) configured therein, and depicts another view of rib enclosures ( 105 a - c ). The concave shape of rib enclosures ( 105 a - c ) may be deep enough in width to completely house the entire shape of ribs ( 202 a - c ) protruding from housing ( 201 ). In the present view, rib enclosures ( 105 a - c ) may be formed as separate elements within cavity ( 105 ), but as mentioned earlier, other embodiments may differ in shape without deviating from the scope of the present disclosure.
[0048] In another embodiment of cavity ( 105 ), cavity ( 105 ) may be both dome shaped and may contain threaded grooves around its circumference (not shown). Such threaded grooves may be complementary in shape to another embodiment of light element ( 200 ) which may contain threaded groves around it circumference. Light element ( 200 ) may be inserted and fixed into cavity ( 105 ) by screwing in light element ( 200 ) into cavity ( 105 ) via the complementary grooves of each. Light element ( 200 ) may be tightened therein, and removed such as when light element ( 200 ) may need to be replaced or changed, or removed for any other reason. Such embodiment of cavity ( 105 ) may be reinforced with additional plastic material and may be rigid in nature so that when screwing light element ( 200 ) therein, cavity ( 105 ) does not warp, deform, or otherwise collapse as a result. Further, such embodiment of cavity ( 105 ) may be used in combination with elements such as rib enclosures ( 105 a - c ) and other variations thereof. Similarly, such embodiment of light element ( 200 ) may contain one or more ribs ( 202 a - c ) and other variations thereof without limiting the scope of the present disclosure.
[0049] FIG. 11 depicts a perspective view of an example lanyard element ( 300 ) for use with exemplary illuminated liquid vessel ( 100 ), in accordance with one embodiment. Lanyard ( 300 ) may be coupled with liquid vessel ( 100 ) when in use by a user, such as when a user is at an event or other outing, and may desire to hold liquid vessel ( 100 ) around the user's neck, shoulder, or arm. Lanyard ( 300 ) may be comprised of a collar ( 301 ) that may measure from 1-2 feet in length, or other similar lengths in order to accommodate the comfort level of a user when positioning and using lanyard ( 300 ). Collar ( 301 ) may be comprised of a sturdy, heavy duty fabric, including nylon or polyester of different weave patterns, thickness, and lengths without deviating from the scope of the present invention. Lanyard ( 300 ) may also contain an adjustable mechanism ( 302 ) for collar ( 301 ) as well as a securing element ( 303 ) for attaching lanyard ( 300 ) to the neck ( 102 a ) of liquid vessel ( 100 ). Securing element ( 303 ) may further comprise a solid circular ring ( 303 a ) that attaches to collar ( 301 ) on opposite ends of security element ( 303 ). Ring ( 303 a ) may contain a plurality of teeth ( 303 b ) positioned within its inner circumference for purposes of holding securing element ( 303 ) in place. Ring ( 303 a ) may also comprise an adjustable mechanism ( 303 c ) for opening and closing ring ( 303 a ), and which also enable it to be fitted around neck ( 102 a ), or removed from neck ( 102 a ). Lanyard ( 300 ) further comprises safety element ( 304 ), described in further detail in FIG. 12 .
[0050] FIG. 12 depicts a close-up view of a safety element ( 304 ) of lanyard ( 300 ), in accordance with one embodiment. Safety element ( 304 ) may be attached to fabric collar ( 301 ) at opposite ends of safety element ( 304 ), and may be comprised of two pieces ( 304 a and 304 b ) that snap together one or more inner prongs ( 304 c - e ). Inner prongs ( 304 c - e ) may be comprised of two generally rectangular inner end pieces (in this view ( 304 c ) and ( 304 d )) and a middle oval piece ( 304 e ) that may secure safety piece ( 304 a ) into safety piece ( 304 b ). Piece ( 304 b ) contains an opening ( 3040 to allow a user to exert pressure on oval piece ( 304 e ) there within in order to remove safety piece ( 304 a ) from safety piece ( 304 b ). Also, when lanyard ( 300 ) is in use, safety piece ( 304 a ) may release and separate from safety piece ( 304 b ) on its own in the event of an emergency, such as strangulation, twisting, or other adverse movement of lanyard ( 300 ) via the exertion of pressure thereupon. Safety piece ( 304 a ) may release from safety piece ( 304 b ) or may be released when a user engages oval piece ( 304 e ) through opening ( 3040 .
[0051] FIG. 13 illustrates a perspective view of another embodiment of an illuminated liquid vessel ( 100 ), with another embodiment of light element ( 200 ) and an alternate embodiment of cavity ( 105 ), where light element ( 200 ) is configured to fit within a recess, such as cavity ( 105 ) via a pressure fit. Cavity ( 105 ) may be situated within base ( 103 ) of vessel ( 100 ), and may be situated at a height above indentations ( 103 a, b, c, d , and e). Cavity ( 105 ) may be configured as a pressure-fit cavity, in which a pressure force may be utilized to hold and retain light element ( 200 ) within vessel ( 100 ) as the overall shape of cavity ( 105 ) may be substantially similar in shape, dimension, and size as light element ( 200 ). Cavity ( 105 ) may also be configured to have an inner body that is substantially cylindrical in shape with a top portion of cavity ( 105 ) slightly tapered inwardly in shape (See FIG. 14 for additional detail). In this embodiment, cavity ( 105 ) may be formed with additional plastic material (such plastic material being a material that may be utilized for vessel ( 100 )) so that it is reinforced as well as thicker in nature than the rest of vessel ( 100 ). In this embodiment, cavity ( 105 ) may be rigid so as to enable such pressure fit around light element ( 200 ) that is stable and may retain light element ( 200 ) therein.
[0052] When inserting light element ( 200 ) into cavity ( 105 ), the top portion of cavity ( 105 ) may be configured to slightly expand in size as light element ( 200 ) is initially pushed toward the top area of cavity ( 105 ). As light element ( 200 ) is further inserted within cavity ( 105 ), the expansion of size in cavity ( 105 ) is reduced, with the resulting reduction in size of cavity ( 105 ) creating pressure around the circumference of light element ( 200 ) to firmly hold light element ( 200 ) within cavity ( 105 ).
[0053] When light element ( 200 ) is pressure-fit within cavity ( 105 ), the top portion of cavity ( 105 ) may be positioned slightly above in height to an upper edge of light element ( 200 a ) so that there is a small space between the upper edge of light element ( 200 ) and the top portion of cavity ( 105 ). Such space may between light element ( 200 ) and the upper portion of cavity ( 105 ) may assist with creating a pressure, including a suction pressure, around light element ( 200 ) when inserted therein.
[0054] The resulting pressure around light element ( 200 ) may be strong enough in nature so that a user cannot manually extract or otherwise remove light element ( 200 ) from vessel ( 100 ) without having to apply a substantially high amount of force to vessel ( 100 ), or dismantling the vessel ( 100 ) altogether. Further, and as shown in this view, there may be a negligible amount of space, if any, between light element ( 200 ) and cavity ( 105 ) once light element ( 200 ) is placed therein, so as to prevent a user from being able to pry, remove, or otherwise dislodge light element ( 200 ) from cavity ( 105 ).
[0055] FIG. 14 illustrates a perspective view of the illuminated liquid vessel ( 100 ) embodiment of FIG. 13 , without a light element ( 200 ) configured within the pressure-fit cavity ( 105 ) of the vessel ( 100 ). The generally cylindrical shape of cavity ( 105 ) is shown in this view, including its top portion which is tapered inwardly, as explained earlier.
[0056] In another embodiment of cavity ( 105 ), cavity ( 105 ) may be both cylindrical in shape and contain threaded grooves around its circumference (not shown). Such threaded grooves may be complementary in shape to another embodiment of light element ( 200 ) which may contain threaded groves around it circumference (not shown). Light element ( 200 ) may be inserted and fixed into cavity ( 105 ) by screwing in light element ( 200 ) into cavity ( 105 ) via the complementary grooves of each cavity ( 105 ) and light element ( 200 ). Light element ( 200 ) may be tightened therein, and removed such as when light element ( 200 ) may need to be replaced or changed, or removed for any other reason. Such embodiment of cavity ( 105 ) may be reinforced with additional plastic material and may be rigid in nature so that when screwing light element ( 200 ) therein, cavity ( 105 ) does not warp, deform, or otherwise collapse as a result. Further, such embodiment of cavity ( 105 ) may be used in combination with elements such as rib enclosures ( 105 a - c ) and other variations thereof. Similarly, such embodiment of light element ( 200 ) may contain one or more ribs ( 202 a - c ) and other variations thereof without limiting the scope of the present disclosure.
[0057] FIG. 15A-F illustrate the various perspective, side, top, bottom, and cross-section views of another embodiment of light element ( 200 ) that is configured to fit within vessel ( 100 ) via a pressure fit/force as discussed earlier with respect to FIGS. 13 and 14 . Such pressure force allows light element ( 200 ) to fit within cavity ( 105 ) without the need for adhesives, or external retaining mechanisms.
[0058] In this embodiment of light element ( 200 ), light element ( 200 ) is substantially cylindrical in shape, and may be slightly tapered or slanted in shape toward a top portion ( 204 ) of light element ( 200 ). In this embodiment, top portion ( 204 ) may be substantially planar in shape excepting such area that is slightly tapered or slanted in shape. Around the circumference of housing ( 201 ) of light element ( 200 ) are a series of ridges ( 220 ) that are positioned vertically around light element ( 200 ) (See FIGS. 15 A-F for additional detail). As indicated earlier, housing ( 201 ) may contain the internal lighting components that are known in the industry.
[0059] Ridges ( 220 ) surround the entire circumference of the housing ( 201 ) of light element ( 200 ), and may be slightly rounded in nature (See FIG. 5C ). Ridges ( 220 ) may serve to further reinforce the pressure fit of light element ( 200 ) within cavity ( 105 ), including by creating an additional layer of friction between light element ( 200 ) and vessel ( 100 ) when light element ( 200 ) is inserted into cavity ( 105 ). Ridges ( 220 ) may also prevent light element ( 200 ) moving within cavity ( 105 ) as well as from rotating therein. Other variations in the shape of ridges ( 220 ) may be utilized in connection with the present embodiment without deviating in scope from the present invention.
[0060] Various aspects of the present invention are described herein with reference to illustrations and/or diagrams according to embodiments of the invention. While particular forms of the invention have been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except by the claims.
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An illuminable container device, comprising a housing for containing a liquid; a recess configured within a base area of said housing, with said recess extending upwardly into said housing and in a substantially cylindrical shape; a light device, comprising a light housing with a substantially cylindrical shape, said light housing comprising a plurality of ridges, which are positioned vertically around a circumference of said light housing; said light device configured to fit into and substantially fill said recess being held therein by a pressurized fit.
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FIELD OF THE INVENTION
This invention relate to devices for assaying samples for the presence or absence of a substance of interest, to qualitative and semi-quantitative methods of using such devices and to diagnostic reagents and kits incorporating such devices. Such devices, methods, diagnostic reagents and kits have applications in the biologic research and medical fields for assaying drugs, hormones, peptides, proteins, enzymes, nucleic acids, antibodies, haptens, antibiotics, viri, infectious agents, tumor markers and the like, in the laboratory, the physicians' office, the veterinarian's office and the home.
More particularly, this invention relates to devices and methods, diagnostic reagents and kits embodying such devices for use in ligand/anti-ligand assays and the qualitative or semi-quantitative detection of a substance of interest thereby through use of light or photon detecting systems such as reflectometers, colorimeters, fluorimeters and the human eye.
BACKGROUND OF THE INVENTION
Techniques for assaying a sample for the presence and/or concentration of specific substances are known to those skilled in the art. Examples of such techniques include nucleic acid hybridization assays, various protein-binding methodologies including radioimmunoassay, enzyme immunoassay, enzyme-linked immunoassays. All of these techniques involve the binding of a compound to some sort of specific receptor and accordingly fall into the general category of ligand/anti-ligand assays, a category not limited to any special type of interaction occurring in the assay or to any particular type of components participating in the reaction.
All ligand/anti-ligand assays are based on two premises: (1) that certain pairs of substances (the ligand and the anti-ligand) have a strong and specific affinity for each other, that is, they will tend to bind to each other, while binding little or not at all to other substances; and (2) that methods and devices can be developed that allow detection of ligand/anti-ligand binding interactions once complexes have formed. As used herein, ligand is defined as the substance to be detected, and anti-ligand as the substance used to probe for the presence of the ligand.
Ligand/anti-ligand reactions can be detected by a variety of methods, using various markers to label either the ligand or anti-ligand to permit detection of the reaction product. Currently, the most commonly used markers include enzymes and fluorochromes and radioactive compounds. Immobilization of either the ligand or anti-ligand will facilitate detection in many cases.
Ligand/anti-ligand assays can be generally classed into two categories, heterogeneous and homogeneous. Heterogeneous assays require separation of the bound-labeled component from the free-labeled component prior to detection of the reaction product. Homogeneous assays do not require such a separation step. These assays can further be (1) competitive, for example, where ligand competes for labeled anti-ligand with a solid-phase ligand or where anti-ligand competes with labeled anti-ligand for a solid-phase ligand or (2) noncompetitive where there is a direct relationship between label and ligand or anti-ligand.
Ligand/anti-ligand assay methods can be applied to fluorescent immunoassay, enzyme immunoassay and radioimmunoassay techniques to detect the presence or absence of antibodies or antigens, i.e., the ligand, in a sample. In recent years the use of enzyme immunoassays (EIA) and enzyme-linked immunoassays (ELISA) has become increasingly important for the qualitative and semi-quantitative detection of a wide variety of substances. In ELISA methodology, antigens can be labeled directly or indirectly by use of enzyme-labeled antibodies which, under appropriate conditions, catalyze a reaction with a substrate. The enzyme activity is detected by formation of a colored reaction product i.e., a colored end point that may be easily detected by eye or measured by spectroscopic or reflectance means. Several enzymes, including alkaline phosphatase, horseradish peroxidase (HRP) and glucose oxidase, have been coupled to both antigen and antibody. HRP is commonly used and several substrates are available for it. For visual detection in an HRP assay, the substrate will usually comprise a solution of a peroxide such as hydrogen peroxide and a chromogenic material such as o-phenylenediamine or tetramethylbenzidine which manifests a color upon oxidation.
In fluorescent immunoassay techniques antigens can be labeled either directly or indirectly with fluorochrome-labeled antibodies. Fluorochromes are dyes that absorb radiation (e.g., ultraviolet light), are excited by it, and emit light (e.g., visible light). The most commonly used fluorochromes are fluorescein isothiocyante and tetramethylrhodamine isothiocyanate.
Ligand/anti-ligand assays also include protein binding assays wherein a specific binding protein is used as an anti-ligand to probe a sample for the protein which it binds. The reaction product of such protein-binding assays, can also be detected using radioactive, fluorescent or enzyme labels. Either the binding protein or its target protein may be labeled.
Yet another ligand/anti-ligand assay that is becoming increasingly important is the nucleic acid hybridization assay, e.g., the DNA probe assay, which uses a "probe" strand of nucleic acid as an anti-ligand to test for the presence of a complementary DNA sequence. DNA probe assays, like immunoassays, often use radioactive labels, fluorescent labels or enzyme labels. Both immunoassays and DNA probe assays have used luminescent labels as well.
In many cases, ligand/anti-ligand techniques require large sample volumes, are time consuming and involve multi-step procedures. For these reasons, it is desirable to carry out such assays with the aid of a device which facilitates the reaction between ligand and anti-ligand, for example, by using a minimum amount of sample, requiring fewer steps, and enabling the reaction to take place rapidly, within the device without transfer of the ligand being assayed. It is also desirable to carry out such assays with the aid of a device which facilitates detection of the reaction product, in some cases, by eliminating the need for detection equipment or by providing the reaction product in a form which is detectable by equipment without further processing of the reaction product.
Immobilization of either the ligand or anti-ligand will facilitate detection in many ligand/anti-ligand assays. Useful ligand/anti-ligand assay systems for assaying drugs, hormones, peptides, proteins, enzymes, nucleic acids, antibodies, haptens, antibiotics, viri, infectious agents, tumor markers and the like commonly are solid phase systems using ligands or anti-ligands immobilized on a water-insoluble carrier such as metal, glass, or plastic.
U.S. Pat. No. 4,090,849 provides a diagnostic device for the detection of biological particles wherein a metal sheet is used as the solid phase upon which a layer of protein is applied.
U.S. Pat. No. 4,280,992 provides immunologically active substance-frosted glass conjugates for use in assays of physiologically active substances using the same. The glass solid phase of '992 is frosted by physical means, e.g., sandblasting, or by chemical treatment, e.g., etching. '992 teaches use of these glass conjugates in the form of frosted tubes and beads.
The ability of proteins to absorb to plastic materials is a well-known phenomenon to those skilled in the art, and various ligand/anti-ligand assays have been developed in which a protein is immobilized on plastic.
U.S. Pat. No. 4,197,361 discloses an immunoassay for the sandwich technique in which antibody (or antigen) is bound to a plastic, and after reaction with a test sample and then fluorescently tagged antibody (or antigen), fluorescense is read directly from the strip in a fluorometer. '361 further discloses sandblasting the plastic strip to increase the surface area.
Assays have also been developed wherein groups reactive with a particular type of ligand or anti-ligand are grafted to the surface of the plastic. U.S. Pat. No. 4,317,810 discloses a water insoluble polymeric matrix which has a layer of reactive groups grafted onto its opposing surfaces, wherein the surfaces have a designed configuration in the form of a plurality of ridges and depressions so that when the matrix is placed in a vial containing solution both surfaces will be substantially in complete contact with the solution and there will be a minimum of surface-to-surface contact between the matrix and the bottom of the vial.
Although presently available test devices have provided means to increase the sensitivity and ease of carrying out ligand/anti-ligand assays, more sensitive and easier assays are needed. Thus, alternative devices are being sought which require, for example, smaller amounts of sample and fewer steps, and which provide a more convenient methodology.
SUMMARY OF THE INVENTION
The present invention provides devices and methods, diagnostic reagents and kits embodying such devices for the qualitative and quantitative assay of samples for the presence of ligands by forming within the device the reaction product of a ligand and at least one anti-ligand therefor. Carrying out ligand/anti-liquid assays in accordance with the present invention provides assays of improved sensitivity. Furthermore, use of such device facilitates the washing steps in such assays.
Devices according to the present invention for assaying a sample for the presence of a ligand by forming within the device a reaction product of the ligand with at least one anti-ligand therefor comprise: a plastic member defining at least one well having a bottom; a plurality of spaced projections extending upward from the well bottom to increase the surface area thereof the projections being spaced to define interconnecting channels therebetween. In preferred embodiments the projections are pyramidal, columnar, conical, rectangular, cylindrical or dome-shaped.
The number and dimensions of wells defined by the plastic member 5 will depend upon the nature of the assay to be conducted. In some embodiments of the present invention the well bottom further comprises a ligand or anti-ligand. In yet other embodiments the well bottom further comprises a chromogen. In yet other embodiments the well bottom comprises reactive groups.
Devices according to the present invention and methods, diagnostic reagents and kits incorporating such devices, can be used for carrying out a variety of ligand/anti-ligand assays provided that the reaction product of a ligand and at least one anti-ligand therefor can be immobilized in the well. In general the ligand/anti-ligand reaction product is formed in the well bottom and is detected by methods well known to those skilled in the art. For example, in carrying out ligand/anti-ligand assays according to the present invention either a ligand or anti-ligand may be immobilized in the well. Accordingly, the present invention provides devices, and diagnostic reagents and kits incorporating such devices, for carrying out competitive assays wherein a ligand is immobilized in a well and sample ligand competes with immobilized ligand for labeled anti-ligand. The present invention also provides devices, and diagnostic reagents and kits incorporating such devices, for carrying out (i) competitive assays wherein the anti-ligand is immobilized and sample ligand competes with labeled ligand for the immobilized anti-ligand; (ii) sandwich assays wherein a first anti-ligand, immobilized on a membrane, captures a ligand and a second anti-ligand reacts with the immobilized ligand to form a reaction product capable of being detected; and (iii) assays where, e.g., a bacterial cell or virus, is immobilized on the surface of the well and the RNA or DNA is subsequently extracted therefrom and also immobilized in or on the membrane.
Devices according to the present invention may also be used advantageously in enzyme-amplified immunoassays. (See, e.g., Stanley, C. J. et al., Am. Clin. Prod. Rev. October, 1985, P. 34) In its simplest form, the enzyme label in an immunoassay (the primary system) is used to provide a trigger substance for a secondary system that can generate a large quantity of colored product. The enzyme-amplified immunoassay differs from the conventional type in that the product from the enzyme label need not, in itself, be measurable but can instead act catalytically on the secondary system.
Enzyme-channeling immunoassays such as that described by Litman, D. J. et al., Clin. Chem. (1983) 29:1598, are another example of ligand/anti-ligand assays which may be conducted using devices according to the present invention, and diagnostic reagents and kits embodying such devices. The Litman et al. assay involves sequential enzyme reactions catalyzed by the glucose oxidase/horseradish peroxidase channeling pair wherein the ligand/anti-ligand reaction product is an insoluble chromophore.
Accordingly, the present invention provides a method for assaying one or more samples for the presence of at least one ligand with the aid of a device for assaying one or more samples for the presence of a ligand by forming within the device a reaction product of the ligand with at least one anti-ligand therefor and detecting the reaction product, the device comprising: a plastic member defining at least one well having a bottom, the well comprising at least one anti-ligand; and a plurality of spaced projections extending upward from the well bottom to increase the surface area thereof, the projections being spaced to define interconnecting channels therebetween; the method comprising: (1) introducing the sample into the well bottom; (2) forming in the well bottom a ligand/anti-ligand reaction product; and (3) detecting the ligand/anti-ligand reaction product. In yet other embodiments the well bottom comprises at least one ligand and the method comprises: (1) introducing the sample into the well bottom; (2) forming in the well bottom a ligand/anti-ligand reaction product; and (3) detecting the reaction product.
The devices, and diagnostic reagents of the present invention may be used in the production of kits for assaying a sample for the presence of a ligand. For example, one kit according to the present invention comprises the following in combination: a device, in accordance with the present invention, for assaying one or more samples for the presence or absence of at least one ligand by forming within the device a reaction product of the ligand with at least one anti-ligand, the device comprising: a plastic member defining at least one well having a bottom, the well bottom comprising a first anti-ligand; and a plurality of spaced projections extending upward from the well bottom to increase the surface area thereof, the projections being spaced to define interconnecting channels therebetween; a first anti-ligand immobilized in the well bottom; and a second anti-ligand capable of being detected.
One kit for an ELISA according to the present invention comprises in combination a first antibody immobilized in the well bottom; a second antibody conjugated with an enzyme; a substrate for the enzyme; and a chromogen. In one such ELISA, the enzyme comprises horseradish peroxidase, the chromogen comprises tetramethylbenzidine, and the substrate comprises hydrogen peroxide.
In yet other embodiments of kits according to the present invention, the kit comprises the following in combination: a device for assaying one or more samples for the presence or absence of at least one ligand by forming within the device a reaction product of the ligand with at least one anti-ligand, the device comprising: a plastic member defining at least one well, the well comprising a ligand; and a plurality of spaced projections extending upward from the well bottom, the projections being spaced to define interconnectiong channels therebetween; and a ligand capable of being detected e.g. for competitive binding assays. In yet other embodiments for competitive binding assays the ligand rather than the antiligand is bound to the well and the anti-ligand is provided in the kit in a form capable of being detected.
Kits for enzymic inhibition assays, another type of ligand/anti-ligand assay, are also encompassed in the present invention. In such embodiments of the kit the well bottom comprises an enzyme, and a solution of an anti-ligand is provided which binds near the active site of the enzyme. The presence of bound ligand inhibits product formation from a substrate.
Thus, it is seen that devices, methods and kits according to the present invention are particularly suitable for qualitatively and quantitatively detecting a reaction product of a ligand with at least one anti-ligand therefor wherein the reaction product is detectable by a color change or production, or the emission or change in emission of light, e.g., luminesence, or fluoresence or phosphorescence. The configuration of these devices is such that assays may be carried out completely within the device, if desired, thus eliminating the additional step of removing the sample for measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the invention may be had by referring to the accompanying drawings, wherein:
FIG. 1 is a plan view of one embodiment of a device according to the present invention.
FIG. 2 is a side view, partially in section, of FIG. 1.
FIG. 3 is an enlarged view of a section of the well bottom of FIG. 1 along line 3--3 of FIG. 1.
FIG. 4 is an enlarged isometric view of a well bottom showing pyramidal projections.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIGS. 1, 2, 3 and 4 illustrate a device according to the present invention for assaying a sample for the presence of a ligand by forming within the device a reaction product of the ligand with at least one anti-ligand therefor, said device comprising a plastic member 5 defining two wells 10; and a plurality of spaced pyramidal projections 20 extending upward from the well bottom 25, the projections being spaced to form interconnecting channel therebetween.
The plastic member 5 may be selected from a variety of plastic materials. The material of choice will be determined by the nature of the assay to be carried out, e.g., ability to bind the ligand or anti-ligand. In preferred embodiments, the material will be a plastic selected from the group polyethylene, polypropylene, polystyrene, polycarbonate, polysulfone, polymethylmethacrylate or any plastic that can be molded or otherwise formed to a desired shape. A preferred plastic in the streptoccus A assay of Example I below is polymethylmethacrylate. In the allergen assay of Example II, polystyrene is a preferred plastic. In embodiments wherein the device is molded, a preferred plastic is a thermoplastic which can be injection molded. In embodiments the plastic member 5 is transulucent or transparent so that a light can be passed through it. For example, if the detection is by a fluorimeter technique, it may be desirable to visualize the sample by exciting from below from a fluorescent light source.
The plastic member 5 may be of any shape which will accommodate a desired number of wells 10. The dimensions, shape, number and positioning of the wells 10 depends, in part, upon the nature of the assay carried out and the means used to detect the reaction product. In some embodiments of the present invention, one or more wells may be used to carry out an assay on a control or comparison sample. In some embodiments of the present invention, the well 10 comprises at least one ligand or anti-ligand. In yet other embodiments the well 10 comprises reactive chemical groups grafted thereto. Techniques for grafting such groups on plastic are well known to those skilled in the art. The well may also comprise a chromogen or a species which emits light or fluoresces under the conditions of the assay.
In a preferred embodiment of the present invention shown in FIGS. 1-4, the projections 20 extending upward from the well bottom 25 are pyramidal. However, the projections may be of any shape which will increase the surface area of the well 10 without creating areas that are hard to wash, e.g., crevices and capillaries. According to preferred embodiments of the present invention the projections are pyramidal, columnar, conical, rectangular, cylindrical or dome-shaped. The projections are spaced to form interconnecting channels therebetween to enable the sample and reagents to spread over the well bottom 25.
Devices according to the present invention offer advantages with respect to increased surface area for binding of the ligand or anti-ligand and reproducibility. It is desirable to increase the surface area of the well bottom 25, so as to maximize formation of reaction product, such as in assays of substances which may be present in low concentration. The surface area of the well bottom in devices according to the present invention can be controlled and thus the amount of ligand or anti-ligand adsorbed or bound can be controlled, to provide for reproducible results from assay to assay. The reaction of ligand with anti-ligand occurs primarily in the volume of liquid contained in the space surrounding the projections.
The depth of the well depends on the total well volume desired. However, increasing the depth makes the surface harder to wash since the geometry becomes more like a tube than a flat surface as the depth of the well increases. It is preferred that liquid sample and other reactants be easily rinsed from the well 10 so that the assay may be carried out rapidly with adequate washing. In preferred embodiments the sides of the well are contoured so that they meet the well bottom at an obtuse angle, i.e., without forming a crevice or capillary which is difficult to wash. In preferred embodiments the wells may be flushed with a continuous stream of reagent. This method of washing offers an advantage over the dilution type of wash that is achieved in a tube configuration. Too low a depth makes the device prone to spills and requires inconveniently small volumes of reagents.
The sides of the well meet the well bottom in a manner to enhance washability. For example, in the embodiment shown in FIGS. 1-4 the sides of the well meet the bottom at an angle so that wash water flows over the well bottom without creating a dead pocket.
In the embodiment of a device according to the present invention shown in FIGS. 1-4 it has been found that a well volume of from 0.05 ml to 0.2 ml is preferred for ligand/anti-ligand assays. With this preferred volume range, a well depth of from 2 to 3 mm is preferred.
The height of the projections is determined from a consideration of the desired sample volume, together with the dimensions of the well bottom. For example, in a rectangular well bottom as shown in FIGS. 1-4 having a 1 cm × 1 cm size test area, a desirable height for the projections is between 0.05 cm and 0.2 cm. A depth of about 0.1 cm is preferred in some embodiments.
In the embodiment shown in FIGS. 1-4, the surface area enhancement, a function of the ratio of the height to the width of the pyramidal projections, is about 4, with a ratio of about 2. Ratios higher that about 2 or 3, when combined with the height and test area limitations described above, are not practical since the width of the projections would become very small and hard to wash (i.e. they will begin to behave like crevices).
In carrying out assays by means of devices according to the present invention it may be desirable to simultaneously assay in the same device a sample to be tested and one or more control samples to serve as a reference, e.g., in competitive binding ligand/anti-ligand assays and/or to verify that the reagents being used to carry out the assay are functioning properly. In such embodiments, the plastic member will define two or more wells. FIGS. 1-4 show a two well embodiment of the present invention wherein one well may be used to assay a sample to be tested, the other, for example, to assay a control sample.
Devices aocording to the present invention can be used for any assay procedure wherein the ligand reacts with an anti-ligand therefor to give one or more reaction products which can be immobilized in the well. Accordingly, the present invention provides a method for assaying one or more samples for the presence of a ligand by forming within the device a reaction product of the ligand with at least one anti-ligand therefor and detecting the reaction product, said device comprising: a plastic member defining at least one well having a bottom, the well comprising at least one anti-ligand; and a plurality of spaced projections extending upward from the well bottom to increase the surface area thereof, the projections being spaced to form interconnecting channels therebetween; the method comprising: (1) introducing the sample to the well bottom and forming in the well bottom a ligand/anti-ligand reaction product; (2) forming a detectable reaction product; and (3) detecting the detectable reaction product. In some embodiments step 2 takes place together with Step 1. In yet other embodiments washing steps are included.
Devices, according to the present invention, are particularly useful for qualitatively or semi-quantitatively detecting reaction products of a ligand with an anti-ligand therefor, wherein detection of the reaction product is by a color change, the emission of light or fluorescence.
Ligand/anti-ligand reaction products may be detected, if present in the well bottom, by techniques well known to those skilled in the art. Where the reaction product in the well is detectable by a color change, the sample may be detected by measuring the reflectance of the well bottom using instruments and techniques known to those skilled in the art. The present device is particularly suited for permitting visual detection of reflectance of the well bottom.
Devices according to the present invention are useful for assaying samples for the presence of a variety ligands such as drugs, hormones, peptides and proteins. In a preferred ELISA method according to the present invention, the ligand comprises an antigen and the well bottom further comprises a first antibody; and step 2 comprises the steps of (i) introducing to the well bottom a second antibody conjugated with an enzyme; (ii) allowing the second antibody to react with the antigen/first antibody reaction product, (iii) washing the well, (iv) introducing a solution comprising a substrate for the enzyme and a chromogen to the well bottom and (iv) detecting, visually or with an appropriate instrument, the reaction product of the first and second antibodies with the antigen. The method may further comprise additional washing steps. A particularly preferred enzyme is horseradish peroxidase and a particularly preferred substrate/chromogen comprises H 2 O 2 and tetramethylbenzidine.
Thus, we have described and provided examples of unique devices for assaying a sample for the presence of a ligand by forming and detecting a reaction product of the ligand at least one anti-ligand therefor; qualitative and semi-quantitative methods of using such devices; and diagnostic reagents and kits incorporating such devices. The ease with which ligand/anti-ligand assays may be carried out using devices and methods according to the present invention, makes such devices particularly suitable for diagnostic reagents and kits for the home diagnostic market.
This invention will be further understood with reference to the following examples which are purely exemplary in nature and are not meant to limit the scope of the invention.
EXAMPLES
EXAMPLE I
Device Procedure For Detection Streptococcus A Antigen
A strep A assay was established using a device similar to that shown in FIGS. 1-4 by immobilizing antibody in the well in the manner described below. The device was made of molded polymethylmethacrylate.
Group A Streptococcal antigen was simultaneously extracted from a sample of cells and captured by an immobilized antibody therefor. The assay is a solid-phase, two-site, enzyme-liked immunoassay using two polyclonal antibodies, one immobilized on a solid-phase and the other in solution and conjugated to horseradish peroxidase. The polyclonal antibodies were raised in rabbits and prepared using techniques known to those skill in the art. The assay is a qualitative or semi-qualitative procedure.
In this assay, the sample was taken from the throat. The data was run in duplicate. Sample swabs, each containing about 10 6 bacteria were used to inoculate the test well bottoms. Inoculation of the test well bottoms was accomplished by rolling and rubbing the tip of the swab against the test well bottom (antibody coated), thereby transferring the bacteria to the well. Negative controls were run by adding the same sequence of reagents to uninoculated wells (negative well) as to test wells.
Procedure
1. The specimen was collected on a dacron tipped swab. The swab was then applied to the test well bottom (as described above) coated with a first polyclonal antibody to Group A Streptococca antigen.
Antigen: Rabbit Anti-Strep A antibody was affinity purified using N-acetyl glucosamine agarose (Sigma Chemical. St. Louis).
Antibody Coating Devices: The well bottoms were coated with polymerized (0.002% gluteraldehyde) anti-strep A antibody at 5 microgram/well in 250 microliters of PBS with 0.1% azide overnight. The wells were washed once with a phosphate buffer, pH 7, and incubated in a phosphate buffered saline with 4% BSA at pH 7.4 for two hours. The wells were then washed and the devices were ready for use.
2. 50 microliters of reagent A was added to the test and negative control well bottoms followed by 50 microliters of reagent B. Finally, 50 microliters of reagent C was added to the well bottoms. The reagents were constituted as follows:
Reagent A: sodium nitrite solution was made by adding 138 grams per liter sodium nitrate in distilled water.
Reagent B: acetic acid solution was made by adding 7.102 milliters of glacial acidic acid to 1 liter of distilled water.
Reagent C: conjugate solution was made by adding to one liter of distilled water, 10.46 grams per bis tris, 500 milliters per liter conjugate, one milliliter per liter TWEEN 20, pH 6.
Conjugate: Rabbit Anti-Strep A antibody, affinity purified, and conjugated with HRP using a modification of the Nakane method (P. K. Nakane and A. Kawasi). (J. Histochem. Cytochem. 22, 1084 (1974)).
3. These reagents were incubated for about three minutes.
4. Next, 50 microliters of wash solution was added to each well bottom.
Wash solution was constituted of the following: 14.09 grams per liter potassium phosphate, monobasic; 60.36 grams per liter potassium phosphate, dibasic; 8.10 grams per liter sodium chloride 90 milliters per liter TRITON×100, Q5 to one liter with distilled water, pH 7.3.
5. The wells were flooded with water and tamped to prevent dilution of the next set of reagents.
6. 100 microliters of reagent D and 50 microliters of reagent E were added to the well bottoms.
Reagent D is the substrate solution and was constituted of 13.615 grams per liter trihydrous sodium acetate, 0.47 grams per liter urea peroxide, 1.0 molar citric acid solution to pH the solution to pH 5, all dissolved in distilled water.
Reagent E is a chromogen solution and was made by adding •milliters of methanol to 500 milliters of glycerol and adding 1.27 grams of TMB to that one liter of solution. TMB is 3,3',5,5'-tetramethylbenzidine.
7. The contents of the wells were incubated for two minutes.
8. To determine the reaction, the color in the test well was noted against the color in the negative well. A dark color in the test well indicated a positive reaction, i.e., the presence of Step A.
EXAMPLE II
Device Procedure for the Detection of Allergens
This is an example of a solid phase protein binding assay. To test for allergic reaction one or more allergen extracts (Ventrex) were immobilized via direct adsorption in the well bottom of a polystyrene device similar to that shown in FIGS. 1 to 4.
The assay procedure was as follows:
1. Allergens were immobilized in the well bottoms by direct adsorption as follows:
(a) allergen extracts were diluted to a predetermined concentration in a carbonate buffer pH 9.5.
(b) the coating volume per well bottom was equal to 400 microliters.
(c) the well being used for the assay's negative control was not coated
(d) The wells were allowed to coat overnight at room temperature, then washed and dried the next day.
2. Allergen extracts were added to the test well bottoms.
(a) pollen extract--2 grasses, 2 trees and 2 weeds
(b) cat/dog extract
(c) dust mold/mold extract
3. Assay Procedure
(a) 100 microliters patient sample was added to each test well and negative control well.
(b) 100 microliters conjugate was added to each well.
(c) The device was shaken lightly to mix.
(d) The device was covered to prevent evaporation and incubated overnight at room temperature.
(e) The wells were flushed with deionized water.
(f) 3 drops substrate buffer and 3 drops chromogen were added.
(g) The blue color in test well was observed and compared with the color in negative control well. If the test well was darker, the test was positive for 1 or more allergens in the particular well.
(h) materials
1. Enzyme-antibody conjugate used is goat antibody (polyclonal) to human IgE (g'hIgE) (Ventrex) conjugated to horseradish peroxidase (HRP) (Beohringer-Mannheim) via procedures known to those skilled in the art (See, e.g., Nakane procedure, Wilson, B. M. et al., Immunofluorescense and Related Techniques, at p. 215, 1978, Elsevier/North-Holland Biomedical Press)
2. Wash solution (0.01M PBS, 0.2% Triton X-100, pH 7.4) (Ventrex).
3. Substrate-chromogen solution (prepared immediately before use): 5(% 0.127% tetramethylbenzidine (Sigma) in absolute methanol (Fischer), 50% 4.7 mM H 2 O 2 in 0.1M citrate-acetate, pH 5.0) (Ventrex). A blue color indicates binding of IgE in the test liquid to the allergen immobilized on the disc. White indicates the absence of reactive IgE in the liquid.
It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof that will be suggested to persons skilled in the art are to be included in the spirit and review of this application and the scope of the approved claims.
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This invention relates to devices and to methods, diagnostic reagents and kits embodying such devices for use in ligand/anti-ligand assays and the qualitative or semi-quantitative detection of a substance of interest thereby through use of light or photon detecting systems such as reflectometers, colorimeters, fluorimeters and the human eye. Such devices, methods and kits have applications in the biologic research and medical fileds for assaying drugs, hormones, peptides, proteins, enzymes, nucleic acids, antibodies, haptens, antibiotics, viri, infectious agents, tumor markers and the like, in the laboratory, the physicians' office, the veterinarian's office and the home.
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[0001] This application claims benefit of U.S. Provisional Application No. 61/667,077 filed Jul. 2, 2012, the contents of which are incorporated herein by reference.
GOVERNMENT SUPPORT
[0002] This invention was made with Government support under contract number DE-AC02-98CH10886, awarded by the U.S. Department of Energy and the U.S. Department of Energy ARPA-E grant DE-AR00000470. The Government has certain rights in the invention.
BACKGROUND
[0003] Triacylglycerol compounds (TAGs), which consist of three fatty acids (FA) esterified to a glycerol backbone, are the predominant store of carbon in the majority of seeds and particularly seeds of oilseed crops. While they may account for more than 60% of the weight of seeds, triacylglycerols normally accumulate only to very low levels in non-seed/vegetative tissues, typically <0.1% (Yang and Ohlrogge, 2009, Plant Physiol. 150:1981-1989). Fatty acids from the seeds of oilseed crops have long been recognized for their nutritional value and for their use as industrial feedstocks. More recently their use as biodiesel is being contemplated and encouraged. However, using today's commercial oilseed crops to meet biodiesel production targets is not currently feasible.
[0004] Because the biomass ratio of vegetative tissue to seed tissue in crop and non-crop plants is so substantial, it is an intuitive certainty that a small, but significant, increase in the weight percent of TAGs stored in non-seed biomass could provide an enormous boost to the amount of biodiesel that could be produced during a single growth cycle. To accomplish this one needs to first understand and then to manipulate the metabolic controls that normally limit the accumulation of fatty acids, particularly in the form of TAGs, in the vegetative tissues of plants. Various preliminary studies have suggested different lines of approach.
[0005] TAGs have been shown to accumulate in non-seed tissues in a variety of plant mutants. For example, mutation of the Arabidopsis homologue of the human CGI-58 gene (At4G24160) resulted in the accumulation of neutral lipid droplets in mature leaves (James, et al. 2010, Proc. Natl. Acad. Sci. USA 107:17833-17838 and US20100221400A1). Mutation of trigalactosyldiacylglycerol (TGD) proteins (tgd1 mutants) involved in fatty acid (FA) transport from the endoplasmic reticulum (ER) to the plastid had a similar effect (Xu, et al. 2010 Plant Cell Physiol. 2010, 51:1019-1028). Mutations of pickle, a chromatin remodeling factor involved in switching from embryonic expression to vegetative expression, lead to TAG accumulation in vegetative tissue (Ogas, et al. 1999, Proc. Natl. Acad. Sci. USA 96:13839-13844). However none of these mutant plant strains accumulated TAG levels in excess of about one percent of dry weight.
[0006] The accumulation of biological molecules is a balance between the rate of synthesis and the rate of degradation. Disruption of fatty acid breakdown, which occurs via β-oxidation in the peroxisome, can lead to increased TAG levels. The pathway is initiated by uptake of FA via a peroxisomal ABC transporter, CTS, followed by β-oxidation within the organelle. Slocombe et al. (Plant Biotech. J. (2009) 7:694-703) show that leaf TAG levels can be increased significantly (10-20 fold) by blocking fatty acid breakdown. They surmised that their results suggest that recycled membrane fatty acids can be captured as TAG compounds by expressing seed program genes in senescing tissue or by blocking fatty acid breakdown, or both. Together, data from the tgd1 mutants and the CTS mutants suggest that the increased TAG accumulation is a response to increased FA supply levels.
[0007] A transcription factor, wrinkled1 (WRI1) (Cernac and Benning (2004) The Plant J. 40:575-585) controls the coordinate expression of many genes of fatty acid synthesis (FAS) and therefore represents an excellent target for increasing the supply of fatty acids (Pouvreau et al. 2011, Plant Physiol. 156:674-686). Seedlings expressing WRI1 require elevated glucose or fructose levels in order to facilitate increases in vegetative TAG (Cernac and Benning, 2004).
[0008] The starch biosynthetic pathway is a competing sink for photosynthetic carbon (for example, see Fan et al. 2012, Plant Cell Physiol. 53:1380-1390). Down-regulation of this pathway using an RNAi approach targeting ADP-glucose pyrophosphorylase with AGPRNAi in WRI1 overexpressing lines increased the levels of hexoses and the level of TAG accumulation was 6-fold higher than in lines overexpressing either mutant alone (Sanjaya et al. 2011, Plant Biotechnology J. 9:874-853).
[0009] In another promising approach, a second transcription factor leafy cotyledon 2 (LEC2) (Santos Mendoza et al. 2005, FEBS Lett. 579:4666-4670), which is epistatic to WRI1, was co-expressed in the cts-2 mutant, resulting in oil accumulation in vegetative tissue (Slocombe et al., 2009). While this approach yielded interesting results, the expression of LEC2 can have undesirable pleiotropic effects.
[0010] None of these early studies has established commercially relevant plant strains having a small, but significant, increase in the weight percent of TAGs stored in vegetative tissue (non-seed biomass).
SUMMARY
[0011] A combination of genes is described for enhancing the accumulation of triacylglycerol fatty acids in vegetative tissues of plants when introduced for expression in such plants. Also described herein is a method for enhancing the accumulation. This involves introducing into the plant the combination of genes for expression. The combination of genes may include for example, genes that generally increase fatty acid synthesis, genes that encode oleosin or other similar proteins, genes that encode diacylglycerol acyltransferases, genes that encode phospholipid:diacylglycerol acyltransferases, genes that encode medium chain thioesterases and combinations of such genes. As a result of the present combination of genes and methods for using an altered crop plant may be generated. The altered crop plant may have a weight percent of triacylglycerol compounds (TAGs) in one or more vegetative tissues that is at least two-fold higher than the weight percent in one or more vegetative tissues of a parent plant from which the altered crop plant was derived. Also, described is an altered crop plant wherein a harvestable TAG is twenty-fold higher than a harvestable TAG from one or more vegetative tissues of its parent plant.
DRAWINGS
[0012] FIG. 1 : Depiction of normal leaf metabolism showing the assembly of TAG in the cytoplasm and/or endoplasmic reticulum (ER).
[0013] FIG. 2 : Depiction of modified leaf metabolism showing the proposed effect of co-expression of four genes, wrinkled1 (WRI1); medium chain thioesterase (MCT or T); diacylglycerol acyltransferase (DGAT) and olesin 1 (Ole1).
[0014] FIG. 3 : Thin layer chromatography showing results of transient expression in Nicotiana benthamiana leaves by the control inoculant (C); Ole1 inoculant (O); DGAT inoculant (D); WRI1 inoculant (W); Ole1, DGAT, and WRI1 triple inoculant (ODW) and Oli1, DGAT, WRI1 and MCT tetra inoculant (ODWT). Gene Bank accession numbers for the genes used in initial experimentation are shown and their references include DGAT1, Xu et al., 2008 Plant Biotechnology Journal. 6:799-818; OLE1, Shimada and Hara-Nishimura 2010 Biol. Pharm. Bull. 33:360-363; OLE1, Hu et. al. 2009 Plant Cell Rep 28:541-549; WRI1, Cernac A, Benning C. 2004 Plant J. 40:575-85; Vegetative TAG, Sanjaya et. al., 2011 Plant Biotechnology Journal, 9:874-883; MCT Voelker et. al., 1992, Science 257:72-74.
DETAILED DESCRIPTION
[0015] High oil content in vegetative tissues of plants may be achieved using a balance of up-regulation and down-regulation of various interacting and competing metabolic pathways. Fatty acid synthesis and accumulation in general may be up-regulated through a combination of a strategic choice of the genetic background of the plant and, potentially, overexpressing fatty acid synthase genes and suppressing genes diverting fatty acids to other pathways. The transfer of fatty acids from various metabolic precursors to form triacylglycerols may be enhanced, nascent oil bodies may be protected, for example, by coating with protein, and FA turnover or diversion to other carbon sink pathways may be suppressed.
[0016] Up-regulation of FAS is achieved by ectopic expression of Arabidopsis WRI1 (Pouvreau et al. 2011). Expression of higher level transcription control factors such as LEC2 and or FUS3 (the B-3 domain transcription factor FUSCA3) may be considered while recognizing that this may increase the possibility that pleiotropic effects could be substantial.
[0017] Expression of DGAT along with WRI1 enhances increases in TAG accumulation, indicating that its levels are limiting the conversion of FA-CoAs to TAG via the Kennedy pathway (Xu et al. 2008, Plant Biotechnol. 6:799-818; Zheng et al. 2008, Nat. Genetics 40:367-372).
[0018] Because of the complementary overlapping function of phospholipid:diacylglycerol acyltransferase 1 (PDAT1; At5g13640) and acyl-CoA:diacylglycerol acyltransferase 1 (DGAT1) (Zhang et al. 2009, The Plant Cell 18:3885-3901), overexpression of PDAT1 also enhances TAG accumulation. Overexpression of PDAT1 in a mutant background in which sub-cellular lipid transfer between the endoplasmic reticulum (ER) and thylakoid is disrupted (the tdg1 Arabidopsis mutant, see Xu, et al. 2003) leads to considerable enhancement of TAG accumulation in vegetative tissue.
[0019] Creating a stable storage pool for vegetative TAG accumulation by ectopically expressing oleosins, key proteins that coat oil bodies in seeds, is beneficial to this effort because oleosin expression levels are normally very low in vegetative tissues (Shimada and Hara-Nishimura 2010, Biol. Pharm. Bull. 33:360-363). In Brassica napus the level of oleosin expression is correlated with oil content (Hu et al. 2009, Plant Cell Rep. 28:541-549), and in Arabidopsis mutants deficient in oleosins, oil content is decreased relative to wild type (Siloto et al. 2006, Plant Cell 18: 1961-1974). Further, the ectopic expression of oleosin in non-seed tissues of Arabidopsis led to FA accumulation in the ER, suggesting that such a background would be ideal for oil body formation and chaperoning newly synthesized FA from the ER into oil bodies (Beaudoin and Napier 2000, Planta 210:439-445). Co-expression of Arabidopsis OLE1, the major seed isoform, along with WRI1 and DGAT1 and co-expression of OLE1 and PDAT1 in the tgd1 strain both lead to substantial accumulation of TAG in vegetative tissue. Co-expression of WR1, DGAT1, PDAT1 and OLE1 in a tgd1 strain may produce additional accumulation of TAGs. Combining enhanced expression of these genes with down-regulation of competing pathways, the starch synthetic pathway and the β-oxidation breakdown pathway, is also contemplated to enhance TAG accumulation in vegetative tissues.
[0020] Suppression/down-regulation of competing pathways for carbon storage, in particular the starch synthesis pathway, is complementary to the up-regulation improvements in TAG accumulation in vegetative tissue. Using RNAi to down-regulate AGP, the gene encoding the key enzyme ADP-Glucose pyrophosphorylase reduces the diversion of triose phosphates into the competing, starch biosynthetic pathway.
[0021] In addition to down-regulating the strength of a competing carbon sink, providing high levels of sugar may lead to increased accumulation of TAG as was shown for expression of WRI1 in high sugar lines of tobacco (Andrianov et al. 2010, Plant Biotechnol. J. 8:277-287). p024 Another consideration to improving TAG accumulation is to prevent the β-oxidation degradation of the FAs that accumulate in vegetative tissues (see Kunz, et al. 2009, The Plant Cell 21:2733-2749). To achieve down-regulation of a-oxidation the ABC transporter, PXA1, and the core β-oxidation enzyme, KAT2, may be suppressed, knocked out or knocked down by appropriate means.
[0022] Another gene considered as a target for suppression is the CTS-2 (COMATOSE locus), which appears to regulate transport of Acyl-CoAs to the peroxisome (Foottit et al. 2002, EMBO J. 21:2912-2922). As in the case of over-expression of the higher level transcription control elements, suppression of CTS-2 may lead to additional pleiotropic effects.
[0023] Expression of a medium chain thioesterase (MCT) in Brassica napus resulted in the accumulation 60 mol % of laurate in TAG (Voelker et al. 1992, Science 257:72-74). Further investigation revealed that only 50% of the laurate synthesized was recovered in lipid, and that enzymes of β-oxidation were elevated in these plants suggesting that both FAS and β-oxidation were induced upon the expression of MCT. (Eccleston and Ohlrogge, 1998, Plant. Cell 10:613-621). MCT interrupts FAS releasing C12 FA from 12:0-ACP, thereby decreasing the levels of long chain acyl-ACPs. Increased FAS is attributable to increased acetyl-CoA carboxylase (ACCase) activity upon the removal of product inhibition by long chain acyl-ACPs (Shintani and Ohlrogge, 1995, Plant Journal 7:577-587); the feedback signal is now identified as 18:1-ACP (Andre, et al. 2012, Proc. Natl. Acad. Sci. USA 109:10107-10112). Thus, a present strategy involves introduction of the MCT to reduce ACCase inhibition by terminating the ACP track of FA biosynthesis at the C12 step, thus lowering the accumulation of the inhibitory signal, 18:1-ACP. MCT may be co-expressed with OLE1, WRI1 and DGAT1, and possibly PDAT1. These constructs may be assessed for their ability to convey increased TAG accumulation. Subsequently an attempt may be made to reduce β-oxidation by down-regulation of PXA1 or CTS-2 and KAT2 with the use of appropriate RNAi constructs. Using the tgd1 background strain with these combinations is also contemplated.
[0024] Relatively rapid testing of various co-expression combinations can be achieved using the Nicotiana benthamiana transient expression system as described by Petri et al. (Plant Methods (2010) 6:8), with minor modifications. Genes may be expressed under the control of the 35S promoter. To test combinations of genes, single genes are established in individual Agrobacterium lines. These are combined and co-infiltrated into the abaxial surface of the tobacco leaves. All co-infections are performed with the P19 protein. After phenotypic screening for TAG content, thin layer chromatograph and ESI mass spectrometry (Bates, et al. 2009, Plant Physiol. 150:55-72) may be used to quantitate the contribution of each gene to oil (TAG) accumulation.
[0025] Despite the fact that the quantitation in the transient expression scheme is better within than between experiments, the rapid studies provide indicators of the optimal combinations to be processed in stable transformation and genetic line development. Optimal combinations of genes identified in the transient expression analyses are used to establish stably transformed Arabidopsis strains, tobacco transformants and additional plants such as sugar cane and sorghum. In Arabidopsis , well characterized knock out and knock down mutants of appropriate nature can be used as the genetic background recipients of the gene combinations.
[0026] Over expression of the combination of genes: 1) WRI1, DGAT1 and OLE1; 2) WRI1, DGAT1, OLE1 and MCT; 3) WRI1, DGAT1, PDAT1, and OLE1; and etc., in vegetative tissues of crop plants, or non-crop and specifically energy crop/non-crop (e.g., miscanthus, camelina) plants will serve for purposes of increasing the levels of storage oil (TAG) in such tissues. It is anticipated to combine FUSS and LEC2 as transcription factors that control the expression of WRI1 either in place of WRI1 or in combination with it to achieve further enhancements in TAG accumulation. Tgd1 mutant recipient strains for transformation of the gene combination may be preferred.
[0027] Further enhancements of vegetative TAG accumulation are expected by suppressing ADP-G pyrophosphorylase, i.e., the competing starch pathway and by suppressing PXA1, a component of the peroxisomal FA uptake complex.
[0028] Generation of stable transgenic plants expressing various combinations of the genes identified herein may result in crop plants capable of generating valuable oil compositions in tissues more typically considered to be sources of ‘bio-ethanol’ or material for re-cycling by plowing into fallow fields (e.g., corn stover and the like). The production of useful oil compositions in vegetative tissues of plants greatly enhances the energy density of plant tissue.
[0029] Vegetative plant tissue may be defined as any non-seed plant tissue, examples of which include leaf, stem, root, tuber, bark, and the like. Vegetative plant tissue comprises the non-seed biomass of plants. For purposes of harvesting TAG from plant biomass, seed may be harvested prior to harvesting the remaining plant, but seed may be included in the total harvest of the plant for recovery of TAG.
[0030] Incorporation of the genes into expression constructs having appropriate promoters and regulatory sequences may generate plants having coordinated expression of the combinations of genes in tissues of choice, depending upon the targeted crop plant. The choice of promoter and regulatory sequences will be governed by the selection of the target tissue in the target plant.
[0031] Preliminary experiments are carried out using constitutive promoters for controlling expression of the introduced activating or inhibitory genes. Constitutive promoters, tissue-specific promoters, growth stage-specific promoters, and inducible promoters may be independently selected for use for each introduced gene and a particular promoter type may be used for enhancing genes and a separate or identical or similar particular type for inhibitory genes that are introduced. Combinations of promoters for the various genes that produce the optimal accumulation of TAG compounds in vegetative tissue with the least disruption of plant growth and seed productivity and germination are preferred.
[0032] A small but significant enhancement of the accumulation of TAGs (weight percent) in non-seed/vegetative tissue means an increase in TAG weight percent of greater than 2-fold over the weight percent of TAGs in the same vegetative tissue of the plant from which the altered plant was originally derived (parent plant). Preferred embodiments are plants in which TAG weight percent in vegetative tissue is more than 5-fold higher than the weight percent in the same tissue of the parent plant and even more preferred embodiments are plants in which TAG weight percent is 10-fold and especially preferred embodiments are plants in which TAG weight percent is 20-fold or more increased over the weight percent in the same tissue of the parent plant. An upper limit of the increase in the weight percent of TAG in the vegetative tissue may be the weight percent wherein for a particular plant species plant growth, seed production and/or seed germination are negatively affected to such an extent that there is no net gain in harvestable TAG.
[0033] Genes and gene combinations that may be overexpressed include for example, genes that generally enhance fatty acid synthesis, genes encoding diacylglycerol acyl transferases (e.g., DGAT1 and PDAT1), genes encoding oleosin and oleosin-like proteins (proteins that coat or protect oil droplets in cells) (e.g., OLE1) and genes for medium chain thioesterases.
[0034] The genetic background of plants to receive these combinations of genes may include for example, tdg1 mutants, and/or mutant strains with knocked out or knocked down genes encoding enzymes of competing carbon pathways, such as the starch synthetic pathway or the fatty acid breakdown (e.g., β-oxidation pathway). The availability and viability of such recipient strain will dictate their selection.
[0035] Genes and gene combinations for expression may also include genes encoding, for example, RNAi constructs for inhibiting competing carbon pathways in plant cells. The genes targeted by such RNAi constructs include genes of the starch biosynthetic pathway (e.g., AGD) and genes for the β-oxidation pathway (e.g., PXA1 and KAT2)
[0036] Each of the genes to be introduced, whether for enhancement or reduction of activity, will be introduced in an expression configuration that optimizes the desired outcome (a small, but significant increase in TAG accumulation in vegetative tissue) while minimizing potential negative effects of the altered metabolism on plant growth, seed production and seed germination. The optimal expression configuration may include the optimal selection of the promoter from constitutive, inducible, tissue-specific, growth stage-specific and the like.
[0037] Plants optimally expressing the enhancement and reduction of activity genes may be developed such that they have suitably normal growth, suitably normal seed production and suitably normal seed germination. Such plants may further carry other transgene conferring traits such as disease resistance and/or herbicide or pesticide resistance.
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Combinations of genes are used to enhance the accumulation of triacylglycerol compounds in vegetative tissues of plants. Fatty acids in the form of triacylglycerol compounds accumulate in vegetative tissues in excess amounts compared to untreated plants.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a transparent electromagnetic radiation shield material and a transparent electromagnetic radiation shield panel for placement in front of a display device or other such source of electromagnetic radiation to shield the viewer from electromagnetic radiation, and to methods of producing the material and panel. It particularly relates to a panel suitable for a large plasma display.
2. Description of the Background Art
An electromagnetic radiation shield material for placement in front of a display device or other source of electromagnetic radiation is required to have not only excellent electromagnetic radiation shielding capability but also excellent transparency (optical transmittance), good clarity (degree of coating blackness etc.), wide viewing angle and the like. Japanese Patent Application Laid-Open No. 9-298384 teaches an electromagnetic radiation shield material meeting these requirements to some extent. Specifically, this laid-open patent application teaches a method wherein "a step of providing a black dyed layer on a transparent base material, a step of providing a metallic layer on the black dyed layer, a step of providing a patterned resist layer on the metallic layer and a step of removing portions of the metallic layer not covered by the resist layer by etching with an etching solution are conducted in succession, portions of the black dyed layer not covered by the patterned metallic layer being decolored in the etching step."
Generally, however, a sufficient degree of coating blackness and good clarity are hard to obtain when a black dye is used in a black resin layer. The dye content and/or the resin layer thickness therefore has to be increased.
Moreover, when the etching solution for the metallic layer is used to decolor and extract the black dye, the metallic layer comes to be over-etched owing to the long time needed for the decoloration.
SUMMARY OF THE INVENTION
For overcoming the aforesaid drawbacks of the prior art, this invention provides:
An electromagnetic radiation shield material comprising at least a mesh-like metallic foil layer, a black resin portion of identical mesh-like pattern to the metallic foil layer and in aligned contact therewith, and a transparent base material;
An electromagnetic radiation shield panel comprising a laminated composite of an electromagnetic radiation shield material and a display panel or a transparent base material, a metallic foil of the electromagnetic radiation shield material being disposed on the side intended to face a source of electromagnetic radiation and a black resin portion being disposed outward of the metallic foil;
A method of producing an electromagnetic radiation shield material comprising a step of providing in order on a transparent base material a black resin layer including a black pigment, a metallic foil layer, and a mesh-like resist layer, a step of etching metallic foil portions not protected by the resist layer to impart the metallic foil with a mesh-like pattern like the resist, and a step of extracting and removing black pigment from a portion of the black resin layer not in contact with the mesh-like metallic foil layer to form a black resin portion, and;
A method of producing an electromagnetic radiation shield material comprising a step of providing in order on a transparent base material an adhesive layer, a black resin layer including a black pigment, a metallic foil layer, and a mesh-like resist layer, a step of etching metallic foil portions not protected by the resist layer to impart the metallic foil with a mesh-like pattern like the resist, and a step of extracting and removing black pigment from a portion of the black resin layer not in contact with the mesh-like metallic foil layer to form a black resin portion.
When the transparent base material is a continuous web (roll) of film, sheets of different sizes can be cut from the obtained transparent electromagnetic radiation shield film while avoiding inclusion of defective portions, whereafter the cut sheets can be easily laminated to display panels or transparent base plates. By this, the invention can achieve high yield and low cost. Since the roll film can be produced by a continuous process, its productivity is higher than when the transparent base material is plate-like. Owing to its flexibility, moreover, the film can also be used to produce curved shields.
In accordance with another aspect of the invention, a transparent electromagnetic radiation shield panel is produced by laminating a transparent electromagnetic radiation shield film to a display panel or a transparent base plate by an intervening adhesive layer on the surface of the electromagnetic radiation shield layer.
BRIEF EXPLANATION OF THE DRAWING
FIG. 1 is partial sectional view of one example of an electromagnetic radiation shield material according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The base material used in this invention is required to be transparent. It is selected according to intended use from among various materials including, for example, glass plate, plastic film, plastic sheet and plastic plate. The shape of the base material is not particularly limited.
A plastic used as the base material is preferably a resin with high transparency. Preferable examples include acrylic resins, polycarbonate, polyethylene, AS resins, vinyl acetate resin, polystyrene, polypropylene, polyester, polysulfone, polyethersulfone, polyvinylchloride, olefine-maleimide copolymer, and norbornene resins. Among these, olefine-maleimide copolymer and norbornene resins are particularly preferable owing to their high heat resistance.
The plastic should preferably have a thermal-deformation temperature of 140-360° C., a coefficient of thermal linear expansion of not greater than 6.2×10 -5 cm/cm.° C., a pencil hardness of not less than 2H, a bending strength of 1,200-2,000 kgf/cm 2 , a modulus of elasticity in bending of 30,000-50,000 kgf/cm 2 , and a tensile strength of 700-1,200 kgf/cm 2 . A plastic with these properties is resistant to high-temperature warping and scratching, and can therefore be used in a wide range of environments.
The plastic preferably has an optical transmittance of not less than 90%, an Abbe's number of 50-70 and a photoelasticity constant (glass region) of an absolute value of not greater than 10×10 -13 cm 2 /dyne. A plastic with these properties exhibits high transparency (is bright) and little birefringence (is not likely to produce a double image), and therefore does not degrade the image quality, brightness etc. of the display.
The metallic foil used in this invention is not particularly limited regarding type or thickness insofar it has electromagnetic radiation shielding capability and can be etched. Preferable examples include copper, nickel, iron, stainless steel, titanium, aluminum and gold. Among these, copper foil is particularly preferable from the points of shielding property (resistivity) and etchability. A thicker metallic foil is generally better in shielding performance and a thinner one better in etchability. In the case of a copper foil, since the shielding performance does not change substantially at thicknesses above 5 μm, one of a thickness of 5-35 μm, preferably 9-18 μm, is ordinarily used in consideration of handling ease and cost per unit area (18 μm copper foil currently being cheapest).
The pattern and aperture ratio of the metallic foil are not particularly limited insofar as they are within ranges ensuring sufficient electromagnetic radiation shielding performance and optical transmittance. Even a parallel line pattern, for example, provides shielding effect (exhibiting directionality in the near field). Since the effect is insufficient, however, a mesh pattern is ordinarily used. Various basic mesh patterns are available, including grid (tetragonal), triangular, polygonal, circular and elliptical.
The aperture ratio (the ratio of the non-metallic foil portion area relative to the repeated pattern unit area) is determined by the line width and interval (opening width) of the metallic foil pattern. Different patterns with the same aperture ratio have the same optical transmittance. Since the electromagnetic radiation shielding performance increases with decreasing opening width, however, a narrower opening width is ordinarily preferable. Nonetheless, the opening width is finally decided to fall within the range that does not cause occurrence of Moire fringes when the electromagnetic radiation shielding is disposed on the front of the display panel.
The resin in the resin solution containing the black pigment (the black coating liquid) applied to the metallic foil is not particularly limited by type insofar as it is transparent and is capable of efficiently dispersing or dissolving the black pigment.
Since the black pigment in the black coating is extracted and removed chiefly in aqueous solution, the resin used is preferably a hydrophilic transparent resin. Preferable hydrophilic transparent resins include vinyl acetal resins, vinyl alcohol resins, acrylic resins, cellulose resins and the like. Among these, vinyl acetal resins such as polyvinyl butyral and cellulose resins such as cellulose acetate butylate are particularly preferred.
The black pigment used in this invention consists of reduced metal particles or metal oxide particles. The reduced metal particles are colloid particles contained in a reduced metal colloid dispersion or reduced metal powder particles obtained from the metal colloid dispersion. They are not particularly limited as regards type of metal or grain size insofar as they are uniformly dispersable in the coating liquid (coating) and do not impair the coating transparency after extraction and removal. For easy extraction, however, the grain size of the reducing metal particles is preferably not greater than 1 μm. They preferably have high stability with respect to the atmosphere and moisture.
Specific examples of usable reduced metal particles include particles of metals belonging to Group Ib or Group VIII of the Periodic Table of the Elements (Cu, Ni, Co, Rh, Pd etc.), with reduced Pd colloid particles and reduced Pd powder obtained therefrom being particularly preferable. The reduced metal colloid particles can be produced by the methods described in Japanese Patent Application Laid-Open No. 1-315334. Specifically, a colloid dispersion can be obtained by reducing a salt of the metal in a mixed solution consisting of a lower alcohol and an aprotic polar compound.
The metal oxide particles are not particularly limited as regards type of metal or grain size insofar as they are uniformly dispersable in the coating liquid (coating) and do not impair the coating transparency after extraction and removal. For easy extraction, however, their grain size is preferably not greater than 1 μm. The metal oxide particles should best remain stably dispersed in the coating liquid (coating). Preferable examples include particles of oxides of metals belonging to Group Ib or Group VIII of the Periodic Table of the Elements such as iron, copper, nickel, cobalt and palladium.
The amount of these black pigments included is preferably in the range of 1-100 PHR (parts by weight based on 100 parts by weight of resin), more preferably 5-50 PHR. When the amount used is less than 1 PHR, the degree of coating blackness is low. An amount exceeding 100 PHR degrades the coating property.
The solvent for the resin solution in this invention can be of any type insofar it can dissolve or be used to prepare a dispersion of the resin and the black pigment.
Preferable solvents include one or a mixture of two or more of, for example, water, methanol, ethanol, chloroform, methylene chloride, trichloroethylene, tetrachloroethylene, benzene, toluene, xylene, acetone, ethyl acetate, dimethylformamide, dimethylsulfoxide, dimethylacetamide and N-methylpyrrolidone. A solvent appropriate for the combination of resin and black pigment is selected.
The amount of solvent used is selected so as to obtain an appropriate viscosity and fluidity and to make the solution appropriate for application to the base material.
The solution of the resin and black pigment (black coating liquid) is applied to the metallic foil and dried to form a coating containing the black pigment. The application of the solution can be carried out by brush coating, spraying, dipping, roller coating, calender coating, spin coating, bar coating or other conventional method selected in view of the shape of the metallic foil.
The conditions (temperature, time etc.) for coating formation are determined based on the type and concentration of the resin, the coating thickness and the like. The nonvolatile content of the solution is normally 0.05-20 wt %. The thickness of the dried coating is 0.5-50 μm, preferably 1-25 μm. No blackness is observed and the clarity is poor at a thickness of less than 0.5 μm. Extraction of the unnecessary portion is difficult at a thickness exceeding 50 μm.
A laminated article is formed by adhering the coated side of the metallic foil formed with the black coating to a transparent base material either directly or via an intervening transparent adhesive. Usable transparent adhesives include polyvinylacetate, acrylic, polyester, epoxy and cellulose type adhesives. The thickness of the adhesive layer is generally not less than 1 μm, preferably about 5-500 μm.
As viewed from the side of the transparent base material (thickness: 2 mm, refractive index: 1.49, optical transmittance: 93%, average roughness Ra: 40 Å) of the laminated article, the coating preferably has a degree of blackness, expressed as optical density, of not less than 2.9 (angle of incidence of 7°; assuming no specular component). When the optical density is less than 2.9, clarity of the final transparent electromagnetic radiation shield material is poor owing to the low blackness of the coating. (The intensity of plating glare increases with decreasing optical density.) When the optical density is 2.9 or greater, the blackness of the coating is adequate and clarity excellent (definition high). Clarity as perceived by the naked eye does not improve substantially above an optical density of 4.0.
Next, a resist portion patterned identically to the desired pattern of the metallic foil layer of the electromagnetic radiation shield material is formed on the metallic foil of the laminated article. The resist portion can be formed by a generally known method such as printing or photolithography. The resist portion can be either transparent or colored.
Unnecessary portions of the metallic foil where no resist is present are removed with an etching solution. Removal of black pigment from the coating is preferably effected by soaking in the same etching solution or a separate acidic or alkaline treatment liquid at a temperature of around 10-30° C. for around 1-10 min. Removal can be effected by solution spraying rather than soaking. The removal can be promoted by application of ultrasonic waves.
As a result, the coating is formed under the patterned metallic foil layer with a black portion of the same pattern. The portions where the metallic foil layer and the black pigment in the coating have been removed is transparent. The resist portions are then removed by soaking in or spraying with an exfoliating solution such as an aqueous alkali solution or other such solution capable of dissolving the resist.
Methods that can be used to remove the black pigment include not only the aforesaid extracting but also laser working, sand blasting and the like.
The foregoing processes enable the fabrication of a transparent electromagnetic radiation shield material having a metallic foil layer formed in a desired pattern.
The transparent electromagnetic radiation shield material preferably has an optical transmittance of not less than 65% and a shielding performance of not less than 40 dB in the range of 30 to 1000 MHz. An optical transmittance of less than 65% is too dark and a shielding performance of less than 40 dB is not sufficient for practical applications.
The etching solution is selected as appropriate for the type of metal of the metallic foil layer. In the case of copper foil, for example, ferric chloride or the like can be used as the etching solution.
When the foregoing production method is applied to a transparent film to fabricate a transparent electromagnetic radiation shield film, the transparent electromagnetic radiation shield film is thereafter laminated to a display panel or a transparent base plate, using an intervening transparent adhesive if necessary, to fabricate a transparent electromagnetic radiation shield panel. The transparent film is preferably one constituted as a continuous web that can be continuously processed into a roll. Such films include plastic films having a thickness in the approximate range of 5-300 μm made of polyethylene terephthalate (PET), polyimide (PI), polyethersulfone (PES), polyether-etherketone (PEEK), polycarbonate (PC), polypropylene (PP), polyamide, acrylic resin, cellulose propionate (CP), and cellulose acetate (CA).
An example of a transparent electromagnetic radiation shield material provided by the invention will now be explained with reference to FIG. 1. FIG. 1 is a sectional view showing the laminated structure of the shield material, which comprises a mesh-like metallic foil layer 1 and a transparent base material 4 sandwiching a black resin portion 2 containing black pigment.
The transparent base material 4 and the black resin portion 2 are adhered to each other by an intervening transparent adhesive layer 3.
The transparent base material and the black resin portion can instead be directly adhered without use of an adhesive. This can be achieved, for example, by rolling, spraying or otherwise applying molten or dissolved black resin on the transparent base material and then drying the applied coating.
Transparent resin 5 removed of the black pigment by extraction is present at interstices in the black resin portion.
EXAMPLE 1
A black coating liquid was prepared by uniformly dispersing black pigment [A] (cupric oxide fine powder, product of Nihon Kagaku Sangyo Co., Ltd.) in an alcohol (ethanol) solution of polyvinylbutyral (PVB) (#6000-C, product of Denki Kagaku Kogyo, Co., Ltd.). (Coating solution composition: cupric oxide/PVB/ethanol=50/100/1850.)
The coating liquid was applied to one surface of 12 μm electrolytic copper foil (CF T9 SV, product of Fukuda Metal Foil and Powder Co., Ltd.) and dried to obtain a black coating (25 μm). The coated surface was laminated to an acrylic plate (Delaglas K, product of Asahi Chemical Industry Co., Ltd.) using an acrylic adhesive to obtain a laminated article.
The copper foil side of the laminated article was coated with a positive etching photoresist (PMER P-DF40S, product of Tokyo Ohka Kogyo Co., Ltd.), prebaked, exposed, developed and post-baked to form a resist pattern.
The resist-patterned article was soaked in etching solution (aqueous solution of 20% ferric chloride and 1.75% hydrochloric acid) to dissolve and remove the copper foil layer at the non-resist portions, the cupric oxide powder in the portions of the black coating exposed by removal of the copper foil was further extracted and removed in the same etching solution (extraction solution), and the resist was then peeled off to produce an electromagnetic radiation shield material.
The electromagnetic radiation shield material exhibited shielding performance of 40-80 dB (30-1000 MHz) and transparency (optical transmittance) of 65%, as well as excellent clarity (degree of coating blackness), copper foil adherence, and base plate flatness.
EXAMPLE 2.
An electromagnetic radiation shield material was fabricated in the same manner as in Example 1 except that the cupric oxide fine powder used to prepare the black coating liquid was replaced with black pigment (iron oxide fine powder; Tetsuguro P0023, product of Daido Chemical Industry Co., Ltd.) and that a 5% aqueous hydrochloric acid solution was used as the extraction solution for the black pigment in the coating.
The electromagnetic radiation shield material exhibited excellent performance characteristics similar to those of that obtained in Example 1. It was particularly excellent in clarity (degree of coating blackness).
EXAMPLE 3
An N-methyl-2-pyrrolidone (NMP)/ethanol solution of palladium acetate and an ethanol solution of PVB were mixed under stirring (and heating as required) to prepare a reduced palladium colloid base black coating liquid. (Coating solution composition: palladium acetate/PVB/NMP/ethanol=25/100/1250/2625.)
This coating liquid was used to fabricate an electromagnetic radiation shield material under the same conditions as in Example 1 except that the coating thickness was made 10 μm.
The electromagnetic radiation shield material exhibited excellent performance characteristics similar to those of that obtained in Example 1. It was particularly excellent in clarity (transmittance: 70%)
EXAMPLE 4
An N-methyl-2-pyrrolidone (NMP)/ethanol solution of palladium acetate and an ethanol solution of PVB were mixed under stirring (and heating as required) to prepare a reduced palladium colloid base black coating liquid. (Coating solution composition: palladium acetate/PVB/NMP/ethanol=25/100/1250/2625.)
The coating liquid was applied to one surface of 12 μm electrolytic copper foil (CF T9 SV, product of Fukuda Metal Foil and Powder Co., Ltd.) and dried to obtain a black coating (10 μm). The coated surface was laminated to polyethylene terephthalate (PET) film using an acrylic adhesive to obtain a laminated film.
The copper foil surface of the laminated film was coated with a positive etching photoresist (PMER P-DF40S, product of Tokyo Ohka Kogyo Co., Ltd.), prebaked, exposed, developed and post-baked to form a resist pattern. The resist-patterned film was soaked in etching solution (aqueous solution of 20% ferric chloride and 1.75% hydrochloric acid) to dissolve and remove the copper foil layer at the non-resist portions, the reduced palladium colloid particles in the portions of the coating exposed by removal of the copper foil were further extracted and removed in the same etching solution (extraction solution), and the resist was then peeled off to produce an electromagnetic radiation shield material.
A 10 μm transparent acrylic adhesive layer was formed on the film side of the electromagnetic radiation shield film and the electromagnetic radiation shield film was laminated to a glass plate (thickness: 4 mm) by the adhesive layer to fabricate a transparent electromagnetic radiation shield panel.
The electromagnetic radiation shield panel exhibited shielding performance of 40-80 dB (30-1000 MHz) and transparency (optical transmittance) of 70%, as well as excellent clarity (degree of coating blackness), copper foil adherence, and base panel flatness.
EXAMPLE 5
The transparent electromagnetic radiation shield film of Example 4 was applied on its copper foil pattern side with a transparent adhesive layer as in Example 4 and thereafter laminated to a plasma display panel (PDP) by the adhesive layer to fabricate a transparent electromagnetic radiation shield panel. The electromagnetic radiation shield panel exhibited excellent performance characteristics similar to those of that obtained in Example 4.
EXAMPLE 6
A transparent electromagnetic radiation shield film was produced in the manner of Example 4 except that the PET film of Example 4 was replaced with a triacetyl cellulose (TAC) film laminate obtained by laminating a protective film to TAC film via a transparent acrylic adhesive layer.
The protective film was peeled off the electromagnetic radiation shield film and the electromagnetic radiation shield film was laminated to an acrylic resin plate to fabricate a transparent electromagnetic radiation shield panel. The electromagnetic radiation shield panel exhibited excellent performance characteristics similar to those of that obtained in Example 4.
EXAMPLE 7
A transparent electromagnetic radiation shield film was produced in the manner of Example 4 except that the PET film of Example 4 was replaced with a near infrared (NIR) cut film.
The electromagnetic radiation shield film (the copper foil pattern side thereof) was laminated to a glass plate formed with a transparent adhesive layer to fabricate a transparent electromagnetic radiation shield panel. The electromagnetic radiation shield panel exhibited excellent performance characteristics similar to those of that obtained in Example 4.
EXAMPLE 8
Electromagnetic radiation shield panels were fabricated as in Example 4 except that the acrylic plate used as the transparent base material in Example 4 was replaced with transparent heat-resistant plastic plates made of olefine-maleimide copolymer (TI-160, product of Tosoh Corporation) and norbornene resin (Arton, product of Japan Synthetic Rubber Co., Ltd.).
The electromagnetic radiation shield panels exhibited excellent performance characteristics similar to those of that obtained in Example 4. They were superior to the electromagnetic radiation shield panel of Example 4 in base panel flatness (noticeably less warp for a base panel of the same thickness and area).
When an electromagnetic radiation shield panel utilizing a plastic base panel low in heat resistance and rigidity is disposed in front of a (plasma) display, pronounced warping of the base panel owing to heat from the display frequently causes the display to crack or produce Moire fringes. The electromagnetic radiation shield panels obtained in this Example were totally free of these problems.
EXAMPLE 9
A transparent electromagnetic radiation shield material was produced in the manner of Example 1 except that the copper foil was replaced with 15 μm aluminum foil (product of Toyo Aluminium Foil Products K.K.).
The electromagnetic radiation shield material exhibited excellent performance characteristics similar to those of that obtained in Example 1. Use of aluminum foil enables production of light and inexpensive electromagnetic radiation shield materials.
COMPARATIVE EXAMPLE 1
A coating liquid was prepared in the manner of the black coating liquid of Example 1 except that the cupric oxide fine powder was replaced with black metal-containing acid dye (LC2951 LY BLACK BG EX CC, product of Sumika Dyestuffs Technology Co., Ltd.). However, owing to the occurrence of a precipitate (thought to be Glauber's salt Na 2 SO 4 ), the coating liquid was filtered and the filtrate (slightly reddish black) was used as the final coating liquid.
An attempt was made to use the coating liquid to fabricate a transparent electromagnetic radiation shield material in the same manner as in Example 1 except for forming the coating to a thickness of 50 μm. However, difficulty was encountered in effecting discoloration (extraction and removal) with the etching solution. An attempt was therefore made to effect discoloration with the discoloring solution (extraction solution) changed to ethanol. Since a considerable amount of resin dissolved out in conjunction with this discoloration, the treated resin coating exhibited a rough surface and low transparency.
Although the electromagnetic radiation shield material provided about the same shielding performance as that of the Example 1, it was extremely poor in clarity. Specifically, the blackness of the black pattern (degree of coating blackness) was low (the coating thickness was double that in Example 1) and the resolution was poor. Transparency (optical transmittance) was a low 40%.
COMPARATIVE EXAMPLE 2
A coating liquid was prepared in the manner of the black coating liquid of Example 1 except that the cupric oxide fine powder was omitted.
The coating liquid was used to form a coating on the copper foil as in Example 1, but to a thickness of 50 μm.
The copper foil formed with the coating was soaked for 1 hr in the same black dye aqueous solution as that of Comparative Example 1 (a somewhat bluish black solution). The blackness (degree of coating blackness) was deficient to the point that is was obvious that any electromagnetic radiation shield material fabricated would have bad clarity. The processing was therefore discontinued.
TABLE 1__________________________________________________________________________ Transparency.sup.2)Black resin coating Transparent Shielding (Optical Clarity.sup.3) (Degree(Black pigment/resin) Metallic foil base material performance.sup.1) transmittance) of coating blackness) Remarks__________________________________________________________________________Example1 Cupric oxide powder/ Cu (12 μm) Acrylic plate ∘ ∘ ∘ PVB (25 μm)2 Iron oxide fine " " ∘ ∘ ⊚ powder/PVB (25 μm)3 Reduced Pd colloidal " " ∘ ⊚ ∘ particles/PVB (10 μm)4 Reduced Pd colloidal " PET film ∘ ⊚ ∘ Laminated to glass plate particles/PVB (10 μm) to make panel5 Reduced Pd colloidal " " ∘ ⊚ ∘ Laminated to PDP to particles/PVB (10 μm) make panel6 Reduced Pd colloidal " TAC film ∘ ⊚ ∘ Laminated to acrylic particles/PVB (10 μm) plate to make panel7 Reduced Pd colloidal " NIR cut film ∘ ⊚ ∘ Laminated to glass plate particles/PVB (10 μm) to make panel8 Reduced Pd colloidal Cu (12 μm) PET film ∘ ⊚ ∘ Laminated to heat- particles/PVB (10 μm) resistant resin base plate.sup.4) to make panel9 Cupric oxide powder/ Al (15 μm) Acrylic plate ∘ ∘ ∘ Light/inexpensive PVB (25 μm)ComparativeExample1 Metal-containing acid Cu (12 μm) Acrylic plate ∘ x x dye/PVB (50 μm)2 Metal-containing acid " -- -- -- x Dyed with metal- dye/PVB (50 μm) containing acid__________________________________________________________________________ dye Remarks: .sup.1) Electric field shielding performance (dB) at 30-1000 MHz measured by electromagnetic radiation shielding performance tester (TR17301, product of Advantest Corporation). ∘: 40-80 dB .sup.2) Transmittance (%) at wavelength 550 nm measured by spectroanalyze (UV240, product of Shimadzu Corp.). ⊚: ≧80% ∘: <80%-≧65% x: <50% .sup.3) Optical density (angle of incidence of 7°; assuming no specular component) measured by spectrophotometric colorimeter (CMS35SP), product of Murakami Color Research Laboratory, Ltd. ⊚: ≧2.9 ∘: <2.9-≧2.7 x: <2.7 .sup.4) Base plate of olefinemaleimide copolymer or norbornene resin.
The present invention provides the following advantageous effects:
(1) Pattern design is subject to little restriction.
(2) The degree of blackness and the resolution of the black pattern on the transparent base material side are high, providing outstanding clarity. The long-term stability of these properties is excellent.
(3) An earth lead line can be easily connected.
(4) Conductivity is high owing to the use of metallic foil, giving a high shielding effect, and high optical transmittance can be obtained since the aperture ratio can be set high. The long-term stability of these properties is excellent.
(5) Since no plating is necessary, the problem of decreased adhesiveness between the coating and the base material and between the plating and the coating that occurs during plating does not exist.
(6) Material and production costs are markedly lower than by the plating method.
(7) The viewing angle is wide.
(8) Yield is good because the sheets to be laminated to transparent base plates can be cut to different sizes from a web (roll) of the transparent electromagnetic radiation shield film while avoiding inclusion of defective portions.
(9) Curved shields can also be produced.
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An electromagnetic radiation shield material and an electromagnetic radiation shield panel suitable for placement in front of a display device to enable a viewer to see images displayed on the display device through the plate or panel while shielding the viewer from electromagnetic radiation and methods of producing the material and the panel are provided. The electromagnetic radiation shield material comprises at least a mesh-like metallic foil layer, a black resin portion of identical mesh-like pattern to the metallic foil layer and in aligned contact therewith, and a transparent base material. The electromagnetic radiation shield panel comprises a laminated composite of the electromagnetic radiation shield material and a display panel or a transparent base plate and is constituted so that the metallic foil layer is on the side facing the display device and the black resin portion is located outward of the metallic foil layer.
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FIELD OF THE INVENTION
This invention relates to an apparatus for loading a stack of containers into a chute which holds the stack and allows containers to be dispensed from the bottom of the stack.
BACKGROUND OF THE INVENTION
With the advent of high speed container filling machines, such as those used in the filling of coffee creamer containers, condiment containers, small serving deserts, fruit cups and yogurt containers, it has become desirable for each operation of the filling machine to be simplified to allow the operator sufficient time to observe the performance of the machine. One of the functions that the operator must monitor is the container supply system and, as this supply becomes low, new containers must be added. As the output capacity of these machines continues to increase, the time required to maintain a supply of containers in the chutes increases and, therefore, the method of loading the containers into the chutes should be simplified where possible. As the size of the contaienrs increases, the rigidity of the stack similarly increases, and facilitates improved handling of the containers.
The simplest and most common method of loading containers into chutes on automatic filling machines is by top entry into a stationary chute which requires the entire stack to be raised to the upper part of the chute and placed in the opening for slid insertion within the chute enclosure. Although this system is satisfactory for many applications, it can prove difficult in that the operator must reach to the upper portion of the chute, maintaining control over the stack of containers and, therefore, the size of the chute is certainly limited.
To overcome this problem, various arrangements have been used which allow the stack of containers to be positioned horizontally and subsequently moved to the vertical position within chutes. One such structure is shown in U.S. Pat. No. 4,077,180, in which individual rows of containers are placed one by one into a hopper provided on an upright conveyor system which conveys individual stacks of containers upwardly to an area which is aligned with tubes which lead to the filling machine chutes. The stacks of containers are pushed through the tubes downwardly into the chutes to provide a supply of containers. This system is particularly suitable for small coffee creamer containers, where the output speed of the machine is high and, therefore, the additional cost is automating the container feed system is justified.
A slightly different approach is taken in our copending Canadian patent application Ser. No. 344,142, filed Jan. 22, 1980 entitled "Automatic Container Feed for Container Handling Device", in which stacks of containers are placed on a horizotal conveyor bed and moved to align with supply chutes of the automatic filling machine for advancement through a sidewall opening in the container chute and subsequently dropped within the supply chute for dispensing. Again, this automatic approach is particularly suited to high speed filling machines in which the output rate is sufficiently high to justify this mechanized approach.
Another prior art structure for use with small creamer containers utilizes a hinged horizontal platform on which stacks of containers are placed, with this platform being moved upwardly to cooperate with other support members which, in combination with the hinged member, define the chutes for the machine.
The present invention provides a simple mechanical apparatus which facilitates load of containers into chutes of an automatic filling machine.
SUMMARY OF THE INVENTION
A container chute for maintaining nested containers in a generally vertical manner to allow the containers to be dispensed with the assistance of gravity comprises support means positioned to positively maintain such containers in a generally vertical manner, a portion of said support means being movable to an open position to allow insertion of a stack of containers into said support means. The movable portion is then returned to a closed position to positively maintain such inserted stack. Therefore, according to the invention a major portion of the stack of containers passes laterally into the cavity defined between these support means as a portion of the support means is moved or cammed outwardly. Once the stack is inserted, the support means is returned to the initial position thereby positively maintaining the inserted stack of containers.
According to an aspect of the invention, the movable portion of the support means is biased to return to the closed position after the insertion of the stack into the chute.
According to a further aspect of the invention, the movable portion is cammed outwardly by pressing a stack of nested containers thereagainst, thereby creating an opening of sufficient size to allow the containers to pass through into the chute defined by the support means.
According to yet a further aspect of the invention, a container chute for receiving and maintaining nested containers in a generally vertical manner, comprises at least three supports positioned to maintain a stack of containers therebetween, wherein one of said supports is movable outwardly away from the other supports to define a larger opening for inserting such stack of containers into the chute. The movable support remains generally parallel to the other supports during movement thereof and remains in contact with the side of such column of containers during insertion of the containers into the chute.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings wherein:
FIG. 1 is a perspective view of three container chutes commonly mounted on a base member;
FIG. 2 is a partial perspective view of the lower support member of the container chutes.
FIG. 3 is a top view of a container chute with a stack of containers being inserted into the chute; and
FIG. 4 is similar to FIG. 3 however the containers are now positioned within the chute member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Three container chute assemblies according to the present invention are shown in FIG. 1 commonly mounted on a base member 20. Each of these chutes 2, have a pair of moveable portions 4 located either side of a stationary support rod 5. The moveable portions 4 which partially define the container chute are pivotable about rod 7 which may be either directly secured to the base member or may be pivotally secured within the base member and the upper support member 22 such that these moveable portions do pivot about its longitudinal axis. Associated with each of these moveable portions 4 is a spring member 14 which urges the associated moveable portion to the closed position about a stack of nested containers generally shown as 30 in FIG. 1.
Turning to FIG. 2 it can be seen that a base member 17 has been used in place of the block member 20 and supports the moveable portions 4 and the rear support rod 5 which in combination, generally define the container chute. Each of these moveable portions has an arm 12 pivotally secured to the base member 17 generally beneath rod 7 with rod 10 extending upwardly from the arm 12. This arm also extends beyond support rod 7 to cooperate with a spring member 14 which is secured to the arm 12 through a pin member 15 and the spring is secured to the base member 17 through pin 16. This spring urges the moveable member to the closed position shown in FIG. 2 which is positively defined by the stop pin 19 secured to the base member. Supports rods 10 on corresponding moveable portions 4 in combination with a stationary support rod 5 define the container chute and the spacing between any of these rod members is less than the maximum diameter of the containers to be inserted into the chute such that in the closed position a stack of containers is positively maintained within the chute. It can also be appreciated that the distance `A` shown in FIG. 2 is greater than the radius of the containers such that rods 5 and 10 are positioned about the stack of containers and positively maintain the stack within the chute.
The top view of FIG. 3 illustrates the insertion of a stack of containers 30a into the chute 2 with each of the moveable portions 4 camming outwardly such that the distance between the rods 10 on either side of the containers is sufficient to allow insertion of the containers into the chute. The operator merely has to press the stack of containers against these moveable portions and the interaction of the containers with the rods 10, if the operator applies pressure in the lateral direction of arrow 50, will force these moveable portions outwardly and the containers may be conveniently placed within the chute.
FIG. 4 illustrates the stack of containers 30a positioned within the chute member and the spring 14 urges the rod 10 to move inwardly after the maximum diameter of the container has passed through the gap between these rods. Stop pins 19 limit the movement of rods 10 towards each other and in so doing define a container chute which loosely maintains the stack of containers such that the containers can move under gravity downwardly as containers are dispensed from the bottom of the chute. The support rods which define the container chute should not have projecting edges which possibly could interact with the containers and bind them within the chute.
As shown in FIGS. 3 and 4 it is also possible that one spring member 14a may be connected to the adjacent arm 12 of the next container chute whereby the requirement for pins 16 for these arms is eliminated. As shown in FIG. 3, during the insertion of the stack of containers 30a into the container chute, arm 12b remains in its closed position while arm 12a is cammed outwardly due to the interaction of the stack of containers as it is pushed into the container chute.
As can be seen in FIGS. 1 and 2 the moveable portions of the container chutes and particularly the rods 12 are secured such that during insertion of a stack of containers these moveable portions cam outwardly while remaining generally parallel with the stationary support member 5. After the containers have been inserted into the chute these members again move inwardly towards one another and in the closed position, positively maintain the stack of containers therein.
The spacing between two adjacent arms of the moveable portions 12a and 12b shown in FIGS. 3 and 4 is sufficient to allow camming of this arm outwardly without interfering with the adjacent arm which remains in the closed position. If these arms were too close together they would interfere with the movement of each other and would not function in the manner shown.
Although we have shown a container chute having two moveable portions, it can easily be appreciated that one of these moveable portions could be stationary with the other moveable portion being cammed outwardly through a greater distance to allow the insertion of the containers. When two moveable portions are used the movement of each of these is reduced.
In all cases the movable portions of the container chute need not extend over the entire height of the chute. A stack of nested containers generally has some flexibility along its length which would allow the moveable portion of the chute to be reduced to a length less than the height of the stack being inserted with this stack being pressed inwardly and upwardly whereby the top of the stack moves above the movable portions within the chute to allow the lower portion of the stack to be inserted into the chute. This is not the preferred embodiment as it complicates the insertion of containers into the chute however it may be suitable in some operations.
Although preferred embodiments of the invention have been described herein in detail it will be understood that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
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A container chute according to the present invention utilizes movable portions which are normally biased to the closed position but may be moved outwardly to facilitate insertion of a stack of nested containers into the container chute. The container chute is normally used in automated packaging machines which use preformed nested containers. This approach simplifies the container loading operation giving the operator additional time for other responsibilities.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of frequency converters, as are commonly used in RF and other communication systems.
[0003] 2. Prior Art
[0004] It is common in RF communications to place data to be transmitted on the inphase (I) and quadrature (Q) components of a baseband signal, to mix these components with the inphase and quadrature components of a local oscillator, and to combine the components so mixed for RF (or other) transmission. Similarly, on reception, the reverse process is carried out to recover the baseband I and Q components for recovery of the data. In the disclosure herein, the present invention will be described with respect to downconverters as used in RF receivers, though the invention is applicable to both downconverters and upconverters, whether for RF communication systems or other communication systems. Accordingly, for direct comparison purposes, the prior art with respect to downconverters will be discussed.
[0005] A typical prior art downconverter with ω LO >ω RF for the unwanted image frequencies is illustrated in FIG. 1. Mixers M 1 and M 2 mix the received RF signal Cos((ω RF t) with mixer pumping signals comprising inphase (0°) and quadrature (−90°) components of the output of quadrature divider driven by a local oscillator signal Cos(ω LO t) to recover the inphase (I) and the quadrature (Q) components of the baseband signal. However, in a typical receiver, there will be amplifiers and filters in each leg, not shown in FIG. 1 for purposes of clarity but causing phase and amplitude errors in a real system, as well as mixer imperfections and imperfections in the orthogonality between the inphase and quadrature components of the output of the quadrature divider. These imperfections cause the appearance of image frequencies in the I and Q baseband signals, diminishing the accuracy of data recovery.
[0006] The foregoing imperfections may be categorized as a combination of two effects, namely phase shifts so that the I and Q baseband signals at the output of the downconverter (typically but not necessarily coupled to a digital signal processor (DSP)) are not truly orthogonal, and gain differences so that the I and Q baseband signals at the output of the downconverter do not have the same amplitude. The accumulated phase shifts may be lumped into an equivalent phase shift between the inphase and quadrature components of the signals from the quadrature divider. Taking the inphase component of the quadrature divider signal as a reference, the phase errors may be lumped into the corresponding phase error in the quadrature component of the quadrature divider signal as follows:
phase error=0°/ −(90 °+ΔLO )
[0007] where:
[0008] ΔLO=the cumulative phase error in the Q baseband signal relative to the I baseband signal.
[0009] The amplitude errors may be lumped as an amplitude error of the Q baseband signal relative to the I baseband signal, though it may be more instructive in light of a later analysis of the present invention to assign a conversion gain error to each of the I and Q component legs of the downconverter as follows:
Mixer M 1 conversion gain error=Δ 1
Mixer M 2 conversion gain error=Δ 2
PHASE ERROR ANALYSIS—PRIOR ART
[0010] Using the phase error assumption, the I and Q components output by mixers M 2 and M 1 of the converter of FIG. 1, respectively, due to the lumped phase error ΔLO of a single quadrature divider ΔLO, are:
M1 ( Q ) 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO ) ] M2 ( I ) 1 2 Cos [ ( ω LO - ω RF ) t ]
[0011] The effect of the phase error may be evaluated by running the output of the mixers through a quadrature combiner, actual in some systems, or simulated for purposes of performance analysis of the converter, as is shown in FIG. 2. The Q component of the converter output would be shifted back 90 degrees by the quadrature combiner, so that the total output of a quadrature combiner for the unwanted image frequencies would be:
1 2 Cos [ ( ω LO - ω RF ) t ] + 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO ) - 90 ∘ ] = 1 2 Cos [ ( ω LO - ω RF ) t ] - 1 2 Cos [ ( ω LO - ω RF ) t - Δ LO ] Or : 1 2 { Cos [ ( ω LO - ω RF ) t ] ( 1 - Cos Δ LO ) } - 1 2 { Sin [ ( ω LO - ω RF ) t ] Sin Δ LO }
[0012] Using the Taylor series expansions, assuming the phase errors are small:
Sin ( Δ LO ) = Δ LO - ( Δ LO ) 3 3 ! + ( Δ LO ) 5 5 ! … , and Cos ( Δ LO ) = 1 - ( Δ LO ) 2 2 ! + ( Δ LO ) 4 4 !
[0013] The Sin[(ω LO −ω RF )t] term in the unwanted image frequencies becomes:
1 - Cos Δ LO = - ( Δ LO ) 2 2 ! + ( Δ LO ) 4 4 !
[0014] If, by way of example, ΔLO is 5 degrees, (ΔLO) 2 / 2! is (5π/180) 2 /2=0.0038.
[0015] The Sin[(ω LO −ω RF )t] term in the unwanted image frequencies due to a phase error in a conventional I/Q converter, proportional to SinΔLO, is not a small term, but a rather large term directly proportional to the phase error, namely:
Sin ( Δ LO ) = Δ LO - ( Δ LO ) 3 3 ! + ( Δ LO ) 5 5 !
[0016] Thus there is a first order (ΔLO) effect. For a 5 degree phase error, the error is (5π/180)=0.087, or 8.7%.
AMPLITUDE ERROR ANALYSIS—PRIOR ART
[0017] Using the following mixer conversion gain errors and assuming no phase errors:
Mixer 1 conversion gain error=Δ 1
Mixer 2 conversion gain error=Δ 2
[0018] The output (Q) of the first mixer and its difference frequency term is:
(1+Δ1) * Cos(ω RF t ) * Cos(ω LO t— 90°)
[0019] [0019] Difference frequency term = 1 2 ( 1 + Δ1 ) Sin ( ω LO t - ω RF ) t
[0020] The output (I) of the second mixer and its difference frequency term is:
(1+Δ2) * Cos(ω RF t ) * Cos(ω LO t )
[0021] [0021] Difference frequency term = 1 2 ( 1 + Δ2 ) Cos ( ω LO t - ω RF ) t
[0022] The output IRM_OUT of a quadrature combiner on the mixer outputs (FIG. 2) for the image frequencies would be:
1 2 ( 1 + Δ1 ) Sin ⌊ ( ω LO - ω RF ) t - 90 ∘ ⌋ + 1 2 ( 1 + Δ2 ) Cos ( ω LO - ω RF ) t = 1 2 ( Δ2 - Δ1 ) Cos ( ω LO - ω RF ) t
[0023] If (Δ 2 −Δ 1 )=0, the image rejection will be perfect (IRM_OUT=0 for the image frequencies). This illustrates the point that the important error is the gain mismatch between the two mixers. In most prior art systems, variable gain amplifier/attenuators are used to control the amplitudes of the I and Q signal outputs in unison, leaving the difference in the mixer conversion gains as the important gain error parameter.
[0024] Prior art using double quadrature conversion mixers is described in “CMOS Mixers and Polyphase Filters for Large Image Rejection,” authored by Farbod Behbahani et al. Starting on page 880, double quadrature upconversion is described. As shown in FIG. 17 on that page, the inputs to the four mixers are I in , Q in , {overscore (I)} in and {overscore (Q)} in , with the outputs being I RF , Q RF , {overscore (I)} RF and {overscore (Q)} RF . Thus at least one quadrature divider is required on the input side of the four mixers, adding an additional source of gain and phase errors over the present invention. Similarly, starting on page 881, quadrature downconversion is described, with double quadrature downconversion described on page 882. As shown in FIG. 20 on that page, a double quadrature downconverter in accordance with this prior art receives I and Q signal inputs, as well as I and Q mixer pumping inputs, to generate II+QQ and IQ+QI outputs, thus requiring a quadrature divider on the input to the downconverter. Particularly where the input is a high frequency such as an RF frequency, the quadrature divider also causes a high insertion loss, and a high noise figure for the downconverter. In the present invention, such quadrature dividers are not used, and the image rejection is primarily dependent on the matching of errors in circuits, not the errors themselves.
BRIEF SUMMARY OF THE INVENTION
[0025] Precision inphase/quadrature up-down converter structures generally neither requiring trimming at the time of fabrication nor calibration during use. The converters use four mixers arranged to down convert to provide Q, I, {overscore (I)} and Q baseband signals (or up convert Q, I, {overscore (I)} and Q baseband signals), the combination of which signals has a very substantially reduced unwanted image frequency content. The use of an increased number of mixers in effect shifts the primary errors from absolute gain and phase errors, to gain and phase error mismatches between elements in replicated circuits, which mismatches can be held to a minimum in circuits replicated in a single integrated circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 is a diagram showing a typical prior art downconverter.
[0027] [0027]FIG. 2 is a diagram of the typical prior art downconverter of FIG. 1 with a quadrature combiner on the converter output.
[0028] [0028]FIG. 3 is a block diagram of one embodiment of downconverter in accordance with the present invention.
[0029] [0029]FIG. 4 is a block diagram of the embodiment of downconverter of FIG. 3 with a quadrature combiner on the converter outputs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring to FIG. 3, a block diagram of one embodiment of the present invention may be seen. As shown therein, an RF signal Cos(ω RF t) is applied to four mixers, M 1 through M 4 . Again assuming, for purposes of illustration only, a downconverter with ω LO >ω RF for the unwanted image frequencies, the second or pumping signal inputs to the mixers are provided by the 0 degree and−90 degree outputs of quadrature dividers LO 2 and LO 3 controlled by the 0 degree and −90 degree outputs of quadrature divider LO 1 , itself driven by a local oscillator signal Cos(ω LO t). The four mixer outputs are Q, I, {overscore (I)} and Q. Neglecting any phase errors, it can be seen that the first Q (quadrature) output is generated by mixer M 1 by mixing the RF signal Cos(ω RF t) with Cos(ω LO t) as shifted −90 degrees by quadrature divider LO 2 , the I (inphase) output is generated by mixer M 2 by mixing the RF signal Cos(ω RF t) with Cos(ω LO t), the {overscore (I)} (the inverse of inphase) output is generated by mixer M 3 by mixing the RF signal Cos(ω RF t) with Cos(ω LO t) as shifted −90 degrees by quadrature divider LO 1 and another −90 degrees by quadrature divider LO 3 , and the second Q (quadrature) output is generated by mixer M 4 by mixing the RF signal Cos(ω RF t) with Cos(ω LO t) as shifted −90 degrees by quadrature divider LO 1 . The two Q components, of course, are ideally the same quadrature component of the signal, but determined by the use of different quadrature dividers. Similarly, the I and {overscore (I)} components are complementary inphase components of the signal, but again, determined by the use of different quadrature dividers.
[0031] Another way of looking at the outputs of each of the four mixers is to consider the effect of the respective output of quadrature divider LO 1 , and then the effect of the output of quadrature divider LO 2 or LO 3 , as the case may be. For instance, the 0 degree output of quadrature divider LO 1 , would cause an inphase (I) output of a mixer, the −90 degree output of quadrature divider LO 1 would cause a quadrature (Q) output of a mixer, the 0 degree output of quadrature divider LO 2 , would cause an inphase (I) output of a mixer, the −90 degree output of LO 2 would cause a quadrature (Q) output of a mixer, etc. Using this analysis, the output of mixer M 1 is IQ=Q, the output of mixer M 2 is II=I, the output of mixer M 3 is QQ={overscore (I)}, and the output of mixer M 4 is QI=Q.
[0032] The following are analyses of the effect of phase errors and amplitude errors in the converter to illustrate the advantages of the present invention. PHASE ERROR ANALYSIS:
[0033] Since the inphase (0 degree) outputs of quadrature dividers LO 1 , LO 2 and LO 3 are essentially direct pass throughs of the local oscillator signal Cos(ω LO t), assume there will not be any phase error in these components. The quadrature outputs (−90 degree components) however will have some phase error. Thus also assume:
LO 1 phase error=0°/ −(90 °+ΔLO 1 )
LO 2 phase error=0°/ −(90 °+ΔLO 2 )
LO 3 phase error=0°/ −(90 °+ΔLO 3 )
[0034] With this assumption, the output (Q) of the first mixer is:
Cos ( ω RF t ) * Cos ⌊ ω LO t - ( 90 ∘ + Δ LO2 ) ⌋ = 1 2 { Cos [ ( ω RF + ω LO ) t - ( 90 ∘ + Δ LO2 ) ] + Cos [ ( ω RF - ω LO ) t + ( 90 ∘ + Δ LO2 ) ] }
[0035] The output (I) of the second mixer is:
Cos ( ω RF t ) * Cos ( ω LO t ) = 1 2 { Cos [ ( ω RF + ω LO ) t ] + Cos [ ( ω RF - ω LO ) t ] }
[0036] The output ({overscore (I)}) of the third mixer is:
Cos ( ω RF t ) * Cos ⌊ ω LO t - ( 90 ∘ + Δ LO1 ) - ( 90 ∘ + Δ LO3 ) ⌋ = 1 2 Cos [ ( ω RF + ω LO ) t - ( 90 ∘ + Δ LO1 ) - ( 90 ∘ + Δ LO3 ) ] + 1 2 Cos [ ( ω RF - ω LO ) t + ( 90 ∘ + Δ LO1 ) + ( 90 ∘ + Δ LO3 ) ]
[0037] The output (Q) of the fourth mixer is:
Cos ( ω RF t ) * Cos ⌊ ω LO t - ( 90 ∘ + Δ LO1 ) ⌋ = 1 2 { Cos [ ( ω RF + ω LO ) t - ( 90 ∘ + Δ LO1 ) ] + Cos [ ( ω RF - ω LO ) t + ( 90 ∘ + Δ LO1 ) ] }
[0038] Only the difference frequency components are of interest in the exemplary embodiment, the sum frequency components being out of the passband of the system and thereby filtered out. The inphase signal output I out is taken as the combined inphase signals, namely I−{overscore (I)}. Thus:
I out = 1 2 Cos ( ω RF - ω LO ) t + 1 2 Cos [ ( ω RF - ω LO ) t + Δ LO1 + Δ LO3 ]
[0039] The quadrature signal output Q out is taken as the combined quadrature signals, namely Q+Q (see FIG. 3). Thus:
Q out = - 1 2 Sin [ ( ω RF - ω LO ) t + Δ LO2 ] - 1 2 Sin [ ( ω RF - ω LO ) t + Δ LO1 ]
[0040] The effect of the four mixer configuration of the present invention on the image frequencies may be seen by passing the signals through a quadrature combiner as shown in FIG. 4 to form an image rejection mixer, and then to look at the image remnants remaining. Since ω LO >ω RF for the unwanted image frequencies in the example being described, and recognizing that Cos(−θ)=Cos(θ), the difference frequency outputs for the four mixers can be rewritten as:
M1 ( Q ) 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO2 ) ] M2 ( I ) 1 2 Cos [ ( ω LO - ω RF ) t ] M3 ( I _ ) 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO1 ) - ( 90 ∘ + Δ LO3 ) ] M4 ( Q ) 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO1 ) ]
[0041] The quadrature combiner will shift the Q components back 90 degrees and the {overscore (I)} component back 180 degrees, and then combine the four signals for the quadrature combiner output IRM_OUT. Thus the output of the quadrature combiner for the image will be:
1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO2 ) - 90 ∘ ] + 1 2 Cos [ ( ω LO - ω RF ) t ] + 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO1 ) - ( 90 ∘ + Δ LO3 ) - 180 ∘ ] + 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO1 ) - 90 ∘ ] - 1 2 Cos [ ( ω LO - ω RF ) t - Δ LO2 ] + 1 2 Cos [ ( ω LO - ω RF ) t ] + 1 2 Cos [ ( ω LO - ω RF ) t - Δ LO1 - Δ LO3 ] - 1 2 Cos [ ( ω LO - ω RF ) t - Δ LO1 ]
[0042] Using the identity Cos(x+y)=Cos(x)Cos(y)−Sin(x)Sin(y), where x=(ω LO −ω RF )t, this becomes:
1 2 Cos [ ( ω LO - ω RF ) t ] [ - Cos Δ LO2 + 1 + Cos ( Δ LO1 + Δ LO3 ) - Cos Δ LO1 ] - 1 2 Sin [ ( ω LO - ω RF ) t ] [ + Sin Δ LO2 - Sin ( Δ LO1 + Δ LO3 ) + Sin Δ LO1 ]
Or:
1 2 Cos [ ( ω LO - ω RF ) t ] [ 1 - Cos Δ LO2 + Cos ( Δ LO1 + Δ LO3 ) - Cos Δ LO1 ] + 1 2 Sin [ ( ω LO - ω RF ) t ] [ Sin ( Δ LO1 + Δ LO3 ) - Sin Δ LO2 - Sin Δ LO1 ]
[0043] For perfect image rejection:
1−CosΔ LO 2 +Cos(Δ LO 1 +Δ LO 3 )−CosΔ LO 1 =0,
[0044] and
Sin(Δ LO 1 +Δ LO 3 )−SinΔ LO 2 −SinΔ LO 1 =0
[0045] If ΔLO 2 =ΔLO 3 =0, or if ΔLO 1 =0, there will be perfect image rejection. Also if ΔLO 2 =ΔLO 3 <<ΔLO 1 , there will be nearly perfect image rejection. Most important, however, is the case where the phase errors for the three quadrature dividers are non-zero, but equal. In an integrated circuit, it is much easier to match circuit phase errors by simply replicating the same circuit, than it is to try to eliminate the phase error in a single circuit, unit to unit, over the temperature operating range, etc. Thus with this assumption:
Δ LO 2 =Δ LO 3 =Δ LO 1 =Δ LO
[0046] Now the image rejection will be proportional to:
1−2CosΔ LO +Cos( 2 Δ LO )
[0047] and
Sin 2 Δ LO − 2 SinΔ LO
[0048] Using the Taylor series expansions, again assuming the phase errors are small:
Sin ( Δ LO ) = Δ LO - ( Δ LO ) 3 3 ! + ( Δ LO ) 5 5 ! … , and Cos ( Δ LO ) = 1 - ( Δ LO ) 2 2 ! + ( Δ LO ) 4 4 ! …
[0049] the foregoing equations become:
1 - 2 Cos Δ LO + Cos ( 2 Δ LO ) = 1 - ( 2 - 2 ( Δ LO ) 2 2 ! + 2 ( Δ LO ) 4 4 ! … ) + ( 1 - 4 ( Δ LO ) 2 2 ! + 16 ( Δ LO ) 4 4 ! … ) = - ( Δ LO ) 2 + 7 ( Δ LO ) 4 12 … ,
and Sin 2 Δ LO - 2 Sin Δ LO = 2 ( Δ LO ) - 8 ( Δ LO ) 3 3 ! + 32 ( Δ LO ) 5 5 ! … - ( 2 ( Δ LO ) - 2 ( Δ LO ) 3 3 ! + 2 ( Δ LO ) 5 5 ! … ) = - ( Δ LO ) 3 + ( Δ LO ) 5 4 …
[0050] Thus if ΔLO 1 =ΔLO 2 =ΔLO 3 =ΔLO, the undesired image will be present to the extent of:
1 2 Cos [ ( ω LO - ω RF ) t ] ( - ( Δ LO ) 2 + 7 ( Δ LO ) 4 12 … ) , and 1 2 Sin [ ( ω LO - ω RF ) t ] ( - ( Δ LO ) 3 + ( Δ LO ) 5 4 … )
[0051] This may be compared to the I and Q components in the prior art (such as the outputs of the mixers M 2 and M 1 of FIG. 1, respectively), due to a phase error ΔLO of a single quadrature divider. The I and Q components, generalized as to a general phase error ΔLO as described in the prior art section, are:
M1 ( Q ) 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO ) ] M2 ( I ) 1 2 Cos [ ( ω LO - ω RF ) t ]
[0052] The Q component would be shifted back 90 degrees by a quadrature combiner, so that the total output of a quadrature combiner would be:
1 2 Cos [ ( ω LO - ω RF ) t ] + 1 2 Cos [ ( ω LO - ω RF ) t - ( 90 ∘ + Δ LO ) - 90 ∘ ] = 1 2 Cos [ ( ω LO - ω RF ) t ] - 1 2 Cos [ ( ω LO - ω RF ) t - Δ LO ] Or: 1 2 { Cos [ ( ω LO - ω RF ) t ] ( 1 - Cos Δ LO ) } - 1 2 { Sin [ ( ω LO - ω RF ) t ] Sin Δ LO }
[0053] Thus the magnitude of the 1−CosΔLO term due to a phase error in a conventional I/Q converter is to be compared with the magnitude of the 1− 2 CosΔLO+Cos( 2 ΔLO) term due to a uniform phase error in a four mixer I/Q converter in accordance with the present invention, and the magnitude of the SinΔLO term due to a phase error in a conventional I/Q converter is to be compared with the magnitude of the Sin 2 ΔLO− 2 SinΔLO term due to a uniform phase error in a four mixer I/Q converter in accordance with the present invention. Using the foregoing Taylor series expansion for the CosΔLO term:
1 - Cos Δ LO = - ( Δ LO ) 2 2 ! + ( Δ LO ) 4 4 ! … 1 - 2 Cos Δ LO + Cos ( 2 Δ LO ) = - ( Δ LO ) 2 + 7 ( Δ LO ) 4 12 …
[0054] Thus assuming ΔLO is fairly small, the magnitude of the Cos[(ω LO −ω RF ) t] term in the unwanted image frequencies has been increased by use of the present invention by a factor of 2. However this term is small anyway if ΔLO is reasonably small. By way of example, if ΔLO is 5 degrees, (ΔLO) 2 is (5π/180) 2 =0.0076 compared to 0.0038 for a conventional converter with the same phase error.
[0055] The Sin[(ω LO −ω RF )t] term in the unwanted image frequencies due to a phase error in a conventional I/Q converter (proportional to SinΔLO) is not a small term, but a rather large term directly proportional to the phase error. Comparing the magnitude of the SinΔLO term due to a phase error in a conventional I/Q converter with the magnitude of the Sin 2 ΔLO− 2 SinΔLO term due to a uniform phase error in a four mixer I/Q converter in accordance with the present invention:
Sin ( Δ LO ) = Δ LO - ( Δ LO ) 3 3 ! + ( Δ LO ) 5 5 ! … , and Sin 2 Δ LO - 2 Sin Δ LO = - ( Δ LO ) 3 + ( Δ LO ) 5 4 …
[0056] Thus a first order (ΔLO) effect has been reduced by the present invention to a third order ((ΔLO) 3 ) effect, reducing the effect for a 5 degree phase error from a (5π/180)=0.087 effect to a (5π/180) 3 =0.00066 effect.
[0057] In summary, for the 5 degree phase error illustrative example used herein, the largest term in the unwanted image frequencies due to a phase error in a conventional I/Q converter is 0.087, whereas the largest term in a four mixer I/Q converter in accordance with the present invention is 0.0076, an improvement by more than an order of magnitude.
[0058] The improvement in the suppression of image frequencies, or in the rejection of the image itself just illustrated was based on being able to achieve uniform phase errors in the three quadrature dividers (ΔLO 1 =ΔLO 2 =ΔLO 3 =ΔLO) with some degree of accuracy. This is much more readily achievable than a very low phase error in one quadrature divider, particularly in an integrated circuit, as one only has to replicate the same quadrature divider structure for the three quadrature divider circuits, preferably the three phase shifters being close to each other on the integrated circuit. While the phase errors of the phase shifters will differ, integrated circuit to integrated circuit, and will drift with temperature, and to some extent with time, all three phase shifters on a particular integrated circuit will match and drift together without trimming for alignment, or calibration during use. As long as the phase errors of the three phase shifters are substantially equal, the magnitude of the phase errors doesn't matter much, provided the phase errors remain within reasonable and readily achievable limits.
Amplitude Error Analysis
[0059] [0059]FIGS. 3 and 4 are simplified diagrams for a typical converter in accordance with the present invention, in that the output circuits of the mixers will typically include amplifiers and filters, both of which will effect the amplitude of the ultimate I/Q output signals. These errors can be lumped with the conversion gain errors of the mixers and represented by an overall conversion gain error for each I/Q path. Thus normalizing the desired gain to unity, the overall mixer conversion gain errors can be represented as follows:
Mixer M 1 conversion gain error=Δ 1
Mixer M 2 conversion gain error=Δ 2
Mixer M 3 conversion gain error=Δ 3
Mixer M 4 conversion gain error=Δ 4
[0060] Assuming the foregoing conversion gain errors but no phase errors, the output (Q) of the first mixer and its difference frequency term is:
(1+Δ1) * Cos (ω RF t ) * Cos(ω LO t −90°)
[0061] [0061] Difference frequency term = 1 2 ( 1 + Δ1 ) Sin ( ω LO t - ω RF ) t
[0062] The output (I) of the second mixer is:
(1+Δ2) * Cos(ω RF t ) * Cos(ω LO t )
[0063] [0063] Difference frequency term = 1 2 ( 1 + Δ2 ) Cos ( ω LO t - ω RF ) t
[0064] The output ({overscore (I)}) of the third mixer is:
(1+Δ3) * COS (ω RF t ) * COS(ω LO t − 180°)
[0065] [0065] Difference frequency term = - 1 2 ( 1 + Δ3 ) Cos ( ω LO t - ω RF ) t
[0066] The output (Q) of the fourth mixer is:
[0067] (1+Δ4) * COS (ω RF t) * COS(ω LO t 90°)
[0068] [0068] Difference frequency term = 1 2 ( 1 + Δ4 ) Sin ( ω LO t - ω RF ) t
[0069] The output IRM_OUT for the image frequencies will be:
1 2 ( 1 + Δ1 ) Sin ⌊ ( ω LO - ω RF ) t - 90 ∘ ⌋ 1 2 ( 1 + Δ2 ) Cos ( ω LO - ω RF ) t - 1 2 ( 1 + Δ3 ) Cos ⌊ ( ω LO - ω RF ) t - 180 ∘ ⌋ + 1 2 ( 1 + Δ4 ) Sin ⌊ ( ω LO - ω RF ) t - 90 ∘ ⌋ = 1 2 ( Δ2 + Δ3 - Δ1 - Δ4 ) Cos ( ω LO - ω RF ) t
[0070] If (Δ2+Δ3−Δ1−Δ4)=0, the image rejection will be perfect (IRM_OUT =0 for the image frequencies). Thus:
IRM_OUT=0 when Δ1=Δ2 and Δ3=Δ4,
IRM_OUT=0 when Δ2+Δ3=Δ1+Δ4,
IRM_OUT=0 when Δ1+Δ3 and Δ2=Δ4,
[0071] and
IRM_OUT=0 when Δ1−Δ2=Δ3−Δ4
[0072] As in the prior art, the important term is the difference in conversion gain errors, though with the present in invention, there should be some reduction in the effect of the conversion gain errors on the unwanted image frequencies because of the averaging effect resulting from the use of 4 mixers in the present invention as opposed to just the 2 mixers of the prior art.
[0073] The exemplary embodiments of the invention have been described in detail with respect to downconverters wherein ω LO >ω RF for the unwanted image frequencies (ω RF >ω LO for the wanted frequencies). It will be recognized by those skilled in the art however, that the invention is equally applicable to downconverters wherein ω RF >ω LO for the unwanted image frequencies, and ω LO >ω RF for the wanted frequencies, by simply making certain phase changes (reversals) in the downconverter.
[0074] The invention is applicable to downconverters wherein the I and Q outputs are baseband signals. Using a quadrature combiner as in the embodiment of FIG. 4, an image rejection mixer is provided for providing a downshifted (or an up-shifted) intermediate frequency (IF) substantially free of image frequencies. The invention is also directly applicable to upconverters, wherein the I and Q components of a baseband signal is applied to the mixers, the outputs of which are combined to provide an RF (or intermediate frequency) signal, such as for transmission. In general, not only will the quadrature dividers be formed by replicating a single quadrature divider circuit on a single integrated circuit, but also the mixers, and the amplifiers and filters in each mixer leg will be replicated circuits, so that the overall or lumped phase errors will be as equal as possible and track each other over temperature changes, etc., as will amplitude mismatches. Thus while certain preferred embodiments of the present invention have been disclosed in detail herein, such disclosure has been for purposes of illustration and not for purposes of limitation. Thus various changes in form and detail of the present invention will be obvious to those skilled in the art without departing from the spirit and scope of the invention.
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Precision inphase/quadrature up-down converter structures generally neither requiring trimming at the time of fabrication nor calibration during use. The converters use four mixers arranged to down convert to provide Q, I, {overscore (I)}and Q baseband signals (or up convert Q, I, {overscore (I)} and Q baseband signals), the combination of which signals has a very substantially reduced unwanted image frequency content. The use of an increased number of mixers in effect shifts the primary errors from absolute gain and phase errors, to gain and phase error mismatches between elements in replicated circuits, which mismatches can be held to a minimum in circuits replicated in a single integrated circuit.
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FIELD OF THE INVENTION
The present invention is generally directed to hand tools and more specifically to devices for mounting a drill bit on a hand tool that rotates or drives the drill bit.
BACKGROUND OF THE INVENTION
In many trades and other work situations, an operator must repeatedly exchange drill bits or replace drill bits with other tools, such as a driver or screw driver tip, while performing successive, repetitive operations using the electric drill. For example, construction workers or carpenters regularly change drill bits during numerous types of construction projects, often times when the worker is in a position where it is difficult to change the drill bit, such as on a ladder. To change a drill bit, the carpenter must loosen the chuck, remove the old bit from the chuck, insert the new bit and tighten the chuck. Drill bit changes typically require both hands, which can interrupt the carpenter's work, resulting in inconvenience and thereby increased costs due to the inefficient use of time required by the changing of drill bits. Tool changes are especially a problem when the carpenter is temporarily holding an object in place with one hand while attempting to switch drill bits with the other. An expensive alternative is to use multiple drills having different drill bits or tools attached to each.
Several devices have been developed to attempt to simplify the process for exchanging drill bits or replacing drill bits with other tools, such as a driver or screw driver tip. In one device, for example, the multiple prongs of an adaptor are inserted into the cavities in the drill chuck. Although the device does provide a simpler method for exchanging tools, the prongs can be difficult to align with the cavities. Through wear, the ability of the prongs to grip the chuck can decrease over time. As a result, the adaptor can wobble on the chuck during use and get stuck in the drilled hole during removal.
Another device for exchanging tools includes an adaptor having a drill bit at one end and a driver at the other end. A holder receives a selected one of each of these two ends. During the drilling operation, the drill bit is exposed and the driver is within the holder. After drilling and when it is desired to then utilize the driver, this adaptor is grasped and removed from the holder. The drill bit end is then inserted into the holder. However, such an adaptor is subject to heat build-up during such usage. This heat can cause discomfort or burn the operator's fingers upon reversing the ends of the adaptor. Additionally, such heat build-up can cause the adaptor to expand and become jammed in the holder. This is especially a problem when sawdust and other debris collects in the holder from the drill bit when it is placed in the holder. Furthermore, when the drill bit breaks off from the adaptor, unwanted complications occur in replacing the broken drill bit with a new drill bit.
Other prior art devices for exchanging tools include drill bits that have similar or the same drawbacks, particularly when performing back-and-forth drill and drive operations. That is, operations that involve alternating and repeated uses of the drill bit and the driver. For example, alternating the drilling of a hole using a drill bit and performing a fastening or other operation using a driver.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide a drill adaptor tool that can be conveniently and rapidly engaged with a drill and chuck in order to facilitate the back-and-forth drill and drive operations. Related objectives include providing a low cost, less complex drill adaptor tool, a drill adaptor tool that will not dislodge from the drill or chuck or become jammed in the drill or chuck during use, and a drill adaptor tool that will not become difficult to handle due to heat buildup during use.
Another objective is to create a tool system in which different tools are mounted on a number of interchangeable drill adaptor tools for rapid tool changes.
This and other objectives are addressed by the adaptor tool of the present invention. The adaptor tool includes: (i) a tool body; (ii) a working piece, such as a drill bit, connected to the tool body; (iii) a lock member for locking the tool body to a driver engaging the drill; (iv) a sliding member that is moveable relative to the tool body to cause the lock member to move to permit the unlocking of the driver; and (v) a spring for engaging at least one of the sliding member and lock member to cause the sliding member to return to a locked position of the lock member when released by a user and cause the adaptor tool to be held on the driver.
To facilitate changes of tools from the drill and thereby the alternating drill and drive operations, the sliding member in one embodiment of the present invention is positioned to facilitate grasping and moving thereof by the user. The user can easily use the same hand to move the sliding member to unlock the driver and remove the adaptor tool from the driver in a single continuous operation. The lock member locks firmly to the driver and prevents the adaptor tool from dislodging from the driver during use. Accordingly, the user does not have to remove a tool or driver from the drill chuck but can simply slide the adaptor tool onto the driver and, when completed, slide the adaptor tool off. As part of the drill and drive operations, the adaptor tool enables a user to rapidly drill a number of holes and insert screws in the holes. The user first uses the adaptor tool to drill one or more holes and then removes the adaptor tool and uses the driver to insert screws in the holes.
The lock member and tool body have passages that engage the driver. The passages preferably have substantially the same shape as the driver to facilitate proper connection between the adaptor tool and the driver. When this is achieved, appropriate parts of the adaptor tool are driven or rotated using the driver without complications including undue wear of adaptor tool parts.
To permit the sliding member to move the lock member to an unlocked position, the back face of the sliding member (i.e., the face adjacent to the driver) engages one or both of the spring and lock member during movement of the sliding member. In one configuration, the lock member is positioned between the back face and the tool body to engage the driver.
To facilitate movement of the sliding member, the sliding member can include a bushing member located inwardly of the cap member. The bushing member has a diameter smaller than the cap member to engage the cap member. The bushing member facilitates movement of the sliding member by transferring the thrust from the sliding member to the bushing member.
The spring preferably has a sufficient strength to return the sliding member to a locked position, even if opposed by the combined weight of the sliding member and lock member. Preferably, the spring has a force constant of about 0.75 lbs./sq. in.
In another embodiment, the adaptor tool includes a device, located on at least one of the tool body and sliding member, for restraining movement of the lock member. The device thereby permits alignment of the lock member passage with the tool body passage and rotation of the tool body by the driver when the lock member alone engages the driver. This feature facilitates tool changes by permitting the adaptor tool to be pushed easily onto the driver. The operator using the adaptor tool need only employ a slight twist of the adaptor tool when it is not aligned in order to align the driver with the lock member and the tool body passage. The lock member is also capable of transferring rotation from the driver to the tool body, even if the tool body passage fails to engage the driver. In this manner, the restraining device provides a fail safe solution to overcome operator error.
The restraining device can be in a variety of configurations. In one configuration, the device includes a slot on a collar member and a projection on the lock member that is received in the slot. In another configuration, the device includes a projection on the collar member that is received in a slot on the lock member.
In another embodiment, the back face of the lock member is located (at the shortest distance) at a distance of no more than about 0.50 inch from the back face of the cap member. This permits the lock member to engage a driver that is not long enough to engage the tool body passage. If a standard driver is inserted all the way to the back of the chuck, the protruding portion of the chuck will generally be no more than about 1.00 inch. The lock member can thus engage the driver and transfer rotation from the driver to the tool body even if the driver fails to engage the tool body passage.
To reduce the likelihood that the driver will fail to contact the tool body passage, the opening of the tool body passage can be located no more than about 0.75 inch from the back face of the cap member.
To provide a bearing surface for the driver and thereby permit a user to apply a force to the drill during operation, the bottom of the tool body passage can be located an appropriate distance from the back face of the cap member to engage the tip of the driver. The bottom is preferably located at a distance of no more than about 1.0 inch from the back face.
As is evident from the foregoing, the adaptor tool of the present invention enables the operator to rapidly perform repeated alternating drill and drive operations. This will greatly facilitate tool changes and decrease the manhours required to perform various tasks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a disassembled view of a drill bit adaptor tool according to a first embodiment of the present invention;
FIG. 2 is a side elevational view of the drill bit adaptor tool of FIG. 1;
FIG. 3 is a longitudinal cross-sectional view of the drill bit adaptor tool of FIG. 1;
FIG. 4 is a side elevational view of portions of the drill bit adaptor tool of FIG. 1 in cross-section illustrating the driver being prepared for connection to the tool;
FIG. 5 is a side elevational view, similar to FIG. 4, but showing the driver connected to the drill bit adaptor tool;
FIG. 6 is a side elevational view, similar to FIG. 5, but showing movement of the driver in the opposite direction for disconnection from the drill bit adaptor tool;
FIG. 7 is a disassembled view of a drill bit adaptor tool according to a second embodiment of the present invention;
FIG. 8 illustrates a longitudinal cross-sectional view of a second embodiment of a drill bit adaptor tool;
FIG. 9 is an enlarged, perspective view of the drill bit adaptor tool of the second embodiment with portions thereof being cut-away;
FIG. 10 is a disassembled view of a drill bit adaptor tool according to a third embodiment of the present invention;
FIG. 11 is a longitudinal cross-sectional view of a third embodiment of the drill bit adaptor tool together with a drill bit held by the tool;
FIG. 12 is an enlarged, exploded view of the third embodiment with portions thereof cut-away;
FIG. 13 is a disassembled view of a drill bit adaptor tool according to a fourth embodiment of the present invention;
FIG. 14 is a longitudinal cross-sectional view of the drill bit adaptor tool of a fourth embodiment together with a drill bit;
FIG. 15 is an exploded view of the fourth embodiment of the drill bit adaptor tool with portions thereof cut-away;
FIG. 16 is a disassembled view of a drill bit adaptor tool according to a fifth embodiment of the present invention;
FIG. 17 is a longitudinal cross-sectional view of a fifth embodiment of the drill bit adaptor tool;
FIG. 18 illustrates a perspective view of portions of the drill bit adaptor tool of the fifth embodiment;
FIG. 19 illustrates an adaptor tool having a number of lock members;
FIG. 20 is a side elevational view, partly in cross-section, of the embodiment of FIG. 19;
FIG. 21 illustrates an exploded, perspective view of the embodiment of FIG. 19 in which the tool is aligned with the driver to which it is to be connected; and
FIG. 22 depicts a lock member having a different inner passage shape to enhance engagement with the driver.
DETAILED DESCRIPTION
FIGS. 1-3 depict a drill bit adaptor tool 40 according to a first embodiment of the present invention. The drill bit adaptor tool includes a tool body assembly 42 to receive a drill bit 48, a lock member 52, a sliding member assembly 56, and a spring 60. The sliding member assembly 56 further includes cap member 64 and a bushing member 76. The tool body assembly 42 further includes a tool body 44, a collar member 68 and a snap ring 72. As will be appreciated, the present invention can be used for any tool bit that is attached to a tool that rotates, such as a drill, braces, drill presses and electric drills.
Referring to FIGS. 1-6, the tool body 44 is a cylindrical member having a front passage 80 to receive the drill bit, a back passage 84 to receive a driver 88 of the drill (not shown), and a central passage 92 connecting the other two passages. A set screw 96 can be included to hold the drill bit firmly in position in the front passage 80.
To permit the driver 88 to rotate the tool body 44, the back passage 84 is sized and shaped such that it contacts and interlocks with the driver exterior. Generally, the back passage 84 will have a shape similar to that of the driver exterior. By way of example, for angular shaped drivers, the back passage 84 can have an angular shape, and for hexagonal shaped drivers, the back passage can have a hexagonal shape, such as a twelve-sided configuration. A rounded back passage fails to permit the driver 88 to rotate the tool body 44 because of the lack of an interlocking surface in the passage.
To permit relatively short drivers to engage the back passage 84, the back face 100 of the tool body 44 is preferably located at a distance of no more than about 0.50, and most preferably no more than about 0.25 inch from the back face 104 of the cap member 64. The cap member's back face 104 is the surface of the drill bit adaptor tool that contacts the drill chuck. The chuck holds the driver in position. The distance from the cap member's back face 104 to the bottom 108 of the back passage 84 is preferably sufficient for the driver tip 112 to contact the bottom 108.
The lock member 52 locks the tool body 44 to the driver 88 and thereby prevents the drill bit adaptor tool from becoming dislodged from the driver during use and aligns the driver 88 with the back passage 84 of the tool body 44. An inner passage 124 of the lock member 52 is sized and shaped such that it contacts and interlocks with the driver exterior. Generally, the inner passage 124 will have the same shape as the back passage 84 and a shape similar to that of the driver exterior. By way of example, for angular shaped drivers, the inner passage 124 can have an angular shape and for hexagonal shaped drivers, the inner passage 124 can have a hexagonal shape. A rounded inner passage 124 would fail to align the driver 88 with the back passage 84 of the tool body 44 and would fail to cause the driver 88 to rotate the tool body 44 if the driver 88 did not engage the back passage 84.
The lock member 52 includes an upper flange 128 and a lower flange 132 which are received by upper slot 136 and lower slot 140 in the collar member 68 of the sliding member assembly 56 to restrain the rotational movement of the lock member 52 relative to the tool body 44. This permits not only the inner passage 124 of the lock member 52 to be aligned with the back passage 84 of the tool body 44 to facilitate insertion of the driver 88 therein but also the lock member 52 is useful in permitting the tool body 44 to rotate if the driver is too short to engage a portion of the back passage 84. To permit the lock member 52 to engage shorter drivers 88, the back surface 144 of the lock member 52 is preferably located (at its shortest distance) at a distance of no more than about 0.50, more preferably no more than about 0.25, and most preferably no more than about 0.125 inch, from the back face 104 of the cap member 64 when the lock member 52 is in its locked position. The lock member preferably has a thickness ranging from about 0.02 to about 0.10 inch, with 0.03 inch being the optimal thickness.
The lock member 52 locks against the driver 88 when the angle θ between the plane of the lock member 52 and the longitudinal axis of the driver 88 is acute and unlocks the driver 88 when the angle θ is substantially normal. θ preferably ranges from about 75° to about 90° and more preferably from about 85° to about 90°.
The sliding member assembly 56 slides along the tool body 44 to permit the lock member 52 to lock or unlock the driver 88. At the "at rest" position of the sliding member assembly 56, the lock member 52 locks against the driver 88. In this position, it is important that there be a gap between an inner lip 148 of the cap member 64 and the edge 150 of the lock member 52 so that no unwanted pressure is applied to the lock member 52 that would impede its locking function. From this position, the sliding member assembly 56 is moved to unlock the lock member 52 from the driver 88.
To provide a fixed point for movement of the lock member 52 in response to movement of the sliding member assembly 56, the collar member 68 is stationary relative to the sliding member assembly 56. The collar member 68 is pressure fitted to the tool body 44. In this manner, the sliding member assembly 56 moves independently of the collar member 68.
To permit the unlocking of the lock member 52 from the driver 88, the snap ring 72 engages the upper flange 128 of the lock member 52 to form a pivot point for the lock member 52. The lock member 52 rotates about the pivot point to an unlocked position as the sliding member assembly 56 is moved towards the tool body 44. The inner lip 148 of the cap member 64 engages the lower flange 132 of the lock member 52 to move the lock member 52 as the sliding member assembly 56 is moved. The snap ring 72 engages the lock member 52 during movement of the sliding member assembly 56 and causes the lock member 52 to move to a position that is substantially normal to the tool body's longitudinal axis. In this lock member position, the driver 88 moves freely throughout the inner passage 124.
To permit free movement of the sliding member assembly 56 and lock member 52, the relative sizes of various components are important. The inner diameter of the bushing 76 is larger than the outer diameter of the tool body 44 and the outer diameter of the lock member 52 is less than the inner diameter of the sleeve 152 of the collar member 68 (to permit the lock member 52 to rotate about the pivot point inside of the sleeve 152). In addition, the collar member 68 includes the upper and lower slots 136, 140 to receive the upper and lower flanges 128, 132. The snap ring 72 is received by the back portion of the collar member 68 to restrain upper flange movement. The open end of the snap ring 72 permits the lower flange 132 and lock member 52 to move freely inside of the sleeve 152.
To assemble the components of the sliding member assembly 56, the sleeve 152 of the collar member 68 is received inside of the bore 156 of the cap member 64 and is held in position by the tool body 44. In one embodiment, the bushing 76 is pressure fitted to the interior of the cap member 64. In another embodiment, a crimp-like or other suitable connection is utilized. The outer diameter of the sleeve 152 is less than the inner diameter of the bore 156 to permit assembly of the various parts. The location of the cap member 64 on the exterior of the drill bit adaptor tool facilitates grasping and moving of the sliding member assembly by a user regardless of the lock member's position.
The spring 60 engages the sliding member assembly 56 such that the spring 60 opposes movement of the sliding member assembly 56 and thereby causes the sliding member assembly 56 to return to its original ("at rest") position after the sliding member assembly 56 is released by the user. In this at rest position of the sliding member assembly 56, the lock member 52 is in the locked position. The spring 60 has an inner diameter larger than the outer diameter of the sleeve 152 but smaller than the inner diameter of the bore 156 to permit the spring 60 to be located in the channel 160 between the cap member 64 and the collar member 68. The inner lip 148 of the cap member 64 engages the spring 60 to permit the spring 60 to return the sliding member assembly 56 to the locked position.
The spring 60 preferably has a sufficient tension to move each of the sliding member assembly 56 and the lock member 52 to its locked position. It is important that the spring 60 have sufficient strength to move the sliding member assembly 56 to its original position, even if the weight of the sliding member assembly 56 opposes the assembly 60. The force constant of the spring 60 preferably is about 0.75 lbs./sq. in. Movement of the sliding member assembly 56 against the force of the spring 60 moves each of the sliding member assembly 56 and the lock member 52 to its unlocked position.
In operation, a driver 88 is placed in the drill chuck and the chuck tightened. The driver 88 preferably extends no less than about 1 inch from the face of the chuck to permit the driver 88 to engage the drill bit adaptor tool 40. The driver 88 is roughly aligned with the inner passage 124 of the lock member 52 and pushed towards the front of the adaptor tool. As the operator engages the adaptor tool with the driver, the adaptor tool operator typically will slightly twist the adaptor tool 40 in order to align the driver 88 with the lock member inner passage 124. The driver 88 is then passed through the inner passage 124 of the lock member 52 and into the back passage 84 of the tool body 44. The sliding member assembly 56 is then released by the user. The sliding member assembly is returned to its original (locked) position by the spring 60. In this position, the inclined lock member 52 firmly grips the driver 88 and prevents disengagement of the driver 88 from the adaptor tool during use. As the driver 88 is rotated, the driver will rotate the tool body and therefore the drill bit.
To remove the adaptor tool after use, the sliding member assembly 56 is moved by the user in the direction of the unlocked position. The sliding member assembly 56 and back face 100 of the tool body 44 together cause the lock member to pivot about the snap ring 72 to an upright and unlocked position. As the sliding member assembly 56 reaches its unlocked position, the adaptor tool is removed from the driver 88 as part of a single, continuous removal operation.
The drill bit adaptor tool can be made in a variety of other embodiments. By way of example, FIGS. 7-9 depict a second embodiment of the present invention in which the lock member 200 has only one flange 204 and the spring 60 is located inside of the sleeve 208. To accommodate the lock member 200, the collar 212 has a single slot 216. The sleeve 208 forms a channel 222 with the tool body 44 to receive the spring 60. When the sliding member assembly 220 is released, the spring 60 forces the lock member 200 towards the back face 204 of the cap member 224. The lock member 200 engages the cap member 224 and forces the sliding member assembly 220 into its original (locked) position.
FIGS. 10-12 depict a third embodiment of the present invention which differs from the second embodiment in that the lock member 250 is without flanges and the sliding member assembly is without a bushing member and consists of only the cap member 270. A projection 258 is inserted through the sleeve 262 of the collar member 266 to act as the pivot point for the lock member 250. The absence of flanges permits the sleeve to be without any slots to receive the flanges. As noted above, the cap member 270 is able to move relative to the collar member 266. The snap ring 72 is located in a groove 274 in the cap member 270 near the cap member's front face 278. As the cap member 270 is moved by a user, the snap ring 72 moves in the groove 274. The snap ring 72 permits the lock member 250 and spring 60 to return the cap member 270 to the original (locked) position.
FIGS. 13-15 depict a fourth embodiment of the present invention which differs from the third embodiment in that inner and outer springs are employed. The outer spring 300 is used with the inner spring 304 to further enhance the ability of the cap member 308 to return to the original (locked) position after it is released by a user. The inner and outer springs 300, 304 are housed in inner and outer bevelled channels 312, 316 of the collar 320.
FIGS. 16-18 depict a fifth embodiment of the present invention which differs from the first embodiment in that the lock member 350 includes a slot 354, rather than flanges that interacts with a bent tab 358 in the collar member 362 to form the lock member pivot point. The bent tab 358 is received by the slot to prevent the lock member 350 from rotating independently of the tool body 366 and align the inner passage 370 of the lock member 350 with the back passage 374 of the tool body 366. The front face 380 of the cap member 384 is compressed inwardly to retain cap member 384 on the collar 362.
This embodiment further illustrates that the adaptor tool is not limited to drill bits. The tool body 366 can include a rectangular head 388 to be received by a socket. As will be appreciated, such sockets are used to tighten or loosen bolts or nuts.
In a sixth embodiment of the present invention shown in FIGS. 19-21, the adaptor tool includes a plurality of lock members 386, 390. The lock members are located adjacent to one another, with the adjacent, planar surfaces of the lock members being substantially parallel. The use of multiple lock members is intended to improve the locking between such lock members and the driver 395 of the tool body 44 and provide increased strength for rotation of the adaptor tool by the driver 395 when the driver fails to engage the back passage 84.
Lastly, with reference to FIG. 22, another lock member 400 is illustrated and characterized by its differently configured inner passage 404. The inner passage 404 reduces the area of contact between the lock member 400 and the driver. Such a reduced amount of contact area between the lock member 400 and the driver results in increased friction so that unwanted unlocking of the lock member 400 is eliminated or at least substantially reduced. With regard to this design for reduced engagement between the inner passage 404 and the driver, the contact area of the inner passage 404 with the driver should be about 25% to 75% of the total available or potential contact area of the inner passage 404.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the scope of the present invention, as set forth in the following claims.
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A drill bit adapter tool is provided having a lock member, sliding member, and spring that are slidably positioned on the tool body. The lock member engages the driver of a drill and thereby holds the adapter tool to the drill. The lock member is disengaged to permit removal of the adapter tool from the driver by moving the sliding member, lock member, and spring relative to the tool body. The adapter tool facilitates convenient and rapid replacement of drill bits or other working pieces.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 61/624,190, “METHOD AND APPARATUS TO FORM A VIRTUAL POWER GENERATION COLLECTIVE FROM A DISTRIBUTED NETWORK OF LOCAL GENERATION FACILITIES,” Attorney Docket WYAT-P0001.PRO, David Wyatt, filed Apr. 13, 2012, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] Embodiments according to the present invention generally relate to systems involving power generation and distribution and more specifically to methods for measuring and accounting for generated and distributed power.
BACKGROUND OF THE INVENTION
[0003] Historically, electrical power has been delivered from a power generation facility, for example, Northern California Power Agency (“NCPA”), to an end-consumer at a home or business facility through an electricity distributor, for example, Pacific, Gas and Electricity Company (“PG&E”). The power can usually be provisioned from any kind of power generation facility, for example, a hydroelectric, coal or steam plant. The electricity distributor, on the other hand, owns the grid of wires and sub-stations that distribute power to the consumers and is typically unrelated to the power provisioning facility. The end-consumer, traditionally, has not had any means to produce power locally at his or her home or business facility. The local home or business facility, therefore, has only needed to be equipped with electricity meters capable of measuring electricity drawn from the grid for supplying the power demands of the facility.
[0004] FIG. 1 illustrates a historical power generation and distribution system. Power is generated by a power generator 150 and then delivered to electricity consumers 160 through a power distributor or grid provider 155 .
[0005] This historical model has presently evolved into one where the end consumers have the capability of generating their own power, for example, through the advent of home solar electric panels, blume gas generators, fuel cells, and wind turbines. Therefore, the traditional electricity meters have needed to be adapted to also account for how much power is being supplied back into the grid. This is accomplished, for example, by allowing the meters to “run backwards,” whereupon the grid provider would provide a refund for the amount of kilowatt-hours (“kwh”) supplied back into the grid. However, under the present model, the electricity provider is still in charge of accounting for contributions and determining the compensation scale for the contribution.
[0006] FIG. 2 illustrates a conventional power generation and distribution system as it exists presently. Power is generated by a power generator 250 and distributed to the consumers through an electricity distributor 255 similar to historical systems. However, in the conventional power generation and distribution systems of today, certain consumers 275 have means of generating electricity at their own facility through the use of, for example, solar panels.
[0007] The problem with the present model of power distribution and accounting is that consumer power generation capabilities are in effect competing with corporate generation, and the corporations, in particular, the grid providers, may choose to reward contributions back into the grid at a much reduced rate, substantially lower than the price the electricity supplier would charge consumers drawing from the grid. This is problematic especially because while the purchase and installation cost of the solar electric panels is less per kwh over the life of the solar panels than the cost of the electricity drawn from the grid, it is typically more expensive than the amount refunded by the electricity distributor corporations for supplying power back into the grid.
[0008] These constraints have, in effect, placed an economic limit on the practical size of a home or business solar panel installation for a typical consumer. In short, if the installation produces more electricity than the typical electrical demand of the home on which it is fitted, it simply cannot recoup the cost of the installation through the money refunded through oversupply going back into the grid. Unfortunately, this leads to an artificial constraint on the typical home generation installation, wherein the policy of the electricity distributor for the amount of money refunded rather than the installation area or other physical capability of the installation site is the key determinative factor governing the size of the clean solar home generation installation.
[0009] For example, a typical electricity supplier or distributor may charge $0.41 per kwh for a tier one electrical consumer at the peak demand time, while refunding surplus electricity contributed back into the grid at only $0.11 per kwh. Meanwhile, a typical solar installation may cost $0.22 per kwh over the life of the panel. Under this model, it makes little economic sense for a typical consumer to utilize a solar installation with excess capacity over what the consumer's home or business demands, because any oversupply contributed back into the grid will not be compensated at the same rate as the power consumed. Similarly, a factory employing wind turbines would face a similar dilemma if the size of the turbine results in excess capacity over what the local facility demands.
[0010] Since the electricity generated by solar panel, wind turbine, or a coal fired generating facility is the same once it is on the grid, there is no reason why one form of power generation should earn less per kwh than any other method, whether it is solar, wind, geothermal or other. However, the problem with sources of electricity being fungible is that it is challenging to distinguish electricity contributed by one provider from another. Therefore, it is problematic to account for the contributions from the various different types of electricity providers.
BRIEF SUMMARY OF THE INVENTION
[0011] Accordingly, a need exists for a system wherein the electrical contribution of any generation facility can be accounted for fairly and securely. Also what is needed is a robust method of accounting for electricity contribution at the source of the power supply into the grid. Using the beneficial aspects of the systems described, without their respective limitations, embodiments of the present invention provide a novel solution to address these problems.
[0012] Disclosed herein is a method whereby each facility's power contribution can be recorded, tallied and time-stamped by one or more independent auditing bodies allowing the formation of virtual electricity suppliers.
[0013] In one embodiment, a method of accounting for electrical power contributions is presented. The method comprises receiving encrypted data from a plurality of facilities, wherein the plurality of facilities is operable to generate electricity, and wherein the encrypted data comprises information concerning electricity contributions to a power grid by the plurality of facilities. The method further comprises decrypting the encrypted data to access information concerning electricity contributions. Finally, the method comprises tracking electricity contributions from each of the plurality of facilities using decrypted data. The method can also comprise compensating each of the plurality of facilities based on the respective electricity contribution of each facility.
[0014] Embodiments include the above and further comprise determining compensation for each of the first plurality of facilities based on the respective electricity contribution of each facility.
[0015] Embodiments include the above and wherein the encrypted data is encrypted using a public key cryptographic system.
[0016] Embodiments include the above and wherein the public key cryptographic system is selected from a group comprising: public key distribution system, digital signature system and public key cryptosystem.
[0017] Embodiments include the above and wherein the public key cryptographic system uses a RSA algorithm.
[0018] Embodiments include the above and wherein the first plurality of facilities is further operable to consume electricity, and further wherein the encrypted data comprises information concerning electricity consumption from a power grid by the first plurality of facilities.
[0019] Embodiments include the above and further comprising accounting for electricity consumption by each of the first plurality of facilities using the decrypted data.
[0020] Embodiments include the above and further comprising: (a) receiving data from a second plurality of facilities, wherein the second plurality of facilities is operable to consume electricity, and wherein the data comprises information concerning electricity consumption from the power grid by the second plurality of facilities; and (b) accounting for respective electricity consumption for each of the second plurality of facilities using received data.
[0021] Embodiments include the above and further comprising determining a compensation amount for a grid provider for a portion of electricity consumed by the first plurality of facilities and the second plurality of facilities, wherein the portion of electricity is contributed by the grid provider, and wherein determinations for a compensation amount to the grid provider are based on information concerning electricity consumption received from the first plurality of facilities and the second plurality of facilities.
[0022] Embodiments include the above and wherein the first plurality of facilities and the second plurality of facilities form a virtual power generation network.
[0023] Embodiments include the above and further comprising selling surplus electricity produced by the first plurality of facilities to consumers within the virtual power generation network.
[0024] Embodiments include the above and wherein the encrypted data comprises data packets, wherein the data packets comprise: (a) power contribution measured as an integral of power over time; (b) a timestamp comprising the time of day at which the power contribution is recorded; and (c) a period of time over which the power contribution is measured.
[0025] Embodiments include the above and wherein the encrypted data is received from the first plurality of facilities by querying a monitoring station located at each of the first plurality of facilities.
[0026] In one embodiment, an apparatus for measuring power is presented. The apparatus comprises a meter coupled to a power generation plant at a local facility, wherein the meter comprises: (a) a current sense module operatively coupled to a processor, wherein the processor in conjunction with the current sense module is operable to compute power contributed by the power generation plant; (b) a memory operable to store computed power contribution, and a first set of encryption keys used to communicate securely with a grid provider; and (c) a network interface operable to communicate with the grid provider, wherein a communication between the meter and the grid provider is secured using the first set of encryption keys, and wherein the communication comprises relaying the computed power contributions to the grid provider.
[0027] In another embodiment, a system of accounting for electrical power contributions is presented. The system comprises an accounting server communicatively coupled to a plurality of facilities, wherein the plurality of facilities is operable to generate electricity. The accounting server comprises a memory operable to store accounting information concerning electrical contributions from the plurality of facilities and a tracking application. The server also comprises a network interface for communicating with the plurality of facilities and a processor coupled to the memory and the network interface. The processor is configured to operate in accordance with the tracking application to (a) receive encrypted data from the plurality of facilities, wherein the encrypted data comprises information concerning electricity contributions to a power grid by the plurality of facilities; (b) decrypt the encrypted data to access the information concerning electricity contributions; and (c) track electricity contributions from each of the first plurality of facilities using decrypted data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Embodiments of the present invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements.
[0029] FIG. 1 illustrates a historical power generation and distribution system.
[0030] FIG. 2 illustrates a conventional power generation and distribution system as it exists presently.
[0031] FIG. 3 illustrates an electricity generation and distribution system in accordance with one embodiment of the present invention.
[0032] FIG. 4 is an exemplary computing system for a facility power generation meter (“FPGM”) in accordance with embodiments of the present invention.
[0033] FIG. 5 is a block diagram of an example of a network architecture in which client FPGMs and servers may be coupled to a network, according to embodiments of the present invention.
[0034] FIG. 6 is a block diagram illustrating a more detailed view of a virtual electricity distribution system at the source of the power supply in accordance with embodiments of the present invention.
[0035] FIG. 7 is a high level block diagram illustrating the components of a virtual electricity generation and distribution system in accordance with one embodiment of the present invention.
[0036] FIG. 8 depicts a flowchart 800 of an exemplary process of securely accounting for electricity contribution according to an embodiment of the present invention.
[0037] FIG. 9 depicts a flowchart 900 of an exemplary process of sensing electricity contributions and securely transmitting packets reporting electricity contribution to an accounting server according to an embodiment of the present invention.
[0038] FIG. 10 is a block diagram illustrating the flow of data at an accounting server according to one embodiment of the present invention.
[0039] FIG. 11 is a block diagram illustrating the flow of data at a FPGM in accordance with one embodiment of the present invention.
[0040] In the figures, elements having the same designation have the same or similar function.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Reference will now be made in detail to the various embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. While described in conjunction with these embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments. On the contrary, the disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure as defined by the appended claims. Furthermore, in the following detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be understood that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present disclosure.
[0042] Some portions of the detailed descriptions that follow are presented in terms of procedures, logic blocks, processing, and other symbolic representations of operations on data bits within a computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. In the present application, a procedure, logic block, process, or the like, is conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those utilizing physical manipulations of physical quantities. Usually, although not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as transactions, bits, values, elements, symbols, characters, samples, pixels, or the like.
[0043] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present disclosure, discussions utilizing terms such as “determining,” “accounting,” “receiving,” “tracking,” “encrypting,” “decrypting,” “allocating,” “associating,” “accessing,” “determining,” “identifying,” or the like, refer to actions and processes (e.g., flowchart 800 of FIG. 8 ) of a computer system or similar electronic computing device or processor (e.g., system 110 of FIG. 4 ). The computer system or similar electronic computing device manipulates and transforms data represented as physical (electronic) quantities within the computer system memories, registers or other such information storage, transmission or display devices.
[0044] Embodiments described herein may be discussed in the general context of computer-executable instructions residing on some form of computer-readable storage medium, such as program modules, executed by one or more computers or other devices. By way of example, and not limitation, computer-readable storage media may comprise non-transitory computer-readable storage media and communication media; non-transitory computer-readable media include all computer-readable media except for a transitory, propagating signal. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. The functionality of the program modules may be combined or distributed as desired in various embodiments.
[0045] Computer storage media includes 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, random access memory (RAM), read only memory (ROM), electrically erasable programmable ROM (EEPROM), flash memory or other memory technology, compact disk ROM (CD-ROM), digital versatile disks (DVDs) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can accessed to retrieve that information.
[0046] Communication media can embody computer-executable instructions, data structures, and program modules, and includes any information delivery media. 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, radio frequency (RF), infrared, and other wireless media. Combinations of any of the above can also be included within the scope of computer-readable media.
[0047] Method and Apparatus to Form a Virtual Power Generation Collective from a Distributed Network of Local Generation
[0048] Embodiments of the present invention relate generally to collecting measurements of power contribution and more specifically to a method and system of determining power generation capability in a distributed network of local generation facilities. Accordingly, embodiments of the present invention provide a system wherein the electrical contribution of any generation facility can be accounted for fairly and securely. Also embodiments of the present invention provide a robust method of accounting for electricity contribution at the source of the power supply into the grid. With the fair and secure accounting of electricity contributions of the present invention, an open market can be realized wherein any producer of electricity can be fairly rewarded according to the size and efficiency of their contribution.
[0049] FIG. 3 illustrates an electricity generation and distribution system in accordance with one embodiment of the present invention. Power is generated by a power generator 350 and distributed to the consumers through an electricity distributor 355 similar to conventional systems discussed above. However, for certain consumers 370 that have a means for generating electricity at their own facility, one embodiment of the present invention provides a virtual electricity and distribution hub 390 that aggregates and keeps track of the various power contributions from the home electricity producers 370 .
[0050] Another embodiment of the present invention allows power generated by each local facility 370 to be recorded and robustly acknowledged so that each producer at the local facility 370 can verify that their contribution is recognized and further verify that they are being fairly compensated for their contribution.
[0051] One embodiment of the present invention allows for verification that the power generated by one or more local facilities 370 represents an actual contribution to the grid. This is important because it allows the local facilities 370 to recognize, verify and accept that the contribution made by other contributing facilities into the grid is not being falsified.
[0052] Another embodiment of the present invention keeps track of and accounts for the time at which the power contribution is made, thereby, providing support for flexible compensation for power generation. The compensation can be adjusted to more fairly compensate electricity provided from local generation facilities and from providers that generate electricity on demand or at times when wind, sun and other natural sources of electricity are less abundant. For example, entities that generate power at night, when solar panels at the local facilities are not running as efficiently, can be compensated at a higher rate to compensate their higher cost of power generation.
[0053] In one embodiment, once the contribution of one or more facilities to the grid can be robustly and accurately recognized, the facilities can form a conglomerate or a virtual power generation organization for the purpose of keeping track of and accounting for the contributions of conglomerate members and creating a single virtual organization. Such a virtual organization would have the advantage of presenting a single face to promote and charge consumers, and to facilitate the distribution of funds to producers according to contribution. For example, virtual electricity generation and distribution hub 390 in FIG. 3 can, in one embodiment, be a virtual power generation organization comprising a plurality of local power generation facilities that keeps track of the contributions from its various members and apportions funds accordingly. In one embodiment, the virtual power generation organization could be set up to allow any participating facility within the organization to purchase electricity directly from another participating facility. For example, a facility could end up purchasing electricity directly from a neighboring facility under this arrangement.
[0054] Individual home electricity contributors can benefit from joining other home contributors in the formation of a virtual power generation collective. One advantage in forming a virtual power collective is that it would simplify the accounting and billing process. The virtual power generation organization may take a percentage of the total amount collected to cover their costs and overhead. Further, the compensation paid out by the virtual power collective may be applied more fairly by the contributors within the conglomerate towards the future development of new facilities or larger facilities for electricity production.
[0055] Further, compensating the individual contributors fairly would likely encourage continued investment in larger home generation facilities. Another advantage of the present invention is that by making installation of larger home generation facilities more economically attractive, demand for more generation capability and, in particular, more efficient generation capability is driven up. Accordingly, facilitating virtual power generation capability can create a new power generation economy by providing an organically created economic stimulus for purchasing of local electricity generation capabilities, for example, home solar panels. It can also drive an increased investment in technologies to improve the efficiency of small scale power generation capabilities, e.g. home fuel cells.
[0056] Additionally, the ability to recognize and distinguish the contributions from the various facilities, or conglomerate of facilities, into the grid can provide consumers the ability, in one embodiment, to choose to compensate whichever entity they prefer to pay for their supply of electricity. For example, a consumer may choose to pay a local virtual power generation organization formed from the combined contributions of multiple local home power generation facilities within the consumer's community.
[0057] One objective of the present invention is to connect suppliers and consumers via a virtual electric grid formed from networked micro-generation capable facilities. Connecting the suppliers and consumers allows small scale producers of solar, wind and geothermal energy to collaborate together to collect compensation or funding for facility maintenance and improvement. As an increasing number of local electricity generating facilities such as solar panels are being installed on a smaller scale, for example, in residential homes and corporate facilities, the ability of these facilities to contribute power back into the grid as well as support local demand for further installations continues to grow.
[0058] As the number of distributed local generation facilities grows, the opportunity arises for these facilities to collect and pool their contributions by forming a Virtual Power Generation Network (“VPGN”). A VPGN can be a collection of power generation facilities, which operate collectively to form a distributed power generation capability. When a VPGN is available on a grid as a power provider, other electricity consumers have an option to then purchase electricity from the VPGN. Since the VPGN is established via a robust data collection through accounting for each facility's contribution to the VPGN, it is then possible to account for the contribution of each local generation facility and to distribute funding according to amount of contribution and the time stamp on when the contribution was made. In essence, the power distribution and accounting system of the present invention allows all the contributions from the various facilities to be accounted for in a “cloud”, whereby individual consumers can buy electricity for their personal use directly from the cloud.
[0059] In one embodiment, a facility power generation meter (“FPGM”) is located at each facility, which counts the power either drawn from or supplied to the grid from the facility generation plant (“FGP”). The FGP is the power generation capability local to a particular facility, e.g., solar panels at the facility. Each FPGM is connected to a grid provider (“GP”), which is the owner of the neighborhood electrical connection to the facility.
[0060] FIG. 4 illustrates an exemplary computing system 110 for a facility power generation meter (“FPGM”) in accordance with embodiments of the present invention. Computing system 110 broadly represents any single or multi-processor computing device or system capable of executing computer-readable instructions. In its most basic configuration, computing system 110 may include at least one processor 114 and a system memory 116 .
[0061] Processor 114 generally represents any type or form of processing unit capable of processing data or interpreting and executing instructions. In certain embodiments, processor 114 may receive instructions from a software application or module. These instructions may cause processor 114 to perform the functions of one or more of the example embodiments described and/or illustrated herein.
[0062] System memory 116 generally represents any type or form of volatile or non-volatile storage device or medium capable of storing data and/or other computer-readable instructions. Examples of system memory 116 include, without limitation, RAM, ROM, flash memory, or any other suitable memory device. Although not required, in certain embodiments computing system 110 may include both a volatile memory unit (such as, for example, system memory 116 ) and a non-volatile storage device (such as, for example, primary storage device 132 ).
[0063] Computing system 110 may also include one or more components or elements in addition to processor 114 and system memory 116 . For example, in the embodiment of FIG. 4 , computing system 110 includes a memory controller 118 , an input/output (I/O) controller 120 , and a communication interface 122 , each of which may be interconnected via a communication infrastructure 112 . Communication infrastructure 112 generally represents any type or form of infrastructure capable of facilitating communication between one or more components of a computing device. Examples of communication infrastructure 112 include, without limitation, a communication bus (such as an Industry Standard Architecture (ISA), Peripheral Component Interconnect (PCI), PCI Express (PCIe), or similar bus) and a network.
[0064] Memory controller 118 generally represents any type or form of device capable of handling memory or data or controlling communication between one or more components of computing system 110 . For example, memory controller 118 may control communication between processor 114 , system memory 116 , and I/O controller 120 via communication infrastructure 112 .
[0065] I/O controller 120 generally represents any type or form of module capable of coordinating and/or controlling the input and output functions of a computing device. For example, I/O controller 120 may control or facilitate transfer of data between one or more elements of computing system 110 , such as processor 114 , system memory 116 , communication interface 122 , display adapter 126 , input interface 130 , and storage interface 134 .
[0066] Communication interface 122 broadly represents any type or form of communication device or adapter capable of facilitating communication between example computing system 110 and one or more additional devices. For example, communication interface 122 may facilitate communication between computing system 110 and a private or public network including additional computing systems. Or, for example, communication interface 122 may facilitate communication between the FPGM and the grid provider. Examples of communication interface 122 include, without limitation, a wired network interface (such as a network interface card), a wireless network interface (such as a wireless network interface card), a modem, and any other suitable interface. In one embodiment, communication interface 122 provides a direct connection to a remote server via a direct link to a network, such as the Internet. Communication interface 122 may also indirectly provide such a connection through any other suitable connection.
[0067] Communication interface 122 may also represent a host adapter configured to facilitate communication between computing system 110 and one or more additional network or storage devices via an external bus or communications channel. Examples of host adapters include, without limitation, Small Computer System Interface (SCSI) host adapters, Universal Serial Bus (USB) host adapters, IEEE (Institute of Electrical and Electronics Engineers) 1394 host adapters, Serial Advanced Technology Attachment (SATA) and External SATA (eSATA) host adapters, Advanced Technology Attachment (ATA) and Parallel ATA (PATA) host adapters, Fibre Channel interface adapters, Ethernet adapters, or the like. Communication interface 122 may also allow computing system 110 to engage in distributed or remote computing. For example, communication interface 122 may receive instructions from a remote device, for example, at the grid provider's end, or send instructions to a remote device for execution.
[0068] In one embodiment, the communication interface 122 on the FPGM can connect to the network through one of various protocols, e.g., wirelessly through a Wi-Fi connection, or through a wired Ethernet connection or even by communicating using Ethernet over power cables.
[0069] As illustrated in FIG. 4 , computing system 110 may also include at least one display device 124 coupled to communication infrastructure 112 via a display adapter 126 . Display device 124 generally represents any type or form of device capable of visually displaying information forwarded by display adapter 126 . Similarly, display adapter 126 generally represents any type or form of device configured to forward graphics, text, and other data for display on display device 124 .
[0070] As illustrated in FIG. 4 , computing system 110 may also include at least one input device 128 coupled to communication infrastructure 112 via an input interface 130 . Input device 128 generally represents any type or form of input device capable of providing input, either computer- or human-generated, to computing system 110 . Examples of input device 128 include, without limitation, a keyboard, a pointing device, a speech recognition device, or any other input device.
[0071] As illustrated in FIG. 4 , computing system 110 may also include a primary storage device 132 and a backup storage device 133 coupled to communication infrastructure 112 via a storage interface 134 . Storage devices 132 and 133 generally represent any type or form of storage device or medium capable of storing data and/or other computer-readable instructions. For example, storage devices 132 and 133 may be a magnetic disk drive (e.g., a so-called hard drive), a floppy disk drive, a magnetic tape drive, an optical disk drive, a flash drive, or the like. Storage interface 134 generally represents any type or form of interface or device for transferring data between storage devices 132 and 133 and other components of computing system 110 .
[0072] In one embodiment, the FPGM can also include storage 148 to store encryption keys used to communicate with the grid provider or VPGNs. Storage 148 can be separate from or part of the primary storage device 132 . Also, in one embodiment, all the storage employed in system 110 would either be secure or use code signing techniques to ensure secure storage and execution of programs and software on the FPGM.
[0073] In one example, databases 140 may be stored in primary storage device 132 . Databases 140 may represent portions of a single database or computing device or it may represent multiple databases or computing devices. For example, databases 140 may represent (be stored on) a portion of computing system 110 and/or portions of example network architecture 200 in FIG. 2 (below). Alternatively, databases 140 may represent (be stored on) one or more physically separate devices capable of being accessed by a computing device, such as computing system 110 and/or portions of network architecture 200 .
[0074] Continuing with reference to FIG. 4 , storage devices 132 and 133 may be configured to read from and/or write to a removable storage unit configured to store computer software, data, or other computer-readable information. Examples of suitable removable storage units include, without limitation, a floppy disk, a magnetic tape, an optical disk, a flash memory device, or the like. Storage devices 132 and 133 may also include other similar structures or devices for allowing computer software, data, or other computer-readable instructions to be loaded into computing system 110 . For example, storage devices 132 and 133 may be configured to read and write software, data, or other computer-readable information. Storage devices 132 and 133 may also be a part of computing system 110 or may be separate devices accessed through other interface systems.
[0075] In one embodiment, the processor 114 is capable of processing data from power detection (or current sense) circuit 146 that is received subsequent to being processed through an analog to digital converter 144 . The processor 114 , in one embodiment, can also be programmed to compute a history of power production and consumption.
[0076] Many other devices or subsystems may be connected to computing system 110 . Conversely, all of the components and devices illustrated in FIG. 4 need not be present to practice the embodiments described herein. The devices and subsystems referenced above may also be interconnected in different ways from that shown in FIG. 4 . Computing system 110 may also employ any number of software, firmware, and/or hardware configurations. For example, the example embodiments disclosed herein may be encoded as a computer program (also referred to as computer software, software applications, computer-readable instructions, or computer control logic) on a computer-readable medium.
[0077] The computer-readable medium containing the computer program may be loaded into computing system 110 . All or a portion of the computer program stored on the computer-readable medium may then be stored in system memory 116 and/or various portions of storage devices 132 and 133 . When executed by processor 114 , a computer program loaded into computing system 110 may cause processor 114 to perform and/or be a means for performing the functions of the example embodiments described and/or illustrated herein. Additionally or alternatively, the example embodiments described and/or illustrated herein may be implemented in firmware and/or hardware.
[0078] FIG. 5 is a block diagram of an example of a network architecture in which client FPGMs 210 , 220 , and 230 and servers 240 and 245 may be coupled to a network 250 , according to embodiments of the present invention. Servers 240 and 245 may, in one embodiment, belong to the VPGN, where they, among other things, keep track of the contributions made by the FGPs and communicated to the VPGN servers using the client FPGMs 210 , 220 and 230 . Servers 240 and 245 may also, in another embodiment, belong to the grid provider's network and be used to collect information about the contributions from the various FGPs. In a different embodiment, server 240 may belong to the VPGN while server 245 may belong to the grid provider's network. Client systems 210 , 220 , and 230 generally represent any type or form of computing device or system used on a FPGM, such as computing system 110 of FIG. 4 .
[0079] Similarly, servers 240 and 245 generally represent computing devices or systems, such as application servers or database servers, configured to provide various database services and/or run certain software applications. Network 250 generally represents any telecommunication or computer network including, for example, an intranet, a wide area network (WAN), a local area network (LAN), a personal area network (PAN), or the Internet.
[0080] With reference to computing system 110 of FIG. 4 , a communication interface, such as communication interface 122 , may be used to provide connectivity between each client system 210 , 220 , and 230 and network 250 . Client systems 210 , 220 , and 230 may be able to access information on server 240 or 245 using special purpose client software used to communicate with the FPGMs. Such software may allow client systems 210 , 220 , and 230 to access data hosted by server 240 , server 245 , storage devices 260 ( 1 )-(L), storage devices 270 ( 1 )-(N), storage devices 290 ( 1 )-(M), or intelligent storage array 295 . Although FIG. 5 depicts the use of a network (such as the Internet) for exchanging data, the embodiments described herein are not limited to the Internet or any particular network-based environment.
[0081] In one embodiment, all or a portion of one or more of the example embodiments disclosed herein are encoded as a computer program and loaded onto and executed by server 240 , server 245 , storage devices 260 ( 1 )-(L), storage devices 270 ( 1 )-(N), storage devices 290 ( 1 )-(M), intelligent storage array 295 , or any combination thereof. All or a portion of one or more of the example embodiments disclosed herein may also be encoded as a computer program, stored in server 240 , run by server 245 , and distributed to client systems 210 , 220 , and 230 over network 250 .
[0082] FIG. 6 is a block diagram illustrating a more detailed view of a virtual electricity distribution system at the source of the power supply in accordance with embodiments of the present invention. A local facility 630 that is part of the VPGN may have a local facility generation plant (“FGP”) as discussed above. For example, the FGP may comprise solar panels 650 as shown in FIG. 6 . Where solar panels are being used to generate power, a solar inverter 640 may be part of the installation at the local facility. Inverter 640 converts the variable direct current (DC) output of a photovoltaic solar panel into a utility frequency alternating current that can be fed into a commercial electrical grid or used by the local off-grid electrical network. The FPGM 620 that is at the source of the power supply may be used to keep track of the electricity contribution and consumption of the respective facility 630 to which it is connected.
[0083] In one embodiment, each FPGM 620 at each facility needs to have a secure means of communicating over the network, e.g., to a grid provider 660 or the VPGN 610 . This can be done by ensuring that all data transmitted to and from a FPGM is encrypted. Encrypting the data ensures that there is integrity to the system and that each facility's contribution can be accounted for accurately. In one embodiment, public key cryptography using asymmetric key algorithms such as RSA can be used to encrypt the data. In another embodiment, any of the three primary kinds of public key cryptography systems can be used, namely, public key distribution systems, digital signatures system, and public key cryptosystems. The three kinds of public key systems can perform both public key distribution and digital signature services. For example, well known algorithms such as Diffie-Hellman key exchange, which is a type of public key distribution system, and Digital Signature Algorithm, which is a type of digital signature system, can be used. However, the invention is not limited to only using public key cryptographic algorithms. Any number of various methods and algorithms may be used to encrypt FPGM data.
[0084] Where public key cryptographic techniques are used, each FPGM at a subscriber's site may comprise a private key and a public key pair. This private and public key pair can be provided by, for example, the grid provider. The FPGM may report its power consumption or contribution to the grid provider server 660 using Energy Contribution Count data packets (“ECC”) over network interface 122 as discussed above.
[0085] The ECC data packets can comprise the power contribution measured as an integral of power over time (watt-hours). It can also include a timestamp, including the time of day in which the contribution was recorded. Also, it can include a number identifying its order in the sequence of ECC packets transmitted. Further, it can include the unit of time over which the energy consumption or production was measured. It may include the amount of power, the direction of power flow, and the duration of flow. In addition, it can also include the integral of contribution over the time interval. It may include one or more historical integrals summing the contribution over longer intervals. It may include facility location or location within the facility, facility identifier, as well as the type of generation. It may include the method of power generation at the facility, such as whether wind, solar, thermal or other generation method. Finally it may include recipient supplied information such as recipient and facility identifiers, recipient supplied cryptographic nonce. By including the integrals of contributions over certain time intervals, the ECCs protect against data being lost due to network outages or other potential transmission errors, because the integrals may used to reconstruct the contribution data.
[0086] In one embodiment where public key cryptography is used, the FPGM 620 can sign the ECC with a private key provided by the grid provider. It also can include a certificate signed by the grid provider (or other recognized signing authority), which includes a matching public key, thereby, allowing the ECC to be decrypted at the receiving end.
[0087] In one embodiment, the FPGM 620 may be programmed to include signatures of the prior ECCs in subsequent ECCs as a way to protect against tampering. Further, forensic data collection techniques can be used to examine the history of ECC packets to verify lost data packets. Also, the FPGMs can be programmed to continue including past ECC signatures in subsequent packets until receipt of transmission from the grid provider acknowledging receipt of the ECC. This mechanism allows the history of contribution and consumption for a particular FPGM to be recreated easily.
[0088] In one embodiment, the FPGM includes a mechanism to perform a handshake with the auditing server, e.g., the grid provider's server 240 or 245 in FIG. 5 . For example, the auditing server can transmit certain verification information to be introduced into the signature in order to verify the data received from the FPGM. The verification information can comprise timestamps, recipient supplied nonce, sequential numbers, or other identification information that can be integrated into the signature by the FPGM to provide robustness for the information being transmitted.
[0089] In another embodiment, the FPGM may utilize one of many different techniques to transmit the energy count to the grid provider's network using the ECCs. For example, the FPGM can transmit data over the grid's wired network to the sub-station. Alternatively, the FPGM may transmit the ECCs over local facility wireless networks, e.g., through WiFi access points at the local facility. Or the FPGM may transmit the energy counts to the grid provider via wireless mesh networks formed from neighboring facilities with similar FPGMs.
[0090] The sub-station collects the ECC packets transmitted by the various FPGMs, verifies the signatures and accumulates the contributions of each FGP. It can also run audit checks. The auditing process can identify tampering or falsified contributions. It can also identify situations where an FGP's ECC data is missing, e.g., due to a local network failure.
[0091] In one embodiment, where data collection is not possible over the network, for example, because of a network outage or because of a facility's remote location, or where the data may need to be collected manually, for example, to detect tampering or falsification, a technician may visit a FGP at the local facility 630 and collect the data manually from a FPGM 620 using a handheld collection device. Holding the device in close proximity to the FPGM, the FPGM may transmit data to the handheld collection device using Infra-Red, Near Field wireless technologies, Bluetooth, Electromagnetic Induction, or other non-contact, and direct electrical interface contact data transmission mechanisms.
[0092] In one embodiment, as the handheld collection device downloads ECC data from the FPGM 620 , the meter and device may confirm each time interval recorded. The FPGM may subsequently insert this download confirmation into subsequent ECC data signatures. The confirmation may comprise a serial number of the handheld collective device, the last timestamp collected and the time intervals collected.
[0093] As discussed above, in one embodiment, the ECC is signed with a timestamp, recording when a unit of power has been supplied into the grid. By including the unit of time over which an energy contribution was made, the ECC allows both power and time to be factored into the running integral, thereby, allowing a long term average to be computed. As acknowledgements of the ECCs are received back from the VPGN, these may be accumulated in the long term average, to allow the facility to observe the net amount of electricity supplied versus net amount accounted for by the VPGN, and thus verify contributions are being recognized.
[0094] Similar to how the FPGM 620 reports information to the grid provider, the FPGM, in one embodiment, may also communicate with the VPGN server 610 via the network interface 122 or through a manual collection process. The FPGM sends the ECC and the signature to the VPGN server 610 . The VPGN server records and performs the accounting for all FGP contributions by examining the ECC and verifying it using the respective signature. If verified, the VPGN can respond to the FPGM with another signature of the ECC using a separate private/public key pair from the one used to securely communicate with the grid provider, in instances where public key cryptographic techniques are being utilized. Upon recognizing that the VPGN has processed an ECC, the FPGM may convey the pertinent information to the local electricity producing consumers. The consumers can use this information to verify that their contribution have been received and accounted. As the VPGN verifies each ECC received, it accumulates and records the contribution of each FGP so that in the subsequent payment cycle, each respective FGP may be appropriately compensated according to its contribution.
[0095] In one embodiment, the VPGN may also receive packets from the FPGMs corresponding to the electricity consumed by the local facilities subscribing to the VPGN power distribution and supply network. However, existing meters operated using conventional methods can also be used to report back the power consumption by the local facilities. The power production and consumption data received from each local facility can be used to compute the amount billed to each local facility consumer in the event that more power is drawn than contributed by the respective local facility consumer, or compute the amount to be compensated to each local facility consumer in the event that more power is contributed by the facility than drawn from the grid.
[0096] FIG. 7 is a high level block diagram illustrating the components for a virtual electricity generation and distribution system (i.e. a VPGN) in accordance with one embodiment of the present invention. Each VPGN can be a conglomerate of distributed local electricity generation facilities. A VPGN, in one embodiment, may not only be a collection of power generating facilities 720 , but also be available on a grid as a power provider, thereby, allowing electricity consumers 730 to also be part of the VPGN. When a VPGN is available on a grid as a power provider, other electricity consumers have an option to then purchase electricity from the VPGN. The power distribution and accounting system of the present invention allows all the contributions from the various distributed production facilities 720 to be accounted for in a cloud 750 . Also, individual electricity consumers 730 can buy electricity for their personal use directly from the cloud 750 . At the back-end, an accounting server 740 , similar to servers 240 and 245 illustrated and discussed in FIG. 2 , can keep track of the contribution and consumption levels of the various local facilities.
[0097] In one embodiment, producers 720 may be able to query the FPGM at their own local facility to verify their contribution or consumption history, and also query the accounting server 740 at the VPGN to determine whether their contributions are being fairly accounted for. For example, a producer 720 may be equipped with its own handheld collection device to collect data from the FPGM or the producer 720 may have some other manual means of doing a data dump from the FPGM. Alternatively, the FPGM could be connected through network interface 122 to the producer's personal computer allowing the consumer to interface with the FPGM through a Wi-Fi or web interface. One advantage of storing all the consumers' and producers' data in a cloud 750 is the ability for all the various entities that are part of a VPGN to be able to verify their respective contribution and consumption conveniently.
[0098] In one embodiment, the VPGN and the grid provider could also collaborate in order to, among other things, verify that all the contribution and consumption amounts have been accounted for fairly and accurately. If a VPGN and the grid provider are to share a grid, some type of collaboration between the two entities would be envisioned under the scheme proposed by the present invention. For example, a grid provider would need to audit the various compensation amounts to the local facilities so as to ensure that they are paying out accurate and fair amounts for the power contributed to the grid by the facilities and also being compensated for any net power being consumed by the facilities.
[0099] Further, collaboration between a VPGN and the grid provider, e.g., PG&E would facilitate compensation sharing between the various power provisioning entities. For example, in one embodiment, there could be an accounting for the percentage of power contributed by the grid provider to the facilities that constitute a particular VPGN network versus the percentage of power contributed by the facilities within the VPGN. In this way, the grid provider could be fairly compensated for the percentage of power contributed by it, while each of the facilities within the VPGN could be compensated for the amount of power contributed by the respective facility. In one embodiment, instead of splitting compensation on a percentage basis, each of the facilities, including the grid provider, could be compensated per kwh contributed to the grid.
[0100] In one embodiment, the grid provider may continue to charge the consumers directly for the net power consumed by them as determined from the auditing info received from the various FPGMs at the local facilities.
[0101] In another embodiment, the consumers could buy their power directly from the VPGN rather than the grid provider and VPGN could sub-contract with the grid provider to buy power during certain time periods. For example, where the facilities in a VPGN comprise FGPs that generate power predominantly through the use of solar panels, the VPGN could sub-contract with the grid provider to buy power during the night when solar panels are less efficient. The facilities within the VPGN could pay the VPGN for their usage based on the auditing information and the VPGN could compensate the grid provider directly on a lump sum basis. Because the grid provider also receives the ECCs from the various FPGMs, it could use that information to audit the amount paid to it by the VPGN. In a different embodiment, each net electricity consumer could receive two separate bills, one from the grid provider and one from the VPGN for power provided during different times of the day. In this embodiment, the consumer would handle their bill for power consumed from the grid provider and the VPGN separately.
[0102] In another embodiment, the entities that sell the consumers the FGPs, e.g., solar panels, could effectively become the consumer's power supply company. In this embodiment, instead of charging the consumer for the solar panel, the solar panel manufacturer would, in effect, be leasing the consumer's roof space and get compensated for generating power and contributing it to the grid. Meanwhile, the consumers could pay the solar panel manufacturer directly for any power it consumes.
[0103] FIG. 8 depicts a flowchart 800 of an exemplary process of securely accounting for electricity contribution from local production facilities according to an embodiment of the present invention. The invention, however, is not limited to the description provided by flowchart 800 . Rather, it will be apparent to persons skilled in the relevant art(s) from the teachings provided herein that other functional flows are within the scope and spirit of the present invention. Flowchart 800 will be described with continued reference to exemplary embodiments described above, though the method is not limited to those embodiments.
[0104] At step 802 , the VPGN accounting server 740 receives information including cryptographic data from the FPGMs at the various local electricity producer facilities 720 . As discussed above, the data, in one embodiment, can be transmitted in the form of ECC packets 710 and can be encrypted or signed using public key certificate techniques. In one embodiment, the data can be received by an accounting server controlled by the grid provider. In another embodiment, the server can also receive data from the electricity consuming facilities 730 , in addition to the electricity producer facilities 720 , regarding electricity consumed by the respective facilities.
[0105] At step 804 , the data 710 is verified or decrypted to access information regarding electricity produced and consumed by the facilities. In one embodiment, the encrypted data only comprises information regarding electricity produced, while information regarding electricity consumed is conveyed by conventional means, e.g., using a regular meter.
[0106] At step 806 , the data is used to track electricity contributions made by each of the local electricity producer facilities 720 . In one embodiment, the data is also used to track electricity consumption by all the various facilities 720 and 730 . In one embodiment, either the grid provider or the VPGN accounting server receiving the encrypted data could be running a tracking application that is operable to verify or decrypt the received data and keep track of the electricity contribution and consumption amounts for the various connected facilities.
[0107] At step 808 , the various electricity producer facilities 720 are compensated for the surplus electricity each of them has contributed back to the grid. The servers at either the grid provider's or the VPGN's facilities are programmed to accurately, securely and robustly keep track of the contributions from the various facilities so that the integrity of the system can be relied upon.
[0108] In the embodiment where the VPGN keeps track of the various contributions, at step 810 , the grid provider can be compensated for the portion of electricity contributed by the grid provider to facilities 720 and 730 . For example, the grid provider may need to contribute electricity at overcast days when the solar panels installed at the producer facilities 720 are not as efficient. Therefore, while electricity provided by the producer facilities 720 may be prioritized within the VPGN network, the VPGN may still need to draw power from the grid provider on certain occasions and compensate the grid provider accordingly.
[0109] FIG. 9 depicts a flowchart 900 of an exemplary process of sensing electricity contributions and securely transmitting packets reporting electricity contribution to an accounting server according to an embodiment of the present invention. The invention, however, is not limited to the description provided by flowchart 900 . Rather, it will be apparent to persons skilled in the relevant art(s) from the teachings provided herein that other functional flows are within the scope and spirit of the present invention. Flowchart 900 will be described with continued reference to exemplary embodiments described above, though the method is not limited to those embodiments.
[0110] At step 902 , a FPGM or “monitoring station” 620 installed at a facility 630 senses the outgoing current passing through the meter using current sense circuit 146 and computes the power that is contributed by the local FGP 650 .
[0111] At step 904 , the FPGM may store the computed power contributions in system memory 116 or a primary storage device 132 .
[0112] At step 906 , the FPGM packetizes the computed power contribution data into ECC data packets. The ECC data packets, as discussed above, comprise power contribution measured as an integral of power over time (watt-hours). They may also include a time-stamp and a unit of time over which the energy contribution was measured.
[0113] At step 908 , the ECC data is encrypted using the encryption keys stored in the key storage module 148 .
[0114] Finally, at step 910 , the ECC data packets can be transmitted to remote accounting server 740 .
[0115] FIG. 10 is a block diagram illustrating the flow of data at an accounting server according to one embodiment of the present invention. The encrypted data packets are received by a data receiver 1010 at accounting server 740 . The packets are decrypted by the receiver and forwarded to contribution engine 1020 for determining the contribution amounts from the decrypted data.
[0116] Contribution engine 1020 is operable to recognize contributions from the various monitoring stations at the connected power generating facilities 720 and keep track of the contribution from each of the facilities. For example, in FIG. 10 , contribution engine 1020 keeps track of the contribution 1050 from Facility 1 separately from contribution 1060 from Facility N.
[0117] The respective contribution information is then passed to a compensation engine 1070 . The compensation engine 1070 is responsible for converting the contribution amounts from each of the respective facilities to compensation amounts. For example, compensation engine 1070 will determine a separate compensation amount 1090 for Facility 1 based on the contribution amount 1050 for Facility 1. Further, it will determine a separate compensation amount 1080 for Facility N based on the contribution amount 1060 for Facility N.
[0118] FIG. 11 is a block diagram illustrating the flow of data at a FPGM in accordance with one embodiment of the present invention. As discussed in relation to FIG. 9 , current sense module 146 determines the amount of outgoing electricity at a FPGM 620 . The data collected by current sense module 146 is used by the power contribution computation engine 1102 to determine the amount of power contributed back into the grid from FGP 650 . The data packetizer 1104 transforms the power contribution data from power contribution computation engine 1102 into ECC packets 710 . Data packetizer 1104 also receives timing information, wherein the timing information is used to time-stamp the ECC data packets.
[0119] The ECC data packets 710 are encrypted using data encryption engine 1106 . Data encryption engine 1106 may receive encryption, certificates and signing keys from keys storage module 148 . The encrypted or signed data is subsequently transmitted to an accounting server using data transmitter module 1108 .
[0120] While the foregoing disclosure sets forth various embodiments using specific block diagrams, flowcharts, and examples, each block diagram component, flowchart step, operation, and/or component described and/or illustrated herein may be implemented, individually and/or collectively, using a wide range of hardware, software, or firmware (or any combination thereof) configurations. In addition, any disclosure of components contained within other components should be considered as examples because many other architectures can be implemented to achieve the same functionality.
[0121] The process parameters and sequence of steps described and/or illustrated herein are given by way of example only. For example, while the steps illustrated and/or described herein may be shown or discussed in a particular order, these steps do not necessarily need to be performed in the order illustrated or discussed. The various example methods described and/or illustrated herein may also omit one or more of the steps described or illustrated herein or include additional steps in addition to those disclosed.
[0122] While various embodiments have been described and/or illustrated herein in the context of fully functional computing systems, one or more of these example embodiments may be distributed as a program product in a variety of forms, regardless of the particular type of computer-readable media used to actually carry out the distribution. The embodiments disclosed herein may also be implemented using software modules that perform certain tasks. These software modules may include script, batch, or other executable files that may be stored on a computer-readable storage medium or in a computing system. These software modules may configure a computing system to perform one or more of the example embodiments disclosed herein. One or more of the software modules disclosed herein may be implemented in a cloud computing environment. Cloud computing environments may provide various services and applications via the Internet. These cloud-based services (e.g., software as a service, platform as a service, infrastructure as a service, etc.) may be accessible through a Web browser or other remote interface. Various functions described herein may be provided through a remote desktop environment or any other cloud-based computing environment.
[0123] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as may be suited to the particular use contemplated.
[0124] Embodiments according to the invention are thus described. While the present disclosure has been described in particular embodiments, it should be appreciated that the invention should not be construed as limited by such embodiments, but rather construed according to the below claims.
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A method of accounting for electrical power contribution and consumption is presented. The method comprises receiving information, from a plurality of facilities, wherein the plurality of facilities is operable to generate and/or consume electricity, and wherein the data comprises information concerning electricity contributions to a power grid, and/or consumptions from the grid by the plurality of facilities. The method further comprises applying a robust system of cryptographic processes to said information concerning electricity contributions, and attest to the authenticity of the information, as well as to the correct attribution of the facility claimed. Finally, the method comprises tracking and accounting electricity contributions and/or consumptions from each of the plurality of facilities using decrypted and verified information in a manner that allows contributions to be independently verified through audits. The method can also comprise compensating each of the facilities based on the respective electricity contribution and/or consumption of each facility.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
A portable vibratory machine for compacting and leveling a layer of fluid floor covering as it is moved thereover.
2. Description of the Prior Art
Numerous machines have been proposed and used in the past to smooth or finish the surface of a freshly poured floor covering such as concrete or the like, as well as to compact the material. Such equipment has often been very heavy and cumbersome and not adapted for use on areas such as sidewalks and hallways. Additionally, it was often necessary to make many passes over the surface with the machine in order to derive a smooth surface while completely eliminating any air pockets within the floor covering. The present invention overcomes these advantages by providing a portable, manually operable compacting machine to concurrently vibrate the material and smooth the surface in a shorter period of time.
SUMMARY OF THE INVENTION
A vibratory compacting machine for compacting and leveling a poured floor covering such as terrazzo or the like is provided and includes a generally horizontal frame having two depending longitudinal flanges on the opposite sides thereof. A plurality of transversely aligned rollers are rotatably mounted by the flanges for contacting the floor covering and supporting the weight of the machine. A foldable reversible handle is provided so that the machine may be moved easily in opposite directions. A single vibratory motor is secured to the frame and transmits vibratory compacting forces to the rollers. A plurality of transverse strengthening channels are secured to the underside of the frame to evenly distribute the vibratory forces to the rollers. The rollers may be mounted in a single plane or in a curved, generally downwardly convex relationship.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a vibratory compacting machine embodying the concepts of the present invention;
FIG. 2 is a side elevational view of the machine of FIG. 1, showing multiple positions of the handle;
FIG. 3 is a side elevational view, similar to FIG. 2, showing the handle folded for storage; and
FIGS. 4A and 4B are schematic views of alternate roller mounting relationships.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A vibratory compacting machine, generally designated 10 (FIGS. 1 and 2), embodying the concepts of the present invention includes a generally flat, rectangular frame plate 14 fabricated of steel or other suitable material. A pair of depending, longitudinal flanges (FIGS. 2 and 3) are provided on opposite sides of the frame plate 14 for mounting a plurality of rollers 18. The rollers 18 each are independently rotatably mounted by appropriate bores 20 in the flanges 18. Preferably, the rollers 18 are of a conventional type having internal sealed bearings mounting the cylindrical roller portion on an axle. A spring biased end (not shown) on each of the axles permits easy insertion and removal of the rollers 18 from the machine for cleaning or replacement. The rollers 18 may be aligned by the respective bores 20 in a single plane as shown in FIG. 3. Alternatively, the rollers 18 may be arranged in a generally arcuate downwardly convex path as shown in FIG. 4A. The distance D between the centerline of the endmost roller and central lowermost roller can range approximately from 1/64 to 1/4 of an inch when the rollers are, for instance, 2-1/2 inches in diameter. A third variation in the arrangement of the rollers is shown in FIG. 4B. In this arrangement, the end and centermost roller centerlines lie in the same plane while the remaining rollers lie on a pair of downwardly convex curves. Again, the distance D between the end rollers and the lowermost roller can range from approximately 1/64 to 1/4 of an inch. Of course, these dimensions would vary greatly depending upon the size of the rollers and the machine.
The vibratory compacting machine 10 is designed to be a portable device and therefore a pair of appropriate U-shaped carrying handles 30 are provided on opposite sides of the frame plate to facilitate carrying of the machine.
A plurality of transverse U-shaped strengthening ribs 32 (FIG. 2) are securely fastened, for example by welding, to the underside of the frame plate 14 to add rigidity to the plate, as will be described in detail hereinafter. Each of the support ribs 32 comprises a channel having a pair of downwardly directed wall portions 34.
Vibratory means is provided in the form of a conventional vibratory motor 38 mounted to the top of the frame plate 14 by a plurality of bolts 40, or the like. The vibratory motor is of the eccentric weight or electromagnetic type for imparting reciprocal vibratory forces to the entire unit. The strengthening ribs 32 described above serve to facilitate distributing the vibratory forces over the plurality of rollers 18 for distribution of compacting forces to the layer of floor coverng and to additionally aid in leveling or smoothing of its surface. FIGS. 4A and 4B show specific configurations which concentrate energy at the lowermost points of the respective curves.
The machine 10 is designed for one man operation in opposite directions and a reversible handle, generally designated 44, is pivotally connected to the frame plate 14 so that it can be pivoted from one side to the other to facilitate reversing the direction of travel. The handle 44 is generally T-shaped and include a pair of elongated generally square cross sectional arms 46. The arms are pivotally connected by a pin 47 between a pair of upstanding flanges 48 provided on the top of the frame plate 14. Each pin 47 includes a pull ring 50 and detent means in the form of a spring biased ball (not shown) to facilitate removal of the pins from the flanges 48 to disconnect the handle 44. Additionally, the elongated arms 46 have hinges 52 at approximately their midpoints to permit folding or collapsing of the arms onto one another for storage on top of the frame plate 14 as shown in FIG. 3. A clamp 53 maintains the arms in their open position. When the handle 44 is folded and placed on the base plate 14, the pins 47 can be reinserted through holes 55 midway along the length of the lower arms 46. A pair of connector braces 54 are secured between the respective portions of the elongated arms and serve to add rigidity and strength to the handle 44.
A top cross bar, generally designated 58, is secured at the upper, free end of the handle 44 for manual grasping by the user. The cross bar 58 includes an inner threaded shaft 60 which is enclosed by a rotatable metal sleeve 62. An outer three part rubber sleeve 64A-64C is wrapped about the metal sleeve 62 and facilitates absorbing some of the vibrations from the motor 38.
A support leg structure, generally designated 68, is pivotally mounted by a shaft 70 between the elongated arms 46 to support the handle 44 at the desired angle for the user, as shown in FIG. 2. The leg structure 68 includes a pair of cross braces 72 which are connected to the shaft 70 by a pair of vertical end feet 74. A suitable resilient or rubberized base 76 is provided on the bottom of each of the feet 74 to further reduce the amount of vibrations transmitted through the handle to the operator.
A "flag pole", generally designated 80 is provided to support the electrical supply cord well above the surface of the machine 10 and to prevent the cord from dragging on the floor. The flag pole 80 includes a vertical, fragmented pipe 82 which extends approximately eight feet above the top of the frame plate 14 and a ring 84 on the top thereof through which the electrical cord is passed and suspended. The sectional pipe 82 is preferably manufactured of four lengths, each being approximately two feet long so that they can be disassembled and stored on top of the frame plate 14. The vertical pipe 82 is received within a short base pipe 86 of slightly larger internal diameter than the pipe 82 so that it can be easily removed for storage. The base pipe 86 is mounted by a pivotal block 88 which is pivotally mounted and secured to the base plate 14 by a bolt and wing nut 90. When in use, the flag pole 80 is pivoted to a position outside the perimeter of the base plate 14 (as shown in FIGS. 1 and 2) so that the handle 44 may be pivoted back and forth without interfering with the elongated vertical pipe 82. The flag pole, when collapsing the machine for storage, is pivoted to a position so that the mounting block 88 is generally parallel with the edge of the base plate 14 and again locked by the wing nut 90 as shown in FIG. 3.
When the handle 44 and the flag pole 80 are disassembled or collapsed for storage, both the sections of the flag pole and the two collapsible lengths of the handle 44 will lay on top of the base plate 14 within the confines of the perimeter of the base plate to facilitate storage. Additionally, the weight of the handle and flag pole sections are evenly balanced about a general mid-longitudinal centerline of the base plate so that the machine can be easily carried by the handles 30 when in the collapsed position.
As described, the vibratory compacting machine 10 of the present invention provides a vibratory force which permits the installation of a terrazzo floor covering, concrete, or the like, in a shorter period than is normally required. The machine 10 permits the use of a dryer mix which will, when set, provide a harder, stronger floor and the vibratory forces also serve to float the marble or other aggregates within the terrazzo floor or other system to the top surface to provide a more pleasing and aesthetic finished product. The plurality of rollers 18 also will provide a flatter and smoother surface so that less grinding, or less trowelling when the finished product is trowelled, will be necessary in order to finish the surface. The collapsible nature of the particular handle reduces set up time and also makes a convenient small, portable device which can easily be moved from various construction sights, while requiring a minimum of space.
The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom as some modifications will be obvious to those skilled in the art.
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A portable vibratory compacting machine for compacting and flattening a poured floor covering. The machine includes a generally horizontal frame including a pair of depending flanges on its opposite sides. A plurality of transversely aligned rollers are rotatably mounted by the longitudinal flanges for contacting the floor and supporting the weight of the machine. A reversible handle is provided so that the machine can be pushed or pulled in either direction, and a vibratory motor is secured to the top of the frame for vibrating the rollers. A plurality of transverse strengthening channels are connected to the frame to evenly distribute the vibratory forces across all of the rollers.
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[0001] This patent application is a Divisional of prior, co-pending U.S. patent application Ser. No. 10/393,150, filed Mar. 20, 2003, which U.S. patent application Ser. No. 10/393,150, filed Mar. 20, 2003, was a Divisional of U.S. patent application Ser. No. 09/796,394, filed Mar. 1, 2001, now U.S. Pat. No. 6,572,240—.
[0002] This Application is a Continuation-In-Part of prior copending application U.S. Ser. No. 09/514,089, now U.S. Pat. No. 6,119,697.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] This invention relates to airport runway light support apparatus and methods. In one aspect, this invention relates to height and azimuth adjustable container apparatus and methods for embedded container light supports for airport runways and the alignment of their light fixtures. In one aspect, this invention relates to adjustable airport runway lights and to apparatus and methods for specialized, set-in-the-ground lighting systems utilized for the purpose of guiding pilots during their approach to an airport runway and during the landing and taxi of aircraft.
[0005] 2. Background
[0006] Conventional lighting fixtures forming part of specialized, set-in-the-ground airport runway lighting systems are mounted on certain steel containers. The steel containers for these airport runway inset lights can be one-part or two-part and, sometimes, three-part containers and are set below the surface of runways, taxiways, and other aircraft ground traffic areas. The bottom sections of the containers are sometimes called shallow light bases. The top sections are called fixed-length extensions and are manufactured in different fixed lengths and diameters. Flat spacer rings are installed between the extensions and the lighting fixtures for providing further height and azimuth adjustments. These conventional steel containers, in addition to servings as bases for mounting the lighting fixtures, also serve as transformer housings and junction boxes to bring electrical power to the lighting fixtures.
[0007] In the installation of airport runway touchdown zone, centerline, and edge lighting systems, as well as in the construction or installation of taxiway centerline and edge lighting systems, and other lighting systems, these containers are embedded in the runway, taxiway, and other pavements at the time the runway and taxiway pavements are poured (concrete) or placed (bituminous). These containers, hereinafter referred to as embedded containers, vary in length and diameter. Conventional embedded containers provide an inverted flange at their top portion, which flange has a standard set of threaded holes to allow for the runway, taxiway, edge, and other light fixtures to be bolted onto them above the pavement surface, or to allow for the top section of the container to be bolted onto the bottom section, if it is a two-section container. A great majority of these existing, conventional containers are two section containers, bolted together at their inverted flanges. The light fixture then is bolted onto the top inverted flange of the top section of the two-section container. The top section of the two-section container is referred to as the fixed-length extension, which is part of the conventional embedded containers.
[0008] The top portions of the lighting fixtures are installed at a close tolerance, slightly above the pavement surface. Installations of the containers and their lighting fixtures are required on two different occasions. The first is when the runways, taxiways, and other aircraft ground traffic areas are built for the first time. The second is for resurfacing or repaving of the runways, taxiways, and other aircraft ground traffic areas. The latter is the most common, i.e., most frequent.
[0009] The light fixtures installed on the embedded containers, otherwise known as airport inset lights, have to be aligned with respect to each other in a precise, straight line on the horizontal plane known as azimuth correction, and their height has to be set within a fixed, strict tolerance measured from the pavement surface.
[0010] Each airport paving project may consist of installing hundreds or thousands of lighting fixtures and their airport inset light containers.
[0011] Runways, taxiways, and other aircraft ground traffic areas deteriorate with years of usage. This creates the need for resurfacing or repaving, i.e., replacing the asphalt of these ground surfaces. Repavement is a much more common, i.e., frequent, occurrence than the construction of new pavements.
[0012] When a runway, taxiway, or other aircraft ground traffic area is first built, or when upgrading or modernizing, or when maintenance projects require their resurfacing (repavement), the flanges on the embedded containers get buried under the pavement. This creates the need for height adjusting devices with flanges identical to those of the embedded containers to adapt the container up to the final surface and for the lighting fixtures to be installed and aligned above the payment. In many instances, this requires core-drilling the newly poured or placed pavement to reach down to the now buried top flange of the embedded container.
[0013] Depending on the lengths of the runways and taxiways, thousands of these embedded containers are affected, and a wide variety of height adjustments can be involved for each given size of embedded containers. In such an adjustment system, fixed-length extensions must be made available in many different lengths, so as to provide the many different gross height adjustments. A combination of one or more flat spacer rings, which are manufactured in thicknesses of {fraction (1/16)}, ⅛, {fraction (1/4 )}, and {fraction (1/2)} inch (1.6, 3.2, 6.3, and 12.7 millimeters, approximately), and other thicknesses, can be used to provide the final height.
[0014] These fixed-length extensions have one inverted flange on each end to bolt onto the embedded container, and then flat rings are added on top of the fixed-length extension top flange before the lighting fixture is bolted onto the flange.
[0015] The fixed-length extensions and the flat spacer rings must be individually ordered to the required length. This adjustment system makes for a difficult and tedious conventional installation procedure involving (1) field measurement of each individual fixed extension length and flat spacer ring required for every container (2) record keeping of all those field measurements and locations for ordering and verification; (3) ordering, receiving, and delivering to the field each size according to its location; and (4) frequently having to install more than one flat spacer ring to achieve the required height. The listed complications for the difficult conventional installation procedure are further magnified by the fact that the embedded containers are made in 4 different sizes: 10, 12, 15, and 16 inches (25.4, 30.5, 38.1, and 40.6 centimeters, approximately) in diameter.
[0016] These embedded containers below the pavement surface serve as light fixture bases. They also serve as transformer housings and junction boxes.
INTRODUCTION TO THE INVENTION
[0017] Depending on the location where these containers are installed, they are exposed to varying degrees and types of corrosive chemicals and materials applied to them by the aircraft and other vehicular traffic in that location. For example, runway and taxiway light fixtures, and the containers they are bolted onto, are subjected to rain water and to chemicals such as chemicals applied to the aircraft for the purpose of deicing.
[0018] It is therefore an object of the present invention to provide non-corrosive apparatus and method for mounting an airport runway light and adjusting with precision and simplicity the height and the azimuth of a runway embedded container and for aligning with efficiency, simplicity, and precision a lighting fixture installed upon the non-corrosive apparatus of the present invention.
[0019] A further object of the present invention is to provide non-corrosive apparatus and method for adjusting the height of a runway embedded container without having to install individual fixed-length extensions or flat spacer rings.
[0020] A still further object of the present invention is to provide non-corrosive apparatus and method for adjusting the height and azimuth of an array of airport runway embedded containers in a lighting system without having to install individual fixed-length extensions or flat spacer rings.
[0021] It is an object of the present invention to provide non-corrosive apparatus and method for adjusting with precision and simplicity the height and the azimuth of a container, previously installed and embedded as an airport inset light, and for aligning with efficiency, simplicity, and precision a lighting fixture installed upon the apparatus of the present invention.
[0022] It is a further object of the present invention to provide an alignment adjustments assembly that does not require the installation of a separate mud dam.
[0023] It is a further object of the present invention to provide a non-corrosive alignment adjustments assembly that does not require the installation of a separate mud dam.
[0024] A further object of the present invention is to provide non-corrosive apparatus and method for adjusting the height of a container, previously installed and embedded as an airport inset light, without having to install individual fixed-length extensions or flat spacer rings.
[0025] A still further object of the present invention is to provide non-corrosive apparatus and method for adjusting the height and azimuth of an array of containers, previously installed and embedded as airport inset lights, in a lighting system without having to install individual fixed-length extensions or flat spacer rings.
[0026] It is an object of the present invention to provide a non-corrosive alignment adjustments assembly which corrects the problem of tilting of the assembly from the vertical axis which increases the angle at which the light beam from an inset lighting fixture is projected, diverting the light beam away from incoming airplanes.
[0027] It is also another object of this invention to provide a non-corrosive alignments adjustments assembly which corrects the problem of the rotation of the assembly which alters the azimuth alignment of the lighting fixture, which in turn would impede the pilot of an incoming airplane from seeing the light.
[0028] It is yet another object of the present invention to provide a non-corrosive alignments adjustments assembly which will allow the longer, angled bottom type inset lights be installed upon it.
[0029] It is yet a further object of the present invention to provide a non-corrosive alignment adjustments assembly which does not require installing a separate flat spacer ring, with a groove on its top flat side.
[0030] These and other objects of the present invention will become apparent from a careful review of the detailed description and the figures of the drawings which follow.
SUMMARY OF THE INVENTION
[0031] Novel non-corrosive airport inset light adjustable alignment container set apparatus and method of the present invention include a light fixture and stainless steel support for airport runway, taxiway, or other aircraft ground traffic areas. A variable length means rotatably adjusts height by a vertical displacement and mounting means for mounting the airport inset light. Rotation locking means are provided for securing the rotatable adjustment apparatus from further rotation. A top flange is adapted to receive various different designs of inset lights and to provide a stainless steel protection ring “mud dam.”
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is an elevation view, partially in section, of the exciting fixed-length extensions installed on an embedded container and a lighting fixture installed thereon. FIG. 1 also shows a concrete encasement and three layers of pavement.
[0033] FIG. 2 is an elevation view, partially in section, of the same existing fixed-length extensions of FIG. 1 but now shown tilted.
[0034] FIG. 3 is a pictographic view, partially in section, showing a landing passenger jet airplane, a runway, and a tilted runway centerline inset lighting fixture.
[0035] FIG. 4 is an elevation view, partially in section, of the adjustable extension component of the present invention showing a mud dam and an “O” ring with its groove.
[0036] FIG. 5 is an elevation view, partially in section, showing an Allen-set screw component of the present invention.
[0037] FIG. 6 is an elevation view, partially in section, of the adapter flange component of the present invention.
[0038] FIG. 7 is an elevation view, partially in section, of an airport inset lighting fixture, showing a straight bottom.
[0039] FIG. 8 is an elevation view, partially in section, of an airport inset lighting fixture, showing an angled bottom.
[0040] FIG. 9 is a plan view of the lighting fixture of FIG. 7 and of FIG. 8 .
[0041] FIG. 10 is an elevation view, partially in section, of a mud dam protection ring.
[0042] FIG. 11 is an elevation view, partially in section, of the alignments adjustments assembly of the present invention shown installed on an existing embedded container. FIG. 11 also shows an airport inset lighting fixture mounted on the adjustments assembly.
[0043] FIG. 12 is a plan view of the top flange of the embedded container of FIGS. 1, 2 , and 11 .
[0044] FIG. 13 is an elevation view, partially in section, of the universal top adjustment container of the present invention and shows an airport inset lighting fixture and an “O” ring.
[0045] FIG. 14 is a plan view, i.e., a top view, of the universal top adjustment container of the present invention as shown in FIG. 13 without the lighting fixture.
DETAILED DESCRIPTION
[0046] The present invention provides a height and azimuth adjustable container set, utilized for all the purposes embedded containers are utilized, i.e., to serve as bases for lighting fixtures, as transformer housings, and as junction boxes, but with a major difference from conventional embedded containers. The adjustable container sets of the present invention also are utilized for the precise and simplified, economic mounting and adjusting of the height of the lighting fixture to be mounted upon it. Also, the adjustable containers of the present invention provide for precise and simplified, economic aligning of the azimuth of the lighting fixtures and aligning the lights with respect to each other, by virtue of the azimuth alignment.
[0047] The adjustable container set of the present invention is used to improve existing containers, while being efficiently and economically adjustable. These containers are installed in airport runways, taxiways, and other aircraft ground traffic areas to serve as bases for lighting fixtures, transformer housings, and junction boxes. The adjustments take place when the containers and their lighting fixtures are installed initially, e.g., when new runway, taxiway, and other aircraft ground traffic areas are first built and every time they are repaved.
[0048] The present invention provides a height and azimuth alignments adjustments assembly utilized for the more economic, precise, and simplified adjusting of the heights of concrete embedded containers and the azimuth alignment of airport inset lighting fixtures mounted thereon. These containers of the present invention are installed and reused in airport runways and taxiways and other aircraft ground traffic areas to serve as bases for lighting fixtures, transformer housings, and as junction boxes.
[0049] In the actual testings and installations of the alignments adjustments assembly disclosed and described in U.S. patent application Ser. No. 08/002,014 filed Jan. 8, 1993 and entitled “Alignments Adjustments Assembly Apparatus and Method,” now U.S. Pat. No. 5,541,362, I have discovered certain aspects which could be modified.
[0050] One drawback is that airport runway light bolts used to install the airport runway light on or in the airport runway light support can be part of a corrosion problem. Corrosive materials such as deicing chemicals used on the aircraft can accelerate corrosive problems between the light bolts and the light support. The airport runway light stainless steel bolts can accelerate corrosive attack by a galvanic action between dissimilar metals.
[0051] The present invention provides an alignment adjustments assembly which corrects the problem of corrosion.
[0052] One drawback is that a great number of the existing conventional, fixed-length extensions installed as stacked-on embedded containers have tilted from their vertical axis. This tilting, which at the place of tilting is relatively small, nevertheless increases the angle at which the light beam from an inset lighting fixture is projected, thereby diverting the light beam away from incoming airplanes. At one-half mile (1 kilometer) away from the approach area, it is difficult for the pilot of a landing airplane to see the light because of the very large divergence at that point from the point at which it should otherwise be, when properly height-adjusted.
[0053] The present invention provides an alignment adjustments assembly which corrects the problem of tilting.
[0054] Another drawback encountered is that the new larger and heavier airplanes, now becoming more common, exert a larger torsional force upon the inset lighting fixtures. Tests made to simulate those larger torsional forces on the alignment adjustment assembly disclosed and described in U.S. Patent Application Serial No. filed Jan. 8, 1993 and entitled “Alignments Adjustments Assembly Apparatus and Method,” now U.S. Pat. No. 5,541,362, proved that a very slight rotational movement occurs, even though considered relatively insignificant today. Nevertheless, even heavier airplanes could provide a more significant rotational movement that would alter the azimuth alignment of the lighting fixture, which in turn would impede the pilot of an incoming airplane from seeing the light.
[0055] The present invention provides an alignments adjustments assembly which corrects the problem of the rotation of the assembly.
[0056] Yet another drawback encountered is the need to install a separate component called the mud dam, consisting of a flat, three-quarters inch (19 mm) thick spacer ring with a flat, thin steel band welded all around the periphery of the flat spacer ring. This band is about one and a quarter inches (3.3 cm) wide.
[0057] The present invention provides an alignment adjustments assembly that does not require the installation of a separate mud dam.
[0058] A further drawback encountered is that there are two types of inset light construction with respect to its bottom side. The bottom on one type is short and flat. The bottom on the other is longer and at an angle with respect to the light base vertical axis. The longer, angled bottom does not allow the light to fit properly on the top flange of the apparatus as disclosed and described in U.S. patent application Ser. No. 08/002,014 filed Jan. 8, 1993 and entitled “Alignments Adjustments Assembly Apparatus and Method,” now U.S. Pat. No. 5,541,362.
[0059] The present invention provides an alignments adjustments assembly which will allow the longer, angled bottom type inset lights to be installed upon it.
[0060] Yet a further drawback encountered is that, in a great many occasions, an “O” ring seal is specified. In such cases, a separate flat, three-quarters inch (19 mm) thick spacer ring, with a groove on its top flat side, is installed between the fixed-length extension and the lighting fixture.
[0061] The present invention provides an alignment adjustments assembly which does not require installing a separate flat spacer ring with a groove on its top flat side.
[0062] The invention includes an existing embedded container with an inverted flange on one end onto which an adapter flange bolts. The adapter flange has Acme threads in its center aperture. The apparatus and method of the present invention also include an outside Acme threaded adjustable extension, which threads down into the adapter flange, to provide the precise height required and the precise alignment of its lighting fixture. The adjustable height extension has a top flange to provide a base upon which the specified lighting fixture can be bolted.
[0063] The present invention provides height and azimuth light support sets utilized for the more efficient and economic, precise, and simplified adjusting of the heights of exiting art embedded containers and the alignment of their light fixtures. These containers are installed in airport runways and taxiways to serve as bases for lighting fixtures, as transformer housings, and as junction boxes.
[0064] Referring now to FIGS. 1 and 2 , a container 1 is represented schematically with three fixed-length extensions 2 , 7 , and 11 bolted together. Container 1 is embedded in concrete 25 at the time an airport runway, taxiway, and other aircraft ground traffic areas (hereinafter aircraft ground traffic areas) are first built. These ground traffic areas generally are built upon a compacted granular sub-base 26 .
[0065] Steel containers 1 , in addition to serving as bases for mounting airport inset lighting fixtures 95 also serve as transformer housings and junction boxes to bring electrical power to lighting fixture 95 , as shown in FIGS. 1, 2 , and 7 . Fixed-Length extension 2 is bolted to top flange 30 on container 1 , which has 12 threaded bolt holes 136 , as shown in FIG. 12 , by means of its bottom flange 4 and bolts 3 . Fixed-length extension 2 is bolted to bottom flange 6 of fixed-length extension 7 by means of its top flange 5 and bolts 8 . Fixed-length extension 7 is bolted on top of fixed-length extension 2 .
[0066] Fixed-length extensions have twelve bolt holes in both of their flanges, i.e., top flange 5 and bottom flange 4 of extension 2 , as shown in FIG. 1 . The bolt holes, not shown, on the top flanges of the extensions are threaded, while the bolt holes, not shown, on the bottom flange are not threaded. Nevertheless, the bolt holes in both flanges of the fixed-length extensions are on a bolt hole circle diameter identical to bolt circle diameter 137 , as shown in FIG. 12 , of container 1 .
[0067] Fixed-length extension 7 is bolted to bottom flange 10 of fixed-length extension 11 by means of its top flange 9 and bolts 12 . Fixed-length extension 11 is bolted on top of fixed-length extension 7 .
[0068] Fixed-length extensions provide only a gross height adjustment. One or a plurality of flat spacer rings 15 are required for providing the more precise final height adjustment.
[0069] Flat spacer rings 15 are installed on top flange 13 of fixed-length extension 11 , as shown in FIG. 1 , i.e., the top fixed-length extension, to provide the final height adjustment 17 for inset lighting fixture 95 . Flat spacer rings 15 can be one or more. They are fabricated as thin as {fraction (1/16)} inch (1.6 mm) and as thick as three-quarters inch (19 mm) or thicker. Mud dam 36 , as shown in FIGS. 1 and 10 , comes next on top of spacer rings 15 . The inset lighting fixture 95 is bolted together with flat spacer rings 15 and mud dam 36 onto the top flange 13 of the top fixed-length extension 11 by means of bolts 14 .
[0070] Continuing to refer to FIGS. 1 and 2 , several layers of pavement 19 , 20 , 21 are shown, to exemplify the fact that fixed-length extensions 2 , 7 , and 11 are utilized for height adjustments every time an aircraft ground traffic area is first built or upgraded by the installation of new pavement, i.e., each new layer of pavement 19 , 20 , and 21 . The new layers create new surfaces 22 , 23 , and 24 and therefore new heights.
[0071] These airport aircraft ground traffic area upgrades create the need for heights adjusting devices, with flanges identical to those of the embedded container 1 , in order to adapt the container 1 to the new surface, i.e., the new height and further in order for the lighting fixture 95 to be installed slightly above the new pavement surface, i.e., surface 22 , 23 , or 24 , at a close tolerance 17 above new pavement surface 24 , for example.
[0072] In order to seal pavement layers 19 , 20 , 21 around container 1 , grout 18 is utilized. Pavement rings 36 , commonly known in the industry as mud dam 36 , as shown in FIGS. 1 and 10 , are installed on top of spacer rings 15 to protect lighting fixture 95 from being splashed by the grout 18 at the time of its application.
[0073] Inset lighting fixture 95 is set inside mud dam protection ring 36 , as shown in FIG. 10 . Mud dam 36 consists of a flat ring 38 , as shown in FIG. 10 , generally of {fraction (3/4)} inch (19 mm) in thickness, with a 1 to 1¼ inch (2.54 to 3.27 cm) wide, flat, thin steel band welded around the periphery of flat ring 38 . Flat ring 38 has bolt holes 39 which match bolt holes, not shown, on flat spacer rings 15 , on fixed-length extension 11 as well as on lighting fixture 95 . Bolt holes on fixed-length extension 11 are threaded. Lighting fixture 95 is bolted onto fixed-length extension 11 , together with mud dam 36 and flat spacer rings 15 by means of bolts 14 . Mud dams 36 are generally provided with grooves 43 in order to accept “O”-ring gasket 44 .
[0074] When any one layer of pavement is first placed, it is done by placing it over the entire surface, i.e., surface 31 . Then the pavement 19 is core-drilled at the location of each container 1 to remove the pavement at that location to install fixed-length extension 2 , any flat spacer ring 15 , mud dam 36 , and finally lighting fixture 95 at the new height created by pavement 19 and surface 22 , by way of example. This process is repeated every time a new layer of pavement is added, i.e., for further layers 20 and 21 . The core drilled hole is larger in diameter than the diameter of container 1 , hence the requirement to utilize grout 18 to fill in the void and therefore the need to install a mud dam 36 , as shown in FIG. 10 , to protect lighting fixture 95 , as shown in FIGS. 1, 2 when grout 18 is poured.
[0075] A new method has been used for a few years already, whenever an aircraft ground traffic area reconstruction takes place, i.e., resurfacing or repaving. Instead of adding a new layer of pavement on top of the last one installed, the last one layer, i.e., pavement layer 21 , is milled down by large roto-milling machines. This method is extensively explained in my U.S. Pat. No. 5,431,510 entitled “Overlay Protection Plate Apparatus and Method.”
[0076] Prior to roto-milling the pavement top layer, i.e., layer 21 , the lighting fixtures, any spacer rings, the mud ring, and the top, existing fixed-length extensions have to be removed. An overlay protection plate, not shown, is bolted to top flange 30 , on container 1 , to prevent debris from falling into container 1 . After roto-milling, a new layer of pavement is installed, and the new pavement is core-drilled at the location of each container 1 to replace the items removed back to their original position. Core drilling at each embedded container location is done to provide access for reinstalling the items previously removed. Nevertheless, in a great percentage of the cases, i.e., at each of the individual container locations, differences of height occur, creating the need for the installation of additional flat spacer rings 15 on top of the ones removed and being reinstalled.
[0077] Referring to FIGS. 1 and 2 , lighting fixture 95 is installed at a close tolerance 17 slightly above pavement surface 24 . The optical system, not shown, inside the lighting fixture, projects its light beam 32 through lens 107 in window 108 of lighting fixture 95 at a precise angle 34 from surface 24 to allow a pilot landing aircraft 51 , as shown in FIG. 3 , see light beam 32 , from a distance of about one-half mile (1 kilometer), when landing at night or under other low visibility conditions. Lighting fixtures 95 are also known as centerline lights because they are installed on the embedded containers in the center of the aircraft ground traffic areas, i.e., runways, taxiways, and others.
[0078] The continuous landing of aircraft, day and night, year after year, on top of these lighting fixtures can provide a slight tilting 41 , as shown in FIG. 2 , of the lighting fixture and fixed-length extension 11 , as represented by 41 (not to scale), as shown in FIG. 2 , for the purpose of making this explanation more clearly understood. This tilting 41 will alter the installed height tolerance 17 , as shown in FIG. 1 , which now would be larger as represented by 42 in FIG. 2 . The maximum installed height tolerance 17 is {fraction (1/16)} inch (1.6 mm), per F.A.A. (U.S. Federal Aviation Administration) specifications. Tilting 41 is shown as a separation of flange 10 of fixed-length extension 11 from flange 9 of fixed-length extension 7 .
[0079] Even the slightest tilting of lighting fixture 95 and the associated extension produces an angular deviation, angle 35 , as shown in FIGS. 2 and 3 , which is larger than the precise angle 34 obtained by a combination of the precise height adjustment of lighting fixture 95 and the angle at which light beam 32 is emitted from lighting fixture 95 , through its lenses 107 , in windows 108 , as shown in FIGS. 1 and 2 . This lighting fixture emitted light beam angle is set at the factory and is precisely established by F.A.A. regulations.
[0080] An increased angle 35 would project emitted light beam 33 away from a line of sight from the pilot when landing aircraft 51 , as shown in FIG. 3 , as it descends for landing. As a result, the pilot of aircraft 51 would not be able to see light beam 33 when landing at night or during poor visibility conditions. An increase in the height adjustment 17 of lighting fixture 95 would have the same effect, i.e., the light beam would not be visible to the pilot at landing. In addition, an increased installed height creates the danger of the lighting fixture being plowed-off, during winter time, when snow is regularly plowed off airport ground traffic areas. This creates the danger of lighting fixtures, bolts, rings, and other components, being thrown onto these traffic areas, with the resulting danger to landing aircraft.
[0081] Conventionally, tilting is field-corrected by installing a thick tapered spacer ring, not shown. These tapered rings are custom made, per field measurement, and they are installed after first removing some of the existing flat spacer rings 15 , to correct angular deviation 35 of light beam 33 to the correct angular adjustment 34 of the light beam. Tilting of the fixed-length extension is corrected, when the apparatus and methods of the present invention are utilized, because fixed-length extensions, bolted one on top of the other are no longer required.
[0082] Referring to FIGS. 7, 8 , and 9 , lighting fixtures today are manufactured with two different types of bottom portions. FIG. 7 shows lighting fixture 95 with six non-threaded, counter sunk bolt holes 109 drilled through mounting flange 106 . Bolt holes 109 are set apart at an angle 115 of 60 degrees one from another, in bolt circle 114 . Lighting fixture 95 is provided with optical lenses 107 in countersunk windows 108 and with a flat, short, straight down bottom portion 100 . Electrical wires 111 and connector 112 are provided for bringing electrical power to lighting fixture 95 from an isolation transformer, not shown, in conventional container 1 , as shown in FIGS. 1 and 2 .
[0083] Lighting fixture 105 of FIG. 8 has six non-threaded, countersunk bolt holes 109 drilled through mounting flange 106 . Bolt holes 109 are set apart at an angle 115 of 60 degrees one from another, in bolt circle 114 . Lighting fixture 105 is provided with optical lenses 107 in countersunk windows 108 and with a long, angled bottom 110 , hence the novel angled 66 opening 67 of adjustable extension 55 , as shown in FIG. 4 . Angled 66 opening 67 allows lighting fixture 105 to be installed on flange 62 of the extension, in addition to allowing also the installation of lighting fixture 95 , as shown in FIG. 7 .
[0084] Continuing to refer to FIG. 8 , lighting fixture 105 is also provided with wires 111 and connector 112 for bringing electrical power to lighting fixture 105 from conventional embedded container 1 , as shown in FIGS. 1 and 2 .
[0085] Azimuth orientation arrows 113 are engraved on mounting flange 106 in the countersunk windows 108 area. Arrows 113 are also engraved in countersunk windows 108 of lighting fixture 95 . The difference between lighting fixture 95 and lighting fixture 105 is in the short, flat bottom portion 100 of fixture 95 versus the longer, angled bottom portion of fixture 105 .
[0086] Engraved azimuth arrows 113 are required for aiding a lighting fixture installer in orienting lenses 107 , on windows 108 , directly to the exact azimuth alignment, to correctly align, in azimuth, the light beam projected through lenses 107 with the aircraft landing direction. The azimuth alignments are required when the lighting fixture is first installed and on every occasion maintenance is performed on the fixture, i.e., removal for bulb change and others.
[0087] FIG. 9 is a top view, i.e., a plan view, of the lighting fixtures of FIGS. 7 and 8 . The lighting fixtures 95 , 105 have six countersunk bolt holes 109 each on bolt circle 114 , with a bolt circle diameter identical to the diameter of the bolt circle, not shown, of bolt holes 64 , on top flange 62 , as shown in FIG. 4 .
[0088] The bolt circle diameter, the number and size of bolts and bolt holes in the lighting fixtures, as well as in the flange where the lighting fixtures are to be installed, i.e., top flange 62 , as shown in FIG. 4 , or in conventional top flange 13 , as shown in FIG. 1 , are specified by specifications known as Circulars, issued by the F.A.A.
[0089] Referring now to FIGS. 4, 5 , and 6 , adjustable extension 55 and adapter flange 85 represent the preferred embodiment of the alignments adjustments assembly of the present invention.
[0090] Adjustable extension 55 consists of a tubular, cylindrical section, defined by a non-threaded top portion 58 which has its bottom portion 57 threaded with Acme threads 56 , e.g., by way of example at four threads per inch (2.54 cm). Top portion 58 and bottom threaded portion 57 are the wall of the cylindrical portion, i.e., the wall of a tubular cylinder, shown in elevation, partially in section, in FIG. 4 .
[0091] Acme threaded portion 57 is threaded for approximately six inches (15 cm) from bottom end 61 . Threaded portion 57 has a minimum of six vertical rows of threaded holes 59 , 60 , i.e., parallel to its vertical axis 68 , as opposed to three vertical rows of holes at 120 degrees apart, disclosed in U.S. patent application Ser. No. 08/002,014 filed Jan. 8, 1993 entitled “Alignments Adjustments Assembly Apparatus and Method,” now U.S. Pat. No. 5,541,362. Holes 59 are on a horizontal plane different from holes 60 , i.e., intercalated, i.e., staggered as shown in FIG. 4 , so that at all times there will be a minimum of four and a maximum of six holes 59 , 60 for threading Allen set-screws 81 , as shown in FIG. 5 , through them and for tightening against inside threaded surface 87 of adapter flange 85 , as shown in FIG. 6 . By the method of the present invention, at least one Allen set-screw 81 , as shown in FIG. 5 , protruding through holes 59 or 60 , penetrates at least one eighth inch (3.2 mm) into a drilled aperture 86 , as shown in FIG. 6 , on inside threaded surface 87 of adapter flange 85 .
[0092] Allen set-screws are threaded through both holes 59 and 60 , shown threaded through hole 59 on FIG. 5 for simplification purposes. Allen set-screws are of a minimum {fraction (1/2)} inch (1.3 cm) nominal diameter.
[0093] Top flange 62 is welded at top portion 71 of the tubular, cylindrical portion of the extension 55 . Top flange 62 has 12 threaded bolt holes 64 through it, when seeing it in plan, but shown only in section in FIG. 4 . These threaded bolt holes 64 have a bolt circle diameter, not shown, that coincides with bolt circle diameter 114 , as shown in FIG. 9 , of lighting fixture 95 and 105 , as shown in FIGS. 7 and 9 , respectively. The bolt circle and bolt size are mandated by the F.A.A. specifications, i.e., U.S. Federal Aviation Administration specifications. All features shown on FIG. 9 , a plan view, coincide with a plan view, not shown, of FIG. 7 in all respects, i.e., they are substantially identical. Therefore, either lighting fixtures of FIG. 7 or FIG. 8 can be bolted onto top flange 62 .
[0094] Top flange 62 has opening 67 at an angle 66 of approximately 45 degrees. In addition to accepting lighting fixture 95 , as shown in FIG. 7 , it also accepts lighting fixture 105 , as shown in FIG. 9 .
[0095] Preferably top flange 62 and tubular cylindrical portion 57 are made of stainless steel. The stainless steel assembly 55 of the present invention provides an alignment adjustments assembly which corrects the problem of corrosion from materials such as corrosive deicing chemicals or by a galvanic action between dissimilar metals between the light bolts and the light support.
[0096] Novel mud dam protecting ring 69 , consisting of a 1 to 1¼ inches wide (2.54 to 3.27 cm), thin, stainless steel band, is built in one piece with top flange 62 , if adjustable extension 55 is built in one piece, which is the preferred method. Mud dam protecting ring 69 can also be welded all around the outer periphery of top flange 62 if adjustable extension 55 is built of individual components. Mud dam 69 is positioned to protect the lighting fixture and its lenses 107 , as shown in FIGS. 7, 8 , and 9 from grout 122 , as shown in FIG. 11 , when grout 122 is poured. Groove 65 is provided on surface 63 of top flange 62 in order to accept “O”-ring 70 , shown lifted from groove 65 , on FIG. 4 .
[0097] The adjustable extension of the present invention can be cast, in one piece, e.g., from stainless steel, comprising the 1′, tubular, cylindrical portion as well as the top flange 62 and mud dam protection ring 69 . It can then be machine-finished including groove 65 and mud dam protection ring 69 . Acme-threads 56 are cut for a minimum of up to 6 inches (15 cm) or more from bottom end 61 . All holes 59 , 60 , and 64 are then drilled and tapped. Preferably, each individual component is made of stainless steel.
[0098] The adjustable extension can also be made of individual components, i.e., a tubular piece, to obtain the cylindrical portion and a standard steel plate, machine-finished to obtain the top flange 62 , to which a thin, steel band is welded to make the protection ring 69 . Then the flange 62 is welded at 71 , top end of non-threaded portion 58 of the tubular piece, i.e., the cylindrical portion. Any additional machine-finishing then is done, including groove 65 . Acme threads 56 are cut for a minimum of 6 inches (15 cm) or more from bottom end 61 . All holes 59 , 60 , and 64 are then drilled and tapped.
[0099] Optionally, Acme threads 56 could be cut, and holes 59 and 60 drilled and tapped in the field at the point of use.
[0100] The order in which the fabrication steps are herein described, i.e., for casting in one piece or for individual components, is not intended to limit the many variations of manufacturing sequencing, as those skilled in the art would recognize. Therefore, all sequencing steps, whether listed or not, are part of the apparatus and method of the present invention.
[0101] As it can be readily understood by those skilled in the art, the adjustable extension can be made in any overall length, including any length of its threaded portion 57 . This feature provides the design engineers a great advantage in planning for future aircraft ground traffic changes, i.e., additional layers of pavement or the replacement of existing layers of pavement with new, thicker layers, to upgrade these aircraft traffic areas to new generations of larger, heavier aircraft.
[0102] FIG. 5 represents the Allen set-screw 81 component of the present invention shown threaded-in and protruding through threaded portion 57 of the adjustable extension.
[0103] FIG. 6 represents the circular adapter flange 85 component part of the present invention shown in elevation. Non-threaded aperture 86 is at least {fraction (1/8)} inch (3.2 mm) deep, drilled into Acme threaded surface 87 in opening 88 . Inside opening 88 is threaded with 4 Acme threads per inch (2.54 cm) in order to thread extension 55 into it. Non-threaded holes 89 are 12 in number (only two shown) and are drilled through surface 90 . Bolt holes 89 are drilled on a bolt circle, not shown, identical to the bolt circle 137 , as shown in FIG. 12 , on top flange 30 of conventional embedded container 1 , as shown in FIGS. 1 and 2 . Adapter flange 85 thereby provides the means for the installation of adjustable extension 55 onto embedded stainless steel container 1 A, as shown in FIGS. 11 and 12 .
[0104] For the installation of the alignments adjustments assembly of the present invention on airport runway embedded stainless steel container 1 A, adapter flange 85 is bolted onto top flange 30 , as shown in FIGS. 1, 2 , and 12 of embedded container 1 after removing bolts 3 , as shown in FIGS. 1 and 2 and all fixed-length extensions 2 , 7 , and 11 . When adapter flange 85 is bolted onto stainless steel container 1 A, the adjustable extension 55 can be threaded into adapter flange 85 , through Acme threaded opening 88 , in order to install an airport inset lighting fixture upon top flange 62 , as shown in FIGS. 4 and 11 , of adjustable extension 55 .
[0105] All Allen set screws are threaded through holes 59 , 60 of extension 55 and torqued to a minimum of 60 foot-pounds (8 kilogram-meters) against Acme threaded surface 87 of adapter flange 85 , one of them, torqued against the inside of drilled aperture 86 .
[0106] Referring now to FIG. 11 , a completed installation of the apparatus of the present invention is represented. Aperture 86 on Acme threaded surface 87 is drilled as follows. First, adjustable extension 55 with “O” ring 70 , in groove 65 and with lighting fixture 105 bolted onto it, as shown in FIG. 11 , is threaded into adapter flange 85 , which has been bolted already onto stainless steel container 1 A by means of bolts 121 . Lighting fixture 105 on adjustable extension 55 then is brought to the exact height and azimuth by threading in adjustable extension 55 until azimuth orientation arrows 113 are aligned to the precise azimuth at the required height. Prior to any installation, a surveyor provides the necessary centerline marks 138 , as shown in FIG. 12 , on the pavement, i.e., of a runway, for aiding the installer in finding the correct azimuth line. At this point, the lighting fixture is removed, and all required Allen set-screws are installed through holes 59 , 60 of adjustable extension 55 and fully torqued at 60 foot-pounds (8 kilogram-meters) against Acme threaded surface 87 to immobilize adjustable extension 55 in place, keeping it at the desired azimuth alignment and height adjustment. Then, aperture 86 is drilled approximately {fraction (1/8)} inch (3.2 mm) into surface 87 of adapter flange 85 , through one of threaded holes 59 or 60 of the adjustable extension 55 . Immediately after aperture 86 is drilled-in, the remaining Allen set-screw 81 is threaded through the respective hole 59 or 60 and fully torqued at 60 foot-pounds (8 kilogram-meters) against the inside of aperture 86 . By making at least one Allen set-screw 81 penetrate at least {fraction (1/8)} inch (3.2 mm) into aperture 86 , on surface 87 of adapter flange 85 , by installing six Allen set-screws, and by making the set-screw {fraction (1/2)} inch (12.7 mm) in diameter, the adjustable extension 55 and the lighting fixture mounted thereupon will not be made to turn by the torque tangentially applied by the force of airplane wheels, including those of the newer, heavier airplanes landing upon the lighting fixtures or by the twisting action created by heavy aircraft locked wheels when turning. All holes 59 , 60 not utilized are plugged-in with threaded, plastic plugs, not shown. When holes 59 , 60 are plugged-in, the lighting fixture is connected to electrical power connector 123 from imbedded container 1 by means of cable 111 and connector 112 . Then the lighting fixture is re-bolted onto top flange 62 of adjustable extension 55 with its azimuth orientation arrows 113 aligned in azimuth, by means of bolts 120 . “O” ring 70 is compressed by the bolting pressure, thereby providing a tight water seal. Angled bottom 110 of lighting fixture 105 fits very well in angled 66 opening 67 , as shown in FIG. 4 , of the adjustable extension.
[0107] At this point, the installation is completed by pouring-in grout 122 all around the alignments adjustments assembly 55 , 85 , of the present invention. It can be seen that the novel protection ring 69 , as shown in FIGS. 4 and 11 , prevents grout 122 from getting on the lighting fixture, especially so on its lens 107 through window 108 . It is also readily understood that groove 65 , as shown in FIG. 4 , provided on surface 63 of top flange 62 of adjustable extension 55 eliminates the requirement for installing a separate spacer ring with a groove on it for the installation of “O” ring 70 .
[0108] The alignments adjustments assembly of the present invention is reusable. When the alignments adjustments assembly is installed and the airport aircraft ground traffic area is modified, creating a higher or Lower surface, i.e., if surface 24 were made higher or lower, extension 55 can be threaded in or out, after first removing all Allen set-screws 81 , to provide a new height adjustment without affecting the azimuth alignment. Azimuth is a straight line, i.e., toward the horizon, in the direction of aircraft landings, with the centerline 138 , as shown in FIG. 12 , of the aircraft ground traffic area runway, taxiway, defining this straight line. Thus the embedded containers with their inset lights mounted thereupon all are installed at a specified distance one from another on this centerline for the length of the aircraft ground traffic area.
[0109] At the time embedded stainless steel container 1 A is first installed, its top flange 30 , as shown in FIG. 12 , is aligned in azimuth, by aligning centerline 138 of the aircraft ground traffic area to pass exactly aligned with two diametrically opposed threaded bolt holes 136 . Prior to its installation, a surveyor provides markings on the pavement for aiding in the azimuth alignment of stainless steel container 1 A. Bolt holes 136 are at an angle 135 of 30 degrees apart, and they are set on bolt circle 137 with a diameter identical to bolt circle 114 , as shown in FIG. 9 , on the lighting fixtures 95 , 105 . Bolt circle diameter 137 on top flange 30 also is identical to the bolt circle diameter, not shown, on adapter flange 85 , which bolts thereupon, by the method of the present invention.
[0110] Adjusting the height of adjustable extension 55 would not affect the azimuth alignment of a lighting fixture installed upon its flange 62 , ax shown in FIG. 11 , because extension 55 Acme threaded portion 57 is provided with at least four Acme threads 56 per inch (2.54 cm). At four Acme threads per inch (2.54 cm), it would take four full, 360 degree turns of adjustable extension 55 , for it to go up or down one inch (2.54 cm). Therefore the adjustable extension will move up or down only {fraction (1/4)} inch (6.3 mm) when rotated 360 degrees about its axis 68 , i.e., one single, complete rotation. A 30 degree turn of adjustable extension 55 will produce a height change of only 0.0208 inches (0.05 mm), up or down, i.e., one twelfth of ¼ inch (6.3 mm). The measure of 0.0208 inches (0.05 mm) is slightly more than {fraction (1/64)} inch (1.6 mm). The overall tolerance 17 , as shown in FIG. 1 is {fraction (1/16)} inch (1.6 mm). A 30 degree turn equals one twelfth of one full 360 degree rotation. Therefore, adjustable extension 55 can be rotated a few degrees about its axis 68 in any direction to obtain a very precise azimuth alignment without negatively affecting its height adjustment. Any azimuth alignment adjustment would always be 15 degrees or less because bolt holes 109 , as shown in FIG. 9 , of the lighting fixtures, by FAA mandate, are spaced apart 60 degrees, i.e., only six holes. Bolt holes 64 on top flange 62 , as shown in FIG. 4 , are spaced at 30 degrees, exactly the same as bolt holes 136 , as shown in FIG. 12 , on top flange 30 of the embedded container, i.e., 12 bolt holes, also by FAA specifications, The diameter of bolt circles 114 , as shown in FIG. 9 , and 137 as shown in FIG. 12 , are also identical to that of the top flange 62 . Accordingly, a 30 degree azimuth alignment adjustment is obtained by properly positioning the lighting fixture upon top flange 62 of adjustable extension 55 , matching its bolt holes 109 with the two bolt holes 64 on flange 62 , positioning arrows 113 closest to the correct azimuth alignment marked on the pavement by a surveyor. The final, precise adjustment of 15 degrees or less is done by simply turning the adjustable extension. From FIG. 9 , it can be seen that windows 108 are centered between two bolts 109 , and, therefore, orientation arrow 113 is at 30 degrees apart from the two adjacent bolt holes 109 .
[0111] Referring now to FIGS. 13 and 14 , a universal top adjustable alignment container 255 is shown in elevation in FIG. 13 and in plan view, i.e. top view, in FIG. 14 . The non-corrosive top adjustable alignment container 255 is another preferred embodiment of the present invention.
[0112] FIG. 13 shows, for the purpose of illustration, an airport inset light 205 , a new type of airport inset lighting fixture, manufactured by Hughes Phillips. The novel features of the universal top adjustable alignment container 255 allow the installation of any of the three types of lighting fixtures that exist in the U.S. market today, e.g., lighting fixture 95 , shown in elevation in FIG. 7 and in plan view in FIG. 9 ; lighting fixture 105 , shown in elevation in FIG. 8 and in plan view in FIG. 9 ; and the newest inset lighting fixture 205 , shown in elevation in FIG. 13 .
[0113] Any of the three lighting fixtures 95 , 105 , and 205 can be installed on the universal top adjustable alignment container 255 without requiring its top flange 262 to have an angled opening 66 ( FIG. 4 ), as it is required for the flange 62 of the adjustable extension 55 of FIG. 4 .
[0114] Continuing to refer to FIG. 13 , the novel top flange 262 of the universal top adjustable alignment container 255 has an opening 267 with a straight inside surface 266 instead of an angled inside surface 66 as shown in FIG. 4 . In addition, the top flange 262 is thicker than the top flange 62 of FIG. 4 . This additional thickness allows a stepped bottom 201 of the lighting fixture 205 to be perfectly fit inside the opening 267 of the top flange 262 , with a flange 206 inside the mud dam 269 .
[0115] The universal top adjustable alignment container 255 of FIG. 13 is preferably cast in one piece, in stainless steel.
[0116] The casting can then be machined to form the top flange 262 , a flat surface 263 , with a groove 265 in it, the mud dam 269 , and an opening 267 , with its straight surface 266 . Twelve threaded holes 264 (only two shown) are drilled and tapped through the surface 263 of the flange 262 . Then acme threads 256 are cut, at four thread; per inch, on a surface 257 for a minimum of six inches from a bottom a 261 of a tubular section 257 . The tubular section 257 is of a required wall thickness 274 to allow for the required strength of the threads to resist shearing forces created by the axial loading forces applied upon the lighting fixtures by landing aircrafts. At this point, holes 259 and 260 are drilled and tapped through the tubular section 257 , through its wall thickness 274 .
[0117] Holes 259 and 260 are intercalated, i.e., staggered. These holes 259 and 260 , if required, could be drilled and tapped in the field instead of in the factory. Nevertheless, drilling and tapping holes 259 and 260 in the field is not the preferred method because it is not cost effective, and it is inefficient.
[0118] Threaded bolt holes 264 of the top flange 262 are a total of twelve, i.e., at 30 degrees 235 from each other, as shown on FIG. 14 . These holes 264 are drilled and tapped through a surface 263 of the flange 262 on a bolt circle 214 ( FIG. 14 ), which is similar to the bolt circle 114 of FIG. 9 , on the lighting fixtures 95 and 105 of FIGS. 7 and 8 , respectively.
[0119] Bolt holes 209 of lighting fixture 205 are drilled through flange 206 on a bolt circle (not shown) similar to bolt circle 214 on top flange 262 . Lighting fixture 205 has six bolt holes (only two shown) spread at sixty degrees apart, similar to the configuration 235 shown of FIG. 9 for lighting fixtures 95 , 105 . The number of holes, sizes, and degrees apart are all mandated by the FAA, i.e., the Federal Aviation Administration, in specifications known as FAA Circulars.
[0120] Lighting fixture 205 of FIG. 13 has a stepped bottom comprising a portion 201 and a portion 200 . The portion 200 provides electrical wires 211 that bring electrical power to the lighting fixture 205 . Flange 206 is utilized to install the lighting fixture upon surface 263 of top flange 262 of universal top adjustable container 255 , inside its mud dam 269 . Lighting fixture 205 , when bolted onto top flange 262 , compresses an “O” ring 270 in a groove 265 , providing a water tight seal between the lighting fixture 205 and the inside of the universal top adjustable alignment container 255 of FIG. 13 .
[0121] Lighting fixture 209 has two countersunk windows 208 , similar to the countersunk windows 108 on lighting fixtures 95 , 105 of FIG. 9 . The lighting fixture 205 also has one azimuth orientation arrow (not shown) engraved in each of countersunk windows 208 . The countersunk windows 208 , engraved azimuth arrows, lighting system, and their angular positioning for all lighting fixtures manufactured in the U.S. are all very similar and they are all mandated by FAA regulations, i.e., FAA Circulars.
[0122] Engraved azimuth arrows (not shown) on the lighting fixture 205 are utilized to aid the installer in aligning the lighting fixture 205 in azimuth, on the runway centerline and in the direction 32 of landing aircraft 51 ( FIG. 3 ).
[0123] Referring now to FIG. 14 , a plan view, i.e., a top view, of the universal top adjustable alignment container 255 , of FIG. 13 , is shown. FIG. 14 shows the top flange 262 , with its mud dam 269 and twelve threaded holds 264 drilled and tapped on the bolt circle 214 , at thirty degrees 235 from each other. FIG. 14 also shows groove 265 in surface 263 of top flange 262 . Groove 265 is provide for receiving “O” ring 270 . In addition, FIG. 14 shows straight surface 266 of inside opening 267 and inside surface 274 of tubular section 257 .
[0124] The universal top adjustable alignment container of the present invention can also be fabricated of individual components, which can be welded together. By way of an example, top flange 262 can be welded at 271 to the tubular section 257 , and mud dam 269 can be made of a piece of thin steel welded to the outer periphery of top flange 262 . Any machining including the cutting of acme threads 256 and the drilling and tapping of holes 259 , 260 , and 264 can be done at the time each component is fabricated or after all or part of the components have been welded together.
[0125] Whether cast in one piece or fabricated of individual components, the universal top adjustable alignment container 255 preferably is made of stainless steel, to provide for corrosion resistance.
[0126] The alignments adjustments precision makes the apparatus of the present invention an efficient and economical apparatus and method for the replacement of conventional, existing fixed-length extensions at the time of renovation, i.e., resurfacing of aircraft ground traffic areas, as well as for new installations of such traffic areas by eliminating the need for installing fixed-length extensions, by eliminating the need for installing several flat spacer rings of various thicknesses, by eliminating the need for installing and angle-correcting, tapered spacer rings, i.e., leveling rings, and by eliminating the need for installing a separate mud dam. In addition, the installation of alignments adjustments assembly of the present invention saves labor costs, and the assembly is reusable.
[0127] Thus it can be seen that the invention accomplishes all of its objectives.
[0128] The apparatus and process of the present invention are not limited to the descriptions of specific embodiments presented hereinabove, but rather the apparatus and process of the present invention should be viewed in terms of the claims that follow and equivalents thereof. Further, while the invention has been described in conjunction with several such specific embodiments, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing detailed descriptions. Accordingly, this invention is intended to embrace all such alternatives, modifications, and variations which fall within the spirit and scope of the appended claims.
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An airport inset light adjustable alignment container set provides a light fixture and stainless steel support for airport runway, taxiway, or other aircraft ground traffic areas. A variable length extension means rotatably adjusts height and azimuth by a rotatable vertical displacement. In one aspect, a previously installed, airport inset light and stainless steel base of the present invention receives a variable length extension assembly for rotatably adjusting the height and azimuth alignment of an airport inset light. Rotation locking means are provided for securing the rotatable adjustment apparatus from further rotation. A novel stainless steel base is adapted to receive various different designs of inset lights and, in one aspect, to provide a stainless steel protection ring “mud dam.”
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for the coating of a running layer of material, in particular paper and/or cardboard.
2. Description of the Related Art
Patent Document EP 0 438 743 B1 describes a process which basically consists of applying two wet coatings on a moving layer of material whereby the second coating is applied while the first coating is still wet. The first coating is spread upon the outer surface of an applicator roller and then the coating material is pressed upon the layer of material as it is moving through a press nip that is formed between this applicator roller and a counter roller which presses the material layer against the applicator roller. The second layer of coating is applied via a jet chamber onto a spreader roller or a spreader blade in direct application on top of the first layer of coating. As an alternative to this combination of spreader roller and jet chamber another device is recommended which employs a scoop roller where a transfer roller scoops the wet coating substance out of a holding basin and directly applies it upon the moving material layer.
DE 39 22 535 C2 also describes a process to apply two layers of coating material, one on top of the other, on a moving layer of material while the bottom layer is still wet, and the equipment to facilitate the process. The first layer of coating is applied indirectly whereby the coating substance is applied onto the outer surface of an applicator roller by a combination of spreading element and jet chamber before it is transferred onto the layer of material as it is moving through a press nip formed in-between the applicator roller and a counter roller. The second layer of coating is subsequently applied directly onto the first layer of coating again with a combination of spreading element and jet chamber, where a spreader blade smoothes the surface of the second layer of coating.
For a number of different products these two processes and the associated machineries provide good results where a pre-coating and a final coating, that is two coatings on top of one another, are required, but other applications demand smoother coatings, especially a smooth top coating is often essential.
SUMMARY OF THE INVENTION
The present invention provides a process and the associated equipment necessary to produce two layers of coatings where the quality of the second layer on top is enhanced.
According to the process prescribed by the present invention, the first step consists of applying a layer of the first of the two sorts of liquid or pasty substances by an applicator implement which determines the precise quantity of this substance before it is spread onto the outer cylindrical surface of a rotating applicator roller. From there the layer of liquid or pasty substance is transferred by the rotation of the applicator roller within a compression gap that is formed between the applicator roller and a counter roller where it is dispensed onto one side of the layer of moving material. The first layer of liquid or pasty substance is therefore applied in an indirect manner onto the moving layer of material since the pasty substance is first applied onto an applicator roller before it is finally from there spread onto the moving layer of material. The first step of this operation also entails an act of compression during which the liquid or pasty substance is squeezed into the material of the moving layer. While this first applied layer is still moist a second layer of another or the same liquid or pasty substance is applied on top of it as a second operation. According to the invention this second layer is also applied in an indirect fashion onto the layer of moving material. Just as the previous operation the second layer of liquid or pasty substance is first applied onto an applicator roller before it is from there spread onto the moving layer of material
According to the invention presented here both layers of the pasty or liquid substance are applied in an indirect way onto the surface of the layer of material, that is to say that an applicator implement is spreading the media onto the outer cylindrical surface of an applicator roller before these media are from there transferred onto the moving layer of material. The first step of the operation, the application of the first layer of liquid or pasty medium, takes place within a compression gap as the medium is being squeezed into the moving layer of material, whereby the medium, for example paint, is loosing the majority of its water content because the majority of the liquid phase enters the layer of material, for example paper, while the solid components remain on the surface of the material layer where the are beginning to form a sort of filter cake. The liquid components will for the most part have entered the material layer and only a very thin film of liquid paint will remain on top of the filter cake. The thickness of this liquid film is small in comparison to the filter cake. This first dehydrated layer of coating, that is filter cake, provides a very good foundation on which the second layer of coating can be applied without an intermediate drying step. Applying the second layer of coating in this prescribed manner brings out a number of different advantages for the various embodiments of the invention.
In the first of the preferred embodiments of the process described by this invention, the second stage of the coating operation begins by applying a predetermined amount of liquid or pasty substance onto the cylindrical surface of a second rotating applicator roller which is subsequently transferred by the applicator roller onto the moving layer of material under the influence of an applied pressure which squeezes the second medium into the material layer as well. This embodiment has the advantage that the second layer of coating also loses a large portion of its liquid phase.
In the second of the preferred embodiments of the process described by this invention, the second stage of the coating operation transfers the liquid or pasty medium from the outer surface of the second applicator roller onto the moving layer of material such that the surface of the applicator roller is moving counter to the relative motion of the material layer. The layer of material is thus receiving the liquid or pasty coating medium as it is running against the relative movement of the applicator roller. This sort of procedure is particularly suited for the application of coating media with a very low viscosity, for example to apply a thermo-sensitive finish coating. Thermal coatings are utilized to produce paper for FAX machines with thermal print devices, which is in essence a paper that darkens under the influence of light. This thermo-sensitive effect is caused by the second layer of coating. This sort of procedure is furthermore utilized to apply a spreading medium that contains micro capsules. Paper that has been coated with a layer of finely distributed micro capsules is being used as the sort copy paper that will produce a copy of the page that is printed on by releasing a color as the micro capsules burst under the pressure of the printing device to, for example, a sheet of paper below it.
The coating process according to this invention, which consists of applying the second layer of coating, that is the finish coating, in an indirect fashion provides on one hand a way to separate the water from the second layer as it is applied, because the second layer is also applied under pressure so that the liquid is squeezed into the layer, on the other hand it can be applied so that the second layer of coating is applied while the applicator roller is moving against the relative direction of the layer of material which allows the coating medium to be applied very gently which is of great concern for the coating of paper with micro capsules which may burst under the pressure of the printing device. The coating procedure according to this invention provides certain advantages for some special purposes where other methods would not produce the same high quality of coating.
An apparatus that can perform the coating procedure according to this invention incorporates a rotating counter roller which supports at least a portion of the moving material layer with its outer cylindrical surface. This apparatus furthermore contains an applicator roller which rotates opposite to the counter roller and which is spaced relative to the location of the counter roller leaving an opening which is the press nip. In the process the moving material layer is guided through this press nip. An applicator implement is aimed at the outer cylindrical surface of the first applicator roller which in the process will dispense the liquid or pasty medium at a predetermined rate. After the moving material layer has passed the first press nip it moves to a second applicator roller while still being supported by the same counter roller whose location is also controlled relative to the second applicator roller. A second applicator implement is aimed at this second applicator roller in order to apply a second coating onto the outer surface of this second applicator roller before the liquid or pasty medium is transferred onto the moving material layer. In other words, there is a common counter roller, whose outer cylindrical surface supports at least a portion of the moving material layer, which at the first location where the moving layer of material is supported (contacted) by this counter roller is met by a first applicator roller which in turn is coated by a first applicator implement with the liquid or pasty coating medium, and which further along the line of the passage of the material layer, at a second location where the moving layer of material is supported (contacted) by this counter roller is met by a second applicator roller which in turn is coated by a second applicator implement with coating medium. The utilization of the common counter roller, which acts in conjunction with two applicator rollers, each with their own associated coating applicator implements, results in a very compact construction.
The first preferred embodiment features the second applicator roller rotating opposite to the direction of the counter roller and it is spaced relative to the counter roller so that a press nip is formed through which the moving layer of material is passing. The devices for applying the second layer of coating, that means the second applicator roller and the second applicator implement, are analogous to the devices for applying the first layer of coating, and each coating process involves the squeezing action with which the coatings are pressed into the moving layers of material.
A special embodiment features the two applicator rollers positioned symmetrically about a plane to which the center axis or the axis of rotation of the common counter roller is a subset so that this plane of symmetry constitutes also a centroidal plane of the counter rollers. Consequently, the axis of rotation of the counter roller and the axes of rotation of both applicator rollers are located on the same plane. This furthermore necessitates that the two points of tangency at which the counter roller and each of the applicator rollers touch one another and which form very thin slit, the press nips, are also located on the same plane which is common to the center axes of each of the rollers. In addition to these peculiar geometrical features, it can also be pointed out that the path of the moving layer of material from where it enters the first press nip between the first applicator roller and the counter roller up to the point where it passes the second press nip between the second applicator roller and the counter roller, forms a trajectory which in itself is also symmetrical with respect to the above mentioned plane of symmetry. This sort of geometrical assemblage results in a very compact and space saving arrangement for the entire machinery. The often referred to plane of symmetry should be preferably kept either vertical or horizontal, but if necessary it can also be inclined in any desirable angle.
A further preferred embodiment of the apparatus which is described in this invention is the introduction of a deflection pulley, rotary stretcher or expander roller which will guide the moving layer of material after it has passed the first press nip and before it enters the second press nip. The introduction of such deflection pulley, rotary stretcher or expander roller allows that the moving layer of material is lifted up from the surface of the counter roller. The purpose behind this maneuver is to prevent the formation of folds or wrinkles within the moving layer of material. In case of the before mentioned planar symmetrical arrangement it would be preferable to position the deflection pulley, rotary stretcher or expander roller in the plane of symmetry.
A second preferred embodiment of the apparatus described by this invention incorporates a second applicator roller which rotates in the same direction as the counter roller. This embodiment does not include a press nip in-between the counter roller and the second applicator roller where pressure is applied onto the moving material layer as it is passing through but the material layer is passing through an open gap at all time and fully supported by the counter roller while the outer cylindrical surface of the applicator roller moves opposite to the relative movement of the material layer. In other word a point on the outer cylindrical surface of the second applicator roller as it moves past this open gap moves opposite to the direction of the nearest point on the outer cylindrical surface of the counter roller. This arrangement of roller rotations causes the second liquid or pasty substance to move against the relative motion of the layer of material at the time of impact as this material layer is guided and supported by the counter roller. The liquid or pasty medium will build up on the side of the open gap where the outer surface of the second applicator roller approaches the open gap. This applicator roller is known as a "Reverse Roll Coater."
A preferred arrangement for the second embodiment, where the second applicator roller rotates in the way as the counter roller, for example looking on ends both would rotate clockwise, features a scooping arrangement in place of the applicator implement where a scoop roller scoops the second liquid or pasty medium out of a container and then transfers it onto the second applicator roller.
A preferred arrangement for the first and second embodiments of the apparatus described by this invention, which on one hand is the embodiment featuring a second press nip and which in the other hand is the embodiment featuring the second applicator roller rotating in the way as the counter roller, that is looking on ends both would rotate clockwise, utilizes a jet nozzle as an implement to apply precisely determined amounts of the liquid or pasty substance onto the second applicator roller. This jet nozzle implement is preferably built as either a free streaming jet applicator implement or as an applicator implement that consists of a combination of spreading element and pressure chamber. The free streaming jet applicator implement is basically a thin crack through which a free stream of liquid or pasty medium is propelled onto the surface of the second applicator roller. The other device consisting of a combination of spreading device and pressure chamber is basically a closed applicator chamber which is formed by a the spreader element, a deckle board and the surface of the second applicator roller. The spreader element in this case can be either singular or plural, either straight or contoured rolling wiper stick(s), coater blade(s), or deckle board(s) which distribute liquid or pasty medium out of the chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic side view of a first embodiment of the apparatus presented by this invention;
FIG. 2 is a schematic side view of a second embodiment of the apparatus presented by this invention; and
FIG. 3 is a schematic side view of a third embodiment of the apparatus presented by this invention.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The first embodiment shown in FIG. 1 includes a counter roller 1 that rotates around its center axis in the direction indicated by the arrow, that is in counter clock wise rotation. A first applicator roller 2 is positioned to the left of counter roller 1 so that the outer surface 2A of the first applicator roller 2 is in intimate contact with outer surface 1A of counter roller 1, forming a first press nip at their point of contact. A second applicator roller 3 is located to the right of counter roller 1, thus forming a symmetrical arrangement around a plane 10 which passes vertically through the center axis of counter roller 1. The second applicator roller 3 is positioned such that the outer surface 3A of first applicator roller 3 is in intimate contact with outer surface 1A of counter roller 1, forming the second press nip in this apparatus at their point of contact. The applicator rollers rotate in the directions indicated by the arrows, both in clock wise rotation, around their respective axes of symmetry, thus both are rotating opposite or "against" the relative rotation of counter roller 1. Both applicator rollers are mounted on supports which can be tilted about the axes 8, so that they can be brought closer to or away from the outer surface of the counter roller. A moving layer of material 4, for example paper, cardboard, or some textile, first enters into the first press nip, moves along a segment where it touches the outer surface 1A of the counter roller 1, is lifted away from the surface 1A of the counter roller 1 by an expander roller 7, then touches back onto the outer surface 1A of the counter roller until it has passed through the second press nip, then is moved away in a direction that is parallel but opposite to the path that brought the material layer 4 to the first press nip. The trajectory of the material layer 4 passing through the apparatus is indicated by two arrows in FIG. 1. It is evident from FIG. 1 that the trajectory of this path along which the material layer 4 moves is symmetrical with respect to the plane of symmetry 10.
The example which is illustrated incorporates an expander roller 7 to stretch the path of the material layer in order to prevent folds or wrinkles to form in the layer of material 4. But it is entirely possible to let the layer of material be supported by the outer surface 1A of the counter roller 1 along the entire path from the first press nip to the second press nip.
The schematic furthermore indicates an applicator implement which is made up of a combination of a spreading device and pressure chamber and which is assigned to the outer surface 2A of the first applicator roller 2. The schematic also shows a second applicator implement 6 which is made up of a combination of a spreading device and pressure chamber and which is assigned to the outer surface 3A of the second applicator roller 3.
The following explanations illustrate the how the apparatus shown in FIG. 1 is intended to function. The applicator implement 5 applies a first liquid or pasty medium onto the outer surface 2A of the first applicator roller 2. This pasty or liquid medium is then transferred onto the moving layer of material 4 as this passes through the first press nip, where the liquid or pasty medium is pressed into the layer of material. The second applicator implement 6 applies a second liquid or pasty medium onto the outer surface 3A of the second applicator roller 3. As the moving layer of material 4 approaches the second press nip and while the first layer of coating is still moist the second medium is transferred from the second applicator roller 3 onto the material layer 4 as a finish coating, which is then pressed into material layer 4 just as the first coating. This process is targeted to apply two layers of coating onto the same side of a moving layer of material without an intermediate drying of the first layer between the two applicator rollers.
The next two examples of the embodiments of this apparatus, illustrated in FIGS. 2 and 3, incorporate similar or identical components which are represented with the same reference numbers as in FIG. 1 and are explained in the following paragraphs.
The lay out of the second example, shown in FIG. 2, corresponds to that shown in the example shown in FIG. 1 with the important difference that the plane of symmetry is horizontal in FIG. 2 while it is vertical in FIG. 1. The layer of material 4 moves initially vertically downward, then turns 900 around a deflection pulley 9 which is positioned in front of the first applicator roller 2, before it enters the first press nip. Similar deflection pulleys can be utilized next to the second applicator roller to control the trajectory of the moving material layer after it leaves the second press nip. The use of deflector pulleys is a useful tool to effectively control the material layer movement in confined spaces.
The example illustrated in FIG. 3 differs from the previous two examples in the way in the way the second layer of coating medium is applied. As indicated by an arrow the second applicator roller 3 in the same way as the counter roller 1, both rotating clockwise around their central axes. The apparatus features the second applicator 3 roller equipped with a scooping arrangement 6 in place of the applicator implement. This scooping arrangement 6 consists of a scoop roller 12 which scoops the second liquid or pasty medium 11 out of a container 13 and then transfers it onto the outer surface 3A of the second applicator roller 3. From there the liquid or pasty medium 11 is moved to the open gap that exists between the second applicator roller 3 and the counter roller 1. The moving material layer 4 is supported by the outer surface 1A of the counter roller 1 as it is guided through this open gap so that the incoming liquid or pasty substance 11 is collecting at the side of the gap where the outer surface 3A of the second applicator roller 3 is approaching the gap. The importance of this process is that the liquid or pasty medium is applied very gently onto the first layer of coating on top of the moving material layer 4.
The components of the first applicator implement 5 are all mounted on a support structure 15. The liquid or pasty medium 11 passes through a distributor pipe 16, then through a supply channel 17, before it enters the applicator chamber, which itself is formed by the spreader element 14, deckle boards 18 as well as the outer surface 2A of the first applicator roller 2. The liquid or pasty medium leaves the pressurized chamber and is distributed by a spreader element, for example a rolling wiper stick, onto the outer surface 2A of the first applicator roller. Excess medium can flow over the deckle board 18 and be caught in the collector bin 19. The procedure illustrated in FIG. 3 is particularly suited for applying coatings with very low viscosities, such as for example thermo-sensitive finish coatings for FAX paper or micro capsule finish coating. This "reverse-roll" process, which employs counter movement of the counter roller 1 to relative to the second applicator roller 3, is especially useful for media that are very sensitive to shearing.
The processes and devices presented in this invention are very useful for applying very thin pre coatings, such as pre coating thicknesses of approximately 5-10 g/m 2 . The thicknesses of the corresponding finish coatings on the other hand can be in excess of 20 g/m 2 .
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A method and apparatus for coating a traveling layer of material, in particular paper and/or cardboard. An applicator implement applies a predetermined and proper amount of a liquid or pasty medium onto an outer surface of a first rotating applicator roller which in turn transfers the liquid or pasty medium onto a first side of the moving layer of material just as it is moving through a press nip. A second layer of coating medium is applied indirectly with a second applicator implement onto an outer surface of a second rotating applicator roller from where it is transferred onto the previously coated side of the moving material layer while the first coat of coating medium is still wet.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of U.S. Provisional Patent Application No. 61/499,001, entitled “PLUNGER LIFT SLUG CONTROLLER,” filed Jun. 20, 2011, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Liquid loading of the wellbore is often a serious problem in aging production wells. Operators commonly use beam lift pumps or remedial techniques, such as venting or “blowing down” the well to atmospheric pressure to remove liquid buildup and restore well productivity. In the case of blowing down a well, the process must be repeated over time as fluids reaccumulate, resulting in additional methane emissions.
[0003] Plunger lift systems are a cost-effective alternative to both beam lifts and well blowdowns and can make use of well energy to lift liquid from the well efficiently, i.e., to lift liquid with little or no slug fallback so that gas can flow without the obstruction of liquid loading for a period of time before the plunger is allowed to fall again. A plunger lift system is a form of intermittent gas lift that uses gas pressure buildup in the casing-tubing annulus and surrounding reservoir to push a plunger, and a column of fluid ahead of the plunger, up the well tubing to the surface. The plunger serves as a piston between the liquid and the gas, which minimizes liquid fallback, and acts as a scale and paraffin scraper.
[0004] The operation of a plunger lift system relies on the natural buildup of pressure in a gas well during the time that the well is shut-in, i.e., not producing. The well shut-in pressure must be sufficiently higher than the sales-line pressure to lift the plunger and liquid load to the surface. A surface valve is controlled by a microprocessor for controlling the on and off time of the plunger lift system during periods when gas is vented to the sales line or when the well is shut-in. The controller is normally powered by a solar recharged battery and can be a simple timer-cycle or have solid state memory and programmable functions based on process sensors.
[0005] During the off times, casing and tubing pressure build as the plunger falls through gas and liquid and then rests on a bumper spring at the bottom of the well. While the well is open, the plunger and liquid rises and the liquid is produced. The plunger is held in the top of the well during an after-flow period by gas flow. As the gas flow diminishes below a critical value, liquid begins to accumulate in the bottom of the tubing. Liquid accumulated in the bottom of the tubing is evidenced by surface measurements that show casing pressure being higher than tubing pressure during the shut in period.
[0006] Operation of a typical plunger lift system involves the following steps: The plunger rests on a bottom hole bumper spring located at the base of the well. As gas is produced to a sales line, liquids accumulate in the well-bore, creating a gradual increase in backpressure that slows gas production. To reverse the decline in gas production, the well is shut-in at the surface by an automatic controller. This causes well pressure to increase as a large volume of high pressure gas accumulates in the annulus between the casing and tubing. Once a sufficient volume of gas and a sufficient pressure is obtained, the plunger and liquid load are pushed to the surface. As the plunger is lifted to the surface, gas and accumulated liquids above the plunger flow through the upper and lower outlets. The plunger arrives and is captured in the lubricator, situated across from the upper lubricator outlet. The gas that has lifted the plunger flows through the lower outlet to the sales line. Once gas flow is stabilized, the automatic controller releases the plunger, dropping it back down the tubing. The cycle repeats. The above is known as a plunger cycle.
[0007] Overall control of a plunger cycle can be implemented in different ways. One simple way involves opening a control valve when high casing pressure is experienced and flowing gas and liquid until a low casing pressure is achieved. Alternatively, the control valve may be opened when a high tubing pressure is experienced or the control valve may be closed when a low tubing pressure is experienced. These simple methods may require trial and error to get to continuous repeating cycles, i.e., to prevent the well from becoming liquid loaded.
[0008] Another example of an overall control algorithm involves monitoring rise velocity of the plunger and liquid. Experience has shown that arrival between 500-1000 fpm is a good operating range. Using this method, if the plunger and liquid come up faster than 1000 fpm, then the controller may be instructed to shut in for a shorter time during a following cycle, which would result in less casing pressure to lift the plunger and liquid. However, the controller must still facilitate a shut in that is long enough for plunger to fall to bottom of the well. Additionally, the well could flow longer during a following cycle, accumulating more liquid to make the plunger and liquid rise more slowly, i.e., within the range of 500-1000 fpm, as longer flow time below critical accumulates more liquid in the tubing. In this example, the controller looks at the current cycle and makes recommendations for timing of control valve opening and closing for the next cycle.
[0009] Using the same method, if the plunger were to rise too slowly, then the shut in time may be increased on the next cycle to give more casing pressure to lift the plunger more quickly. Alternatively, the flow time may be decreased to lift a smaller liquid slug. However, the flow time for the next cycle must be long enough to accumulate some liquid because if no liquid is accumulated, then the plunger will rise too fast and may cause damage.
[0010] The above are examples of overall cycle control. However, the control depends on the current cycle performance for making operational recommendations for the next cycle. A potential drawback is that too much liquid is accumulated in a current cycle, resulting in the plunger not rising in the next cycle, i.e., loading the well. Alternatively, the liquid slug may be too small and the plunger will rise too fast in the current cycle and do damage before adjustments are made.
[0011] New information technology systems have streamlined plunger lift monitoring and control. For example, technologies such as online data management and satellite communications allow operators to control plunger lift systems remotely, without regular field visits. Operators typically visit only the wells that need attention, which increases efficiency and reduces cost.
SUMMARY OF THE INVENTION
[0012] Therefore, one object of the invention is to control the size of the liquid load during the shut in time so that plunger will rise and not stall out. The intra-cycle, i.e., “within the cycle”, method of the invention does not require assessing performance on a completed current cycle to make recommendations for a subsequent cycle. The current practice of making adjustments for subsequent cycles based on information from completed current cycles results in an inability to adjust for the case where the current liquid load is too large, i.e., where the liquid and plunger will not rise. In contrast, with the method of the invention, over all control is still to be used but intra-cycle control will allow dynamic adjustments within a cycle to keep the plunger running and not stalling out or rising too fast.
[0013] A typical plunger lift cycle consists of the following steps:
[0014] First, a plunger is located at the bottom of a well on a bumper spring. Some liquid is present above the plunger. As time passes, some tubing pressure and some casing pressure builds.
[0015] Second, a main valve or tubing valve at the surface opens to lower line pressure and the plunger rises with produced gas. As pressure is reduced, expanding casing gas pushes the plunger from below. The plunger holds the slug together with minimum fall back as the plunger rises.
[0016] Third, as the plunger hits the surface, liquid is pushed out, i.e., into the production line. Flow and pressure hold the plunger at the surface as gas produces out one or two lines from the lubricator to the flow line. The gas flow is initially high and the gas carries liquid out as mist. As the flow drops with time the gas flow drops below critical and liquids begin to be left behind in the tubing below. A check valve may or may not be provided with the bumper spring. The check valve may or may not be spring loaded.
[0017] Fourth, once liquids accumulate in the tubing as measured by casing pressure increase or from a measured difference between casing pressure and tubing pressure on subsequent cycles, then the main valve closes. The plunger will then fall, first through gas and then through the accumulated liquid to rest on the bumper spring. Some additional time may then be needed to build enough pressure in the casing to lift the liquids with the plunger at an appropriate velocity, i.e. between 500 and 1000 fpm. The well must be shut in for at least the time required for the plunger to fall through the gas and liquid. The well may need to be shut in for an additional time to build sufficient pressure lift the liquid. Different styles of plungers fall at different rates through gas/liquid. The cycle then returns back to the first step, discussed above, and the cycle repeats. The phase of the plunger cycle from closure of the main valve in step four through step one, described above, may be referred to as the shut-in period.
[0018] The method of the invention provides intra-cycle, i.e. within the cycle, control by adjusting the size of the liquid slug during the shut in portion of the overall plunger cycle so that the plunger and liquids will rise, but not rise too fast.
[0019] The liquid slug is reduced by opening a control valve for short periods and then re-examining the liquid slug size by determining the difference between casing pressure and tubing pressure at the surface. Opening of the control valve is repeated as necessary during the shut in phase of the plunger cycle to adjust the liquid slug size to a manageable size. The liquid slug size should be below an input large threshold value. If the liquid slug size is maintained at a manageable size, then the plunger and liquids will rise to the surface, i.e., the plunger cycle will not stall out due to a large amount of liquid that inadvertently comes into the tubing.
[0020] Another problem relates to a condition wherein no liquid or too little liquid is present in the tubing. If this condition is encountered, then the amount of liquid in the tubing can be increased by opening the tubing main valve for short periods to lower the line pressure, which will allow more liquid to enter the tubing from the casing. However, if the end of tubing is above the casing perforations where gas and liquids enter the well, there may be no liquids present at the end of the tubing to flow into the tubing.
[0021] The purpose of some existing controllers is to either reduce flow time or increase the shut in time for a following plunger cycle, i.e., to make “next cycle adjustments”, if the liquid in tubing accumulated during the flow period of a current flow cycle is deemed to have been too high, resulting in a low arrival velocity of the plunger.
[0022] Alternatively, the purpose of some existing controllers is to increase the flow time and decrease the shut in time for a following plunger cycle, i.e., to make “next cycle adjustments”, if the liquid in the tubing accumulated during the flow period of a current plunger cycle is too small and the arrival velocity of the plunger is too fast.
[0023] The method of the invention controls the size of the liquid slug within the shut in time of the current plunger cycle and allows adjustments prior to the next cycle adjustments. “Next cycle adjustments” are still deemed desirable. However, reliance on “next cycle adjustments” alone, could allow the well to liquid load or could allow the plunger to arrive too fast if adjustments are made at the completion of the current cycle and prior to the next cycle rather than being made immediately, i.e., within the cycle, as suggested by the method of the invention.
[0024] The method of the invention allows for intra-cycle adjustment, i.e., allows for adjustment during the shut in portion of the total plunger cycle. Intra-cycle adjustments keep the plunger continuously cycling. As stated above, the method of the invention does not exclude controller adjustments of the next total plunger cycle based on performance of the current cycle. For example, if a slug of liquid is too large and the lower vent line valve is opened one or more times to allow the plunger to rise with a reduced load of liquid, the next cycle could still be handled with a cycle to cycle adjustment that is typically made for the case of too much liquid being present. The next cycle may still be adjusted according to current practices.
[0025] Additionally, if the tubing valve was opened during the shut in portion of the total plunger cycle, cycle to cycle adjustments could still take place as if the liquid level was too low regardless of whether the intra-cycle adjustments of the invention were made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows a plunger lift well of the invention;
[0027] FIG. 2 shows a spring loaded check valve for locating at the bottom of the well of FIG. 1 ;
[0028] FIG. 3 lists the events of a plunger cycle of the plunger lift well of Figure. 1 ;
[0029] FIG. 4 is a graphical representation of surface recorded casing and tubing pressures during the plunger cycle shown in FIG. 2 ;
[0030] FIG. 5 is a pressure versus time plot showing the effects of controlling, i.e., reducing to a smaller size, a large liquid slug during the shut-in period of the plunger cycle;
[0031] FIG. 6 is a pressure versus time plot showing the effects of controlling, i.e., increasing to a larger size, a liquid slug of small size during the shut-in period of the plunger cycle;
[0032] FIG. 7 is a graphical representation of changing liquid load due to multiple plunger cycles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring to FIG. 1 , shown is a plunger lift well 10 having casing 12 that extends below a ground surface 14 . Tubing 16 extends into casing 12 , defining annulus 17 therebetween. A tubing stop 18 is affixed at a lower end of tubing 16 . A bumper spring 20 is supported by tubing stop 18 for engaging plunger 22 when plunger 22 falls during shut in of well 10 .
[0034] The bumper spring assembly 20 may include a spring loaded ball and seat assembly 24 ( FIGS. 1 , 2 ) made up of ball 26 received within seat 28 . Relief spring 30 communicates with seat 28 . Spring 30 , having a correctly set spring compression, will prevent liquid in tubing 16 from falling out of tubing 16 during a shut in period of the plunger lift cycle. However, if the compression force of relief spring 30 is low enough, then equalizing pressure between casing 12 and tubing 16 for short intermittent times should still allow for compression of spring 30 and for some liquid to be pushed through seat 28 . If the compression of spring 30 is set too high, then liquids will not be forced through seat 28 when tubing and casing are equalized. The spring loaded ball and seat assembly 24 should not substantially affect inflow of liquids if tubing valve 32 is opened as ball 26 can open over the seat 28 as with any standing valve. In a well where liquids are not been falling out of tubing 16 during well shut in, then a spring loaded ball and seat assembly 24 or other type of check valve is not required.
[0035] An upper portion of tubing 16 may be closed off with tubing valve or master valve 32 . A catcher 34 with arrival sensor is located above tubing valve 32 and a lubricator 36 is affixed to an upper end of tubing 16 . Production line 38 communicates with lubricator 36 above tubing valve 32 . Bypass line 40 communicates annulus 17 between casing 12 and tubing 16 with production line 38 . Upper vent line 41 communicates production line 38 with lubricator 36 . Lower vent line 45 also communicates production line 38 with lubricator 36 . Upper vent line valve 43 is provided to adjust the pressure drop across plunger 22 when plunger 22 has risen to a location within lubricator 36 by controlling an amount of gas flowing through the upper and lower vent lines 41 and 45 .
[0036] Motor valve 42 is provided on production line 38 . Motor valve 42 is preferably a diaphragm-operated device controlled by controller 48 to selectively open and close production line 38 . Shutoff valve 44 is provided on production line 38 upstream of motor valve 42 . Bypass line valve 46 is located on bypass line 40 .
[0037] The apparatus of well 10 , described above, is used to control a size of liquid slug 23 at a bottom of tubing 16 during the shut in phase of a plunger cycle. The method for controlling the size of liquid slug 23 includes the steps of closing one or both of shutoff valve 44 and motor valve 42 to achieve shut in of well 10 . Bypass line valve 46 on bypass line 40 is opened for a short period of time while shutoff valve 44 and motor valve 42 are closed. Opening bypass line valve 46 communicates annulus 17 , which contains “casing pressure”, with tubing 16 , which contains “tubing pressure”. This will begin to equalize pressure in the casing 12 and pressure in tubing 16 as measured at the surface. The pressure equalization will allow liquids in the bottom of tubing 16 to begin to flow back into the casing 12 .
[0038] Measurements are taken to determine whether a pressure differential between pressure in tubing 16 and pressure in annulus 17 of casing 12 , measured at the surface, is below a predetermined threshold value. An example of a desirable pressure differential may be determined by the Foss and Gaul method, described in SPE 120636, “Modified Foss and Gaul Model Accurately Predicts Plunger Rise Velocity” by O. Lynn Rowlan, Echometer Company, SPE Member 0917344 and James F. Lea, PLTech LLC, SPE Member 009772-5 and J. N. McCoy, Echometer Company, SPE Member 0017843, said article incorporated herein by reference. Alternatively, the upper limit for the pressure differential could be determined from a previous plunger cycle wherein liquid slug 23 was found to be large enough to prevent cycling of plunger 22 . A lower limit could be set to ensure that a specific quantity of liquid 23 remained in tubing 16 , e.g., 10% of a barrel of liquid.
[0039] The step of opening bypass line valve 46 for a short period of time is repeated if the pressure differential between pressure in casing annulus 17 , i.e., the casing pressure, and pressure in tubing 16 , i.e., the tubing pressure, is above the predetermined threshold value. Maintaining the pressure differential below the threshold value prevents an accumulation of a large slug of fluid 23 in tubing 16 . Bypass line valve 46 may be opened repeatedly for brief periods to allow liquid to flow from tubing 16 to the casing 12 . Bypass line valve 46 is then shut and measurements are taken to determine if the difference between the pressure in casing 12 and the pressure in tubing 16 has dropped below the threshold value.
[0040] The phases of a plunger cycle are shown graphically in FIG. 3 . As explained above, motor valve 42 is shut after a flow period and liquid 23 accumulates downhole, allowing plunger 22 to fall back downhole. FIG. 3 ( 1 ) shows plunger 22 downhole. FIG. 3 ( 1 ) shows well 10 closed, or shut-in, wherein pressure in casing 12 is building. Plunger 22 rests on bottom hole bumper 20 (not shown in FIG. 3 ( 1 )) at the base of well 10 . FIG. 3 ( 2 ) shows motor valve 42 in an open condition to allow gas to flow from tubing 16 into flow line 38 . Plunger 22 and liquid 23 rise within tubing 16 . FIG. 3 ( 3 ) shows plunger 22 held at ground surface 14 as gas flows through lubricator 36 into production line 38 and through motor valve 42 . FIG. 3 ( 4 ) illustrates that most liquids 23 accumulate when gas velocity drops before motor valve 42 shut. FIG. 3 ( 5 ) shows that when motor valve 42 shuts, plunger 22 falls toward liquid 23 .
[0041] During the time the motor valve 42 is shut, i.e., during the shut-in phase, as shown in FIGS. 3 ( 5 ) and 3 ( 1 ), plunger 22 falls through gas, then falls through liquid 23 and then rests on bottom hole bumper spring 20 .
[0042] FIG. 4 shows surface recorded pressures for casing 12 and for tubing 16 during a typical plunger cycle described above. Pressure in casing 12 , i.e., the casing pressure (Csg P) is higher than the pressure in tubing 16 , i.e., the tubing pressure (Tbg P), due to liquid load downhole. As shown in FIG. 4 , casing pressure (Csg P) and tubing pressure (Tbg P) rise from event (A), when motor valve 42 ( FIG. 1 ) shuts. From event (A) through event ( 1 ), plunger 22 falls through gas. From event ( 1 ) to event ( 2 ), plunger 22 falls through liquid 23 . From event ( 2 ) to event (B), plunger 22 rests on bumper spring 20 . At event (B), motor valve 42 is opened. At event (B), the pressure differential between the casing pressure (Csg P) and the tubing pressure (Tbg P) is indicated by the vertical arrow. From event (B) to event ( 3 ), plunger 22 rises within tubing 16 . From event ( 3 ) to event ( 4 ), liquid slug 23 and plunger 22 arrive at lubricator 36 . From event ( 4 ) to event (C) casing pressure (Csg P) and tubing pressure (Tbg P) continue to drop during an after flow period with plunger 22 in lubricator 36 . At event (C), motor valve 42 closes again and the plunger cycle repeats.
[0043] If, during the shut in portion of the plunger cycle, i.e, from event (A) to (B) in FIG. 4 , liquid leaves the bottom of tubing 16 and flows back to casing 12 , which it sometimes does, pressure in casing 12 and in tubing 16 will begin to equalize. During the shut in portion of the cycle, pressure in casing 12 (Csg P in FIG. 4 ) and pressure in tubing 16 (Tbg P in FIG. 4 ) rise as gas from well 10 pressurizes casing 12 and tubing 16 . Liquid 23 may or may not exit from the bottom of the tubing 16 if no check valve, e.g., ball and seat assembly 24 , is present. To control the conditions under which liquid 23 can escape from the bottom of tubing 16 , a check valve may be added at the bottom of well 10 so that pressure exerted from the surface in tubing 16 will open the check valve, e.g., check valve assembly 24 , and force out liquid 23 from tubing 16 only if pressure in tubing 16 is greater than a desired threshold. This may allow tubing 16 to be unloaded without swabbing or pulling tubing 16 if too much liquid is present in tubing 16 . In the case of moderate liquid loading, liquid 23 may remain in tubing 16 for lifting by plunger 22 as described above.
[0044] In summary, so long as liquid level is not too high, liquid 23 may be allowed to build up and be subsequently lifted by plunger 22 . However, if the liquid level is too high, then the casing pressure and the tubing pressure may be equalized during the plunger cycle, e.g., from event (A) to event (B) in FIG. 4 . Upon pressure equalization, which may be partial or full, liquid 23 flows out of tubing 16 either through a lightly compressed spring check valve, i.e., through check valve 24 , or out of a bottom of tubing 16 having no check valve. Pressure is preferably partially equalized in short spurts during the shut in phase of the plunger cycle to control the amount of liquid 23 present in the well for avoiding a potential liquid loading of well 10 .
[0045] Referring now to FIG. 5 , shown is a graphical representation of the steps for controlling a liquid slug 23 that is too large during the shut in period of a plunger cycle. Event ( 1 ) indicates well shut in. After event ( 1 ), casing pressure (CP) and tubing pressure (TP) begin to rise. Plunger 22 falls through gas, then through liquid 23 . Plunger 22 will then remain for a short time on bottom of tubing 16 , e.g., on bumper spring 20 . At event ( 2 ), controller 48 equalizes casing pressure (CP) and tubing pressure (TP) for short time by opening bypass line valve 46 . As shown in FIG. 5 , a drop in casing pressure-tubing pressure differential occurs after event ( 2 ), which is indicative of a decrease in the size of liquid slug 23 . Pressure equalization action is taken if a difference between casing pressure minus tubing pressure is larger than a predetermined threshold. A large pressure differential indicates a liquid slug 23 at the bottom of tubing 16 that is too large during the shut in period of the plunger cycle. If necessary, at event ( 3 ), controller 48 partially equalizes casing pressure and tubing pressure by briefly opening bypass line valve 46 during shut in. The size of liquid slug 23 then decreases, as is indicated by a drop in the casing pressure-tubing pressure differential. By repeatedly opening bypass line valve 46 , the casing pressure—tubing pressure differential is reduced below an input acceptable value. At event ( 4 ), the size of liquid slug 23 is now below a maximum set point as determined by the set difference between casing pressure and tubing pressure. This keeps a large slug of liquid from stopping the plunger cycles. Plunger 22 is given time to fall through gas, liquid 23 and then arrive at the bottom of tubing 16 . Motor valve 42 is then opened to communicate tubing 16 with production line 38 and plunger 22 rises. A height of liquid slug 23 in the bottom of tubing 16 may be determined from the following equation:
[0000] Height of liquid, ft=( CP−TP , psi)/(0.433 psi/ft× SpGr of liquid)
[0046] Control of the size of liquid slug 23 can occur earlier in the plunger cycle and can occur more than the 2 times illustrated in FIG. 5 .
[0047] Referring now to FIG. 6 , shown are the steps for controlling a liquid slug 23 that is too small during a shut-in period of a plunger cycle. Event ( 1 ) indicates well shut in, e.g., by closure of motor valve 42 . After event ( 1 ), casing pressure (CP) and tubing pressure (TP) rise. Plunger 22 falls through gas, then through liquid 23 and then remains on the bottom of tubing 16 for a short period. Event ( 2 ) indicates that tubing pressure is briefly vented to production line 38 ( FIG. 1 ), e.g., by opening tubing valve 32 . This action may be taken when the difference between the casing pressure and the line pressure is determined to be too small. Venting tubing pressure to production line 38 ensures that tubing 16 is at lower pressure than the pressure in annulus 17 of casing 12 , i.e., than the casing pressure. If liquids are proximate to the bottom of tubing 16 in casing 12 , then the liquids will flow into the bottom of tubing 16 . At event ( 3 ) of the shut in period, tubing pressure is briefly vented to production line 38 for a second time. Venting to production line 38 is undertaken when a difference between casing pressure and line pressure is determined to be too small. Venting tubing pressure to production line 38 allows more fluid in casing 12 to enter bottom of tubing 16 . By venting tubing pressure to production line 38 , a larger casing pressure-tubing pressure differential is achieved. Event ( 4 ) indicates that a size of liquid slug 23 is above a minimum set point as determined by a predetermined set difference between casing pressure and tubing pressure. Plunger 22 is then given time to fall through gas, liquid 23 and then locate on bottom of tubing 16 . Well 10 is then opened, e.g., motor valve 42 is opened, to communicate tubing 16 to production line 38 . Plunger 22 then rises. Control the size of liquid slug 23 can occur earlier in the plunger cycle and can occur more or less than the two times illustrated in FIG. 6 .
[0048] FIG. 7 is a graphical representation of changing liquid load and how the difference between the pressures in casing 12 and tubing 16 can change during controlled plunger cycles to avoid liquid slug 23 becoming too large, which could result in a stoppage of the plunger cycle and liquid loading of well 10 . Lower vent line valve 46 is opened while motor valve 42 and shut off valve 44 are closed during the shut in portion of the plunger cycle. Casing pressure and tubing pressure rise, indicating shut in. Rising pressures allow higher pressure in casing 12 to act on the top of tubing 16 during short trial openings of bypass line valve 46 , which equalizes the casing pressure and the tubing pressure, at least to some extent. If casing pressure and tubing pressure are allowed to completely equalize then liquid slug 23 in tubing 16 falls completely back into casing 12 or drops to a very low level in the bottom of tubing 16 as liquids flow from tubing 16 back into annulus 17 of casing 12 , i.e., into casing 12 , which is at a lower pressure.
[0049] In one aspect of the invention, the pressure difference between the pressure in casing 12 and the pressure in tubing 16 is lowered during the shut in portion of the plunger cycle. Preferably, the two pressures are not equalized, but rather the differential between the pressures are lowered below a threshold input value. By avoiding a large pressure differential, plunger 22 does not have to lift a large slug of liquid 23 and possibly fail to arrive at the surface. Therefore, controller 48 should open bypass line valve 46 for a short time during the shut in period of the plunger cycle to reduce the difference in the tubing pressure above liquid 23 in tubing 16 and the casing pressure to below a threshold input value as measured at the surface. If the pressure differential is above the threshold input value, then the process is repeated. Even if the pressure difference is not reduced by repeating the procedure and checking the pressures, the size of liquid slug 23 may be reduced and the total plunger cycle will have a much better chance to continue to repeat the open and close portions of the normal plunger cycle. The method of the invention prevents plunger 22 from operating with a randomly sized, possibly larger than normal liquid slug 23 in tubing 16 . A large liquid slug 23 is undesirable because it could stop operation of the plunger cycles and result in a need for a restarting procedure. A restarting procedure takes time, manpower, and may stop well production for a period of time.
[0050] If the difference between the surface measured pressures in casing 12 and tubing 16 during the shut in period of the plunger cycle is too small, then this condition indicates that liquid slug 23 in tubing 16 is too small or may be non-existent. To increase the size of liquid slug 23 , motor valve 42 is briefly opened while casing bypass valve 46 is closed and shut off valve 44 is open, to allow some gas to leave tubing 16 and allow more liquid to enter tubing 16 . Controller 48 will repeat this process and measurements will be taken to determine if the tubing pressure and casing pressure differential has risen above the input minimum value. By ensuring that the pressure differential has risen above a minimum value, plunger 22 is prevented from rising with no liquid slug 23 . The presence of only a small amount of liquid 23 or the absence of any liquid 23 can cause rapid arrivals at ground surface 14 of plunger 22 , which can damage well equipment.
[0051] In general, described above is a method to control the size of liquid slug 23 at the bottom of tubing 16 during the off portion, or shut in portion, of a plunger cycle. By controlling the size of liquid slug 23 , controller 48 is allowed to continue cycling and not stop due to a large liquid slug 23 . Additionally, damage to well equipment due to operating with too small of liquid slug 23 may be avoided. Various types of plumbing and valves might be present at the well head but would still allow operation of the invention as described herein.
[0052] Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims.
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A method for controlling the liquid load size of a plunger lift well during the shut in time of the well to facilitate a controlled plunger rise. Intra-cycle control allows dynamic adjustments within a cycle to keep the plunger running and not stalling out or rising too fast. The method includes the steps of shutting in the well to build up pressure within the well, adjusting a size of a liquid slug within the tubing while the well is shut in, opening a valve to relieve pressure within the well and raise the plunger within the tubing, pushing the liquid slug out of the well with the plunger, and closing the valve wherein the plunger falls within the tubing. The intra-cycle adjustments include reducing the size of the liquid slug for preventing fluid loading and increasing the size of the liquid slug for controlling a rise rate of the plunger.
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This application claims the priority of U.S. Provisional Patent Application Ser. No. 61/029,731, filed on Feb. 19, 2008, the disclosure of which is incorporated by reference herein.
TECHNICAL FIELD
This invention is related to apparatus and methods for dispensing liquids and, more particularly, to apparatus and methods for dispensing liquids from a cartridge.
BACKGROUND
In certain applications it is sometimes necessary to dispense liquids out of a cartridge or similar container and onto a desired target. For example, in the electronics industry, materials such as polyurethane reactive (“PUR”) adhesives may be dispensed out of a syringe-like cartridge and onto a desired target. Conventional apparatus for dispensing viscous liquids from cartridges may result in stringing of the liquid, and this can negatively affect quality and/or control of the dispensing operation.
There is a need, therefore, for apparatus and methods that address these and other issues associated with conventional apparatus and methods.
SUMMARY
In one embodiment, a dispensing valve includes a valve body that is adapted to receive at least a portion of the cartridge therein. A valve member is disposed in the valve body and is adapted for fluid communication with the cartridge. A valve seat element is disposed in the valve body. The valve seat element includes a liquid chamber with a liquid outlet and is mounted for reciprocating movement between a closed position engaged with the valve member to prevent liquid from exiting the liquid outlet and an open position disengaged from the valve member to allow liquid to flow from the liquid chamber through the liquid outlet. The valve body may include a longitudinal axis and a receiving bore extending along the longitudinal axis, with the liquid outlet being substantially co-axial with the receiving bore. Additionally or alternatively, the valve body may include a longitudinal axis and the valve seat element is mounted for reciprocating movement substantially along the longitudinal axis.
The valve body may include a luer connector that is adapted for coupling with the cartridge. The liquid outlet may be disposed in the valve seat element for movement therewith between the open and closed positions. At least one of the valve member or the valve seat element may be formed of a plastic material. The valve body may include an air inlet for receiving actuation air there through, with the valve seat element being in communication with the air inlet and being movable between the open and closed positions by action of the actuation air. The valve body may include a detachable distal portion, with removal of the detachable distal portion providing access to the valve seat element.
In another embodiment, an assembly is disclosed for dispensing liquid from a cartridge. The assembly includes a valve body that is adapted to receive at least a portion of the cartridge therein. A solenoid valve is coupled to the valve body and is in fluid communication therewith. A valve member is disposed in the valve body and is adapted for fluid communication with the cartridge. A valve seat element is disposed in the valve body and has opposed surfaces in communication with the solenoid valve and a liquid chamber with a liquid outlet. The valve seat element is mounted for reciprocating movement between a closed position engaged with the valve member to prevent liquid from exiting the liquid outlet and an open position disengaged from the valve member to allow liquid to flow from the liquid chamber through the liquid outlet. The reciprocating movement is effected by selective directing of actuation air from the solenoid valve against one of the opposed surfaces of the valve seat element. The valve body may include an actuation air inlet that is adapted for coupling with a source of air, with the actuation air inlet extending through the valve body and communicating with a solenoid air inlet for feeding of actuation air into the solenoid valve.
In yet another embodiment, a method of dispensing liquid from a cartridge supported within a bore of a valve body includes maintaining a valve member with a liquid flow passage fluidly coupled to the cartridge and substantially fixed relative to the valve body. A valve seat element reciprocates between open and closed positions respectively into engagement and out of engagement with the valve member to control flow of the liquid from the cartridge through the liquid flow passage and out of the valve body. The method may include coupling the valve member with the cartridge outside of the valve body prior to insertion of the cartridge into the bore of the valve body. Alternatively or additionally, the method may include pressurizing the liquid within the cartridge. The method may include heating the liquid in the cartridge through the valve body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an assembly for dispensing a liquid out of a cartridge in accordance with one embodiment of the invention.
FIG. 2 is a view taken generally along line 2 - 2 of FIG. 1 .
FIG. 2A is a partially sectioned perspective view of a portion of the dispensing valve of FIGS. 1 and 2 .
FIG. 2B is a partially sectioned perspective view similar to FIG. 2A showing a valve seat element in an open position.
FIG. 3 is a perspective view of an exemplary cartridge.
FIG. 4 is a perspective translucent view of a portion of the dispensing valve of FIGS. 1 and 2 .
FIG. 5 is a view taken generally along line 5 - 5 of FIG. 1 .
DETAILED DESCRIPTION
With reference to the figures, and more particularly to FIGS. 1-5 , a dispensing valve 10 is shown for dispensing a liquid 12 such as, and without limitation, polyurethane reactive (PUR) adhesive from a cartridge 14 containing such liquid 12 . A solenoid valve 11 is coupled to the valve 10 for selectively supplying actuation air to the valve 10 , as further explained below. Jointly, the valve 10 and solenoid valve 11 define an assembly 13 for dispensing the liquid 12 from cartridge 14 . The valve 10 includes a valve body 20 configured to receive at least a portion of the cartridge 14 therein to facilitate dispensing of the liquid 12 onto a target such as a schematically-depicted electronic component 22 . In this exemplary embodiment, valve 10 is configured for dispensing liquid 12 from an exemplary syringe-like cartridge 14 having a barrel 24 that defines a volume containing the liquid 12 . Barrel 24 extends between proximal and distal ends 26 , 28 of cartridge 14 and includes a coupling portion for coupling the cartridge 14 with a cooperating feature of the valve 10 , as further discussed below. A cap 30 is disposed at the proximal end 26 of the cartridge 14 and blocks access to the liquid 12 . An orifice 32 in cap 30 permits injection of pressurized air there through to pressurize the interior 34 of barrel 24 and thereby facilitates dispensing of the liquid 12 through a dispensing aperture 36 at the distal end 28 of cartridge 14 . A gripping portion 40 of cartridge 14 facilitates manipulation thereof into and out of a receiving bore 50 of the valve 10 and further facilitates control of the distal placement of the cartridge 14 within valve body 20 .
As discussed, above, valve 10 receives at least a portion of the cartridge 14 therein. In this exemplary embodiment, the receiving bore 50 extends generally along a longitudinal axis 52 of valve body 20 and is suitably shaped and sized to receive the exemplary cartridge 14 of FIG. 3 therein. The receiving bore 50 extends between proximal and distal ends 60 , 62 of valve body 20 and includes, in this embodiment, a tapered section 64 that facilitates closely receiving barrel 24 of cartridge 14 within valve body 20 . Moreover, in this embodiment, the receiving bore 50 includes a coupling portion in the shape of a luer connector 66 ( FIG. 2A ) that cooperates with a luer coupling element 68 ( FIG. 3 ) of cartridge 14 to secure or at least conform cartridge 14 and valve 10 relative to one another.
The luer connector 66 in this exemplary embodiment may include threads (not shown) that engage cooperating threads (not shown) on luer coupling element 68 of the cartridge 14 to thereby secure the cartridge 14 and valve body 20 relative to one another. Those of ordinary skill in the art will readily appreciate that valve 10 may alternatively include a different type of connector or coupling element or no such structure at all.
With continued reference to FIGS. 1-5 , a clasp 70 of the valve 10 is coupled to the proximal end 60 of the valve body 20 and is rotatable into and out of engagement with cartridge 14 , to thereby secure cartridge 14 relative to valve body 20 . More particularly, clasp 70 is rotatable about a reference axis 21 ( FIG. 5 ) defined by a bolt 23 or similar structure, into engagement with the cap 30 of cartridge 14 and is secured in place relative to valve body 20 via one or more fasteners, for example. In this particular embodiment, once rotated into engagement with cap 30 , clasp 70 is secured in place by a bolt or screw 74 ( FIG. 1 ) and a cooperating secondary fastener such as a set screw 75 that frictionally engages bolt or screw 74 . It is contemplated that other mechanisms including or obviating fasteners may substitute the fasteners above described to permit clasp 70 or another similar structure to secure cartridge 14 relative to valve body 20 . Likewise, it is contemplated that such structure may engage other portions of the cartridge 14 such as, and without limitation, the gripping portion 40 .
End surfaces 77 , 78 of valve body 20 accommodate gripping portion 40 of cartridge 14 and thereby facilitate limiting of the distal placement (along longitudinal axis 52 ) of cartridge 14 within valve body 20 . An air conduit 80 is adjacent clasp 70 and extends through orifice 32 of cap 30 to communicate with the interior 34 of barrel 24 . Air conduit 80 permits coupling of an air source (not shown) to pressurize the interior of barrel 24 and thus facilitate dispensing of liquid 12 . To this end, in this embodiment, the exemplary air conduit 80 may include a recess 82 that permits relatively quick coupling of the air source (not shown) with air conduit 80 .
In this exemplary embodiment, valve body 20 is defined by a distal portion 90 and a main portion 92 coupled to one another, for example, via fasteners (not shown). This two-part construction of valve body 20 permits, if desired, separation of the portions 90 , 92 for cleaning or replacement purposes, for example.
As discussed above, valve 10 is configured to dispense liquid 12 from cartridge 14 . To this end, a valve member 100 and a cooperating valve seat element 102 are disposed in distal portion 90 to dispense liquid 12 through a liquid outlet 110 of valve body 20 , as explained in further detail below. In operation, the valve member 100 may be pre-coupled to the cartridge 14 outside of valve 10 and then inserted through an opening into bore 50 at proximal end 60 . Valve member 100 may be made of any suitable material. For example, and without limitation, valve member 100 may be formed of a plastic material which may also facilitate disposability thereof. The valve seat element 102 may be inserted into valve body 20 through an opening 97 at distal end 62 and secured to valve body 20 via a detachable portion 103 . In this exemplary embodiment, detachable portion 103 is in the form of a nut that threadably engages an inner wall 105 of valve body 20 , although other forms of detachable portions are contemplated so long as they provide access to an interior of valve body 20 and, more particularly, access to valve seat element 102 . Such access may be desirable for cleaning or replacement of valve seat element 102 which may be further made of a plastic material to thereby facilitate disposability thereof.
With continued reference to FIGS. 1-5 , the exemplary valve member 100 is a needle-like elongated structure extending generally from the coupling portion 66 of receiving bore 50 and includes a generally L-shaped passage 116 that is in fluid communication with dispensing aperture 36 of cartridge 14 to receive liquid 12 from cartridge 14 . Valve member 100 has a generally fixed position relative to valve body 20 and is generally surrounded by valve seat element 102 . Valve seat element 102 is movable relative to valve body 20 and thus movable relative to valve member 100 . A volume between valve member 100 and valve seat element 102 defines a chamber 104 that fills up with liquid 12 that flows out of passage 116 . Detachable portion 103 surrounds a distal portion of valve seat element 102 and restricts distal movement thereof. Valve seat element 102 reciprocates generally in a direction along or parallel to longitudinal axis 52 between an open position and a closed position. In this regard, valve member 100 includes a contacting surface 120 that engages a proximal entrance 122 into liquid outlet 110 when valve seat element 102 is in the closed position. When valve seat element 102 is in the open position, a gap 126 is defined between contacting surface 120 and proximal entrance 122 , thereby permitting flow of liquid 12 therethrough. More particularly, when in the open position, gap 126 permits flow of liquid 12 from chamber 104 and through liquid outlet 110 , thereby allowing dispensing of liquid 12 out of valve 10 and onto the target (e.g., electronic component 22 ).
Reciprocating movement of valve seat element 102 results in a corresponding reciprocating movement of liquid outlet 110 toward and away from the target. Moreover, the geometric disposition of the different components described above relative to the cartridge 14 facilitates a relative short path for the liquid 12 to travel as it exits dispensing aperture 36 and leaves valve 10 through liquid outlet 110 , which in this embodiment is substantially coaxial with receiving bore 50 .
With continued reference to FIGS. 1-5 , reciprocating movement of the valve seat element 102 is, in this exemplary embodiment, facilitated by pneumatic components. In particular, an actuation air inlet 130 extends from a peripheral surface 132 of detachable portion 90 and into the valve body 20 to facilitate such reciprocating movement. Inlet 130 communicates with an air feed passage 133 that, in turn, feeds actuation air into the solenoid valve 11 ( FIG. 1 ) through a solenoid air inlet 11 a of solenoid valve 11 . Solenoid valve 11 selectively directs actuation air into valve body 20 through upper and lower actuation air passages 135 , 137 disposed within valve body 20 . As used herein, the terms “upper,” “lower,” “up,” and “down” and derivatives thereof are not meant to be limiting but rather refer to the illustrative orientations shown in FIGS. 1-5 . Upper actuation air passage 135 communicates with a volume defined above an upper surface 139 of valve seat element 102 . Lower actuation air passage 137 communicates with a lower surface 141 of valve seat element 102 which is disposed axially opposite from upper surface 139 . When the solenoid valve 11 directs air through the upper actuation air passage 135 , actuation air pushes down on upper surface 139 , thereby causing downward movement of valve seat element 102 . This movement, as discussed above, disengages valve seat element 102 from valve member 100 , thereby permitting flow of liquid 12 through liquid outlet 110 . Conversely, when the solenoid valve 11 directs air through the lower actuation air passage 137 , actuation air pushes up on lower surface 141 , thereby causing upward movement of valve seat element 102 . This movement engages valve seat element 102 with valve member 100 , thereby restricting flow of liquid 12 through liquid outlet 110 .
While this embodiment illustrates actuation through a solenoid valve 11 that selectively directs actuation air to two separate regions of the valve body 20 , those of ordinary skill in the art will readily appreciate that other actuation components and processes may be used instead. For example, and without limitation, actuation may be effected through the combination of air and one or more springs or other biasing elements. Likewise, actuation may be effected through electromagnetic components rather than or in combination with pneumatic and/or mechanical components. Moreover, in the exemplary embodiment of FIG. 1-5 , sealing elements restrict passage of air and/or liquid between different components of valve 10 . These sealing elements are in the form of o-rings 140 of types and materials known in the art. In this regard, those of ordinary skill in the art will readily appreciate that other types of sealing elements or no sealing elements at all may be used instead.
In some applications it may be desirable to heat the contents of the cartridge 14 while in valve body 20 . To this end, a heater box portion 150 of valve body 20 extends along a length of valve body 20 to contain heating components that provide heat to cartridge 14 . In particular, heater box portion 150 includes a bore 154 that is adapted to receive a heating element (not shown) therein. A chamber 156 in heater box portion 150 is adapted to hold wires (not shown) connecting the heating element to a power source (not shown). In this illustrative embodiment, which includes no heating element, a cover 160 blocks access to an interior of heater box portion δ 50 and is secured in place via exemplary screws 170 .
With continued reference to FIGS. 1-5 , the valve body 20 may be coupled to a surrounding structure (not shown) via a mounting block 180 that is spaced from valve body 20 via one or more thermal insulating spacers 188 that reduce the transfer of heat between valve 10 and surrounding structures. This mounting block 180 is merely exemplary and may be replaced by any other type of suitably located mounting structure or no mounting structure at all.
While the present invention has been illustrated by the description of specific embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. The various features discussed herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept.
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A dispensing valve is provided for dispensing liquid from a cartridge. The valve includes a valve body that is adapted to receive at least a portion of the cartridge therein. A valve member is disposed in the valve body and is adapted for fluid communication with the cartridge. A valve seat element is disposed in the valve body and includes a liquid chamber that is in communication with the liquid outlet and is mounted for reciprocating movement between a closed position engaged with the valve member to prevent liquid from exiting the liquid outlet and an open position disengaged from the valve member to allow liquid to flow from the liquid chamber through the liquid outlet. The valve body may include a longitudinal axis and a receive bore extending along the longitudinal axis, with the liquid outlet being substantially co-axial with the receiving bore.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of German Patent 10 2005 005 852.3 filed Feb. 8, 2005 and hereby incorporated by reference herein.
[0002] The present invention provides a nonwoven fabric, in particular for use as a separator in batteries or galvanic cells, having functional fibers made of at least one fibrous material which intrinsically contains at least one substance that is chemically active or activatable in an alkaline medium. The present invention also provides a fiber having a fibrous material which intrinsically contains at least one substance that is chemically active or activatable in an alkaline medium. Finally, the present invention provides a galvanic cell, in particular a battery, having a casing, the casing at least partially accommodating one positive and one negative electrode, as well as a material that permits the transport of charge carriers, and a separator separating the electrodes, the separator including a nonwoven fabric or at least one fiber.
BACKGROUND OF THE INVENTION
[0003] Alkaline batteries or cells require separator materials that have special properties. These properties include resistance to the electrolyte, resistance to oxidation, high mechanical stability, low thickness tolerance, low resistance to the passage of ions, high resistance to the passage of electrons, retention capacity for solid particles coming off of the electrodes, permanent wettability by the electrolyte, and high storage capacity for the electrolyte liquid.
[0004] Depending on the polymer used to manufacture the separator, however, various advantages and disadvantages are associated with such separator materials. Thus, for example, separators made of polyolefins exhibit excellent resistance to chemical attack by highly alkaline electrolytes and to oxidation in the chemical environment of the cells. However, they exhibit poor wettability by the alkaline electrolyte. In contrast, polyamide always exhibits satisfactory wettability, but has inferior hydrolytic stability, especially at elevated temperatures.
[0005] When used in nickel-metal-hydride or nickel-cadmium storage batteries, the separator must perform an additional task. The disadvantage of an accelerated self-discharging arises in such storage batteries. Ions transport the charges in the electrolyte from the negative cadmium or metal-hydride electrode to the positive nickel-oxide electrode. Even in the quiescent state, the cell slowly self-discharges. In the event of an extreme exhaustive discharge, electrodes may become unusable in many cases, leading to a total loss of the storage battery.
[0006] Nitrogen compounds have been discussed as a mechanism of this unwanted self-discharging, which, by undergoing reduction at the negative electrode and oxidation at the positive electrode, are responsible for the transport of the electrons.
[0007] The influence of different separator materials on the self-discharging of nickel-cadmium or of nickel-metal-hydride storage batteries is discussed in the technical literature (P. Kritzer; J. Power Sources 2004, 137, 317-321).
[0008] The purpose of the separator material that is used is to lessen or suppress the self-discharging. This is presently accomplished in that the separator slows the discharging process by trapping ammonia.
[0009] At the present time, such ammonia-binding separators are manufactured in a process which includes the additional operational step of treating nonwoven polyolefin fabrics. The desired properties can be obtained both by the grafting of acrylic acid, as well as by sulfonation using concentrated sulfuric acid. This disadvantageously entails a second operational step following manufacture of the nonwoven fabric. Products manufactured using these production methods are commercially available, for example, from the firm Japan Vilene Co., JP (sulfonated materials) or from the firm Scimat Ltd., UK (materials grafted with acrylic acid).
[0010] Another manufacturing process includes the application of ammonia-absorbing powders or dispersions. In this context, polyolefins grafted with acrylic acid are used. Here, the disadvantage arises that “sealed locations,” which can degrade the battery's performance, can form in such products, in the area of the applied particles. Products manufactured using this method are commercially available from the firm Freudenberg Vliesstoffe (Freudenberg Nonwovens) KG, Weinheim, Germany.
[0011] The nonwoven fabrics of the type described have considerable drawbacks with regard to their manufacture and later use.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to devise a galvanic cell which, in the context of a simple and trouble-free manufacturing, is characterized by a long service life. The present invention provides a nonwoven fabric including functional fibers made of at least one fibrous material intrinsically containing at least one substance chemically active or activatable in an alkaline medium, the substance being incorporated surface-actively in volumetric regions of the functional fibers whose surface areas are able to be acted upon by the medium.
[0013] Properties of a galvanic cell may be determined by the nonwoven fabric used in the galvanic cell or by the fibers used in the galvanic cell. Chemically active or activatable substances may be used effectively and selectively by incorporating them in the fiber matrix and distributing them in the same. By selectively allocating the chemically active substances to merely those regions which are able to come in contact with the medium, an economical and effective use of the substances may be rendered possible. In this respect, only that portion of the fiber matrix requiring modification may be modified by the chemically active substances. This may eliminate a possibility of the overall structure of the fibers being disadvantageously affected by the modification. Incorporating the chemically active substance ensures that, as soon as substances are consumed at the surface, they can be replenishable from the inside of the volumetric region. This ensures an especially long service life for the galvanic cell.
[0014] The functional fibers may include multicomponent fibers. These fiber types are easily manufactured since the methods for manufacturing the same are already well known.
[0015] Given these facts, the multicomponent fibers may conceivably include side-by-side fibers. Commercial side-by-side fibers are easily obtained.
[0016] To achieve such a stabilization, the fibers may include core-sheath fibers, it being necessary for the core to provide the stabilizing action.
[0017] Exclusively one component of the multicomponent fibers may include the substance. This specific embodiment ensures that regions may be created in the fiber whose structures are not affected by the modification produced by the substance.
[0018] The sheath component of a core-sheath fiber may contain the substance. This may make it feasible for the substance to interact with the alkaline medium over the entire peripheral region of a fiber. In this respect, an especially large reactive surface area may be realized.
[0019] The nonwoven fabric may include a fiber blend having a functional fiber content of at least 15% by weight. The lower bound of 15% by weight represents a value at which a long enough discharge duration may be achieved for the galvanic cell. If fewer functional fibers are used, then the self-discharging may be too fast, and the battery may not have an advantage over batteries equipped with conventional separators.
[0020] At least one substance may be constituted of a polymer formed by copolymerization. A copolymerization process produces a material having an especially homogeneous and stable internal structure. This ensures an especially advantageous distribution of chemically active molecules in a volume.
[0021] At least one substance may be constituted of a polymer formed by grafting. In particular, the functional polymers present in the melt or solution or dispersion may conceivably be grafted with acrylic acid and subsequently spun into fibers. Alternatively thereto, the fibers may be grafted with acrylic acid in a dispersion following the spinning process. The fibers may be subsequently further processed in downstream processes into a nonwoven fabric, without undergoing any further chemical modification.
[0022] The fibers may be functionalized using copolymerization or grafting processes in which the polymers are reactively extruded and, as a result, possess functional groups in the molecule or form the same in the alkaline electrolyte that are capable of binding ammonia from the alkaline solution. In this context, the polymers may contain functional groups that are active as Lewis acids in the alkaline medium. This specific embodiment ensures that the functional fibers can bind ammonia in the alkaline solution. This effectively may slow a discharging of the galvanic cell.
[0023] The polymers may include polypropylene (PP), polyethylene (PE) or other polyolefins. In the context of a trouble-free manufacturing, it is advantageous to use such polymers, since their material properties are known and manufacturing processes are able to be easily calculated and reproduced.
[0024] The fibrous material may also be conceivably functionalized in bulk using copolymerization or grafting processes in which a polyolefin, polystyrene, polyphenylene sulfide, polysulfone, ethylene vinyl alcohol or blends thereof are reactively extruded. Likewise conceivable may be a grafting process in a polymer dispersion.
[0025] The nonwoven fabric may be characterized by an ammonia absorbing capacity of at least 0.1 mmol per g of nonwoven fabric weight. This absorbing capacity ensures that the discharge process in the galvanic cell is sufficiently retarded.
[0026] In an especially preferred aspect, a nonwoven fabric may bind at least 0.1 mmol NH3/g of nonwoven composition, 0.2 mmol NH3/g or at least 0.4 mmol NH3/g of nonwoven composition. These selected values represent characteristic values at which the discharge duration may be clearly prolonged.
[0027] The nonwoven fabric may include a fiber blend having fibers that are resistant to hydrolysis in concentrated alkaline solution. This ensures that the nonwoven fabric has a stable structure and does not decompose in an alkaline medium.
[0028] To achieve good wettability, the nonwoven fabric may have hydrophilic properties, in particular hydrophilic surfaces. These may be obtained in a fluorination process, a plasma treatment or in a sulfonation process. It also may be conceivable for the nonwoven material to be grafted with polar, unsaturated, organic substances. In this context, it is also conceivable for a wetting agent to be applied. Commercial wetting agents can be easily obtained.
[0029] The nonwoven fabric may have a substance weight of 15 to 300 g/m 2 . This range ensures that the nonwoven fabric has an adequate fluid absorbing capacity and, at the same time, makes it possible to produce a galvanic cell having a practical weight.
[0030] The nonwoven fabric may have a thickness of 20 to 400 μm. This range makes it feasible to produce a galvanic cell having practical internal and external dimensions.
[0031] The nonwoven fabric may be fabricated using a wet-laid nonwoven technology. This type of manufacturing ensures that the nonwoven fabrics are highly homogeneous.
[0032] It also may be conceivable to manufacture the nonwoven fabric in accordance with a dry-laid nonwoven technology. When this technology is used, no media act on the nonwoven material that would negatively affect the stability of the same.
[0033] The nonwoven fabric may also be fabricated using a spunbond-meltblown technology. This type of fabrication makes it possible to manufacture very thin fibers and, therefore, nonwoven fabrics having a high specific surface area.
[0034] The present invention may also provide a fiber having a fibrous material, containing at least one substance chemically active or activatable in an alkaline medium, the substance being incorporated surface-actively in volumetric regions of the fiber whose surface areas are able to be acted upon by the medium. In order to avoid repetitive descriptions of the inventive step, reference is made to the practical implementation of the same in the production of nonwoven fabric.
[0035] The fibers may have a diameter that is smaller than 5 μm. This makes it possible for super-fine fibers, i.e. microfibers, to be used, resulting in a nonwoven fabric having a large surface area.
[0036] The fibers may be spun from a fibrous material that was only functionalized by the substance after the spinning process. This embodiment makes it possible to produce functional fibers from commercially purchased fibers. In this respect, the fibers may be fabricated and modified at two separate locations.
[0037] The fibers may also conceivably be spun from a fibrous material that is functionalized by the substance. This makes it possible for the functional fibers to be produced at one location.
[0038] The fiber or a multiplicity of fibers may exist in a highly fibrillated state. This embodiment permits the use of pulp material to manufacture nonwoven fabrics. Pulp material has the features of an exceptionally high surface area.
[0039] The fibers claimed in this application may be characterized by a geometric or material form consistent with that of the fibers contained in the nonwoven fabrics described here. In particular, all fiber types, for example core-sheath fibers or the like, may conceivably be selected as a geometric form. In addition, the substances named as fibrous material in this application or used for functionalization purposes may conceivably be used in all practical combinations.
[0040] The present invention also provides a galvanic cell including a casing at least partially accommodating at least one positive and one negative electrode, a material permitting transport of charge carriers, and a separator separating the positive or negative electrodes, the separator including a fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 shows a side-by-side fiber.
[0042] FIG. 2 shows a core-sheath fiber.
[0043] FIG. 3 shows a galvanic cell.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] The present invention may be advantageously embodied and further refined in different ways. FIG. 1 shows a side-by-side multicomponent fiber 10 and FIG. 2 shows a core-sheath fiber 20 with a core 22 and sheath 24 . FIG. 3 shows a galvanic cell 30 having a casing 32 , a transport material 34 and a separator 36 made of nonwoven fabric according to the present invention.
[0045] A) Ammonia-binding polyolefin fibers were produced by way of example, using the following processes:
[0046] 1. Use of an acrylic acid-grafted polypropylene having an acrylic acid concentration of 5.5%.
[0047] Fibers were spun at extruder temperatures from 210-215° C. The spinning nozzle had an aperture of 450 μm. The polymer throughput rate was 0.11 cm 3 /min per nozzle. The fibers were subsequently drawn with a draw ratio of 3 at temperatures of between 80 and 100° C. The resulting fibers had a titer of approximately 2.5 dtex; the ammonia absorption capacity was 0.58 mmol NH3/g.
[0048] 2. Use of an acrylic acid-grafted polyethylene having an acrylic acid concentration of 6.0%.
[0049] Fibers were spun at extruder temperatures from 205-210° C. The spinning nozzle had an aperture of 450 μm. The polymer throughput rate was 0.13 cm3/min per nozzle. The fibers were subsequently drawn with a draw ratio of 3 at temperatures of between 80 and 100° C. The resulting fibers likewise had a titer of approximately 3 dtex; the ammonia absorption capacity was 0.51 mmol NH3/g.
[0050] 3. Use of a core-sheath fiber having a “core” of polypropylene and a “sheath” of an acrylic acid-grafted polyethylene.
[0051] As a core polymer, a polypropylene type from the firm Borealis, Denmark, having an MFI value of 37 at 210° C. was used. The MFI value is known as the so-called melt flow index, which represents the melt flow of a material through a nozzle of a defined diameter at specified pressure and temperature conditions. As a sheath polymer, the modified polyethyelene named in practical example 2 was used. The core/sheath ratio was 50:50. A titer of approximately 1.7 dtex was obtained for the fibers. The ammonia absorption capacity of the fibers was 0.38 mmol NH3/g.
[0052] 4. Use of a polypropylene fiber for the melt blown process.
[0053] Polypropylene of the firm Borealis, Denmark, having an MFI value of 800 was functionalized and spun at T=270° C. A fiber diameter of 4 μm was obtained.
[0054] 5. Modification of supplied short-cut fibers.
[0055] To this end, core-sheath fibers of polyolefin from the firm Daiwabo were used. These had a cut length of 6 mm and a titer of 0.8 dtex. These fibers were acrylic acid-grafted in a dispersion. The modified fibers had an ammonia absorption capacity of 0.3 mmol NH3/g.
[0056] B) Nonwoven fabrics were produced from the fibers of practical examples A) 1. through A) 5. In the process, short-cut fibers having lengths of 6 mm were used as functionalized fibers.
[0057] 1. Use of the modified PP fibers named under A) 1.
[0058] The fibers were dispersed with polyolefin core/sheath fibers having a titer of 0.8 dtex (firm Daiwabo, Japan) in a blend ratio of 60:40, and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at approximately 135° C. and calendered to a thickness of 140 μm. The measured ammonia bonding capacity was 0.32 mmol NH3 per g of nonwoven fabric.
[0059] 2. Use of the modified PE fibers named under A) 2.
[0060] The fibers were dispersed with unblended polypropylene fibers having a titer of 0.8 dtex (firm Daiwabo, Japan) in a blend ratio of 40:60, and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at approximately 140° C. and calendered to a thickness of 140 μm. The measured ammonia bonding capacity was 0.24 mmol NH3 per g of nonwoven fabric.
[0061] 3. Use of the modified core-sheath fibers named under A) 3:
[0062] The unblended fibers were dispersed, and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at 140° C. and calendered to a thickness of 140 μm. The measured ammonia bonding capacity was 0.39 mmol NH3 per g of nonwoven fabric.
[0063] In another example, 70% of the core-sheath fibers were dispersed with 30% unblended polypropylene fibers having a titer of 0.8 dtex (firm Daiwabo, Japan), and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at 140° C. and calendered to a thickness of 140 μm. The measured ammonia bonding capacity was 0.28 mmol NH3 per g of nonwoven fabric.
[0064] 4. Use of the modified PP fibers named under A) 1., together with the modified core-sheath fibers named under A) 3:
[0065] The two fibers were dispersed in a blend ratio of 70:30, and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at 140° C. and calendered at a nip pressure of 10 N/mm to a thickness of 140 μm. The measured ammonia bonding capacity was 0.42 mmol NH3 per g of nonwoven fabric.
[0066] 5. Use of the short-cut fibers modified under A) 5:
[0067] The fibers were dispersed, and a nonwoven was wet-laid. The nonwoven formed having a substance weight of 60 g/m 2 was subsequently thermally bonded at 140° C. and calendered to a thickness of 140 μm. The measured ammonia bonding capacity was 0.3 mmol NH3 per g of nonwoven fabric.
[0068] 6. Comparative example (blank test):
[0069] As a comparative example, one utilized the commercially available product FS 2226-14 of Freudenberg Vliesstoffe (Freudenberg Nonwovens) (substance weight of 60 g/m 2 , thickness of 140 μm), which is made of unmodified polyolefin fibers. The measured ammonia bonding capacity was 0 mmol NH3 per g of nonwoven fabric.
[0070] C) Meltblown nonwoven fabrics made of polymers:
[0071] Using the modified polypropylene described under A) 4., a nonwoven fabric having a substance weight of 35 g/m 2 and a thickness of 120 μm was produced with the aid of meltblown technology and at spinning temperatures of about 270° C. The fiber thicknesses of the material were within the range of 2-4 μm. The nonwoven fabric had an ammonia bonding capacity of 0.62 mmol NH3 per g.
[0072] D) Battery results with respect to self-discharging:
[0073] The nonwoven separators manufactured in B) or C) were installed in batteries and tested to determine their effect on self-discharging. To this end, five nickel-metal-hydride AA size cells having a capacitance of 1200 mAh and containing separators in accordance with B) 3., B) 4., B) 5. and C) or comparative example B) 6, were manufactured. The self-discharging was measured under different conditions.
[0074] To determine the ammonia bonding capacity, a process including the following steps was carried out:
[0075] Approximately 2 g of the separator material were stored in 120 ml of an 8 molar potassium hydroxide solution (KOH) with the addition of 5 ml of 0.3 molar ammonia (NH 3 ) for three days at 40° C. Two blank tests were simultaneously prepared without any starting polymer. Following storage, filter paper was used to take up and remove any oily deposits existing on the surface. From the original 125 ml of the batch, a 100-ml aliquot was taken, and the ammonia was removed by steam distillation and collected in 150 ml of distilled water to which 10 ml of 0.1 molar hydrochloric acid (HCI) and a few drops of methyl red indicator had been added. The acid was subsequently back-titrated with 0.1 normal sodium hydroxide solution (NaOH).
[0076] The following table shows the self-discharging (SD) results obtained for the batteries manufactured using the nonwoven fabric separator materials mentioned.
Ammonia absorption SD (%) SD (%) SD (%) Separator (mmol/g) (28 d, 20° C.) (7 d, 45° C.) (3 d, 60° C.) FS 2226-14 0 28-30 33-36 60-65 (blank test) B) 3. 0.28 21-24 24 34 B) 4. 0.42 20 21 29 B) 5. 0.30 21 22 32 C) 0.62 18 15 16
[0077] It turned out that the ammonia-binding separator materials manufactured in the context of the present investigation yield a clearly improved battery performance with respect to its self-discharge characteristics than do separators which do not have any ammonia-binding capability.
[0078] With regard to other advantageous embodiments and refinements of the teaching of the present invention, reference is made, on the one hand, to the general portion of the specification and, on the other hand, to the appended claims.
[0079] Finally, it is especially emphasized that the above practical examples, are merely intended for purposes of discussing the teaching of the present invention, but not for limiting it to such practical examples.
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A nonwoven fabric, in particular for use as a separator in batteries or galvanic cells, having functional fibers made of at least one fibrous material which intrinsically contains at least one substance that is chemically active or activatable in an alkaline medium. The substance is incorporated surface-actively exclusively in volumetric regions of the functional fibers whose surface areas are able to be acted upon by the medium. A fiber is made from the mentioned fibrous material. A galvanic cell contains this nonwoven fabric as a separator.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to techniques of carrying out correction of feature images which satisfy a predetermined condition. The present invention also includes techniques of detecting special images for the purpose of correction. In addition, the special images also include harmful images which may cause a harm to a human body. Therefore, the present invention relates to a method of detecting harmful images, a method of detecting differences in images, and an apparatus, and in particular relates to a method of detecting harmful images, a method of detecting differences in images, and an apparatus, wherein a difference in the scene configurations of two images is detected to detect the difference in the images. In addition, the harmful images include a flash, rapidly changing image sequences, a subliminal image, and the like.
[0002] In editing images, edition such as deleting and correcting of the feature images is needed. Particularly, with regards to harmful images, there is such a need to do this because of the following reasons. It has been generally found that images such as a flicker image contained in a video which repeats a flash within a short duration, and a subliminal image in which an image of such short duration that people cannot recognize is inserted, may cause a harm to a human body. There are inter-individual differences in the degree of influence on a human body from such images, and even if viewing the same image, there exist influenced people and uninfluenced people. Moreover, this influence is said to vary also depending on the environment for viewing images, and also relates to a positional relationship between a viewer and a video monitor, and to the brightness condition at a place for viewing.
[0003] If the above-described images come into a video such as in TV broadcast which a general public views, the area of influence is extremely huge, and the social liability at the video provider side may be accused. Therefore, video providers, such as a TV station, who provides video to a general public, checks and detects in advance whether such a harmful image has not come into before providing the video. Moreover, National Association of Commercial Broadcasters in Japan (NAB) whose members are broadcasting industry people has set a guideline on such harmful images.
[0004] Because an example of the harmful image is a change in a video within a short duration (from several frames to several seconds), it is difficult to visually check sufficiently, and in case of visual check a personal view of an examiner may enter. The influence of the harmful image also depends on the environment at the viewer side, so even if it is determined that a video does not have a problem under an environment of the examination, an influence may be caused depending on the actual condition of viewing.
[0005] For this reason, a conventional technique concerning a method of mechanically examining the harmful image is described in U.S. Pat. No. 6,937,764. In this conventional technique, a flash scene of video is detected and a feature quantity and a static image of the detected portion at the time of detection are presented as the detection results.
[0006] In the conventional technique described above, only mechanical detection of the harmful image can be carried out and there is no guideline how to correct the detected harmful image, and therefore how to carry out correction with respect to the detected harmful image is not known is a problem. For this reason, the examination result cannot be informed successfully to the video producer, so the corrected video by the video producer may be detected as a harmful image again. Especially, in case of TV broadcasting, the examiner of the harmful image belongs to a TV station and a corrector of the video belongs to the video production, in other words the examination and correction are often carried out by different organizations and different people, thereby causing the above-described problem.
[0007] In order to solve the above-described problem, it may be considered that as a guideline of correction of the harmful image, a correction method, with which correction was made due to a similar reason in the past and it was judged that the correction causes no problem, is utilized. In this case, people need to grasp the correction method of the image which was corrected in order to store the correction method of the image. However, even if only the corrected video is provided by the video corrector, and even if the correction method is provided from the corrector, there is no way to assure that the provided correction method is correct, thus causing a problem that the method of correcting image cannot be grasped correctly.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to allow, as a guideline for correction of a feature image containing a harmful image, an image correction method to be detected from the corrected images in order to grasp the correction method with which the image was corrected correctly. Further, it is another object of the present invention to allow a correction proposal of the image, to which a correction method in the past is applied, to be presented in order to indicate to the corrector the guideline for correction of the feature image.
[0009] The above objective is realized with the following configuration, wherein a feature image (or an image containing this feature) and an edited image, which is made by applying edition to the feature image, are associated and stored in a database in advance, and if it is detected that an image currently to be edited (or to be examined) is a feature image, then a feature image “similar” to the one currently to be edited is retrieved from a database and the edited contents of an edited image corresponding to the retrieved feature image is identified and presented to a user. Here, the edited contents may be identified comparing the retrieved feature image with the edited image corresponding thereto. Moreover, the feature image and the edited contents may be associated and stored in the database, and the edited contents stored corresponding to the retrieved feature image may be identified.
[0010] In addition, a “similar” one refers to the one mutually having a predetermined relationship, and the specific contents of the predetermined relationship include the ones as described in the embodiments of the present invention. In addition, as an aspect of the present invention, the following is targeted for harmful images. According to the present invention, the above objective can be achieved by using a harmful image detecting method of detecting harmful images and presenting a detection result, provided with a database in which correction case examples with respect to the harmful images in the past are stored, the method comprising the steps of: detecting whether or not a harmful image is contained in an inputted video to be examined; if the feature image is contained, retrieving the database by using a reason of harm of the detected harmful image as a key and thereby obtaining a correction case example; creating a correction proposal by applying the correction case example to a harmful portion of the image; and outputting the reason of harm, the harmful portion, and the correction proposal of the detected feature image for the purpose of correction of the harmful image.
[0011] Moreover, the above objective can be achieved by using a harmful image detecting method of detecting harmful images and presenting a detection result, provided with a database, in which correction case examples with respect to the harmful images in the past are stored, and an image difference detecting means, the method comprising the steps of: inputting a video of after carrying out correction to the harmful image as a video to be examined; detecting whether or not the harmful image is contained in this video; if the harmful images is not contained, the image difference detecting means calculating a scene feature quantity for the video before correction and the video after correction on the basis of a feature quantity of a frame image within a scene, comparing chronological lists of the respective scene feature quantities of the two videos, detecting a difference in the scene configurations of the two videos from the difference in the lists of the scene feature quantities, and detecting a correction method to store the same in the database.
[0012] Moreover, the above objective can be achieved by using an image difference detecting method of detecting a difference in two videos each consisting of a plurality of scenes, the method comprising the steps of: calculating scene feature quantities based on the feature quantities of frame images within the scenes of two videos, and comparing chronological lists of the respective scene feature quantities of the two videos; and detecting a difference in the scene configurations of the two videos from a difference in the lists of the scene feature quantities.
[0013] According to an embodiment of the present invention, an image correction method can be detected from a corrected image and the image before correction, and a correction proposal with respect to the harmful image which was detected in detecting a harmful image can be presented.
[0014] Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a block diagram showing a functional configuration and a process of a harmful image detecting system, in which a correction method in the past obtained by using an image difference detecting apparatus according to a first embodiment of the present invention is applied to thereby present a correction proposal of the harmful image.
[0016] FIG. 2 is a block diagram showing a functional configuration and a process of a harmful image detecting system which detects a correction method by using the image difference detecting apparatus according to the first embodiment of the present invention and stores this as a case example, when re-examining the corrected image.
[0017] FIG. 3 is a block diagram showing a functional configuration and a process of the image difference detecting section.
[0018] FIG. 4 is a view explaining a relationship between an image feature quantity and a scene feature quantity in a process of detecting a correction method.
[0019] FIG. 5 is a view showing a relationship between a scene feature quantity sequence of a comparison source and a scene feature quantity sequence of a comparison destination in a matching process of detecting the correction method.
[0020] FIG. 6 is a view explaining an outline of a process in a correction proposal creating section in FIG. 1 .
[0021] FIG. 7 is a block diagram showing a hardware configuration of a harmful image detecting terminal shown in FIG. 1 and FIG. 2 .
DESCRIPTION OF THE INVENTION
[0022] Hereinafter, the embodiments of a method of detecting harmful images, an image difference detecting method, and an apparatus, in which the present invention is applied to harmful images, will be described in detail with reference to the accompanying drawings.
[0023] FIG. 1 is a block diagram showing a functional configuration and a process of a harmful image detecting system, in which a correction method in the past obtained by an image difference detecting apparatus according to a first embodiment of the present invention is applied to thereby present a correction proposal of the harmful image. In FIG. 1 , a reference numeral 1000 represents a flicker subliminal image detecting section, 1010 represents a correction case example retrieving section, 1020 represents a correction proposal creating section, 1030 represents a detection result presenting section, 1100 represents a detection result data, 1110 represents a harmful image data, 1120 represents a correction method, 1130 represents a correction candidate image, 1160 represents a harmful portion, 1170 represents a reason of harm, 1200 represents a video producer, 1210 represents a video to be examined, 2000 represents a harmful image detecting terminal, and 2200 represents a correction case example DB. Here, the harmful image detecting terminal 2000 is realized by the so-called computer. Then, the flicker subliminal image detecting section 1000 , the correction case example retrieving section 1010 , the correction proposal creating section 1020 , and the detection result presenting section 1030 , which are the configuration elements, can be realized as a processor (CPU) which carries out the process in accordance with a program. Moreover, the harmful image detecting terminal 2000 may comprise the above-described program, a storage device and a memory for storing programs (not shown), and the like.
[0024] The harmful image detecting terminal 2000 shown in FIG. 1 has functions required in the processes of detecting harmful images from the video 1210 to be examined which the video producer 1200 produced, and of creating a correction proposal from the correction case examples in the past to return this to the video producer 1200 . This harmful image detecting terminal 2000 comprises the flicker subliminal image detecting section 1000 , the correction case example retrieving section 1010 , the correction proposal creating section 1020 , the detection result presenting section 1030 , and a temporary image data storage device, and the correction case example DB 2200 .
[0025] The video to be examined 1210 , which the video producer 1200 produced and which is to be inputted to the harmful image detecting terminal 2000 , may be recorded on a media, such as a VTR tape, or may be expressed in the form of file, such as MPEG. In case of a VTR tape, the video to be examined 1210 is reproduced on a VTR deck and inputted to the harmful image detecting terminal 2000 . Moreover, if the video to be examined 1210 is constituted in the form of file, the video to be examined 1210 may be inputted to the harmful image detecting terminal 2000 as is.
[0026] The flicker subliminal image detecting section 1000 in the harmful image detecting terminal 2000 detects, with respect to the inputted video to be examined, a flash repeated within a short duration and an insertion of an image within such a short duration that a human cannot be aware of. With respect to this detection, a reference level for a flash or the like may be stored in advance with which the video to be examined is compared, and if satisfying the reference level it may be determined that there exists an insertion. Moreover, the conventional technique described above may be employed. These are the images which may have a harmful effect on a human body. The flicker subliminal image detecting section 1000 outputs as a detection result the detection result data 1100 which is a combination of the harmful portion 1160 and the reason of harm 1170 of the video
[0027] The harmful portion 1160 is a time data (time stamp) indicating the position of the video. If the time code information is given to a record media of a video or to a video file, this time data serves as the time code value thereof, and if there is no time code information, the time code value is the elapsed time after the start of the video. For example, in case of indicating a portion of ten minutes after the start of the video, the time data is a value of “00:10:00:00”. These are the values capable of uniquely indicating the position of the video.
[0028] The reason of harm 1170 is a data which indicates a factor detecting a harmful image. In this data, if the harmful image is a flicker image, there are included the respective information on the “time length of a flash interval”, “rate of change in luminance (%)”, “frequency of change in luminance”, “color component”, and “portion on a screen causing a flash”, and if the harmful image is a subliminal image, there are included the respective information (factors) on the “time length of an inserted subliminal image”, and “portion of the subliminal image on a screen”.
[0029] Here, if all the respective factors are “similar” to each factor of the reason of harm stored in the correction case example DB 2200 , or if a certain number or more of factors are “similar” thereto, it may be determined that this data is “similar” in terms of the image.
[0030] Moreover, if the difference between the respective factors of the video to be examined 1210 and of the reason of harm stored in the correction case example DB 2200 is within a certain range, the “similarity” of the respective factors may be determined as being “similar”, or may be judged as the “similarity” of each factor as follows:
[0031] Time length of a flash interval: that of the video to be examined 1210 is longer within a certain area (including the same time length).
[0032] Rate of change in luminance (%): that of the video to be examined 1210 is larger within a certain area (including the same rate of change).
[0033] Frequency of change in luminance: that of the video to be examined 1210 is larger within a certain area (including the same frequency).
[0034] Color component: the hue of the video to be examined 1210 is nearer to that of the harmful color (including the same hue).
[0035] Portion on a screen causing a flash: that of the video to be examined 1210 is nearer to the center on the screen (including the portion whose nearness thereto is the same).
[0036] Moreover, each factor may be retrieved by comparing with each factor of the reasons of harm stored in the correction case example DB 2200 , respectively. Moreover, the comparison can be made as follows. Namely, with regard to a first factor, (a harmful image of) a “similar” reason of harm is retrieved, and then among the retrieved reasons of harm the one with a second factor being “similar” is retrieved. Then the one with a third factor being “similar” is retrieved and so on, whereby the one with all factors being “similar” or the one with a predetermined factor being “similar” is identified.
[0037] The flicker subliminal image detecting section 1000 records the detection result data 1100 in the temporary image data storage device and passes this to the correction case example retrieving section 1010 . Moreover, in the process of detecting the harmful image, the harmful image data 1110 , in which a harm of the video inputted for detection was detected, is recorded in the temporary image data storage device. This image data 1110 is created and recorded as a proxy video in which the resolution and bit rate of the video is reduced.
[0038] Upon receipt of the detection result data 1100 , the correction case example retrieving section 1010 retrieves from the correction case example DB 2200 whether or not there is any correction case example due to the similar reason of harm in the past by using the reason of harm 1170 of the detection result data 1100 as a search key. If there is a correction case example due to the similar reason of harm, the correction case example retrieving section 1010 obtains the correction method 1120 corresponding thereto. The correction method 1120 includes information on the modification of a scene configuration or the modification of editing effect on a scene. The detail of the data configuration of the correction method 1120 will be described later. With regard to the correction method 1120 in the past, only one correction method corresponding to a reason most similar to the detected reason of harm 1170 may be obtained, or a plurality of correction methods corresponding to the reason having a similarity within a certain threshold may be obtained based on the degree of similarity of the reason of harm. The correction case example retrieving section 1010 passes the detection result data 1100 and the correction method 1120 to the correction proposal creating section 1020 .
[0039] The correction proposal creating section 1020 obtains the image data 1110 from the temporary image data storage area, and applies to the portion of the image indicated as the harmful portion 1160 a modification of a scene configuration or a modification of the editing effect on a scene in accordance with the contents indicated by the correction method 1120 , and then creates the correction candidate image 1130 . The detail of this process will be described later. The correction proposal creating section 1020 passes the detection result data 1100 and the correction candidate image 1130 to the detection result presenting section 1030 .
[0040] The detection result presenting section 1030 displays the harmful portion 1160 , the reason of harm 1170 , and the correction candidate image 1130 as a detection result of the harmful image on a monitor of the harmful image detecting terminal 2000 . Moreover, these data are outputted as a data file.
[0041] If a harmful image was not detected in the inputted video to be examined 1210 at the flicker subliminal image detecting section 1000 , the processes in the correction case example retrieving section 1010 and the correction proposal creating section 1020 are not carried out, and instead a message indicating that a harmful image was not detected at the detection result presenting section 1030 is displayed. The video to be examined 1210 which passed the examination will be utilized as such without being corrected. If it is a video for broadcasting, it is used for broadcasting.
[0042] If a harmful image was detected from the inputted video to be examined 1210 , an examiner delivers to the video producer 1200 the detection result data 1100 and the correction candidate image 1130 which are outputted by the detection result presenting section 1030 . Note that, as the process of delivering this data to the video producer 1200 , other than that a medium in which it is stored is delivered by hand, the detection result data 1100 of interest may be sent via a network to a processing apparatus which the video producer 1200 uses. The video producer 1200 carries out a correction work of the video based on the delivered contents. The correction of the video is implemented by carrying out the image editing processes, such as replacing of the scene configuration, inserting and deleting of a scene, modifying of the scene length, modifying of the flashing luminance, modifying of the frequency of flashing. The corrected video is subject to an examination for the presence of a harmful image, again.
[0043] FIG. 2 is a block diagram showing a functional configuration and a process of the harmful image detecting system which detects, in the re-examination of the corrected video, a correction method by using the image difference detecting apparatus according to the first embodiment of the present invention and stores this as a case example. In FIG. 2 , a reference numeral 1040 represents an image difference detecting section, 1140 represents a revised image data, 1150 represents a correction method, and other numerals are the same as those of FIG. 1 . In addition, the image difference detecting section 1040 shown in FIG. 2 is to be included in the harmful image detecting terminal 2000 shown in FIG. 1 , and only the configuration required for the image difference detection is shown in FIG. 2 for convenience of description. Moreover, similarly, as described in FIG. 1 , the harmful image detecting terminal 2000 comprises a computer having a processor and the like, and carries out each process in accordance with the program.
[0044] With respect to a video 1220 which was corrected based on the detection result data 1100 and the correction candidate image 1130 presented by the processes shown in FIG. 1 , an examination for the presence of a harmful image is carried out again at the flicker subliminal image detecting section 1000 . If a harmful portion is detected again in this examination, the processes shown and described in FIG. 1 are carried out again, and the detection result data is informed to the video producer 1200 , causing he or she to carry out a re-correction of the video.
[0045] If a harmful portion is not detected at the flicker subliminal image detecting section 1000 (i.e., if the correction was made successfully), the flicker subliminal image detecting section 1000 records the video inputted for the purpose of detection into the temporary image data storage device as the revised image data 1140 like in the process shown in FIG. 1 . The image data 1140 to be recorded is a proxy video in which the resolution and bit rate of the video are reduced. Then, the process moves to the image difference detecting section 1040 .
[0046] The image difference detecting section 1040 detects a relevant correction method by comparing the revised image data 1140 which is the image data after correction with the image data before correction 1110 . The detected correction method is outputted as the correction method 1150 of the image. The correction method 1150 is associated with the reason of harm and is recorded in the correction case example DB 2200 .
[0047] FIG. 3 is a block diagram showing a functional configuration and a process of the image difference detecting section 1040 . FIG. 4 is a view explaining a relationship between an image feature quantity and a scene feature quantity in the process of detecting a correction method. Next, the detail of the process in the image difference detecting section 1040 will be described with reference to FIG. 3 and FIG. 4 . In FIG. 3 and FIG. 4 , a reference numeral 1300 represents an image feature quantity calculating section, a reference numeral 1310 represents a scene feature quantity calculating section, and a reference numeral 1320 represents a scene feature quantity comparing section.
[0048] The image difference detecting section 1040 comprises the image feature quantity calculating section 1300 , the scene feature quantity calculating section 1310 , and the scene feature quantity comparing section 1320 . In the image difference detecting section 1040 , upon input of the revised (after correction) image data 1140 and the image data before correction 1110 , the image feature quantity calculating section 1300 first calculates, with respect to the image data before correction 1110 and the image data after correction 1140 , an image feature quantity after correction 1410 and an image feature quantity before correction 1400 , respectively, which are the feature quantities of each frame image, and outputs this. This feature quantity is calculated as one feature quantity 1460 corresponding to each one frame image 1450 , as shown in FIG. 4 . A chronological list of these feature quantities is referred to as the image feature quantity, and such image feature quantity is outputted from the image feature quantity calculating section 1300 corresponding to the image data before correction 1110 and the image data after correction 1140 . The feature quantity of a frame image refers to values indicative of the features of the image, such as a luminance histogram and a color histogram of the image.
[0049] The scene feature quantity calculating section 1310 receives the image feature quantities before and after correction 1400 and 1410 outputted from the image feature quantity calculating section 1300 , as the inputs, and calculates the feature quantities with respect to these feature quantities for each scene. A scene is formed by grouping the frame images based on their similarity when chronologically looking at the feature quantities of the frame images. For example, in FIG. 4 , with respect to frame image feature quantities A 1 -C 6 of the image feature quantity 1400 , if the degree of similarity among the frame images contained in each set of “A 1 to A 5 ”, “B 1 to B 4 ”, and “C 1 to C 6 ” is high, a set of the frame images corresponding to “A 1 to A 5 ” is called as a scene A 1470 , a set of “B 1 to B 4 ” as a scene B 1480 , and a set of “C 1 to C 6 ” as a scene C 1490 . The video of these scenes shows a series of images shot by one camera work, and is generally called a “cut”.
[0050] The scene feature quantity is a value representing the feature of a scene, and although in the embodiment of the present invention an average of the feature quantities of the frame images constituting a scene is used, the feature quantity of a start frame of the scene may be used, or a mean value of the feature quantities of the frame images constituting a scene may be used. Moreover, the scene feature quantity includes information on the scene length. For example, the scene length of the scene A 1470 of FIG. 4 is five. The “ 5 ” in a value “A- 5 ” of the scene feature quantity 1440 of the scene A 1470 indicates that the scene length is five frames, and the “A” in “A- 5 ” indicates an average of the feature quantities of the frame images “A 1 to A 5 ”.
[0051] A chronological list of scene feature quantities is referred to as a “scene feature quantity sequence”. A scene feature quantity sequence 1420 includes a list of the scene feature quantity 1440 of the scene A 1470 , the scene feature quantity 1500 of a scene B 1480 , and the scene feature quantity 1510 of a scene C 1490 .
[0052] The scene feature quantity calculating section 1310 calculates scene feature quantity sequences 1420 and 1430 with respect to the image feature quantities 1400 and 1410 and outputs this.
[0053] The scene feature quantity comparing section 1320 compares two scene feature quantity sequences 1420 and 1430 calculated by the scene feature quantity calculating section 1310 and detects a correction method of the image. The detail of the detection process in the image correction method by this scene feature quantity comparing section 1320 will be described with reference to FIG. 5 .
[0054] FIG. 5 is a view showing a relationship between the scene feature quantity sequence of a comparison source and the scene feature quantity sequence of a comparison destination in a matching process for detecting the correction method.
[0055] The detecting process of a video correction method is carried out by a procedure described below.
[0056] (1) Out of the scene feature quantity sequence 1420 of a video before correction, the scene feature quantities of n scenes before and after about a scene including a portion indicated by the harmful portion 1160 are extracted. The extracted scene feature quantities serve as a scene feature quantity sequence of a comparison source 1600 . In an example shown in FIG. 5 , n is set to 4.
[0057] (2) With respect to the portion indicated by the harmful portion 1160 of the scene feature quantity sequence 1430 of the video after correction, matching with the scene feature quantity sequence of the comparison source 1600 is carried out. The matching is carried out by carrying out a matching calculation about the corresponding scenes between the scene feature quantity sequence of the comparison source 1600 extracted from the scene feature quantity sequence 1420 of the video before correction, and the scene feature quantity sequence 1600 extracted from the scene feature quantity sequence 1430 of the video after correction, while shifting by m scenes forward and backward relative to the position indicated by the harmful portion 1160 of the scene feature quantity sequence 1430 of the video after correction. The matching calculation is a calculation, wherein a total sum of the differences between the scene feature quantities is calculated to thereby make a position where the total sum becomes the lowest to be the matching position. In an example shown in FIG. 5 , m is set to 1 , and the matching calculation is carried out while shifting the position from the matching start position 1610 to 1620 , and to 1630 , one scene after another. In this example, the matching position is determined as 1620 . Then, a portion of the scene feature quantity sequence 1430 of the images after correction corresponding to the matching position is made a scene feature quantity sequence 1640 of the comparison destination.
[0058] (3) The respective scenes of the scene feature quantity sequence of the comparison source 1600 and of the scene feature quantity sequence of the comparison destination 1640 are compared for each scene to thereby detect the difference between the scene feature quantities. The difference of the scene feature quantities of the scene feature quantity sequence of the comparison destination 1640 detected relative to the scene feature quantity sequence of the comparison source 1600 is treated as that the following image correction was made.
[0059] If it is detected that the difference in the detected scene feature quantities is due to a modification of the scene length, a correction for lengthening the scene length, or a correction for shortening the scene length was made.
[0060] If it is detected that the difference in the detected scene feature quantities is due to a change of the order of the scene feature quantities, a correction for changing the order of the scenes was made. For example, the scenes A, B, and C are changed to an order of the scenes B, A, and C.
[0061] If it is detected that the difference of the detected scene feature quantities is due to the presence of a new scene feature quantity, a correction for adding a new scene was made. For example, a scene X is inserted in the scenes A, B, and C to make scenes A, X, B, and C.
[0062] If it is detected that the difference in the detected scene feature quantities is due to a loss of a scene feature quantity, a correction for deleting a scene was made. For example, a scene B is deleted from the scenes A, B, and C to make scenes A and C.
[0063] If it is detected that the difference in the detected scene feature quantities is due to a similarity of the feature quantities, a correction for modifying a video effect of the scene was made. The detectable video effect varies depending on the type of the image feature quantity used in the scene feature quantity. For example, if a luminance histogram is used as the feature quantity, a modification in luminance can be detected. Examples of the image edition include the one wherein the luminance of a scene B out of the scenes A, B, and C is decreased to make a scene B′ and make scenes A, B′, and C, and the like. In addition, if the degree of similarity of the feature quantity is distant by a certain threshold or more, it is to be treated as that a new scene was inserted.
[0064] With respect to the modifications described above, one type of them may be carried out, or a plurality of them may be carried out simultaneously.
[0065] The scene feature quantity comparing section 1320 of the image difference detecting section 1040 shown in FIG. 3 carries out the above-described processes, and detects a correction method of the image, and creates the correction method 1150 . The correction method 1150 comprises “a scene configuration before modification, a scene configuration after modification, and a scene to serve as a harmful portion”. The scene configuration includes information on the scene length and the scene feature quantity.
[0066] The calculation of the feature quantity of each frame image in the image feature quantity calculating section 1300 shown in FIG. 3 may be targeted for only frame images in the periphery of the harmful portion 1160 . In this case, the scene feature quantity sequence is calculated only with respect to the scenes in the periphery of the harmful portion 1160 . The area for calculation of the feature quantity of the frame image may be only an area required for carry out the matching calculation of the scene feature quantity sequence of the comparison source 1600 and the scene feature quantity sequence of the comparison destination 1640 .
[0067] FIG. 6 is a view explaining an outline of the process at the correction proposal creating section 1020 in FIG. 1 . Next, with reference to FIG. 6 the process will be described in which a correction method is applied to a harmful portion to thereby create a correction candidate image.
[0068] The correction proposal creating section 1020 applies, with respect to the harmful image data 1110 in which a harmful portion was detected, the correction method 1120 , which was retrieved from the case example DB using a reason of harm as a key, and corrects the image with respect to a scene B 1700 including the harmful portion of the harmful image data 1110 in accordance with the contents of the correction method 1120 . According to the example shown in FIG. 6 , in the correction method 1120 there is described that the scene length of the scene including the harmful portion is doubled and the luminance in the scene image is decreased by 50%. In accordance with these contents, the correction proposal creating section 1020 doubles the scene length of the scene B 1700 and applies a process of decreasing the luminance by 50% and create a scene B′ 1710 . Specifically, one frame image is added into each frame image of the scene B 1700 , and an image filtering is applied so that the luminance in each frame image may decrease by 50%. Through such processes, the correction candidate image 1130 as the correction proposal is created.
[0069] FIG. 7 is a block diagram showing a hardware configuration of the harmful image detecting terminal 2000 shown in FIG. 1 and FIG. 2 . In FIG. 7 , reference numerals 2010 , 2020 , 2030 represent secondary storage devices, a reference numeral 2040 represents CPU, 2050 represents a memory, 2060 represents a bus, 2070 represents OS, and 2100 represents a video capture unit, and other numerals are the same as those shown in FIG. 1 , FIG. 2 , and FIG. 3 . In addition, each configuration requirement (hardware) is just as described in FIG. 1 and FIG. 2 .
[0070] The harmful image detecting terminal 2000 comprises the secondary storage devices 2010 , 2020 , and 2030 , the video capture unit 2100 for receiving a video signal, CPU 2040 , and the memory 2050 , and these are connected via the bus 2060 .
[0071] In the secondary storage device 2010 , the flicker subliminal image detecting section 1000 , the correction case example retrieving section 1010 , the correction proposal creating section 1020 , the detection result presenting section 1030 , the image difference detecting section 1040 , and the OS 2070 are stored. The image difference detecting section 1040 comprises the image feature quantity calculating section 1300 , the scene feature quantity calculating section 1310 , and the scene feature quantity comparing section 1320 , as described in FIG. 3 . The flicker subliminal image detecting section 1000 operates the image capture unit 2100 to obtain data of a frame image from the video signal.
[0072] The flicker subliminal image detecting section 1000 , the correction case example retrieving section 1010 , the correction proposal creating section 1020 , the detection result presenting section 1030 , and the image difference detecting section 1040 , which are stored in the secondary storage device 2010 , can be configured as a program to cause CPU provided by a computer to execute this program. Moreover, these programs can be stored in a recording media, such as FD, CDROM, and DVD, and provided, and can be provided in the form of digital information via a network.
[0073] The secondary storage device 2020 is used as a temporary storage area, and in this secondary storage device 2020 the detection result data 1100 , the harmful image data 1110 , and the corrected image data 1140 , which the flicker subliminal image detecting section 1000 outputs, are stored. The correction case example DB 2200 is stored in the secondary storage device 2030 .
[0074] The configuration overview of the secondary storage devices 2010 , 2020 , and 2030 are shown in the harmful image detecting terminal 2000 of FIG. 1 and FIG. 2 . In addition, the secondary storage devices 2020 and 2030 may be the same one as the secondary storage device 2010 .
[0075] In the embodiments of the present invention described above, a harmful image is detected, and a correction method is indicated based on a correction case example DB, and then the image difference detecting section compares the corrected image with the image before correction to extract a correction method, and this correction method is then reflected on the correction case example DB. However, the image difference detecting section can be used not only in a case where the images to compare are a harmful image and its corrected image, but also can be used in comparing two images having a certain relationship. For example, in the case where after creating an video for broadcasting or the like, a correction of the video is carried out based on instructions by a producer or the like, two videos are compared to extract a correction method and store this in a database, and at the time of subsequent video creation this correction method can be used by referring to the correction method in the database.
[0076] It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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It is an object of the present invention to detect an image correction method from corrected images, in order to grasp a correction method of a correctly corrected images as a guideline for correction of a harmful image, and to present an image correction proposal to which a correction method in the past is applied, in order to indicate to a corrector a guideline for correction of the harmful image. In order to achieve the above-described objective, the present invention employs the following configuration. With respect to a harmful image data before correction and an image data after correction, a scene feature quantity representing the feature quantity of a scene for each scene of a video is calculated, and by comparing chronological lists of the respective scene feature quantities of the videos, a correction method for the scene configuration is detected.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to a tricyclic hydrocarbon, 5,6-epoxy-1,2,6-trimethyltricyclo[5,3,2,0 2 ,7 ]dodecane and to a process for producing this compound.
2. Description Of The Prior Art
Amber-like fragrant substances are important starting materials for a blended perfume, and, of these substances, ambergris obtainable from sperm whales is the most expensive. The fragrance component of ambergris was clarified by E. Lederer and L. Ruzicka in 1946 to be a substance formed from ambrein which is a triterpene compound. Ever since, many attempts to synthesize amber-like fragrant substances equal to the natural material, or similar substances, have been made. Some of them can be utilized as a substitute for expensive ambergris. For example, manool derivatives, which are diterepene compounds and can be obtained from a special needle-leaf tree, are widely used as such a substitute. However, in general, amber-like fragrant substances are difficult to synthesize and moreover, special natural products are required as a starting material to synthesize amber-like fragrant substances. Therefore, synthetic amber-like fragrant substances are inevitably expensive.
SUMMARY OF THE INVENTION
This invention provides 5,6-epoxy-1,2,6-trimethyltricyclo-[5,3,2,0 2 ,7 ]dodecane having the formula ##SPC2##
And a process for producing 5,6-epoxy-1,2,6-trimethyltricyclo-[5,3,2,0 2 ,7 ]dodecane (hereinafter "Compound (I)") comprising treating 1,2,6-trimethyltricyclo[5,3,2,0 2 ,7 ]dodeca-5-ene (hereinafter "Compound (II)") with a peracid.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is an infrared spectrum of Compound (I) obtained according to the present invention.
FIG. 2 is a mass spectrum of Compound (I) obtained according to the present invention.
FIG. 3 is an NMR spectrum of Compound (I) obtained according to the present invention.
FIG. 4 shows the stereostructural form of a ketone compound obtained by isomerization of Compound (I).
DETAILED DESCRIPTION OF THE INVENTION
Compound (I) produced according to the present invention is a sequiterpene compound having the molecular formula, C 15 H 24 O, and a structure represented by the formula (I). ##SPC3##
According to this invention, Compound (I) can be obtained much more cheaply than conventional amber-like fragrant substances, and is also of industrial value because of its excellent amber-like fragrance.
According to the present invention, Compound (I) can be prepared by reacting one mole of Compound (II) with about 1 to 1.2 moles of a peracid. Examples of suitable peracids which can be used include peracetic acid, perbenzoic acid, perpropionic acid, performic acid, monoperphthalic acid, trifluoroperacetic acid, etc.
The reaction can be conducted in the absence of a solvent, but proceeds more smoothly when a solvent which is inert to the peracid employed such as dichloromethane, chloroform, acetone, methyl ethyl ketone, ethyl acetate, ethyl propionate, etc., is used. Since acids are formed as the epoxidation reaction progresses, it is desirable to add a neutralizing agent to the reaction system from the beginning or during the course of the reaction or after the completion of the reaction in order to neutralize the acids formed. Suitable examples of neutralizing agents which can be employed are the carbonates or acetates of alkali metals such as sodium and potassium and hydroxides of alkaline earth metals such as calcium and barium. The reaction temperature can range from about -5° to about 10°C, preferably 0° to 5°C. The reaction can sufficiently be completed within about 8 hours, and, for example, the reaction proceeds quantitatively in the preferred temperature range as described above and is completed in about 5 hours in this temperature range.
After completion of the reaction, Compound (I) is extracted with a solvent such as dichloromethane, chloroform, etc., and the resulting extract is distilled under reduced pressure, whereby Compound (I) can be obtained in high yield. Compound (II) used as the starting material in the process can be obtained by subjecting 1,5,9-trimethylcyclododecatriene-1,5,9 (hereinafter 1,5,9-TMCDT) which is a cyclic trimer of isoprene to an intramolecular ring closure reaction with an acid catalyst as disclosed in copending U.S. Pat. application Ser. No. 537,004, filed Dec. 27, 1974 filed simultaneously herewith.
Compound (I) is a fragrant substance having a rich natural ambergris-like fragrance and a mystic peculiar wood-like odor reminiscent of a sunshing forest or moist earth, that is, a so called "natural odor" at the same time. When Compound (I) is absorbed in, e.g., filter paper and allowed to stand in a room at room temperature (e.g., about 20°-30°C), the residual fragrance is found to be very strong and to last for over one week. The fragrant odor of Compound (I) is also strong, and even when Compound (I) is diluted with ethyl alcohol, the average person even can perceive Compound (I) even at a one-tenthousandths dilution.
The utility value and application range of compound (I) of this invention are wide as a perfumery material. That is, Compound (I) can be widely used as a perfume, for example, as a component for a rich perfume to a perfume for a relatively inexpensive soap, by utilizing its residual fragrance and economy. It is possible to use Compound (I) together with rich natural amber or musk civet, or as a substitute therefor, by utilizing its ambergris-like fragrance, or together with natural sandalwood oil, or vetiver oil, or as a substitute therefor by utilizing its wood-like fragrance, thereby providing a dry and masculine rough scent necessary for a man's perfume.
Now, the present invention will be described in detail, by reference to the following Reference Example, Examples and drawings. The examples are merely illustrative and are not to be construed as limiting the scope of the present invention. Unless otherwise indicated, all parts, percents, ratios and the like are by weight.
REFERENCE EXAMPLE
In a 1l three-necked flask were charged 150 g of 1,5,9-trimethylcyclododecatriene-1,5,9 (melting point: 91°-92°C), 260 ml of formic acid and 150 ml of dichloromethane, and the materials were mixed. The mixture was then maintained at a temperature of 5°to 10°C. Subsequently, a mixed solution of 7.5 ml of sulfuric acid and 40 ml of formic acid was added dropwise thereto over a period of 30 minutes at 5°to 10°C, and the materials were reacted with stirring at that temperature for 3 hours, and further reacted with stirring at room temperature (i.e., about 20° to 30°C) for 3 additional hours. After completion of the reaction, dichloromethane was recovered by distillation, and then formic acid was distilled off water under reduced pressure. Subsequently, the residue was neutralized and washed with a 3% aqueous sodium bicarbonate solution, washed with water, and dried with anhydrous sodium sulfate, followed by distillation in vacuo at 75°-80°C/0.05 mmHg, whereby 135 g of the fraction of Compound (II) was obtained.
As a result of the IR, NMR, and MAS spectra of Compound (I) and also as a result of X-ray crystal structural analysis of a crystalline ketone compound derived from Compound (II), Compound (II) was determined to have the following structural formula (II). ##SPC4##
EXAMPLE 1
A mixture of 20.4 g (0.1 mole) of Compound (II) and 17 g of sodium carbonate was added to 100 ml of dichloromethane, with stirring. 20.8 g (0.11 mole) of an acetic acid solution containing 40% peracetic acid was added dropwise thereto over a period of 2 hours, while maintaining the solution at 0° to 5°C. The solution was then stirred at that temperature for 2 hours, and further stirred at room temperature for 3 additional hours. Subsequently, the resulting solution was mixed with 200 ml of water and extracted twice with dichloromethane. The extract was washed with an aqueous saturated sodium chloride solution until the extract became neutral, and then dried with anhydrous sodium sulfate. Subsequently, dichloromethane was recovered by distillation, and the residue was then distilled in vacuum, whereby 21 g of an oily fraction having a boiling point of 85°-90°C/0.3 mmHg) was obtained in a yield of 95%.
______________________________________Refractive Index: n.sub.D.sup.25 1.5063Elemental Analysis: C H Calculated (%): 81.76 10.98 Found (%): 81.65 11.09IR Spectrum: Epoxide characteristic absorption: 802 cm.sup..sup.-1, 880 cm.sup..sup.-1, 1240 cm.sup..sup.-1MAS Spectrum: M.sup.+ 220 (molecular ion)NMR Spectrum:______________________________________ ##SPC5##
a. 0.72 ppm (3H, s)
b. 0.75 ppm (3H, s)
c. 1.18 ppm (3H, s)
d. 2.87 ppm (1H, t)
Compound (I) was isomerized with a Lewis acid, using the procedures as disclosed in copending U.S. Pat. application Ser. No. 537,005, filed Dec. 27, 1974, filed simultaneously herewith, whereby a crystalline ketone compound (melting point: 99.5°-100.5°C) was obtained. The structure of the ketone compound thus obtained was directly determined by X-ray crystal structural analysis.
______________________________________X-ray Crystal Structural Analysis of the Ketone Compound:Lattice constant: a=7.975A, b=13.225A, c=7.147A α=95.7°, β=60.0°, γ=104.2°Space group: P1, Z=2Values (A) of X, Y and Z as solid coordinates:Atom RX RY RZ______________________________________C1 0.9791 5.7703 1.7584C2 2.3424 5.6967 2.4672C3 3.1955 4.4961 2.0121C4 2.3586 3.2151 1.9691C5 3.0098 1.9672 1.2955C6 3.6074 2.3334 -0.0927C7 2.4712 2.8519 -1.0345C8 1.5720 3.8637 -0.3559C9 1.1293 3.4170 1.0436C10 0.2013 4.4893 1.6283C11 0.5477 1.9829 0.9738C12 1.7833 1.0214 1.1082C13 -1.1340 4.7008 0.8295C14 1.9438 2.8689 3.4240C15 4.1078 1.2928 2.165701 0.5492 6.8548 1.4110______________________________________
Bonding angle among atoms from the solid coordinates:
Three Atoms Bonding Angle (degree)______________________________________C2-C1-C10 117.21C1-C2-C3 113.06C3-C4-C9 109.94C5-C4-C14 109.74C4-C5-C12 102.04C6-C5-C15 109.29C6-C7-C8 112.52C4-C9-C10 110.05C8-C9-C11 109.68C1-C-10-C13 111.65C5-C12-C11 104.92C2-C1-O1 119.15C2-C3-C4 110.94C3-C4-C14 107.85C9-C4-C14 112.11C4-C5-C15 113.57C12-C5-C15 111.06C7-C8-C9 112.68C4-C9-C11 101.76C10-C9-C11 115.93C9-C10-C13 114.50C10-C1-O1 123.46C3-C4-C5 116.95C5-C4-C9 100.20C4-C5-C6 110.94C6-C5-C12 109.74C5-C6-C7 109.65C4-C9-C8 110.69C8-C9-C10 108.58C1-C10-C9 108.39C9-C11-C12 105.50______________________________________
The stereostructural formula shown in FIG. 4 can be derived from these values.
Molecular Formula: C 15 H 24 O
As a result, the ketone compound was determined to have the stereostructural formula (III): ##SPC6##
From the foregoing result, the stereostructure of Compound (I) of the present invention was determined to be the formula (IV): ##SPC7##
EXAMPLE 2
The reaction was carried out under the same conditions as directed in Example 1, except that a dichloromethane solution containing 15 g (0.11 mole) of perbenzoic acid in place of the acetic acid solution containing 40% peracetic acid and 5.8 g of sodium carbonate were used, whereby Compound (I) was obtained in a yield of 93%.
EXAMPLE 3
The following formulation is suitable as a base for a perfume or an eau-de-cologne:
gVetiveryl Acetate 80Patchouli Oil 150Oak Moth 50Musk Ketone 20Coumarin 10Methyl Ionone 80Ionone 10Hydroxycitronellal 90Cinnamic Alcohol 30Stearyl Acetate 25Phenylethyl Alcohol 40Geraniol 50Terpineol 15Galbanum Oil 10Lavender Oil 20Bergamot Oil 30Ylang-ylang Oil 20Compound (I) 70 800 g
EXAMPLE 4
The following formulation is suitable for a soap perfumery.
______________________________________ gOak Moth Resinoid 50Cabdanum 20Patchouli Oil 50Heliotropine 120Musk Ambrette 150Vanillin 50Benzyl Salicylate 60Amyl Salicylate 240Geranium Oil 70Geraniol 30Anisic Aldehyde 60Lavandine Oil 60Compound (I) 40 1000 g______________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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5,6-Epoxy-1,2,6-trimethyltricyclo[5,3,2,0 2 ,7 ]dodecane having the formula (I) ##SPC1##
and a process for producing this compound. This compound is useful as a perfume.
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This is a continuation of application Ser. No. 777,896, filed Mar. 16, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The antiinflammatory properties of 4-allyloxy-3-chlorophenylacetic acid (briefly referred to as Alclofenac) are known, and its administration through the oral route has been used for some time, especially for therapy of arthrosis forms.
This drug has also a marked analgesic activity, higher than acetylsalicylic acid. Its administration through the intravenous route however is hindered by insolubility of the compound and by the fact that the sodic salt of the acid is scarcely tolerated.
To this purpose the following other solubilizations and esterifications were carried out in order to try to overcome this disadvantage.
(1)--Methylglucamine salt
16 g of N-methylglucamine are dissolved in 100 ml of water; 15 g of Alclofenac are added while stirring. When solution is complete, 600 mg of lidocaine are dissolved in the solution and volume is brought to 180 ml. A solution is obtained, which when properly filtered is injectable. As the salt in solution thus obtained is not very stable, an attempt to obtain the solid form was made. By lyophilization however a very hygroscopic salt is obtained, which may be hardly isolated.
(2)--Mono-ethanolamine solution
One mole of monoethanolamine is placed in water and while stirring one mole of Alclofenac is added. A stable, limpid, yellowish solution with pH 7.5 is obtained. The solid product is isolable only with difficulty. This solution however was discarded for its poor tolerability.
(3)--Arginine salt
15.4 g of base arginine are dissolved in 100 ml of water; 20 g of Alclofenac are added to the solution and stirring is carried on up to complete solution with pH 7.7. The filtered solution is frozen 6 hours at -40° C. Then lyophilization is carried out at a temperature of +40° C. A white-crystalline non-hygroscopic product is obtained, with melting point 192°-194° C., characteristic lR, titer 100%. However, this salt was discarded because of its intrinsic drawback of being scarcely water soluble.
On the contrary, the salt obtained from 4-allyloxy-3-chlorophenylacetic acid with lysine is a salt which is soluble in biological fluids and is well tolerated after either intravenous or intramuscular administration.
Its analgesic, antipyretic and antiinflammatory properties are equal or even superior to those of the starting acid. This happens because to the specific activity of the acid, after salification with lysine, a higher absorption velocity even through the oral and rectal route is added. It is clear that this means higher blood levels and therefore a higher therapeutic efficiency.
The lysine salt of 4-allyloxy-3-clorophenylacetic acid is also better tolerated per os, just because of its higher absorption velocity.
SUMMARY OF THE INVENTION
The present invention therefore is directed to lysine 4-allyloxy-3-chlorophenylacetate, whose structural formula is the following: ##STR1## corresponding to the empirical formula C 17 H 25 O 5 ClN 2 with molecular weight 372.79.
The present invention relates also to the method of preparation of the compound (1) and pharmaceutical compositions containing said compound as an active substance.
According to the present invention the compound (1) is obtained by reacting 4-allyloxy-3-chlorophenylacetic acid with lysine carbonate in hydroalcoholic solution and separating the corresponding salt by addition of precipitants or in a simpler way by concentration of the hydroalcoholic solution.
The two reagents are used in a stoichiometric quantity. The salt has the appearance of a white crystalline solid with tone on the yellowish side and characteristic odor, perfectly characterizable and it is very soluble in water and alcohols while it is insoluble in acetone. The solutions of compound (1) are perfectly stable; for the purpose of the administration through injection it is also useful to employ single dose ampuls containing the salt (1) in the lyophilized form, for instance in doses of 822.57 mg, corresponding to 500 mg of 4-allyloxy-3-chlorophenylacetic acid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the method of preparation according to the present invention. These examples are to be intended as merely illustrative and not limiting the scope of the invention.
EXAMPLE 1
226.6 g of 4-allyloxy-3-chlorophenylacetic acid are dissolved in 1200 ml of 25% ethyl alcohol. Separately 146 g of lysine are dissolved in water which is then, saturated with CO 2 , so as to obtain a 30% solution of lysine carbonate.
The solutions are joined with care in order to avoid an excessive foaming due to CO 2 development. The mixture is then left standing 24 hours at 4° C. to complete the reaction.
Evaporation under vacuum to a small volume is effected. Then crystallization is effected in an ice bath while standing 72 hours. The precipitate is then recovered with some acetone and is filtered with pump. The residue is washed on the filter with ethyl ether and dried under vacuum. 205 g of lysine 4-allyloxy-3-chlorophenylacetate with 99% purity is obtained.
The compound obtained in this way is a non-hygroscopic white crystalline solid with a color tone on the yellowish side, with melting point 158°-162° C. It has a titer of 99%, determined in a volumetric way. pH value of the 10% aqueous solution is 7.7.
The data of the standard analysis correspond to the calculated ones. The UV absorption on an aqueous solution of the product with a concentration of 50 mcg/ml has a characteristic development with a maximum at 279 mμ and a minimum at 250 mμ.
EXAMPLE 2
146 g of lysine are dissolved in water and the solution is saturated with CO 2 so as to obtain a 30% solution of lysine carbonate. Separately 226.6 g of 4-allyloxy-3-chlorophenylacetic acid are dissolved in 800 ml of isopropyl alcohol. The two solutions are joined by pouring the alcoholic solution into the aqueous solution with light stirring. Stirring is continued 5 hours at room temperature.
This solution is then introduced into a vacuum thickener, where working at a temperature of 35° C. and a vacuum of 20 mm Hg the solution volume is concentrated up to one fourth of the original value. Vacuum is removed, solution is cooled and 1800 ml of acetone are added.
Stirring is maintained while holding temperature of the solution at +2° C., and stirring is continued 24 hours. Solution is left standing 12 hours. The obtained residue is filtered under vacuum, and washed with little acetone. 185 g (yield 49%) of the product C 17 H 25 O 5 ClN 2 are obtained with the following characteristics: m.p. 158°-162° C.; K F 0.8%; Titer 99.8%.
EXAMPLE 3
120 g of lysine chlorohydrate are dissolved in 1000 ml of distilled water. The solution is passed through a column charged with Amberlite IRA 120, subsequently washing the same column with distilled water. The lysine solution, including washes, is then saturated with CO 2 by controlling carefully the pH value. Saturation is stopped when pH reaches about 10.7.
To this new solution 148.8 g of 4-allyloxy-3-chlorophenylacetic acid are added little by little and while stirring at room temperature, and stirring is maintained until all the acid is dissolved in the solution. At this point pH is again controlled, because pH must be maintained between 7 and 7.5.
The solution is filtered and lyophilization is effected. The lyophilized product is screened and collected is suitable containers. These last stages of preparation are effected under nitrogen atmosphere.
From the foregoing examples, the general characteristic of the product of the present invention, Alclofenac-lysine of the formula (1), may be summarized as follows:
Molecular weight: 372.79
Powder appearance: crystalline, white with yellowish tone and characteristic odor.
Melting point: 158°-162° C.
Solubility: extremely soluble in water and alcohols; insoluble in acetone.
Water content: below 1%
Purity: Product must contain not less than 25% of C 17 H 25 O 5 ClN 2
pH: Aqueous solution 25% parts/volume must have a pH of 7.4-7.8.
Identification: IR identification with Perkin Elmer apparatus shows a characteristic pattern
UV-Absorption: in aqueous solution, with concentration of 50 mcg/ml it has a characteristic development with a maximum at 279 nmμ and a minimum at 250 nmμ
The present invention succeeds in use of the mentioned specific characteristics of Alclofenac in the preparation of injectable pharmaceutical preparations.
As the Alclofenac molecule is insoluble in the physiological fluids, it is necessary to effect a transformation thereof which allows the dissolution in them. The tested solutions are the sodium salt of the acid, and its salts with methylglucamine, arginine, lysine and ethanolamine.
Apart the considerations of a chemical-physical nature, salt formation with lysine was the form chosen for the pharmacological tests because of its better tolerability at local levels.
Such a tolerability was estimated after injection of equivalent solutions of the various preparations, effected in the rabbit dorsal long muscle, removing muscle 24 hours after injection and estimating the degree of induced irritation through arbitrary scores. The results obtained are summarized in Table 1.
The results clearly indicate that the best Alclofenac soluble pharmaceutical preparation is that obtained with the lysine salt.
This type of preparation was estimated also in comparison with commercially available injectable preparations according to the method of volume increase of rat leg and results are shown in FIG. 1 of the drawings.
Alclofenac-lysine proved to be better more tolerated than a commercially available preparation obtained by solubilization with methylglucamine (Mervan).
The following pharmacological experimentation was carried out in order to estimate the comparative absorption and bioavailability through various administration routes in rabbits of Alclofenac acid and its lysine salt. These data are shown in Tables 2,3,4 and 5.
Alclofenac acid is well absorbed through the oral and rectal route so that its solubilization does not bring clear improvements in either its bioavailability or of blood levels (see FIGS. 3 and 4 of the drawings).
However, it is apparent that the lysine salt is absorbed faster and to a higher extent in comparison with the acidic substance. This appears clearly from data of partial bioavailability shown in Table 5.
Contrary to what was anticipated administration through the intramuscular route did not lead to expected results.
The time levels after intramuscular administration are shown in FIG. 2 of the drawings together with the data relating to an intravenous administration of Alclofenac-Lysine.
Velocity of absorption may be compared with that per os but the instantaneous and sustained blood levels are lower so that it seems this formulation acts as a sustained release form.
TABLE 1__________________________________________________________________________RABBIT MUSCLE mg/mlTREATMENT (as acid) ml injected SCORES at 24 hours Average__________________________________________________________________________Alclofenac-Arginine 131 0.25 1.5 3.5 3 0 0 1.6" 100 0.5 6.5 2.5 3 3.5 3.9Alclofenac-Lysine 131 0.25 2 3 4 4 0 2.6" 100 0.5 2 3 2 2.3Alclofenac-Ethanolamine 100 0.25 3 3.5 2.5 3Alclofenac-Methylglucose 100 0.25 0 3 3 2" 100 0.5 2 5 10 4.5 5.4Brufen-Lysine 131 0.25 2 5 4.5 4 7 4.5Liometacin vial 0.25 4 2 1 2 3.5 2.5" " 0.5 4.5 0 2.2Mervan " 0.25 6 3.5 4.5 3 7 4.8Aspegic " 0.25 2 4 0 0 0 1.2Penetracin " 0.25 4.5 5 3.5 4.3__________________________________________________________________________
TABLE 2__________________________________________________________________________Pharmacokinetic parameters of Alclofenac-Lysine salt after i.v. injectionof 90 mg/kg (as acid) ofthe drug in rabbits.PARAMETERS.sup.-1 RABBIT I RABBIT II RABBIT III RABBIT IV MEAN ± S.E.M.__________________________________________________________________________A mcg × ml.sup.-1 170.51 151.04 209.59 131.86 165.7 ± 16.6α min.sup.-1 0.083 0.113 0.067 0.066 0.082 ± 0.011t1/2α min 8.5 6 10.5 10.5 9 ± 1B mcg × ml.sup.-1 269.19 324.95 269.89 310.16 293.5 ± 14.2β min.sup.-1 0.0017 0.0023 0.0011 0.0026 0.0019 ± 0.0003t1/2β min 408 301 630 266 401 ± 81K.sub.21 min.sup.-1 0.051 0.078 0.038 0.047 0.053 ± 0.009K.sub.12 min.sup.-1 0.030 0.034 0.028 0.018 0.027 ± 0.003Kel min.sup.-1 0.0027 0.0033 0.0019 0.0036 0.0029 ± 0.0004√1 l × Kg.sup.-1 0.205 0.189 0.188 0.204 0.196 ± 0.005√2 l × Kg.sup.-1 0.345 0.432 0.256 0.537 0.392 ± 0.060Vdβ l × Kg.sup.-1 0.330 0.274 0.329 0.285 0.304 ± 0.015CL ml × Kg.sup.-1 × min.sup.-1 0.56 0.63 0.36 0.74 0.57 ± 0.08AUC mcg × min × l.sup.-1 160.4 142.6 248.5 121.3 168.2 ± 28Total__________________________________________________________________________
TABLE 3__________________________________________________________________________Pharmacokinetic costants obtained from plasma levels of Alclofenacfollowing the administration of the acidor lysine salt by different routes. ROUTES OF ADMINISTRATIONKinetic parameter P.OS RECTAL INTRAMUSCOLARUNITS Acid Lysine Salt Acid Lysine salt Lysine salt± E.S.M. 90 mg/kg 90 mg/kg 100 mg/kg 100 mg/kg 80 mg/kg__________________________________________________________________________Ka min.sup.-1 0.0146 ± 0.0018 0.0174 ± 0.0047 0.053 ± 0.10 0.132 ± 0.032 0.0131 ± 0.0031t1/2α min 51.0000 ± 5.0000 37.0000 ± 8.0000 14 ± 3 8 ± 3 60 ± 11tmax min 173 ± 14 131 ± 28 66 ± 9 39 ± 11 277 ± 53Cmax mcg · ml.sup.-1 358.5 ± 47.8 454.5 ± 152.2 424.7 ± 11.9 473.7 ± 24.1 144.2 ± 30Kel min.sup.-1 0.0018 ± 0.0005 0.0023 ± 0.0005 0.0023 ± 0.0003 0.0026 ± 0.0004 0.0007 ± 0.0003t1/2β min 414 ± 40 377 ± 92 307 ± 35 268 ± 71 1407 ± 378Vdβ l · kg.sup.-1 0.326 ± 0.045 0.301 ± 0.050 0.274 ± 0.060 0.248 ± 0.072 0.607 ± 0.090CL ml · kg.sup.-1 · min.sup.-1 0.64 ± 0.06 0.67 ± 0.06 0.54 ± 0.04 0.55 ± 0.03 0.67 ± 0.06__________________________________________________________________________
TABLE 4__________________________________________________________________________Extent of Availability of Alclofenac after different routes ofadministration using intravenousadministration as reference. P.O. P.O. Rectal Rectal I.M. I.V. (acid) (lysine salt) (acid) (lysine salt) (lysine salt)__________________________________________________________________________Practical AUC.sup. amcg · min · l.sup.-1 ± S.E.M. 155.6 ± 5 130.7 ± 14 137.8 ± 11 182.8 ± 14 173.3 ± 14 131.9 ± 26Dose (mg · kg.sup.-1) 90 90 90 100 100 80(% Availability) 100 84.0 88.5 105.7 100.2 95.4Theoretical AUC.sup. bmcg · min · l.sup.-1 ± S.E.M. 168.2 ± 28 150.0 ± 19 139.1 ± 14 162.9 ± 13 166.7 ± 12 231.5 ± 57Dose (mg · kg.sup.-1) 90 90 90 100 100 80(% Availability) 100 89.2 82.7 87.2 89.2 154.8__________________________________________________________________________ .sup.a Practical AUC was calculated using the trapezoidal method. The remaining area after the last observation was calculated according to Wagner using: Ctn.Kel.sup.-1 = Area 24h .sup.b Theoretical AUC was evaluated on the fitted curve by the equations AUC = A/α + B/β for the intravenous administration AUC = Co/Ke for the extravascular administration
TABLE 5__________________________________________________________________________Extent of Availability of Alclofenac after different routes ofadministration usingintravenous administration as reference.__________________________________________________________________________ AUC o → 4h I.V. P.O. Acid P.O. Lysine F Lys. vs acid__________________________________________________________________________Practical AUCmcg · min · l.sup.-1 ± S.E.M. 55.85 ± 2.3 23.69 ± 1.5 32.45 ± 2 --Dose (mg · kg.sup.-1) 90 90 90 --(% Availability) 100 42.4 58.12 <0.01__________________________________________________________________________ AUC o → 2h I.V. Rectal acid Rectal Lys. F Lys. vs acid__________________________________________________________________________Practical AUCmcg · min · l.sup.-1 ± S.E.M. 33.15 ± 1 30.6 ± 1.7 35.23 ± 2.6 --Dose (mg · kg.sup.-1) 90 100 100 --(% Availability) 100 83.24 95.65 ns__________________________________________________________________________
Taking into account also the chemical-physical characteristics of Alclofenac lysine salt, it is be considered to be appropriate for preparations intended for intravenous use. Its appropriateness for forms to be administered per os is retained when these forms require the presence of the drug in a solution.
Furthermore, the shorter residence time at the gastric level enables a better tolerance of the preparation.
The intramuscular form may be considered appropriate when it should be used just as a sustained release preparation for particular therapeutic uses.
Typical examples of formulas for compositions containing Alclofenac-lysine salt as the active ingredient are as follows:
(1) Injectable product
Each vial contains:
Alclofenac lysine--824 mg
Lidocaine--10 mg
Septocombin--5 mg
Mannitol--400 mg
(2) Products for oral use
(A) Syrup containing per 100 ml:
Alclofenac lysine--5 g
Glycerine--2 g
Sodium Septocombin--0.5 g
Flavored sugar syrup q.s. ad 100 ml
(B) Single dose bag
Each bag contains:
Alclofenac lysine--900 mg
Flavored granulate q.s. ad--3 g
(3) Rectal form product
Each suppository contains:
Alclofenac lysine--900 mg
Miogliol 812--100 mg
Witeposal W31 q.s. ad--3 g
(4) Ointment form product
100 g of product contain:
Alclofenac lysine--9 g
Stearic acid--10 g
Pul. sorbitan monostearate--6 g
Sorbitan monostearate--1 g
Propyleneglycol--1 g
Preserver--0.5 g
Water q.s. ad--100 g
From the foregoing it is apparent that the lysine salt of Alclofenac according to the present invention unexpectedly shows for superior properties and characteristics, rendering it a unique antiinflammatory and analgesic drug, especially adapted for intravenous administration.
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Lysine 4-allyloxy-3-chlorophenylacetate is a salt of Alclofenac which is soluble in biological fluids and particularly adapted for intravenous or intramuscular administration. Its method of preparation consists in reacting Alclofenac with lysine carbonate in hydroalcoholic solution and separating the corresponding salt by adding precipitants or by concentrating the hydroalcoholic solution.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of (1) U.S. Provisional Application No. 61/554,543 filed on Nov. 2, 2011, titled “Furnaces, Parts Thereof, and Methods of Making Same,” (2) Chinese Patent Application No. 201220452716.1 filed on Sep. 6, 2012; (3) Taiwan Patent Application No. 101213629 filed on Jul. 13, 2012; and (4) German Patent Application No. 202012007524.1 filed on Aug. 2, 2012, the entire contents of each of which are incorporated herein by reference.
FIELD OF INVENTION
[0002] Embodiments of this invention relate to furnaces, parts thereof, and methods of making such furnaces and parts.
BACKGROUND
[0003] A solar (photovoltaic) cell is a device that is capable of converting electromagnetic radiation, light, into electricity by the photovoltaic effect.
[0004] Photovoltaic materials that have been used in solar cells include: crystalline and amorphous silicon, compound semiconductors, organic dyes and polymers, and nanocrystals commonly referred to as quantum dots. Among these photovoltaic materials, crystalline silicon, c-Si, is by far the most prevalent material.
[0005] c-Si is generally produced as large ingots of material that are shaped and sliced into individual wafers. There are two formats for c-Si materials, monocrystalline and multicrystalline. Monocrystalline silicon is a single crystal of silicon with no grain boundaries. Multicrystalline silicon is comprised of multiple crystals of silicon with a grain boundary between each silicon crystals. The production of c-Si requires substantial energy to affect the heating and melting of the silicon.
[0006] Monocrystalline silicon is produced in rounded ingots of material often using the Czochralski process. In the Czochralski process, silicon is melted in a furnace, a single crystal seed is dipped into the surface of the molten silicon, the seed is slowly withdrawn from the melt while rotating, as the seed is withdrawn the temperature is controlled such that crystal growth results. Through control of the rotation speed, the rate of withdrawal of the seed crystal, and the temperature gradients present in the furnace, it is possible to produce large, cylindrical, single crystals of silicon. Monocrystalline silicon has the advantage of greater conversion efficiency of solar light into electrical energy. Monocrystalline silicon, however, does not efficiently use the cast silicon ingot since the cylindrical ingots must be cut into roughly square ingots prior to be wafering.
[0007] Multicrystalline silicon is produced as square or rectangular ingots of material. In the multicrystalline process, silicon is melted in a furnace, a temperature gradient is created in the furnace and the silicon recrystallizes from one end of the crucible to the other (typically the bottom to the top). The result is a multicrystalline ingot. The grain sizes in the ingot are typically millimeter to centimeter in width and grow in an approximately columnar arrangement from the bottom of the crucible to the top. The process of crystallization is referred to as directional solidification (DS) and furnaces for multicrystalline silicon growth are referred to as directional solidification systems (DSS furnaces). The ingot sizes in DS are sized as whole multiples of the wafer length and width, permitting efficient use of the material. The multicrystalline wafers, however, are not as efficient as monocrystalline wafers in their conversion of light into electrical energy. There are several variants of DSS furnaces including DSS furnaces modified to produce quasi-monocrystalline ingots and gradient controlled crystallization furnaces.
[0008] FIG. 1 shows a typical vacuum furnace designed for casting of multicrystalline or monocrystalline ingots of a material. For photovoltaic applications, the material is typically silicon, generally cast as a multicrystalline ingot. Regardless of the manufacturer of the furnace, the general design principles of the furnace are common. A water cooled furnace shell 1 , typically constructed from steel, surrounds a cage 2 , generally constructed from stainless steel. The cage 2 holds and supports an insulation pack 3 . The insulation pack 3 both reduces the amount of energy required to heat and maintain the core of the furnace at high temperature and protects the furnace shell 1 from temperatures that are capable of melting or recrystallizing the shell materials.
[0009] Interior to the insulation pack 3 are heating elements 4 . Most such furnaces are heated by graphite resistance heating elements where the graphite is connected to a power supply, current is passed through the graphite, and the resistance of the graphite to the flow of electrical current generates heat. It is possible to employ other heating methods including induction heating.
[0010] Interior to the insulation pack 3 and heating elements 4 is a cavity 5 containing a crucible 6 that contains the material 7 [e.g. silicon] being melted or recrystallised, and other graphite parts that surround or support the crucible. The heating elements 4 and cavity 5 together define the “hot zone” to the furnace that is insulated by the insulation pack 3 . The crucibles 6 are typically constructed from fused silica, but other materials may also be employed. Manufacturers of DSS furnaces include: ALD Vacuum Technologies, Centrotherm, Ferrotec, GT Advanced Technologies (formerly GT Solar), Jinggong, JYT, Kayex, PVA TePla, Roth & Rau Zhejian Jingsheng Mechanical & Electrical Co., and others.
[0011] Reduction of the energy used to produced c-Si is a key goal for users of such furnaces as energy demand continues to increase in all markets.
[0012] Typically, insulation packs in such furnaces consist of a series of parts that, once assembled, form a roughly cube-shaped insulation pack. The material used for the individual insulation components is typically a low density composite of carbon fiber and a carbonized resin. The insulation material is typically rigid board, a short-fiber composite made by resin impregnation of chopped carbon fiber, or rigidified board, a long-fiber composite manufactured by resin impregnation of carbon or graphite felt. Examples of commercially available rigid board include: Morgan Advanced Materials and Technology Rigid Board, Americarb CFB-17 Rigid Fiberboard Insulation, Mersen CBCF Rigid Carbon Insulation, GrafTech GRAFSHIELD GRI Thermal Insulation, and others. Examples of commercially available rigidified board include Kureha KRECA FR, SGL Group SIGRATHERM Rigid Graphite Felt, and others. In the following, both rigid and rigidified board will be referred to as rigid carbon fiber based insulation material.
[0013] Rigid carbon fiber based insulation materials have several deficiencies.
[0014] First, the incorporation of a carbonized resin into the insulation matrix raises the thermal conductivity of the material, making it less insulating.
[0015] Second, the insulation materials have an inherent grain structure in that the fibers of the board are preferentially aligned parallel to the board surface, and preferentially not aligned parallel to the thickness of the board. The degree of alignment varies from material to material and the grain structure generally reflects a tendency to alignment rather than strict alignment. The result is that these materials have grossly different insulation properties when heat flow operates against the thickness of the board than when the heat flow operates along the length and width of the board. In the current application, the result of this differential insulation value is a corner anomaly that disrupts standard heat flow and may result in imperfections in the ingot as it is grown.
[0016] Third, the rigid carbon fiber based insulation materials are prone to warp and other distortion during the lifetime over which they are used. The warp of the insulation results in gaps forming between parts, allowing heat to short circuit the insulation.
[0017] Finally, as furnaces age, the cages are prone to distortion and warp. The installation of rigid carbon fiber based insulation materials into warped cages becomes impossible and the cages must be replaced.
[0018] The design of the insulation packs presently used in DSS applications is that the insulation parts are machined boards of rigid carbon fiber based insulation material. The mating between pieces is generally achieved via a simple butt-joint between parts ( FIG. 2 ).
[0019] Butt joints between insulation parts have the deficiency that each butt joint 8 provides a pathway for heat transfer, a “thermal short circuit”, that reduces the overall insulation value of the system, and increases the energy requirement during operation. Thermal short circuiting can also lead to the possibility of “shine-through”, a dangerous condition whereby the light energy from the furnace hot zone shines directly on the outer shell. The heat transferred to the shell is capable of causing a furnace explosion. Additionally, the butt joint provides no reinforcement to limit the effect of the previously described warp and distortion of rigid carbon fiber based insulation materials.
[0020] Finally, the corners of the insulation pack are not uniform in insulation thickness compared to the walls of the insulation pack. In an assembly of side boards 9 as illustrated in FIG. 3 the thickness through the corner 10 is approximately 70% of the thickness of the wall: in an assembly of side boards 9 as illustrated in FIG. 4 , the thickness through the corner 11 is approximately 140% of the wall thickness. This means that the resistance to the flow of heat from a source 12 [e.g. a crucible 5 ] in directions 13 is different from the resistance to the flow of heat in directions 14 , leading to an uneven distribution of heat within heats source 12 .
[0021] The combined result of these deficiencies of prior art constructions are elevated energy use and reduced ingot quality.
[0022] To overcome the aforementioned deficiencies, a new furnace design has been conceived in which a flexible carbon felt is disposed between the side boards and the cage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The scope of the invention is as set out in the appended claims in the light of following illustrative but non-limiting description and with reference to the drawings in which:
[0024] FIG. 1 is a schematic view of a prior art vacuum furnace;
[0025] FIG. 2 is a schematic detail of a conventional manner of joining panels end-to-end;
[0026] FIGS. 3 and 4 are schematic detail of a conventional manner of joining panels at a corner;
[0027] FIG. 5 is a schematic detail analogous to FIGS. 2 and 4 showing a corner detail of insulation from one embodiment of the present invention;
[0028] FIG. 6 is an orthogonal view of a bottom cage and insulation pack from a furnace in accordance with the present invention;
[0029] FIG. 7 is an inverted orthogonal view of a top cage complementary to the bottom of FIG. 6 ;
[0030] FIG. 8 is a sectional view of a cage comprising the bottom cage of FIG. 6 and the top cage of FIG. 7 ;
[0031] FIG. 9 is a schematic showing connection features for portions of the insulation pack of the invention;
[0032] FIGS. 10 and 11 are assembly drawings for a cage and insulation pack as shown in FIGS. 6-8 ;
[0033] FIG. 12 is shows typical thermal conductivity of Morgan Rigid Board and Morgan Carbon Felt.
DETAILED DESCRIPTION
[0034] A typical insulation pack in accordance with the present invention is indicated schematically in part in FIG. 5 and as orthogonal and sectional views in FIGS. 6 , 7 and 8 . In FIGS. 6 , 7 , and 8 a cage comprises an upper cage 15 and lower cage 16 . Lining the side walls of the upper cage 15 and lower cage 16 is a graphite foil outer layer 17 . Interior to, and protected by, the graphite foil outer layer 17 is a layer 18 of a flexible carbon felt. The graphite foil outer layer is optional. The graphite foil outer layer protects the carbon felt from chemical degradation, for example caused by silicon-containing vapor attack on the material. Interior to the layer 18 of a flexible carbon felt are side boards 9 of a rigid carbon fiber based insulation material. The side boards 9 may optionally be coated with graphite foil or graphite paint to reduce the susceptibility of the material to degradation caused by the silicon-containing vapor. This arrangement is implemented on all four sides of the insulation pack.
[0035] Top boards 19 typically comprise boards of rigid carbon fiber based insulation material sandwiching flexible carbon felt. The bottom of the insulation pack comprises an assembly of edge boards 20 and a center board 21 . Although only a single center board is shown, it is possible to use multiple boards. Equally it is possible to use a single board in place of the edge boards 20 and center board 21 although separate provision of edge and center boards has the advantages that separate edge and center boards ( 20 , 21 ) permit a degree of relative movement such that the base can accommodate distortions in the cage. Further, the edge boards 20 can be machined permitting a plain unmachined board to provide the center board 21 .
[0036] Typically, the edge boards 20 and center board 21 or equivalent are formed of rigid carbon fiber based insulation material.
[0037] Dependent on application, other constructions are possible, for example, by providing additional carbon felt insulation to the bottom of the insulation pack.
[0038] A key feature of the new insulation pack design is the incorporation of flexible carbon felt as a replacement for the outermost insulation material conventionally provided on the sides of the insulation pack.
[0039] Carbon felt has a lower thermal conductivity (lower curve in FIG. 12 ) than rigid carbon fiber based insulation material (upper curve in FIG. 12 ). Therefore, its incorporation into the design of the insulation pack can reduce the energy requirement dramatically.
[0040] Secondly, the incorporation of carbon felt into the design permits the insulation to mitigate differential heat flow between the walls and the corners of the insulation pack. This may be accomplished by wrapping the felt insulation around the interior of the insulation cage. The wrap of felt around the corners of the insulation cage improves the thermal uniformity of the hot-zone and may lead to an improvement in the quality of the ingot produced. It is not necessary for a continuous layer of felt to be provided [overlapping sections of felt can be used] however a continuous length of felt has the advantage of providing few junctions where heat may escape and reducing the risk of movement of the felt opening up gaps between sections of felt. Provision of at least one continuous layer of flexible carbon felt wrapped around at least some of the side boards to overlap itself reduces the risk inherent in using sections of carbon felt.
[0041] Carbon felt is typically produced with a large aspect ratio. The typical length of a roll of felt is approximately fifteen meters and the width is less than one meter. The large aspect ratio lends itself to continuous wrapping of the layers of felt material providing a seamless insulation body for the insulation pack.
[0042] A second feature of the new design is the incorporation of design features that prevent a direct path for heat flow from the hot-face of the insulation to the cold-face.
[0043] This is accomplished in two manners. First, the overall number of board parts has been reduced in comparison with conventional designs, reducing the number of potential paths for heat to escape. Second, features have been designed into the junction of each piece of rigid insulation to serve two purposes, firstly to create a non-linear path from the hot-face of the insulation to the cold-face; and secondly to provide optional interengagement and optional interlocking of the board parts.
[0044] As can be seen in FIG. 5 , edge portions of boards 9 have complementary engagement features to provide a junction 16 between the boards 9 giving a non-linear path. This non-linear path from the furnace cavity to the exterior of the insulation mitigates the risk of heat transfer through the junction
[0045] Similarly, a non-linear path from the hot-face of the insulation to the cold-face can be provided:
at the joint area between the top and side boards and the bottom and side boards between side board pieces
[0048] As seen in FIG. 8 , and in more detail in FIG. 9 , the joint area between the top and side boards and the bottom and side boards can be provided by dado joints 23 comprising a groove in the respective top or bottom board receiving an edge of the side board 9 . Similarly, a tongue-and-groove joint 24 may be used between side board pieces by shaping the edges of the side board pieces 9 .
[0049] The joints indicated are illustrative and other joints can be used, the principal features of the illustrated joints are the provision of non-linear paths path from the hot-face of the insulation to the cold-face. Other constructions that can assist in this purpose are illustrated in WO2011/106580.
[0050] Bolt holes 25 through the side boards 9 and corresponding bolt holes 26 in the cages can receive bolts (not shown) to secure to the side boards to the bolt holes. The bolts may be of a carbon composite material.
[0051] As a result of the design, it is difficult for the boards of rigid carbon fiber based insulation material to deform in use. The selection of the joints at each interface between parts provides reinforcement that mitigates or negates warp. For example, the dado joints between the top and sides and the bottom and sides lock the side boards into position. Similarly, the tongue-and groove joint between the side boards positively locks the boards together, eliminating the possibility of warp. Finally, the joint construction between the corners of the side boards provides a similar locking feature.
[0052] The insulation pack may be assembled separately in the top and bottom portions of the cage as shown in FIGS. 6 , and 7 and later mated in the furnace as in FIG. 8 , or they may be assembled as a whole unit.
[0053] To manufacture a furnace cage and insulation pack in accordance with FIGS. 6-8 , the top and bottom segments of the insulation pack are assembled separately. FIG. 10 shows a typical assembly sequence a-f for the bottom segment and FIG. 11 shows a typical assembly sequence a-e for the top segment.
[0054] The upper cage 15 and bottom cage 16 may be cleaned to be free of surface debris. An appropriate adhesive may be sprayed onto the interior side walls of the cage. Examples of an appropriate adhesive include 3M Super 77 and Barnes Distribution Web Tite Adhesive. Sheets of graphite foil 17 , pre-cut to the dimensions of the wall of the cage segment, are installed onto the interior of the cage with the spray adhesive, if present, serving to hold the pieces in place. Examples of a suitable graphite foil include GrafTech GRAFOIL GTA and SGL Group SIGRAFLEX C. The thickness for the graphite foil should be greater than 0.005″ (0.127 mm) and is preferable at least 0.0601-1.52 mm).
[0055] The bottom edge boards 20 , 21 may be installed into the bottom furnace cage 16 and the top insulation parts 19 may be installed into the top furnace cage 15 . The bottom and top boards 20 , 21 , 19 are typically machined from a rigid insulation material, such as Morgan AM&T rigid board.
[0056] A thin, intermittent layer of adhesive may be placed on the interior surface of the graphite foil sheet 17 . Starting at one of the corners, the flexible carbon felt 18 is adhered to the graphite foil 17 and pressed to the sides of the respective cage. To enable the wrap to continue, the spray adhesive may be applied to the interior surface of each concentric layer of carbon felt wrap 18 . The carbon felt wrap 18 is continued in a concentric, continuous manner with one or more pieces of carbon felt until the desired thickness is achieved. The thickness of the felt material is ideally within +/−5 mm of the rigid insulation that it is replacing, but can be outside this limit. For example, if the carbon felt is replacing 45 mm of a rigid insulation, a suitable thickness is between 40 mm and 50 mm. Suitable carbon felt materials include Morgan AM&T VDG carbon felt and Morgan AM&T WDF graphite felt. The side insulation boards 9 are installed into their respective cage half. The side insulation boards 9 are a rigid insulation material, Morgan AM&T rigid board, for example. The side boards 9 lock into position in the receiving dado joint 23 located on the top and bottom boards. The top and bottom cages 15 , 16 with the insulation are then installed in the furnace. The top board 19 is typically constructed from two pieces of machined rigid board that sandwich carbon felt. The bottom boards 20 , 21 are machined rigid board.
[0057] The above description is for illustrative purposes and variant and alternatives will be evident to the person skilled in the art and are encompassed herein to the extent covered by the claims.
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A furnace comprises a cage holding and supporting an insulation pack comprising one or more base boards, one or more top boards and a plurality of side boards each of rigid carbon fiber based insulation material, the one or more base boards, one or more top boards, and plurality of side boards defining a cavity between them. A flexible carbon felt is disposed between the side boards and the cage.
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BACKGROUND OF THE INVENTION
My invention relates in general to drives and more particularly to stepless, variable ratio drives employing a variable stroke mechanism.
An important advance in the use of variable stroke drives for automatic transmissions was the Waddington drive described in U.S. Pat. Nos. 3,803,932 and 3,874,253, and in pending U.S. patent application No. 737,632. The Waddington drive of these earlier descriptions employed a cam which rotated at the input speed to the drive and which was automatically controlled to assume various eccentricities relative to the center of input rotation in order to vary the stroke and thereby the torque ratio of the drive. The instant invention also utilizes a variable stroke drive, but has the feature of a nonrotating cam which allows manual control of the cam eccentricity to regulate the stroke and torque ratio of the drive. The manual control capability is desirable in some situations as, for example, when the drive is used for a bicycle transmission. The manual control would accommodate cyclists who would prefer to manipulate the control themselves to suit their particular needs. Indeed the drive is particularly attractive for use as a bicycle transmission because of its compactness, light weight, moderate cost and immediate adaptability to existing bicycle frames. The earlier Waddington drives were either somewhat heavier because they operated at slow input speed and utilized large overrunning clutches, or required some modification to the standard bicycle frame to incorporate an input speed stepup mechanism.
SUMMARY OF THE INVENTION
The invention is a variable stroke drive wherein the input element comprises a crank driven carrier housing journaled for rotation on a spindle. In the carrier, journaled on individual axles, are four planet gears which mesh with a sun gear. Recessed into one side of each planet gear is a concentric channel with ratchet teeth in its outer circumference. Journaled on the inner circumference of the channel is a crank ring having several pawls to engage the ratchet teeth. The crank ring also has a follower which engages a cylindrical cam channel fixed on and adjustable to various eccentricities relative to the spindle center. Rotation of the carrier housing by the input means imparts to the crank ring an angular oscillation of an amplitude proportional to the eccentricity of the cam channel. As a crank ring is carried around that quarter of a carrier revolution where it is oscillated at highest angular velocities in a direction opposite to the carrier rotation, the pawls of the ring engage the planet gear ratchet teeth and cause rotation of the planet. The sequential engagement of the rings and planets drives the sun gear at a substantially constant output speed which is a multiple of the input speed and is dependent on the cam eccentricity.
Another embodiment of the invention eliminates the crank rings and ratchet teeth. Instead, the planets are provided with a follower which engages the cam channel and oscillates the planets. Provided in the carrier housing are slots for the planet axles which allow the planets sequentially to move to engage and disengage the sun gear during a selected portion of the carrier revolution to accomplish a speed increase, decrease or reversal.
The invention provides three alternate control mechanisms for adjusting the eccentricity of the cam to shift the drive's ratios. The first is a manually manipulated arrangement of lever and cable. The second is an automatic input speed control which utilizes centrifugal weights to engage an outer race when the input speed is above a predetermined value and an inner race when below another value. The races, through a gear arrangement, drive a screw which is linked to the cam. The third control is automatic and responds to the torque across the drive.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in section of an embodiment of the invention as it may be applied for use as a bicycle transmission.
FIG. 2 is a section along the line 2--2 of FIG. 1.
FIG. 3 is a section along the line 3--3 of FIG. 1.
FIG. 4 is a side view, partly in section, of a manual control for shifting the transmission.
FIG. 5 is a section along the line 5--5 of FIG. 4.
FIG. 6 is an end view of the transmission with a torque ratio control sensitive to input speed which is part of the invention.
FIG. 7 is a section along the line 7--7 of FIG. 6.
FIG. 8 is a section along the line 8--8 of FIG. 6.
FIG. 9 is a side view in section of another embodiment of the invention as it may be applied for use as a bicycle transmission.
FIG. 10 is a section along the line 10--10 of FIG. 9.
FIG. 11 is a section along the line 11--11 of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1, 2 and 3, the transmission 10 is mounted by fixing its main spindle 12 in slotted left and right brackets 14 and 16 which are attached to the bicycle rear fork members 18 and 20.
Screwed on the left side of the spindle 12 is a nut 22 which is prevented from turning by its two flats 24 which snugly fit a recess in the left bracket 14. The bracket 14 is clamped between nut 22 and washer 26 by end nut 28.
Similarly screwed on the right side of spindle 12 is pivot hub 30 which is prevented from turning by its end flats 31 which fit into a recess in right bracket 16. The bracket 16 is clamped between the pivot hub 30 and washer 32 by end nut 34. The nut 22 and pivot hub 30 are just sufficiently spaced on spindle 12 for intermediate parts to turn freely.
Adjacent pivot hub 30 is a carrier assembly 36 comprised of a sprocket 38, a left side disk 40 and a cover 42. The sprocket 38 is journaled by a bearing 44 onto the spindle 12. An output sun gear 46 is journaled through its hollow shaft 48 onto spindle 12 by a pair of bearings 50. The carrier left side disk 40 is then journaled onto the shaft 48 by a bearing 52.
The carrier 36 retains four axles 54 on each of which is a planet gear 56 journaled by a bearing 58. The planets 56 have external teeth meshing with sun gear 46. Recessed into one side of each planet 56, concentric with the planet axle 54, is a channel 60. The outer circumference of the channel 60 has a number of ratchet teeth 62. The inner circumference supports a bearing 64 for journaling a crank ring 66 received by channel 60 on which are pivotally mounted several outward oriented pawls 68, shown in FIG. 3, to engage the ratchet teeth 62. Also in the crank ring 66, for each pawl 68, there is a small bore 70 which retains a cantilever spring 72 engaging a recess in its pawl 68 and urging the pawl 68 against the ratchet teeth 62. Retained in a recess in the outer circumference of the channel 60, protruding slightly beyond the ratchet teeth 62 is a resilient ring 74, seen in FIG. 1, on which the pawls 68 noiselessly ride when not engaged.
Each crank ring 66 has a crank pin 76 protruding through an arcuate slot 78 in the sprocket 38 as best seen in FIG. 3. Journaled on each crank pin 76 is a cylindrical follower 80 which follows a circular cam channel 84 constructed in cam plate 88. Cam plate 88 is in turn journaled onto cam plate axle 82 by bearings 86.
As seen in FIG. 2, the cam plate axle 82 has a circular, interior bore 90, the center P of which being offset from the geometric center C of the cam plate axle 82 and the center of the circular cam channel 84. By means of the bore 90, the cam plate axle 82 is itself journaled onto cylindrical surface 92 of the pivot hub 30. The center P of cylindrical surface 92 on the pivot hub 30 is offset from the spindle axis S by the same distance that the center of the interior bore 90 in the cam plate 88 is offset from the geometric center C of the cam plate axle 82. The cam plate axle 82 is rotatably adjustable from concentricity to varying eccentricities relative to the spindle 12 by pivoting about the center P of surface 92. In order to reduce the loads on the follower 80, cam plate 88 is freely rotatable on bearings 86.
Into the cam plate axle 82 is threaded a stop pin 94 which protrudes into a groove 96 angularly spanning 90° of cylindrical surface 92 of the pivot hub 30 in order to limit the adjustability of the cam plate axle 82. In FIG. 2 the center C of cam plate axle 82 is shown swung around the pivot hub center P to its maximum eccentricity relative to spindle center S. A plastic dust cover 98 is provided to protect the cam plate axle 82 and cam plate 88. The means employed for controlling the position of cam plate 88 will be described subsequently. An output wheel hub 102 is journaled onto the output sun gear shaft 48 by a pair of overrunning clutches 100. The hub retains spokes 104 for mounting a wheel (not shown) in the usual way. A washer 106 is interposed between the hub 102 and the nut 22.
In operation the sprocket 38 of the bicycle transmission 10 is rotated (clockwise as viewed in FIG. 2) by a chain 108 driven by a foot crank (not shown) having pedals manipulated by the cyclist. The planet axles 54, being mounted in the carrier 36, of which the sprocket 38 is a part, are rotated on the spindle 12. With the cam plate axle 82 positioned concentric to the spindle 12, the angular position of each follower 80 relative to its corresponding planet axle 54 is maintained throughout a revolution of the carrier 36. Therefore, the cranks 66 are motionless relative to the carrier 36. Because the planets 56 mesh with the output sun gear 46, and the sun gear 46 resists rotation because it is connected to the bicycle wheel, the planets 56 tend to rotate clockwise about their axles 54, but are prevented from such rotation by engagement of the pawls 68 with the ratchet teeth 62. The planets 56 are thereby constrained relative to the carrier 36 and directly transmit the input rotation of the carrier 36 to the sun gear 46. The rotational motion of the sun gear 46 is further transmitted by the overrunning clutches 100 to the output hub 102 and the wheel spokes 104. With the cam channel concentric with the spindle, no speed change occurs across the transmission inasmuch as all of the rotating members are effectively locked together. Coasting with the chain pedals held motionless is possible with a minimum of transmission frictional drag as the overrunning clutches 100 allow the output hub 102 to turn easily on the sun gear shaft 48. Without this feature, coasting could be accommodated by disengagement of the pawls allowing the planets to rotate within the carrier.
When the cam channel 84 is eccentric to the spindle as the carrier revolves, each follower oscillates its radial position toward and away from the spindle. Since each axle is fixed in the carrier at a constant distance from the spindle, this causes each follower to oscillate its crank, i.e., to rotate the crank about its axle in one direction and subsequently in the opposite direction. Since the four axles are circumferentially equally spaced in the carrier, each crank is one-quarter of a cycle out of phase with its adjacent cranks.
So long as a crank rotates with a velocity opposite to, or at a velocity less than that of its planet, the crank pawls ride over the ratchet teeth in that planet. However, as the planet enters that quarter of a carrier revolution where the cam channel eccentricity imparts a rotational velocity to the crank which is in the same direction as, and which begins to exceed that of its planet, its pawls engage. For application of the drive as a bicycle transmission, virtually continuous engagement of the drive's input elements with the load is desirable, or the cyclist will sense engagements as unpleasant jerkiness in the pedals. Consequently a high resolution pawl and ratchet arrangement is shown here.
Only 2° of rotation of the crank in a direction opposite to the planet rotation can take place before a pawl engages inasmuch as the spacing of the five pawls equally divides the 10° angular span of one ratchet tooth. Thus for substantially a quarter of a carrier revolution, each of the four cranks is sequentially rotated relative to its planet so that its pawls engage. The engaged crank then drivingly rotates its planet about its axle in a direction opposite to the carrier rotation. This driving planet imparts to the meshing sun gear a rotational velocity equal to the velocity of the planet about its axle plus the rotational velocity of the carrier. The remaining planets are rotated by the sun gear at the same velocity as the driving planet, and thus their cranks are disengaged during this interval.
The planets sequentially drive the sun gear so that its resultant motion is substantially uniform corresponding approximately to the maximum rotational velocity of the planets superimposed on the velocity of carrier 36. The eccentricity of the cam channel 84 determines the output velocity and, hence, the speed and torque ratios of the drive.
The fixed nature of the cam channel 84 in this invention allows use of a variety of means for controlling its channel eccentricity. The cam eccentricity can be adjusted at any time by the cyclist with the manual control 110 shown in FIGS. 2, 4 and 5. The control 110 comprises a cable 112 attached at one end to the cam plate axle 82 by a pin 114 so that the axle 82 can be pivoted of hub 30 toward greater eccentricity against the forces exerted by the followers 80 which tend to pull the cam plate 88 toward zero eccentricity. A spring 116 is attached to ensure returning of the axle 82 to zero eccentricity when the tension in the cable 112 is released. The cable 112 is routed through a protective sheath 118 to a drum 120 in which the other end of the cable 112 is retained. The drum 120 is journaled on the hub of the adjacent locking plate 122 which itself is journaled on a cylindrical extension of the control support bracket 124 attached to the bicycle crossbar 126. Adjacent to the locking plate 112 and also journaled on the locking plate hub is a front plate 128 which is retained thereon by a washer 130 and a screw 132 threaded into the cylindrical extension of the bracket 124. A second screw 133 passed through an extension of the front plate 128 and threaded into an extension of the drum 120 pivotally supports a lever 134 for locking the drum 120 in a desired angular position.
A spring 136 integral with the front plate 128 urges the lever 134 to pivot so that its locking surface 138 bears against the locking plate 122. The lever locking surface 138 is curved so that increased bearing pressure is produced as the tension in the cable 112 is increased. The lever 134 is released allowing repositioning of the drum when the cyclist manually pivots the lever 134 in a counterclockwise direction as viewed in FIG. 4.
A control 140 sensitive to input speed for automatically adjusting the eccentricity of cam channel 84 to vary the transmission torque ratio may be provided as shown in FIG. 6 and FIG. 7. The control housing is supported from the spindle 12 and the rear fork 20. A U-shaped bracket 144 is spaced from and attached to the cam plate axle 82 by spacers 146 and screws 148. The ends of a link 150 are respectively pivotally connected to the bracket 144 and to the end of a threaded shaft 152 which is screwed into a hollow shaft 154 integral with a bevel pinion 156. The pinion shaft 154 is journaled by ball bearings 158 having an outer race 160 retained by the housing 142.
A location adjusting nut 162 and a locking nut 164 are threaded onto the pinion shaft 154. Meshing with the pinion 156 on the left side of the pinion axis is a left bevel gear 166, and on the right side, a right bevel gear 168. The right bevel gear 168 is fixed on a shaft 170 extending from the inner clutch race 172. The inner clutch race 172 is encircled by the outer clutch race 174 which has a hub journaled on the shaft 170. The left bevel gear 166 is fixed on the hub of the outer clutch race 174.
A pin 176 fixed in the housing 142 journals the shaft 170 and the control input sprocket 178. The input sprocket 178 supports a centrifugally responsive mechanism 180 between the inner and outer clutch races 172 and 174. The centrifugal mechanism 180 comprises two arcuate weights 182 each having an inner groove 184 running the entire inner circumference and an outer groove 186 running the entire outer circumference thereof. The weights are retained on a ring 188 which fits loosely and entirely within the inner circumference grooves 184 by a garter spring 190 which fits entirely within the outer circumference grooves 186. The ring 188 has two ears 192 mounted on pins 194 projecting from the input sprocket 178 so that when the sprocket 178 is motionless the inner circumferences of the weights 182 contact the inner race 172. The input sprocket 178 may be driven by the same chain 108 which drives the transmission 10.
In operation, when the control input sprocket 178 is rotated at less than a predetermined speed, the weights 184 contact and rotate the inner race 172. The right bevel gear 168 rotates the pinion 154 so that the threaded shaft 152 is screwed from the pinion shaft 156 and the cam plate axle 82 is pushed to a position of lower eccentricity. When the control input sprocket 178 is rotated at greater than a predetermined speed the weights 184 contact and rotate the outer race 174. The left bevel gear 166 rotates the pinion 154 so that the threaded shaft 152 is screwed into the pinion shaft 156 and the cam plate axle 82 is pulled to a position of greater eccentricity. The centrifugal mechanism 180 is designed so that the weights are not engaged over the optimum pedalling speed range of a cyclist which is normally 50 to 60 revolutions per minute.
Thus if a cyclist pedalling within this optimum speed range encounters a hill and allows his pedalling speed to drop out of this range because of the increased torque required for pedalling, the speed control 140 will automatically and continuously downshift the transmission toward a lower input-to-output speed ratio until the input pedalling torque required is reduced so that the cyclist is again able to pedal in the optimum speed range. Opposite circumstances will produce upshifting.
Another embodiment of the invention illustrated in FIGS. 9-11 is the transmission 200. It is identical to the transmission 10 previously illustrated with the exception of the cranks and planetary gears. Each planet 56' is journaled on an axle 54' retained by the carrier 36' as previously described. The carrier 36' is comprised of the sprocket 38' and the left disk 40' screwed and having slots 202 in which the axles 54' can move to engage and disengage with the sun gear 46'. A crank pin 76' integral with the planet 56' protrudes through an arcuate slot 78' in the sprocket 38' and journals a follower 80' which engages the cam channel 84' contained in cam plate 88'. Thus a revolution of the carrier 36' causes a crank pin 76' to angularly oscillate its planet 56' about its axle 54' through one cycle.
By sequentially engaging each of the four planets with the sun gear only over a given portion of a carrier revolution, a speed increase, decrease or reversal can be accomplished. For instance, by sequentially engaging each of the planets with the sun gear over a portion of a carrier revolution where a planet has highest angular velocities in a direction common to the carrier rotation, a speed decrease, or even a speed reversal can be accomplished. However, for a bicycle transmission, a speed multiplication is desired. Thus by sequentially engaging each of the planets so that each planet drives the sun gear when that planet has highest angular velocities in a direction opposite to the carrier rotation, a speed multiplication is accomplished. By using four planets, as shown in FIG. 3, and sequentially engaging each planet for substantially a quarter of a revolution when each planet has highest angular velocities opposite to the carrier, a multiplied and substantially constant output speed is obtained.
Retained in a groove cut into the gear teeth on the planets 56' is a ring 74' of resilient material upon which the planets 56' noiselessly ride when not engaged with the sun gear 46'. Several means are provided to engage a planet over the desired driving quadrant, whereas disengagement tends to occur spontaneously as a planet leaves the driving quadrant because the planet and sun gear velocities are forced to become disparate.
One engagement means is to mount the transmission 200 with the rotational plane of the carrier 36' oriented vertically and with the geometric center of the cam plate axle 82' displaceable to maximum eccentricity to the left of the spindle 12'. With the carrier 36' rotating clockwise as seen in FIG. 10, and the crank pins 76' arranged to trail their respective planet axles 54', a planet 56' therefore rotates counterclockwise at maximum velocity when at the top of the carrier 36'. This is the center of the quadrant over which it is desired to have a planet drive the sun gear for the bicycle application. The slots for the planet axles are oriented so that as a planet enters the desired driving quadrant, gravity can bring the planet toward the sun gear. Moreover, with the crank pins arranged to follow the planet axles, the reactant cam force on the follower pushes the planet toward the sun gear as a planet enters the desired driving quadrant. Also, the frictional drag on the rim of the planet produced by the sun gear acts to pivot the planet about its crank pin into engagement with the sun gear. Additionally, springs 204 may be provided to urge the planets 56' against the sun gear 46'.
Any of the means already described for adjusting the cam channel eccentricity may be used to vary the speed and torque ratios of this embodiment. Yet another means, which automatically adjusts the cam channel eccentricity as a function of the torque applied across the transmission, equally applicable to both embodiments, is shown in FIG. 11. A U-bracket 144' is mounted to the cam plate axle 82 and pivotally attached to a link 150' which in turn is pivotally attached to the plunger 206 of a dashpot 208. The dashpot 208 is fixedly mounted on any convenient rigid member of the bicycle frame.
The plunger 206 is loaded by a spring 210 so that as the cam plate axle 82' is moved from maximum to low eccentricity, an increasingly resistant force is applied. When a follower is turning a planet at highest velocities counter to the carrier velocity, the follower applies the highest forces experienced by the cam channel 84, in a direction from the center of the cam channel to the center of the follower. The center of the large cylindrical surface of the pivot hub 30, which is the effective pivot point for the cam plate axle 82, is offset from the line of action of the follower force so that the cam plate axle 82 is urged to pivot toward zero eccentricity. In operation, as the bicycle begins to climb a hill for instance, the output torque requirement increases and a greater force is applied by the followers against the cam channel. If the cyclist continues to pedal at the same rate, this increased force is balanced by the shifting of the cam plate axle 82 against the spring to lesser eccentricity. The decreased speed multiplication and increased torque multiplication of the transmission allow the cyclist to pedal at the same input torque as previously used, but, of course, with reduced output speed. Proper selection of the spring 210 will allow a cyclist to pedal at his optimum speed and torque while the transmission automatically adjusts to meet varying output torque requirements. The dashpot 208 is provided to prevent the transmission 200 from cyclically responding to the variable torque applied by the cyclist to the foot pedals during a revolution of the foot crank.
Although four planet gears have been shown in the drawings and mentioned in the description, the number used depends on the particular requirements of the application. In the case, for instance, where a single cylinder engine is employed to drive the transmission, a single planet, engaging the output gear during the power stroke of the engine may be used in conjunction with a flywheel for providing motion for the parasitic strokes.
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A stepless variable stroke drive particularly suitable for a bicycle transmission has a crank driven input element comprising a carrier housing journaled for rotation on a spindle. Mounted within the carrier, journaled on individual axles, radially spaced to the spindle, are four planet gears which engage an output sun gear. Recessed into one side of each planet gear is a concentric channel whose outer circumference is constructed with ratchet teeth and whose inner circumference journals a crank ring having pawls for engaging the ratchet teeth. The ring also has a follower which engages a cylindrical cam channel fixed on and adjustable to various eccentricities relative to the spindle. As the carrier housing rotates, the crank ring follower engages the cam channel causing the crank rings to angularly oscillate at an amplitude proportional to the cam channel eccentricity. Sequential intermittent engagement of the crank ring pawls with the planet gear ratchet teeth during a portion of each carrier revolution drives the sun gear at a constant speed which is a multiple of the input speed dependent on the cam eccentricity.
In another embodiment, the crank ring is eliminated and the planet gears each have a follower for engaging the eccentric cam channel. The carrier housing has slots for the planet gear axles which allow the planet gear to sequentially move to engage and disengage the sun gear for a selected portion of each planet gear's oscillation to accomplish a speed increase, decrease or reversal. Alternate manual and automatic controls are provided for both embodiments to adjust the cam channel eccentricity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a display apparatus in which a large number of display elements such as luminescent cells or cells for controlling light intensity are arranged in a matrix form, and which displays images, characters, graphics or the like.
2. Description of Related Art
FIG. 1 is a block diagram illustrating the configuration of a typical example of such a display apparatus which is disclosed in U.S. Pat. No. 4,498,081.
The display apparatus of FIG. 1 will be described. At first, an analog composite video signal 1 is inputted to a synchronizing separator circuit 2A. This synchronizing separator circuit 2A separates from the composite video signal 1 a horizontal synchronizing signal and a vertical synchronizing signal which are in turn supplied to a write control circuit 4. A chrominance demodulator circuit 2B independently separates luminance signals for red, green and blue from a separated video signal and outputs them in the form of analog signals to an A/D (analog to digital) converter 3. The A/D converter 3 generates a digital signal for each color in accordance with the corresponding luminance signal. A data multiplexer 5 which receives these digital signals selects one of them successively according to the color arrangement of cathode ray tubes 21 on a display board. The selected digital signals are transferred as the write data to a data latch circuit 6 as they are, and temporarily latched therein until the timing of writing data into a video data memory 8 occurs.
In accordance with the input synchronizing signal, the write control circuit 4 generates a signal for specifying an address in the video data memory 8, i.e., a memory write address signal, and sends it to an address multiplexer 7. The address multiplexer 7 receives a signal from a memory read and write controller 14 which is adapted to set the time sharing of the write period and the read period of each of the video data memory 8, a graphic data memory 9 and a blanking data memory 10, and in response to this signal sends the memory write address signal to the video data memory 8 only during the write period, thereby storing the latched write data into a desired address.
The video data memory 8 comprises a RAM (random access memory) having memory elements the number of which corresponds to the number of ray tubes 21 arranged in a matrix form on the display board. In the video data memory 8, the data are written in positions corresponding to the respective memory write address signals. Similarly, characters and graphics are displayed by using the graphic data memory 9 corresponding to the video data memory 8, and characters or the like are displayed by blanking video signals from the video data memory 8 with data from the blanking data memory 10.
On the other hand, only a particular region of the display board is controlled by using a video mode memory 11, a graphic mode memory 12 and a blanking mode memory 13, so that, in one or more specified areas of the particular region, data from the video data memory 8, the graphic data memory 9 or the blanking data memory 10 are locked. Data from the video mode memory 11 are supplied through an OR circuit 31 to an inhibit terminal of an AND circuit 32, so that data from the video data memory 8 which correspond to an area set by a data processor 16 are locked to the video mode memory 11. Data from the graphic mode memory 12 are supplied to an inhibit terminal of an AND circuit 30, so that data from the graphic data memory 9 which correspond to an area set by the graphic mode memory 12 are locked. Data from the blanking mode memory 13 are supplied to an inhibit terminal of an AND circuit 29, so that data from the blanking data memory 10 which correspond to an area set by the blanking mode memory 13 are locked.
These locking operations can be carried out individually or together depending upon the mode of an automatic-manual switching circuit 17 which is set to the manual mode or the automatic mode. In all the memories 9, 10, 11, 12 and 13 other than the video data memory 8, addresses are specified externally as desired by the data processor 16 and data are written therein with the same timing as that employed for the video data memory 8.
Data read out from the video data memory 8, graphic data memory 9 and blanking data memory 10 are supplied through an OR circuit 33 to a data comparator 18.
A display set and reset address generating circuit 15 receives a timing signal from the memory read and write controller 14, and generates an address signal for reading data from a memory which is in turn supplied to the address multiplexer 7. Upon receiving the timing signal from the memory read and write controller 14, the address multiplexer 7 opens its gate for a predetermined read period. In this operation, reading address signals are supplied to the video data memory 8, and the reading operation is carried out.
Using these reading address signals, all the memory elements of the video data memory 8 are sequentially addressed so that all stored data are read out. When signals are to be read out from the graphic data memory 9 and blanking data memory 10, reading address signals for each of the memories 9 and 10 are supplied in the same manner as the above at every predetermined read period to the address multiplexer 7.
In synchrony with the timing signal from the memory read and write controller 14, the display set and reset address generating circuit 15 supplies "on" discriminating comparison data for the cathode ray tube 21 to the data comparator 18. The data comparator 18 sequentially compares read-out data with the comparison data of each step, and outputs "on" and "off" signals to a data latch circuit 19 according to the levels of the read-out signals.
In response to these signals, column drive circuits 23 are driven to control the brightness of the cathode ray tubes 21. More specifically, a D-type flip-flop 20 is coupled to the cathode of each of the cathode ray tubes 21 through a transistor 22, and the output of the respective column drive circuit 23 is inputted to the data input terminals D of the flip-flops 20. The display set and reset address generating circuit 15 generates an address signal and a set signal, and the set signal is received by a set address discriminating circuit 24 corresponding to the address. The set signal is outputted from a line drive circuit 25 of the corresponding line to the terminals T of the flip-flops 20 which are coupled to the cathode ray tubes 21 in the corresponding line. According to the set signal, these flip-flops 20 are set so that the corresponding cathode ray tubes 21 are turned on or off. Furthermore, the display set and reset address generating circuit 15 also generates an address signal and a reset signal, and the reset signal is received by a reset address discriminating circuit 26 corresponding to the address. The reset signal is outputted from a line drive circuit 27 of the corresponding line to the reset terminals of the flip-flops 20, thereby resetting these flip-flops 20.
If the time interval between the generation of the set signal and the generation of the reset signal is constant, then the brightness of each cathode ray tube 21 corresponds to the data supplied from the data comparator 18. The brightness of the each cathode ray tube 21, i.e., the brightness of the entire screen of the display board can be controlled by changing the time interval between the generation of the two signals.
Graphic data read out from the graphic data memory 9 are supposed on video data through the OR circuit 33, and graphics are displayed on the screen. Since data read out from the blanking data memory 10 are inputted to the inhibit terminal of the AND circuit 32 through the AND circuit 29 and OR circuit 31, video data are blanked in accordance with the blanking data.
Today, in addition to standardized video signals according to NTSC, PAL, SECAM, etc., various video signals produced by computer systems are used. Such video signals including standardized video signals are different in form such as the number of scanning lines. Therefore, it is very difficult for one display apparatus in which display elements are fixedly arranged in a matrix form to reproduce all kinds of video signals.
When the frequency band of a video signal is F, a horizontal display period is T H , and a vertical display period is T V , the numbers m and n of vertical and horizontal display elements required for reproducing the video signal are T V /T H and F·T H , respectively (m=T V /T H and n=F·T H ). If a display apparatus has a screen consisting of M number of display elements along the horizontal direction and N number of display elements along the vertical direction, the original video signal can principally be reproduced in a case that M>m and N>n. A prior art display apparatus is not provided with signal interpolation means for interpolating video signals along the horizontal and vertical directions. Therefore, the prior art display apparatus in which M<m and N<n has a problem in that the original video signal cannot be correctly reproduced.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide a display apparatus which can correctly display any kind of video signal.
It is another object of the invention to provide a display apparatus in which the abilities of a screen can be exhibited fully, thereby allowing any kind of video signal to be correctly reproduced.
The display apparatus according to the invention comprises: a selection circuit for selecting one of a plurality of input video signals; a band-pass filter for limiting the selected video signal to a frequency bandwidth equal to or narrower than the half of a frequency band which is calculated on the basis of the number of display elements along the horizontal direction of a screen; and a computing circuit for computing vertical interpolation video data in order to correct for the difference between the number of display elements along the vertical direction and the number of scanning lines along the vertical direction of the selected video signal.
In the display of video signals in the present display apparatus, the partial omission of reproducing video signals along the horizontal direction is prevented from occurring by the filtering effect of the band-pass filter. Furthermore, the partial omission of reproducing video signals along the vertical direction is prevented from occurring by displaying an image while controlling each display element of the screen in accordance with the computed vertical interpolation video data.
The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the configuration of a prior art display apparatus.
FIG. 2 is a block diagram illustrating the configuration of a display apparatus according to the invention.
FIG. 3 is a graph showing the characteristics of coefficient data for interpolation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described with reference to the drawings illustrating embodiments.
FIG. 2 is a block diagram illustrating the configuration of a display apparatus according to the invention. In the figure, 31 and 32 respectively indicate video signal input terminals to which a plurality of video signals are inputted, and composite synchronizing signal input terminals to which composite synchronizing signals corresponding to the video signals are inputted. Video signals are supplied through the input terminals 31 and an impedance matching circuit 33 to a signal switch circuit 34. One of the input video signals is selected by the signal switch circuit 34, and inputted to a band-pass filter 35. Composite synchronizing signals are supplied through the input terminals 32 and another impedance matching circuit 33 to another signal switch circuit 34. One of the input composite synchronizing signals is selected by the signal switch circuit 34, and inputted to a synchronizing separator circuit 47. These selections of input signals are controlled by an input controller 53.
The band-pass filter 35 limits the input video signal to a frequency bandwidth equal to or narrower than the half of a frequency calculated from the number (M) of display elements along the horizontal direction which are arranged in a matrix form on a screen 46, and then supplies the video signal to an A/D converter 36. The synchronizing separator circuit 47 separates the input composite synchronizing signal into a horizontal synchronizing signal H and a vertical synchronizing signal V. The horizontal synchronizing signal H is sent to a sampling signal generation circuit 48 and a computed data generation circuit 49. The vertical synchronizing signal V is supplied to the sampling signal generation circuit 48, the computed data generation circuit 49, a memory write control circuit 50 and a memory read control circuit 51.
On the basis of data indicative of the horizontal display period (T H ) from the input controller 53 and the number M of display elements along the horizontal direction which has been previously set, the sampling signal generation circuit 48 generates a sampling pulse P H which is synchronized and coincident in phase with the horizontal synchronizing signal H and which has a frequency of M/T H . The sampling pulse P H is supplied to the A/D converter 36, a line memory 37, a data latch circuit 39, the computed data generation circuit 49, the memory write control circuit 50 and the memory read control circuit 51. Furthermore, on the basis of data indicative of the vertical display period (T V ) from the input controller 53 and the number (N) of display elements along the vertical direction of the screen 46 which has been previously set, the sampling signal generation circuit 48 also generates a pulse P V which is synchronized and coincident in phase with the vertical synchronizing signal V and which has a frequency of N/T V . The pulse P V is supplied to the computed data generation circuit 49, the memory write control circuit 50 and the memory read control circuit 51.
The A/D converter 36 performs A/D conversion of the input video signal at the timing of the sampling pulse P H , and the resulting digital video signal is supplied to the line memory 37. The line memory 37 temporarily stores input data. The combination of the line memory 37, the computed data generation circuit 49 and a computing circuit 38 conducts the interpolation computing in the manner described below. The computed result is temporarily stored by the data latch circuit 39.
The memory write control circuit 50 generates a memory write address on the basis of the vertical synchronizing signal V, the pulse P V and the sampling pulse P H , and outputs it to an address switch circuit 41. The memory read control circuit 51 generates a memory read address on the basis of the vertical synchronizing signal V, the pulse P V and the sampling pulse P H , and outputs it to the address switch circuit 41. Video data from the data latch circuit 39 are written into a video memory 40 in accordance with the memory write address from the address switch circuit 41. Video data are read out from the video memory 40 in accordance with the memory read address from the address switch circuit 41, and the read out video data are sent to a comparison circuit 42.
In the comparison circuit 42, weight data is previously set. The comparison circuit 42 compares the video data read out from the video memory 40 with this weight data, and sends M number of data indicative of illumination or non-illumination of a display element to a data latch circuit 43 which in turn temporarily stores these data. The memory read control circuit 51 outputs a driving trigger pulse to a driving signal generation circuit 52. The driving signal generation circuit 52 supplies a driving voltage required for lighting to a line driving circuit 45 and a column driving circuit 44. The line and column driving circuits 45 and 44 control "on" and "off" of each of the M×N display elements of the screen 46.
The operation of the display apparatus of the invention having the above-described configuration will be described.
The signal switch circuits 34, 34 select one of the video signals and one of the composite synchronizing signals which corresponds to the selected video signal, under the control of the output of the input controller 53. The selected video signal is limited by the band-pass filter 35 to the frequency bandwidth equal to or narrower than half of the signal band M/T H The video signal is then sent to the A/D converter 36. In contrast, the selected composite synchronizing signal is sent to the synchronizing separator circuit 47, and separated into the horizontal synchronizing signal H and the vertical synchronizing signal V. The sampling signal generation circuit 48 generates a sampling pulse P H of a frequency of M/T H on the basis of the horizontal display period T H and the horizontal-display element number M, and also the pulse P V of a frequency of N/T V on the basis of the vertical display period T V and the vertical-display element number N.
The video signal inputted to the A/D converter 36 is converted into a digital signal at the timing of the sampling pulse P H , and thereafter temporarily stored in the line memory 37 in the unit of one horizontal line to be used in the later vertical interpolation computing.
The interpolation computing conducted by the computed data generation circuit 49, the line memory 37 and the computing circuit 38 will be described. When the sampling is T, according to the sampling theorem, the time function I(t) of the original video signal can be expressed as: ##EQU1##
From the above expression, the time function I(Δt) of time Δt can be expressed as follows: ##EQU2##
FIG. 3 shows terms of a sampling function of time Δt in the sampling period T obtained by approximating the time function I(Δt) with an approximation expression having five k values (i.e., k=-2, -1, 0, 1 and 2). In this embodiment, the interpolation along the vertical direction is carried out by using this approximation expression. Namely, in the computed data generation circuit 49, the time difference Δt between the pulse P V and the vertical synchronizing signal V is obtained, and values respectively corresponding to those of k shown in FIG. 3 are obtained from this time difference Δt and supplied to the computing circuit 38. In the computing circuit 38, interpolation video data are computed on the basis of these values and actual data for five lines of I(-2T), I(-T), I(0), I(T) and I(2T) which are stored in the line memory 37.
The obtained interpolation video data are temporarily stored in the data latch circuit 39 until the timing of writing data into the video memory 40 occurs.
In accordance with the memory write addresses from the memory write control circuit 50, the data stored in the data latch circuit 39 are written into the video memory 40 during the idle period of the memory read control circuit 51.
In order to assure that the brightness control for all of the M×N display elements is carried out during the vertical display period T V of the input video signal, the memory read control circuit 51 performs the driving process line by line. The gradation control of the luminous strength is done by controlling the period and the lighting number of each display element. For example, the gradation of 1-bit weight can be achieved by switching one line on and off one time during the vertical display period T V . The M number of data for the line selected once in the period of T V /N are read out from the video memory 40, and the read out data are compared with the 1-bit weight data set in the comparison circuit 42. Then, the M number of data (one bit) indicative of lighting or non-lighting are temporarily stored in the data latch circuit 43.
After the process of storing the data, the memory read control circuit 51 supplies the driving trigger pulse to the driving signal generation circuit 52 which in turn supplies the driving voltage required for lighting to the line driving circuit 45 and the column driving circuit 44. This operation is conducted one time for every N lines during the vertical display period T V .
The above-described embodiment is configured so as to process monochrome video signals. When color video signals are to be processed, the circuitry from the impedance matching circuit 33 to the column driving circuit 44 is constructed in triplex.
In the embodiment, the interpolation computing is performed on the basis of data of five continuous lines. According to the invention, the interpolation computing may be performed on the basis of data obtained in another system, for example, data of two lines.
The display elements used in the embodiment are of the luminous type, and driven by controlling their driving period or number. When the present invention is applied to a display apparatus having display elements of the intensity modulation type, the display elements are driven by another driven system.
As seen from the above description, according to the present invention, the frequency band is limited on the basis of the screen display period of a signal selected by switching a plurality of video signals and the number of the display elements, and the interpolation computing along the vertical direction is performed. In the display apparatus of the invention, therefore, the abilities of a screen can be exhibited fully, thereby allowing different kinds of video signals to be reproduced.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims, or equivalents of such metes and bounds thereof are therefore intended to be embraced by the claims.
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The display apparatus has a band-pass filter for limiting an input video signal to a bandwidth equal to or narrower than half of a frequency band which is calculated from the number of display elements along the horizontal direction of a screen. Further a computing circuit computes vertical interpolation video data in order to correct for the difference between the number of display elements along the vertical direction and the number of scanning lines along the vertical direction of the input video signal. Even if various kinds of video signals are input, the display apparatus displays images corresponding to the video signals, by controlling the brightness of display elements arranged in a matrix form.
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This application is a continuation of U.S. application Ser. No. 11/358,425, filed Feb. 21, 2006 now U.S. Pat. No. 7,337,572, which application claims priority from and benefit of the filing date of U.S. provisional application Ser. No. 60/740,537, filed Nov. 29, 2005, and the disclosures of both such applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed generally to the field of firearm safety and security.
2. Description of Related Art
In the debate over gun control, partisans on both sides of the issue agree that handgun-related accidents are tragic, particularly where minors are injured or killed upon gaining access to an unsecured weapon. According to the advocacy group “Americans for Gun Safety” (AGS), over 40% of Americans are gun owners and that there are an estimated 250 million guns in the US today. AGS further noted in 2002 that an estimated 40,000 minors bring guns to school each year. In 2004, estimates by the Department of Justice indicated 475,000 non-fatal firearms-related incidents with the victimization rate in minors ages 12 years and older.
The actual annual number of accidental shootings is difficult to determine, but the above numbers clearly show the need for improvements in handgun safety. However, the currently available safeguards have proven to be inadequate. Typically, a firearm security lock is a separate device that is not an integrated part of the weapon. Such locks are typically externally attached to the firearm to render it inoperative.
One such security device is a “trigger lock.” This device is typically formed into two halves. The trigger guard of the weapon is then placed between the two halves. The trigger lock is then closed and locked, typically with a key. The trigger of the weapon can no longer be accessed, preventing the use of the weapon. However, this device greatly limits the operability of the weapon, since it can be a time-consuming process to remove the trigger guard. Also, the key can be obtained by minors or other unauthorized persons, who can open the trigger lock and obtain use of the weapon.
Another type of security device is a “cable lock.” This device renders the weapon inoperative by pushing a steel cable though the barrel and out the ejection port. The two ends are then locked together by a lock. This device is also a key-locked device, and suffers from the same deficiencies as the trigger lock.
SUMMARY OF THE INVENTION
The difficulties and drawbacks of previous-type systems are overcome by the present invention which includes a locking device for the firing spring in a firearm. A main housing is provided including an internal cylindrical portion for receiving a firing spring. A lock rod is received in the main housing, for selectively engaging the firing spring. The lock rod is movable between an engagement position and a disengagement position with the firing spring. A combination disk is provided for engaging the lock rod, to selectively fix the lock rod in one of the engagement position and the disengagement position.
The invention is intended to replace a firing spring component or components of the weapon. It will perform the original components functions and will also have the capability to disable the firearm by use of a combination or a keyed locking mechanism. The disabled firearm will not be able to fire a round, and the weapon can not be disassembled.
As will be realized, the presently disclosed embodiments are capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an assembled view of the locking device in accordance with a preferred embodiment of the present invention.
FIG. 2A is a side elevational view of the locking device shown in FIG. 1 .
FIG. 2B is a sectional view taken along line 2 B- 2 B in FIG. 2A .
FIG. 3A is back elevational view of the locking device shown in FIG. 1 in an unlocked condition.
FIG. 3B is a sectional view taken along line 3 B- 3 B in FIG. 3A .
FIG. 4A is a back elevational view of the locking device shown in FIG. 1 in an locked condition.
FIG. 4B is a sectional view taken along line 4 B- 4 B in FIG. 4A .
FIG. 5 is an oblique sectional view illustrating the operation of the locking device in accordance with the preferred embodiment.
FIG. 6 is a rear perspective view indicating a mainspring housing pin in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to the drawing figures, where it is understood that like reference numerals are drawn to like elements. Examples are described herein below of various embodiments of an integrated safety lock, preferably for use with a semi-automatic hand gun. The present invention can be a replacement component for use with an original equipment manufacturer (OEM) handgun. However, it can also be included with an OEM handgun or other firearm. It is appreciated that the present invention can be adapted to other applications as would be understood by persons having skill in the art, all without departing from the invention.
The present invention is used in a conventional-type weapon, e.g. an M1911 .45 caliber pistol. Such a weapon is loaded when a round (i.e. bullet) enters into the firing chamber. To enter the round, a slide is pulled back from a receiver allowing a magazine or clip that holds the rounds to push one upward into the firing chamber.
When the slide is pulled back it also pushes back the weapon's hammer and down on an armature (i.e. a mainspring cap) that engages a spring to a depressed position (where the spring is located in the main spring housing). Once the slide is returned to the closed position the round is considered “chambered” (i.e. ready to fire).
The hammer is held back in the firing position and the spring in the main spring housing is held in the depressed position. To fire the weapon, the trigger is pulled, releasing the hammer. The tension on the spring is then disengaged, which thrusts the mainspring cap upward and pushing the hammer forward, striking the firing pin. In turn, the firing pin strikes the round (bullet) allowing it to be discarded. The bullet recoil pushes the slide back and a new round enters the chamber, returning the slide to its closed position. If the trigger is pulled again the process repeats and continues.
FIG. 1 shows a replacement OEM main spring housing 1 in accordance with the present invention having a locking device built in. The main spring housing 1 is provided with one or more combination disks 4 having numbers on the outside edge, so that a combination can be rotatably dialed. In this illustrated embodiment, four combination disks 4 are shown, but it is appreciated that any suitable number of disks can also be used.
The disks 4 are rotated to select the correct sequence of numbers needed to release the locking device and allow the locking rod actuator 10 to slide from the locked to the unlocked positions. The locking rod actuator 10 slides freely as long as the combination disks have the correct sequence of numbers selected. Once the lock rod actuator 10 is in the locked or unlocked position the combination disks 4 are rotated to prevent undesired the movement of the lock rod actuator.
FIGS. 2A and 2B are sectional views that show the lock rod 9 , which is attached to the lock rod actuator 10 by a screw 6 in the unlocked position. The lock rod 9 includes notches that each receive a proximal end of a disk pin 5 . The disk pin 5 includes a proximal end and a distal end. The proximal end of each disk pin 5 is directed inward toward the center of the housing 1 , for engagement with the notches of the lock rod 9 . The distal end of each disk pin 5 is directed outward from the center of the housing 1 for engagement into a depression in the combination disks 4 . The proximal and distal ends of the disk pin 5 are preferably rounded, so as to facilitate their motion into and out of the notches and also the depressions on the combination disks 4 , as will be presently explained.
The proximal ends of the respective disk pins 5 engage a notch on the lock rod 9 . A respective distal end of each disk pin 5 engages a corresponding depression on an interior surface of the combination disk 4 . Engagement of the proximal end with the notch retains the lock pin, and engagement of the distal end with the depression allows movement of the proximal end out of the notches, releasing the lock pin.
When the combination disks 4 are turned to the correct sequence, a depression formed on the interior surface of the disk 4 is lined up to receive a protruding distal end of a disk pin 5 . When all four disks 4 are in the proper alignment positions, the lock rod 9 can then moved up into the “locked” position or moved down to the “unlocked” position, which will allow the disk pins 5 to slide out of the notches in the lock rod 9 and into depressions formed in the combination disks 4 .
As particularly seen in FIG. 2B , the lock pin 9 includes first and second notches to correspond to each disk pin 5 . Engagement of the proximal end of each disk pin 5 with the first notch fixes the lock rod 9 in the unlocked position. When the lock rod 9 has been displaced, engagement in enabled between the second notch and the proximal end of the disk pin 5 , thereby fixing the lock rod in the locked position.
FIGS. 3A and 3B depict the present safety lock unit in the unlocked position. The lock rod actuator 10 is joined to the lock rod 9 with the screw 6 , so that a sliding displacement of actuator 10 allows the lock rod 9 to be displaced. The lock rod 9 is then retracted to allow a mainspring cap 3 to slide freely in the spring cylinder. This unlocked position also allows a dismantle lock pin 7 to slide into a notch at the bottom end of the lock rod 9 . This allows mainspring retainer pin 2 to slide up and allow the mainspring housing pin 12 to be pushed out, as indicated in FIG. 5 . This allows the entire replacement main spring housing 1 to be removed and the rest of the weapon to be disassembled.
FIGS. 4A and 4B depict the present safety lock unit in the locked position, the lock rod 9 is again pushed up using the lock rod actuator 10 . The lock rod 9 jams the mainspring cap 3 , thereby preventing the compression of the main spring 11 , so that the weapon cannot be fired. By locking the movement of the lock rod 9 , the dismantle lock pin 7 is moved into a notch on the mainspring retainer pin 2 (as illustrated), thereby preventing the disassembly of the weapon.
FIG. 5 shows a safety locking unit mounted in an M1911 .45 caliber pistol. A mainspring housing pin 12 is locked in place by the retainer pin 2 , which is in turn retained when the dismantle lock pin 7 is received in the notch on the retainer pin 2 , which itself is held in place by the lock rod 9 when the safety lock is in the locked position.
As described hereinabove, the presently disclosed embodiments solve many problems associated with previous type solutions. However, it will be appreciated that various changes in the details, materials, arrangements of parts and other suitable variations as have been herein-described and illustrated in order to explain the nature of the present embodiments may be made by those skilled in the area within the principle and scope of this disclosure, and will be expressed in the appended claims.
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The difficulties and drawbacks of previous-type systems are overcome by the present invention which includes a locking device for a firing spring housing in a firearm. A main housing is provided including an internal cylindrical portion for receiving a firing spring. A lock rod is received in the main housing, for selectively engaging the firing spring. The lock rod is movable between an engagement position and a disengagement position with the firing spring. A combination disk is provided for engaging the lock rod, to selectively fix the lock rod in one of the engagement position and the disengagement position.
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BACKGROUND OF THE INVENTION
The present invention relates to selectively colorable polymerizable compositions and to a method for forming selectively colored polymeric bodies using such compositions.
A selectively colorable solid object is an object that can be colored at small individual, but specifically defined, sites by irradiating light of a particular wavelength and specific intensity for a specified duration. The light sources capable of producing the selectively colorable solid object include: (a) a laser interfaced with an XY scanner (for polymer films), (b) a laser interfaced with an XYZ scanner (for 3D parts), (c) digital mirror device, (d) UV and Visible lamps with a masking device, etc.
A selectively colorable resin (SCR) system consists of: (a) the matrix (a blend of polymerizable material or a solid polymer), (b) a color former, (c) a color initiator (species that generate other species capable of reacting with color former; may not be needed in some systems); and (d) a chain reaction initiator (radical or cationic or none depending on the system).
The conventional method for forming a colored plastic body is to add a dye or pigment to the liquid prepolymer composition. The composition is then cured with actinic radiation. The latter requires that the absorption spectra of the photoinitiator and the dye/pigment differ. If the dye/pigment absorbs actinic radiation at the same wavelength as the photoinitiator, slower or no cure will be achieved. The color formation method is also not selective. The entire plastic is uniformly colored. Still another problem is that the photopolymerization process requires actinic radiation, but the color forming process requires only that the composition be well mixed. Though one of the processes can be controlled by the intensity/wavelength of the actinic radiation, the other is unaffected by it. Thus there is no selectivity of color formation in the plastic body.
Accordingly, there is a need for selectively colorable polymerizable compositions and for a method of forming selectively colored polymeric bodies using such compositions wherein the colorization process can be controlled as to the location and intensity of the color formed.
SUMMARY OF THE INVENTION
The present invention discloses selectively colorable polymerizable compositions and a method for forming selectively colored polymeric bodies using such compositions. In accordance with the invention, a selectively colorable polymerizable composition comprising both a leucobase color former and a leuconitrile color former is irradiated with light of a particular wavelength and specific intensity for a specified duration. Exposure to actinic radiation cures the composition and activates the color formers. The irradiation dosage can be varied to selectively color the polymeric body whereby the resultant color of any particular area depends on the exposure dose received at that location. By varying the dose, a polymeric body can be prepared having distinctly colored elements at specific locations.
It is believed that, upon irradiation of the polymerizable composition of the present invention containing a polymerizable compound, a leuconitrile color former, a leucobase color former and an onium salt, a number of interacting mechanisms occur for color formation. One mechanism is the generation of a first dye cation upon exposure of a leucobase dye precursor in the presence of an oxidizing agent and a second mechanism is the generation of a second dye cation and a leaving group by heterolysis of a leuconitrile color former. Upon further exposure a third mechanism occurs whereby the first dye cation is bleached in the presence of the second color former. At still higher doses of irradiation the first and second dye cations are both bleached. Accordingly, the composition of the present invention provides a photopolymerizable selectively colorable polychromic system.
In one embodiment of the present invention, a composition is provided which can be exposed to different levels of irradiation to produce a selectively colored polymeric body. Under low dosage, color formation depends primarily on Scheme 1 wherein exposure of a leucobase to light in the presence of a oxidizing agent yields a first dye cation of a first color. The mechanism is illustrated below for a triarylmethane (TAM) leucobase (TAMH) susceptible to oxidation. Ox represents an oxidizing agent and TAM + represents the colored species. It is anticipated that the scheme below will also be valid for diarylmethane (DAM) leucodyes (DAMH and DAMCN).
TAMH+Ox - - - hν→TAM + (colored) Scheme 1
The other mechanism is the heterolysis of a second color former which yields a second dye cation and a leaving group. This mechanism is illustrated below for a triarylmethane leuconitrile (TAM-CN) color former. TAM-CN is susceptible to photochemical heterolysis and forms a colored species through the heterolytic cleavage of the C—CN bond. Accordingly, mechanism 2 also yields a leaving group (CN) upon heterolysis of the leuconitrile color former.
(TAM)′CN - - - hν→(TAM)′ + +CN − Scheme 2
Preferably, the reactants are selected such that mechanism 1 is much faster than mechanism 2 at high concentrations of the oxidizing agent (Ox). Thus, at low doses of actinic exposure the color is primarily determined by TAM + . To increase the color contrast, the leucobase and leuconitrile color formers can be selected such that the dye cation derived from the leucobase (TAM + ) is less stable than the dye cation derived from the leuconitrile ((TAM)′ + ). Accordingly, at higher doses of irradiation, bleaching of the less stable TAM + occurs while the amount of color formed by (TAM)′ + . increases. Therefore, the color of the polymeric body at higher doses of irradiation is primarily determined by the (TAM)′ + cation.
In another embodiment of the present invention, a polychromic polymeric body is produced by increasing the irradiation dose to cause bleaching of both colored dye cations. In accordance with this embodiment, the dye cation formed from heterolysis of the leuconitrile color former is bleachable at high doses of actinic radiation. Therefore, a selectively colorable, polychromic composition is obtained wherein low light exposure creates a polymer of one color, intermediate light exposure changes the color of the polymer and a high dosage of light exposure bleaches the color of the polymer.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, a composition which can be selectively colored by exposure to actinic radiation and a method leading to the formation of selectively colored, polychromic, polymer bodies that can be cured photochemically are provided. The invention is particularly useful for the selective color development and photopolymerization of films using a leucobase color former, a leuconitrile color former and an oxidizing agent. The composition of the present invention can be used in a solid or a liquid.
Those skilled in the art will appreciate that the color determinative irradiation step can be conducted before, after or simultaneously with the polymerization or crosslinking step. Furthermore, selective coloration of a polymeric body in accordance with the present invention can be carried out using one exposure or light source to polymerize or crosslink the composition and a second exposure or light source to induce the photochromic response, or using a single light source to polymerize the composition at a first intensity and using the same light source at a plurality of intensities to induce the photochromic response. The latter system has the advantage that it involves the use of only one light source and it will be appreciated that this system is easily implemented using highly sensitive photohardenable systems, which can be easily polymerized using a lower intensity light exposure. As a general rule, agents, such as photoinitiators, used to initiate polymerization will be more efficient than the photoresponsive agents described below so more or different energy will be required to color the selectively colorable composition than to form the polymeric film or body and colorization will be induced at higher intensities than polymerization.
The present invention involves the interaction of two different color formers to generate a photosensitive, polychromic composition. The first color former yields a first dye cation of a first color upon actinic exposure in the presence of an oxidizing agent. The second color former undergoes heterolysis upon actinic exposure to yield a second dye cation of a second color and a leaving group.
Examples of color formers which yield a colored cation upon exposure to actinic radiation in the presence of an oxidizing agent include thiazine, oxazine and phenazine leuco dyes as well as triarylmethane leuco dyes (TAM-X), diarylmethane leuco dyes (DAM-X) and monoarylmethane leuco dyes (Ar—CR 2 X) wherein X is H, OH, OR, NR 2 , N-heterocycle, and R is hydrogen, alkyl, aryl or aralkyl and the like. Preferably, the color former is a triarylmethane or diarylmethane leuco base susceptible to oxidation, with triarylmethane leuco base (TAM-H) being the most preferred color former.
Examples of triarylmethane based color formers include tris(4-(N,N-dimethylamino)phenyl)methane (Leuco Crystal Violet), bis(4-(N,N-dimethylamino)phenyl)phenylmethane (Leuco Malachite Green), tris(4-aminophenyl)methane (Leuco Basic Fuchsin), bis(4-(N,N-dimethylamino)phenyl)pentafluorophenylmethane, bis(4-(N,N-dimethylamino)phenyl)-2-fluorophenylmethane, bis(4-(N,N-dimethylamino)phenyl)-3-fluorophenylmethane, bis(4-(N,N-dimethylamino)phenyl)-2,6-difluorophenylmethane, bis(3-(2-methylindyl))phenylmethane, Benzoyl Leucomethylene Blue and the like.
Examples of diarylmethane based color formers include bis(4-aminophenyl)methane, bis(4-(N,N-dimethylamino)phenyl)methane, bis(4-amino-3,5-dimethylphenyl)methane, bis(4-amino-3-chlorophenyl)methane, bis(4-amino-2-chloro-3,5-diethylphenyl)methane, bis(4-aminophenyl)methane, 4-aminophenyl-(4-amino-3-bromophenyl)methane and the like.
The second type of color formers useful in the present invention include those which form color primarily through heterolysis to generate a dye cation and a leaving group (L). Suitable color formers of this type are, for example, triarylmethane leuco dyes (TAM′-L), diarylmethane leuco dyes (DAM′-L) and monoarylmethane leuco dyes (Ar′—CR 2 L) wherein L is a leaving group such as CN, SO 2, P(O)OR 2 , or CH 2 -heterocycle, etc. Irradiation of these color formers causes heterolysis with dye formation and release of the leaving group moiety. Examples of preferred color formers susceptible to photochemical heterolysis include triarylmethane leuconitriles such as tris(4-(N,N-dimethylamino)phenyl)cyanomethane (Crystal Violet Leuconitrile), bis(4-(N,N-dimethylamino)phenyl)(phenyl)cyanomethane (Malachite Green Leuconitrile), tris(4-aminophenyl)cyanomethane (Basic Fuchsin Leuconitrile), bis(4-N,N-dimethylamino)phenyl)(pentafluorophenyl) cyanomethane, bis(4-(N,N-dimethylamino)phenyl)-(2-fluorophenyl)cyanomethane, bis(4-(N,N-dimethylamino)phenyl)-(3-fluorophenyl)cyanomethane, bis(4-(N,N-dimethylamino)phenyl)-(2,6-difluorophenyl)cyanomethane, bis(3-(2-methylindyl))phenyl)cyanomethane, bis(4-aminophenyl)-(4-amino-3-methyphenyl)cyanomethane (Unsymmetric Basic Fuchsin Leuconitrile), tris[4-(N-triphenylmethyl)aminophenyl]cyanomethane(Protected Basic Fuchsin Leuconitrile), bis(4-(N,N-diethylamino)phenyl)(1-[4-(N-ethylamino)naphthyl])cyanomethane (Victoria Pure Blue Leuconitrile) and the like. The dye cation generated by the first color former will typically have fewer auxochromic groups in the ortho and para positions than the dye cation formed by the second color former. The reason for this is that auxochromic groups provide more stability to the cationic species. Examples of auxochromic groups are NH 2, NR 2, OH, OR, where R is a hydrocarbon.
Oxidizing agents useful in the present invention include molecular oxygen or compounds which generate an oxidizing agent which, in turn, oxidizes the leuco dye and generates the colored carbocation. Typical photosensitive oxidizing agents include onium salts such as iodonium, sulfonium and the like, transition metals, iron salts, uranyl salts, etc. used in the absence or presence of an oxidizing species such as hydrogen peroxide. The oxidizing agent, to oxidize the leucodye, will have a photoreduction potential less than the first color former.
Onium salts such as sulfonium or iodonium salts are particularly preferred for use as oxidizing agents in the invention. It is believed that upon photochemical or thermal decomposition, an iodonium salt generates radicals and cations, either or both of which can be used to initiate polymerization, while oxidizing the color precursor which converts the color precursor into its colored form.
Self-coloring photohardenable compositions in accordance with the present invention in their simplest form include a curable compound, an onium salt and at least two color precursors. In some cases, the compositions may also include a hydrogen donor, although not essential in the principal embodiments, and for many applications it will also be desirable to include a photoinitiator in the composition.
While triarylsulfonium salts such as triarylsulfonium hexafluoroantimonate or mixtures of triarylsulfonium hexafluoroantimonates and the like are preferred onium salts, other sulfonium salts and iodonium salts are also suitable for use in the invention. Decomposition of triarylsulfonium hexafluoroantimonate can be achieved photochemically. Examples of onium salts useful in the present invention include iodonium salts and sulfonium salts and, more particularly, diaryliodonium hexaflurophosphates, diaryliodonium arsenates and diaryliodonium antimonates. The counter ion of the onium salts is usually a nonnucleophilic semimetal complex such as B(C 6 F 5 ) 4 − , Al(C 6 F 5 ) 4 − , Ga(C 6 F 5 ) 4 − , In(C 6 F 5 ) 4 − , Th(C 6 F 5 ) 4 − , SbF 6 − , AsF 6 − , PF 6 − and BF 4 − . A more complete list of iodonium salts appears in published International Application PCT/US/95/05613. Representative examples of iodonium salts include salts having the following structures: C n H 2n+1 C 6 H 4 I + (C 6 H 5 ), (C n H 2n+1 C 6 H 4 ) 2 I 30 ,(C n H 2n+1 OC 6 H 4 )I + (C 6 H 5 ) and (C n H 2n+1 OC 6 H 4 ) 2 I + were n is preferably 1 to 12 and typically 8 to 12 and most preferably, the diaryliodonium salts such as 4,4′-dimethyldiphenyliodonium tetrafluoroborate and (4-octyloxyphenyl) phenyliodonium hexafluoroantimonate (OPPI). Representative examples of sulfonium salts include triarylsulfonium hexafluoroantimonate, triarylsulfonium hexafluorophosphate, triarylsulfonium tetra(perfluoro)phenylgallate, tetra(perfluoro)phenylborate and the like.
Because decomposition of the onium salt is accompanied by the generation of free radicals and cations, the curable material may be a free radical curable or a cation curable material or a blend of the two. There is a large number of monomers which can be polymerized by cations. These monomers can be classified according to their functionality. They include cyclic ethers, cyclic formals and acetals, vinyl ethers, and epoxy compounds. These monomers can be monofunctional, difunctional and multifunctional. They may also be large molecular weight prepolymers and oligomers. Examples of cationically polymerizable compounds include epoxy compounds, vinyl or allyl monomers, vinyl or allylic prepolymers, vinyl ethers, vinyl ether functional prepolymers, cyclic ethers, cyclic esters, cyclic sulfides, melamineformaldehyde prepolymers, phenol formaldehyde prepolymers, cyclic organosiloxanes, lactans and lactones, cyclic acetals and epoxy functional silicone oligomers.
Epoxy monomers are the most important class of cationic polymerizable substrates. These materials are readily available and the resulting cured polymers possess excellent dimensional and thermal stability as well as superior mechanical strength and chemical resistance. They are widely used in the coating, painting and adhesives industry. Examples of cationically polymerizable epoxy compounds described in the literature include any monomeric, dimeric or oligomeric or polymeric epoxy material containing one or a plurality of epoxy functional groups. Examples of polymerizable epoxy compounds include bisphenol-A-diglycidyl ether, trimethylene oxide, 1,3-dioxolane, 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexyl carboxylate, phenyl glycidyl ether, 4-vinylcyclohexene dioxide, limonene dioxide, cycloaliphatic epoxides such as 1,2-cyclohexene oxide, epichlorohydrin, glycidyl acrylate, glycidyl methacrylate, styrene oxide, allyl glycidyl ether, etc. Resins which result from the reaction of bisphenol A (4,4-isopropylidenediphenol) and epichlorohydrin, or from the reaction of low molecular weight phenol-formaldehyde resins (Novolak resins) with epichlorohydrin have been used alone or in combination with an epoxy containing compound. In addition, polymerizable epoxy compounds include polymeric materials containing terminal or pendant epoxy groups. Examples of these compounds are vinyl copolymers containing glycidyl acrylate or methacrylate as one of the comonomers. Other classes of epoxy containing polymers amenable to cure have also been described in the literature and include epoxy-siloxane resins, epoxy-polyurethanes and epoxy-polyesters. Such polymers usually have epoxy functional groups at the ends of their chains. Epoxy-siloxane resins and the method for making them are more particularly shown by E. P. Plueddemann and G. Ganger, J. Am. Chem. Soc. 81 632-5 (1959), and in Crivello et al., Proceeding ACS, PMSE, 60, 217 (1989). As described in the literature, epoxy resins can also be modified in a number of standard ways such as reactions with amines, carboxylic acids, thiols, phenols, alcohols, etc. as shown in U.S. Pat. Nos. 2,935,488; 3,235,620; 3,369,055; 3,379,653; 3,398,211; 3,403,199; 3,563,850; 3,567,797; 3,677,995, etc. Further examples of epoxy resins are shown in the Encyclopedia of Polymer Science and Technology, Vol. 6, 1967, Interscience Publishers, New York, pp. 209-271.
Examples of vinyl or allyl organic monomers which have been used in the literature in the practice of the cationic polymerization include, for example, styrene, vinyl acetamide, methyl styrene, isobutyl vinyl ether, n-octyl vinylether, acrolein, 1,1-diphenylethylene. R-pinene; vinyl arenes such as 4-vinyl biphenyl, 1-vinyl pyrene, 2-vinyl fluorene, acenapthylene, 1 and 2-vinyl napthylene; 9-vinyl carbazole, vinyl pyrrolidone, 3-methyl-1-butene; vinyl cycloaliphatics such as vinylcyclohexane, vinylcyclopropane, 1-phenyvinylcyclopropane; dienes such as isobutylene, isoprene, butadiene, 1,4-pentadiene, 2-chloroethyl vinyl ether, etc. Some of the vinyl organic prepolymers which have been described are, for example, CH 2 ═CH—O—(CH 2 O)n—CH═CH 2 , where n is a positive integer having a value up to about 1000 or higher; multi-functional vinylethers, such as 1,2,3-propane trivinyl ether, trimetheylolpropane trivinyl ether, polyethyleneglycol divinylether (PEGDVE), triethyleneglycol divinyl ether (TEGDVE), vinyl ether-polyurethane, vinyl ether-epoxy, vinyl ether-polyester, vinyl ether-polyether and other vinyl ether prepolymers such as 1,4-cyclohexane dimethanol-divinylether, commercially available from GAF and others, and low molecular weight polybutadiene having a viscosity of from 200 to 10,000 centipoises at 25° C., etc.
A further category of cationically polymerizable materials are cyclic ethers which are convertible to thermoplastics. Included by such cyclic ethers are, for example, oxetanes such as 3,3-bis-chloromethyloxetane alkoxyoxetanes as shown by U.S. Pat. No. 3,673,216; oxolanes such as tetrahydrofuran, oxepanes, oxygen containing spiro compounds, trioxane, dioxolane, etc. In addition to cyclic ethers, there are also included cyclic esters such as lactones, for example, propiolactone, cyclic amines, such as 1,3,3-trimethylazetidine and cyclic organosiloxanes, for example. Examples of cyclic organosiloxanes include hexamethyl trisiloxane, octamethyl tetrasiloxane, etc. Cyclic acetals may also be used as the cationic polymerizable material. Examples of epoxy functional silicone oligomers are commercially available from General Electric and are described in ACS PMSE Proceeding 1989, Vol. 60, pp. 217, 222.
Because the photoinitiator generates both free radicals and cations, it is possible to utilize a combination of free radical polymerizable and cationic polymerizable monomers. Examples of free radical polymerizable monomers include both monomers having one or more ethylenically unsaturated groups, such as vinyl or allyl groups, and polymers having terminal or pendant ethylenic unsaturation. Such compounds are well known in the art and include acrylic and methacrylic esters of polyhydric alcohols such as trimethylolpropane, pentaerythritol and the like, and acrylate or methacrylate terminated epoxy resins, acrylate or methacrylate terminated polyesters, etc. Representative examples include ethylene glycol diacrylate, ethylene glycol dimethacrylate, trimethylolpropane triacrylate (TMPTA), pentaerythritol tetraacrylate, pentaerythritol tetramethacrylate, dipentaerythritol hydroxypentacrylate (DPHPA), hexanediol-1,6-dimethacrylate, and diethyleneglycol dimethacrylate.
Examples of materials which are both cationically and free radically cured include glycidyl methacrylates, epoxy acrylates, acrylated melamine formaldehyde and epoxidized siloxanes. The simultaneous utilization of a cationically and free radical curable system enables rapid curing to be accomplished and provides a wide latitude in the design of product performance. For example, when a solution of acrylate and epoxy acrylate is used as the dual curable composition, film properties ranging from flexible to rigid can be produced and desired adhesive characteristics can be produced by selection of designed ratios of functional groups. The epoxy functionality provides high temperature resistance, excellent adhesion and reduced oxygen sensitivity whereas the acrylate functionality provides rapid curing speed, excellent weatherability, flexibility and desirable viscosity. Other examples of dual curable systems will be envisioned and appreciated by those skilled in the art. It has been found that a mixture of an acrylate and an epoxy compound is particularly desirable for use herein.
In accordance with one embodiment of the present invention, a photoinitiator is included in the self coloring photohardenable composition. Some typical examples of photoinitiators which are expected to be useful in the present invention are α-alkoxy phenyl ketones, O-acylated-α-oximinoketones, polycyclic quinones, benzophenones and substituted benzophenones, xanthones, thioxanthones, halogenated compounds such as chlorosulfonyl and chloromethyl polynuclear aromatic compounds, chlorosulfonyl and chloromethyl heterocyclic compounds, chlorosulfonyl and chloromethyl benzophenones and fluorenones, haloalkanes, α-halo-α-phenylacetophenones, halogenated paraffins (e.g., brominated or chlorinated paraffin) and benzoin alkyl ethers. A wide range of xanthene or fluorone dyes may be used as photoinitiators in accordance with the invention. Some examples include Methylene Blue, rhodamnine B, Rose Bengal, 3-hydroxy-2,4,5,7-tetraiodo-6-fluorone,5,7-diiodo-3-butoxy-6-fluorone, erythrosin B, Eosin B, ethyl erythrosin, Acridine Orange, 6′-acetyl-4,5,6,7-tetrachloro-2′4′5′,6′,7′-tetraiodofluorescein (RBAX), and the fluorones disclosed in U.S. Pat. No. 5,451,343.
For some applications it may be desirable to include a hydrogen donor in the compositions of the invention. Useful hydrogen donors can be selected from among those known in the art and, more particularly, from known hydrogen donating coinitiators. Non-nucleophilic amines such as aromatic amines of low basicity are particularly useful in the invention. The relative efficiency of the hydrogen donor in cationic polymerization not only depends on the efficiency of radical generation, but also on the efficiency of the oxidation of the radicals to cations as well as on the efficiency of the cation to initiate the cationic polymerization. The hydrogen donor must have a low basicity and low nucleophilicity. If the hydrogen donor is too basic, it will deactivate the cationic center responsible for initiation. Only aromatic amines with a hydrogens are capable of initiating ring opening polymerization of cyclohexene oxide. Aliphatic amines, aromatic amines without a hydrogens and non-amine hydrogen donors are incapable of the initiation with cyclohexene oxide.
Representative examples of N,N-dialkylanilines useful in the present invention are 4-cyano-N N-dimethylaniline, 4-acetyl-N,N-dimethylaniline, 4-bromo-N,N-dimethylaniline, 4-methyl-N,N-dimethylaniline, 4-ethoxy-N,N-dimethylaniline, N,N-dimethylthioanicidine, 4-amino-N,N-dimethylaniline, 3-hydroxy-N,N-dimethylaniline, N,N,N′N′-tetramethyl-1,4-dianiline, 4-acetamido-N,N-dimethylaniline, 2,6-diethyl-N,N-dimethylaniline, N,N,2,4,6-pentamethylaniline(PMA) p-t-butyl-N,N-dimethylaniline and N,N-dimethyl-2,6-diisopropyl aniline. Also useful as hydrogen donors are N-phenylglycine and N,N-dimethyltoluidine. However, the invention is not limited to the use of amines or aromatic amines as hydrogen donors. Other compounds present in the composition may be capable of functioning as a hydrogen donor. For example, many monomers are capable of acting as hydrogen donors and compositions containing these compounds may be used effectively with or without amines. A specific example of such monomer are certain cycloaliphatic epoxides.
Solvents may be necessary to dissolve components of the system including the photoinitiator, the color precursor, etc., if they are not sufficiently soluble in the monomer. Some examples of useful solvents are ethyl acetate, etc. Other useful solvents can be identified readily.
The nature of the monomer or polymerizable material, the amount of the color precursor and onium salt in curable self-coloring compositions in accordance with the present invention will vary with the particular use of the compositions, the emission characteristics of the exposure sources, the development procedures, the physical properties desired in the polymerized product and other factors. With this understanding, compositions in accordance with the invention will generally fall within the following compositional ranges in parts by weight (based on 100 parts total).
Curable compound
60 to 99
Color Precursors
0.001 to 1
Photoinitiator
0 to 10
Onium Salt
0.05 to 15
Compositions in accordance with the invention more typically are anticipated to have the following formulation:
Curable compound
85 to 98
Color Precursors
0.02 to 0.2
Photoinitiator
0.5 to 5.0
Onium Salt
0.1 to 1.0
Preferably, the color formers are present in an amount sufficient to provide a contrast ratio of at least 1.5, more preferably at least 3. The term “contrast ratio” means the ratio of absorbance maximum values at two doses. These doses are the largest dose and the dose at which the polymer is formed unless specified otherwise. As used herein contrast ratio refers to the absorbance of the colored polymeric film or body at the high irradiation dose divided by the absorbance at the low dose at the specified wavelength. Contrast ratio is a function of a number of variables including, but not limited to, the light source, irradiation dosage, curable compound, photoinitiator and color formers.
The number of color formers, type of color formers, the concentration of the color formers, the interaction between the different color formers and the relative concentrations of the color formers influence the contrast ratio. Typically, the color formers are present in a ratio (leucobase to leuconitrile by weight) of from about 0.1 to 20, preferably from about 1 to 10.
The compositions of the present invention are useful in the following applications: creating color contrast in printing plates such as in flexographic plates, other proofing and identification purposes, end of line manufacturing identification, fraud protection, selective imagewise colorization of a wire or other plastic objects, color printing of relief and 3D images with various light sources, and the like. The photohardenable composition of the invention may also be advantageous for use in the three dimensional modeling process taught in U.S. Pat. No. 4,575,330 to Hull and commonly assigned U.S. Pat. No. 5,514,519, the latter being hereby incorporated by reference.
Irradiation of resins consisting of monomers, preferably acrylates or epoxides and most preferably a mixture of acrylates and epoxides, a leuconitrile color precursor, a leucobase color former and a sulfonium salt can result in selectively colored films in which the polymerization process and the color formation occur simultaneously. Alternatively, the polymerization process can be conducted prior to or after the color formation.
In a preferred embodiment of the present invention, a photopolymerizable composition comprising a cationically polymerizable epoxide, a triarylsulfonium salt photoinitiator, an acrylate and a free radical photoinitiator is polymerized in the presence of both a triarylmethane leucobase color former (TAMH) and a triaryhnethane leuconitrile color former ((TAM)′CN). Color formation proceeds according to the following mechanisms:
Mechanism 1: TAMH+Ox - - - hν→TAM +
Mechanism 2: (TAM)′CN - - - hν→(TAM)′ 30 +CN 31
Preferably, mechanism 1 is much faster than mechanism 2 at high concentrations of oxidizing agent (Ox) such that at low doses of irradiation the color is primarily determined by TAM + . Furthermore, the colored cation generated by the oxidation of the leucobase color former (TAM + ) preferably is less stable than the colored cation generated by the heterolysis of the leuconitrile color former ((TAM)′ 30 ). Accordingly, upon further irradiation the less stable TAM + cation is bleached. Although not wishing to be bound by theory, applicants believe that the bleaching effect could be the result of the less stable TAM + trapping the cyanide moiety released during the heterolysis of (TAM)′CN. Reaction of the cyanide moiety shifts the leuconitrile heterolysis equilibrium to the right and increases the production of TAM′ + and consequently, increases the amount of color formed by TAM′ + . Therefore, at higher doses of irradiation the color of the polymeric body depends primarily on the TAM′ + cation.
In another embodiment of the present invention, a composition is provided which can be selectively colored by exposure to actinic radiation which comprises a first color former which yields a first dye cation upon exposure in the presence of an oxidizing agent and a second color former which yields a second dye cation and a leaving group by heterolysis, wherein the first and second dye cations are bleached by further radiation. In accordance with this embodiment, the irradiation dosage can be varied to produce a selectively colorable polychromic composition. Accordingly, the photocurable composition can be irradiated in selected areas to produce lightly colored polymer by exposure to a low dosage, highly colored or different colored polymer by exposure to an intermediate light dosage and bleached polymer by exposure to a high dosage of actinic radiation. The bleaching leuconitrile effect which characterizes this embodiment is typically observed in slightly polar solvents and certain hybrid resins.
EXAMPLE 1
A selectively colorable photocurable composition can be prepared by including both a TAM-H color former and a TAM′-CN color former in a resin called Resin 1 containing cationically polymerizable epoxide(s) (60-90%), triarylsulfonium hexafluoroantimonate photoinitiator(s) (0.5-8%), acrylate esters (5-35%), free radical photoinitiator(s) (0.5-5.0%). Resin 1 can be polymerized in the presence of both a TAM′-CN and TAM-H color former. In a typical 2 color experiment, 0.04% MGH (Malachite Green leucobase) and 0.005% BFCN (Basic Fuchsin leuconitrile) are included in Resin 1. The contrast ratios obtained are 4.4 at 570 nm and 0.3 at 630 rm. The polymer colors are blue and red/purple.
EXAMPLE 2
In accordance with another embodiment of the invention a stereolithography resin is polymerized in the presence of both a TAM′-CN and TAM-H color former wherein both colorformers are bleachable when exposed to high levels of actinic radiation. In a typical polychromic color experiment, 0.05% MGH and 0.0025% BFCN are included in Resin 2 containing cationically polymerizable epoxide(s) (60-90%), triarylsulfonium hexafluoroantimonate photoinitiator(s) (0.1-2%), acrylate esters (5-35%), free radical photoinitiator(s) (1-8%). The following absorbances and polymer color are obtained:
Absorbance
Irr. Dose, mJ/cm 2
at 570 nm
Absorbance at 630 nm
Color
250
˜0.005
0.035
Green/blue
625
0.010
0.014
purple
1250
˜0
˜0
yellowish
Experimental
Samples are prepared as follows:
A 200 μm thin layer is drawn down on a glass slide. It is scanned with a He/Cd (325 nm) laser with a 1.5 mm diameter beam. The dose ranges from 40-800 mJ/cm 2 with a typical maximum dose being 600 mJ/cm 2 . A low dose of 40 to 80 mJ/cm 2 is employed to polymerize the composition. A contrast ratio is measured at the maximum absorption with the absorbance at the high dose being ratioed to the absorbance at the lowest dose at the specified wavelength.
Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
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Selectively colorable polymerizable compositions and a method for forming selectively colored polymeric bodies using such compositions are disclosed. In accordance with the invention, a selectively colorable polymerizable composition comprising both a leucobase color former and a leuconitrile color former is irradiated with light of a particular wavelength and specific intensity for a specified duration. Exposure to actinic radiation cures the composition and activates the color formers. The irradiation dosage can be varied to selectively color the polymeric body whereby the resultant color of any particular area depends on the exposure dose received at that location. By varying the dose, a polymeric body can be prepared having distinctly colored elements at specific locations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor integrated circuits (hereinafter, referred to IC's) suited for computer-aided-design, and more particularly to standard-cell type IC's using poly-cells having improved wiring structure for supplying power.
2. Description of the Related Art
As semi-custom LSI's (Large Scale Integrated circuits) designed in accordance with the customer's specification, the standard-cell type IC's using polycells have been widely used. They are designed by a technique similar to the gate-array type semiconductor integrated circuits (hereinafter, simply referred to the gate-array IC's). In the gate-array process, a plurality of blocks of circuit elements and limited number of wirings are preliminarily formed on a semiconductor chip. An electrical circuit in accordance with the customer's specification is then formed by designing a wiring pattern. The wiring pattern to be designed in the later process include wirings for forming a cell of circuit with the circuit elements in each block, wirings for connecting the cells and wirings for supplying power.
On the other hand, the standard-cell type IC using polycells, the blocks of circuit elements are used in software program for designing an IC. The wirings for forming the polycells of circuit with the circuit elements and for connecting the polycells are also designed by computer-aided-design. All the masks for producing the standard-cell type IC is designed by the computer-aided-design.
In the standard-cell type IC, a plurality of polycells are arranged in lines. The polycells have the same or the substantially same width in a direction perpendicular to the line and arbitrary length in a direction in parallel with the line. The polycells are made of various standardized blocks of circuit elements. The standard-cell type IC's are designed by combining the polycells formed by the standarized blocks. The use of the standardized blocks makes the computer-aided-design of IC easy, resulted in an improvement of design efficiency.
Turning to the design of wirings for power supply, they are designed so as to traverse the polycells and to reach predetermined positions on opposing sides facing the neighbouring polycells. If all the polycells have the same width, the wirings for power supply automatically contact with those in the neighbouring polycells. The cells to be formed in a semiconductor chip, however, may have different dimensions. Cells for specific functions such as RAM (Random Access Memory), ROM (Read-Only Memory), microprocessor, peripheral controller of the microprocessor and PLA (Programable Logic Array) may be included as megacells which have a dimension much larger than the polycells. If the wirings for power supply in the megacells are similarly designed to the polycells, the wirings for power supply differ in position between neighbouring polycell and megacell at their sides facing to each other. Thus, disconnection occurs at contacting sides of those cells having different dimensions.
In the prior art, such disconnection was cured by manual correction of wiring pattern. The manual correction split the production efficiency of the computer-aided-design to raise the production cost and to prolong the production period of term.
SUMMARY OF THE INVENTION
It is therefore, a major object to provide a semi-conductor integrated circuit having a structure of wirings for power supply suited for a computer-aided-design and avoiding the possibility of disconnection between cells having different dimensions.
According to the present invention, there is provided a semiconductor integrated circuit comprising a semiconductor chip; a plurality of first cells of partial circuit formed on the semiconductor chip and arranged in a plurality of lines, the first cells having the substantially same width in perpendicular to the lines and arbitrary lengths in parallel to the lines, the first cells having a first wirings for supplying power to the partial circuit, the first wirings being extended over a plurality of the first cells arranged in the same line in a direction of said same line; a second cell of another partial circuit formed on the semiconductor chip and arranged in neighbouring with some of the first cells, the second cell having a width larger than the width of the first cells and a length and having second wirings for supplying power to the other partial circuit, the second wirings being disposed on periphery of the second cell to surround the other partial circuit and connected with the first wirings in the first cells in the neighbourhood of the second cell; and means for connecting the second wiring with the first wirings in the first cells in the neighbouring of the second cell.
The IC of the present invention has the second wirings for power supply on periphery of the second cells having a width larger than the neighbouring first cells. The first wiring for power supply, therefore, can be connected with the second wiring by prolonging straight. This connection may be easily achieved by the computeraided-design technique which requires only modification of the data for the second wiring pattern of the second cell. Any manual correction of wiring pattern is not required. Thus, an efficiency in designing IC is greatly improved with a slight change of wiring pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic view for explaining the wirings for power supply of the standard-cell type IC in the prior art;
FIG. 2 is a schematic partial view of the first preferred embodiment according to the present invention;
FIG. 3 is a schematic but more-detailed partial plan view of a part in the first preferred embodiment according to the present invention;
FIG. 4 is a sectional view for explaining a structure used in the first preferred embodiment according to the present invention;
FIG. 5 is a schematic partial plan view of the second preferred embodiment according to the present invention; and
FIG. 6 is a schematic partial plan view of the third preferred embodiment according to the present invention.
The wirings for supplying power on polycells arranged in a line in the prior art of a standard-cell type IC is shown in FIG. 1. The polycells 1 have the substantially same width or height and arbitrary length determined by functions such as an inverter, an AND gate, an OR gate and a flip-flop. A plurality of polycells are arranged in a line to form a stripe having the substantially uniform width. Wirings 2 and 3 are programed in a software for designing a standard-cell type IC so as to run predetermined levels in a direction of the width. Therefore, the wirings 2 and 3 are automatically connected between the neighbouring polycells 1 by arranging polycells in a line.
When a megacell having a large dimension and then a large width are combined with the polycells 1, wirings for the power supply between neighbouring polycell and the megacell cannot be connected with each other by the computer-aided-design which is programed so that wiring for the power supply may run on predetermined levels in the width. For avoiding such disconnection of the wirings, a complicated software program for the computer-aided-design or a manual correction of the wirings is required. It is difficult to make such software program commonly applicable to the standard-cell type IC including the megacell having arbitrary dimension. The manual correction of the wirings, therefore, cannot be avoided to lower the efficiency in designing standard-cell type IC's in the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first preferrd embodiment according to the present invention having an improved structure of wirings for power supply is shownn in FIG. 2. A plurality of polycells 11 have the substantially same width (or height). A plural number of polycells 11 are arranged in a line to form a stripe having the substantially uniform width. A plural number of strips of the polycells 11 are disposed in parallel with one another. A megacell 19 having a width of about three times of the width of the polycell 11 is disposed in the parallel arrangement of the stripes of polycells 11. First level wirings 13 for power voltage V DD runs through the stripes of polycells at a predetermined level in the width. First level wirings 12 for power voltage V DD run along peripheries of the megacell 19 in parallel with the stripes of polycells 11 and through the megacell 19 at a one level in the width thereof. Similarly, first level wirings 15 in the polycells 11 and first level wirings 14 in the megacell 19 are formed in parallel with the first level wirings 12 and 13 for supplying power voltage V SS to the polycells 11 and the megacell 19. The first level wirings 12, 13, 14 and 15 directly contact with circuit element in a semiconductor chip and run thereon through an insulator film in a direction in parallel with the stripe of polycells 11.
Second level wirings 16 for supplying power voltage V DD run across the first level wirings 12 to 15 to connect with the first level wirings 12 and 13. Similarly, second level wiring 17 for supplying power voltage V SS run in parallel with the second level wirings 16 to connect with the first level wiring 14 and 15. On the megacell 19, the second level wirings 16 and 17 are disposed on peripheries thereof and on a region thereof in the direction perpendicular to the stripes of polycells 11. The second level wirings 16 and 17 respectively contact with the first level wirings 12 and 13 and the first level wirings 14 and 15 and run on an insulator film disposed on the above-mentioned insulator film on the semiconductor chip.
On the periphery of the megacell 19, the first level wirings 12 and 14 and the second level wirings 16 and 17 surround the circuit-element region of the megacell 19 and contact the second level wirings 16 and 17 on the stripes of polycells 11 and the first level wirings 13 and 15 on the stripes of polycells 11. Those connections are achieved by only extending the wirings 16, 17, 13 and 15 on the stripes of polycells 11. The softwave programing to achieve such connection is easy and is commonly applicable to megacells 19 having arbitrary dimension. Any manual correction is not required to obtain a high efficiency in designing standard-cell type IC's.
A stripe of polycells 11 is partially shown in FIG. 3. The polycells 11 respectively consist of one or more basic cell patterns 50. The cell pattern 50 includes two P-channel MOS FET's and two N-channel MOS FET's. A P-channel MOS FET is made of a gate electrode 51, a source region 53 and a drain region 54, the other being made of a gate electrode 52, a source region 53 and a drain region 55. An N-channel MOS FET is made of a gate electrode 56, a source region 58 and a drain region 59, the other being made of a gate electrode 57, a source region 58 and a drain region 60. The N-channel MOS FET's are formed in a P-type semiconductor substrate 70, the P-channel MOS FET's being formed in an N-type well-region 71 diffused in the semiconductor substrate 70. Those MOS FET's are wired to form a partial circuit of the standard-cell type IC with first level wirings running in parallel with the stripe of polycells 11 and second level wirings running in perpendicular to the stripe of polycells 11. The first level wirings directly contact with the source and drain regions, but the second level wirings contact with them through the first level wirings. To accomplish this structure, a lower insulator film, the first level wirings, an intermediate insulator film, the second level wirings and an upper insulator film are formed on the semiconductor substrate in this order. Those first and second level wirings also connect MOS FET's in different polycells 11 to form a whole circuit of a standard-cell type IC.
Such structure is explanatory shown in FIG. 4 which is drawn only for explaining the concept of the structure and which data not correspond to any actual part of FIGS. 2 and 3. The N-type well region 71 is provided in the P-type substrate 70. P-type source and drain regions 53 and 54 are formed in the well-region 71. The gate electrode 51 is formed on a gate insluator film 77 disposed between the source and drain regions 53 and 54. N-type source and drain regions 58 and 59 are formed in the semi-conductor substrate 70. The gate electrode 56 is formed on a gate insulator film 78 disposed between the source and drain regions 58 and 59. The semiconductor substrate 70 and the N-well region 71 are covered with a phosphosilicate glass 72 having a thickness of 1 μm. The first level wirings 73 made of aluminum, for example, are evaporated on the phosphosilicate glass 72 and connected with the source and drain regions 53, 54, 58 and 59 through holes in the phosphosilicate glass 72. The thickness of the first level wirings 73 is 0.5 μm, for example. The first level wirings 73 runs in parallel with the stripe of polycells 11. A silicon oxide film 74 having a thickness of 1 μm covers the first level wirings 73. The second level wirings 75 having a thickness of 1 μm and made of aluminum, for example, are deposited on the silicon oxide film 74 and connected with the first level wirings 73 through holes in the silicon oxide film 74. The second level wirings 75 runs in perpendicular to the stripe of polycells 11. Silicon nitride film 76 having a thickness of 1 μm covers whole structure except for bonding pads (not shown) as a surface passivation film.
FIG. 5 shows a peripheral portion of the megacell 19 according to the second preferred embodiment which is modified to improve the connection between wirings on the pheriphery of the megacell 19 and wirings on the polycell 11. This second embodiment has two first level wirings 12 and 14 for supplying power voltages V DD and V SS on the central part of the megacell 19. In accordance with position of the wirings 12 and 14, there happens a case where one or two of the wirings 12 and 14 forms straight lines with the first level wirings 13 and 14 on the polycells 11. When the wirings 12 for the power voltage V DD forms the straight line with the wirings 13 for the power voltage V DD , the above-mentioned first embodiment has a possibility that any one of the wirings forming a straight line cannot be connected with the second level wirings 16 or 17 on the periphery of the megacell 19, because those wirings 12 to 15 are made of the same first level wirings.
The second preferred embodiment has additional second level wirings 18 to form three parallel wirings 16, 17 and 18 on the periphery of the megacell 19. The first level wiring 14 connects with the second level wiring 18. The first level wirings 12 and 13 connect with the second level wiring 16. The first level wirings 15 connects with the second level wiring 17. The second embodiment resolved the problem by the additional wiring 17 and requires no difficulty in the software program.
The third preferred embodiment shown in FIG. 6 is another resolusion for the same problem. The first level wiring 13 turns perpendicularly by use of a second level wiring 20 and then connects with the second level wiring 16. This embodiment use only two second level wirings 16 and 17 on the periphery of the megacell 19 to save area.
While some preferred embodiments were explained hereinbefore, the present invention is not limited to those embodiments and many modifications may be applied to them. The present invention can be applicable to the gate-array IC in which macrocell has wirings for power supply on the periphery thereof, similarly to the megacell in the standard-cell type IC. Furthermore, the functions of the first and second level wirings for supplying power voltages may be interchanged. The first and second level wirings respectively have wirings for supplying a high power voltage and a low power voltage or a high or low power voltage and a grounding potential.
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A semiconductor integrated circuit of standard-cell type or gate-array type includes a plurality of first cells arranged in a plurality of parallel lines, the first cells having first wirings for supplying power, the first wirings being extended over a plurality of the first cells arranged in the same line in a direction of the same line of the first cells, a second cell disposed in the neighbourhood of some of the first cells and having a dimension larger than the first cells, said second cell having second wirings on a periphery thereof to surround circuit portion of the second cell and means for connecting the second wirings with the first wirings in the first cells in the neighbourhood of the second cell.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. application Ser. No. 10/914,874, filed Aug. 10, 2004, which is incorporated by reference herein for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of pollution abatement. More particularly, it concerns a method and system for treating liquid runoff, such as rainfall, irrigation, and waste or produced water, to prevent the transportation of solutes.
BACKGROUND OF THE INVENTION
[0003] Undesirable solutes in liquid runoff can originate from a variety of sources, including atmospheric deposition and mobilization of substances occurring on or near a ground surface. Methods to reduce the amount of unwanted solutes in runoff streams include the construction of catchment basins wherein the runoff stream accumulates until it either evaporates or permeates into the ground; grass filter strips wherein the runoff stream's velocity is reduced allowing infiltration; drainage systems incorporating buried permeable reactive barriers wherein runoff drainage is directed through a subsurface packed media bed that immobilizes the solutes as the drainage passes through; and aboveground permeable reactive barriers comprising large three dimensional structures the size of the area to be treated constructed on drainage-way sites and filled with reactive media.
[0004] These present methods are limited in application because they either fail to adequately treat the liquid runoff or they have installation and maintenance requirements that are not suitable for many settings. Catchment basins require a large space that may not be available, particularly at established facilities. Grass filter strips may also require a large space and may be less effective on steep slopes or during high rainfall events. Buried permeable reactive barriers are difficult to access when maintenance is required and may require an additional drainage system to direct liquid runoff to and from the barrier, which increases the cost and complexity of installation. Aboveground permeable reactive barriers constructed by filling a large structure with loose reactive media require special skills and bulk material handling equipment to construct and may be difficult to maintain, partially replace, or augment. Also, it is very difficult to use existing methods to construct a barrier designed to remove several different solutes from liquid runoff by using multiple media types that must be kept separate.
[0005] Another method that could conceivably be used to reduce the amount of undesirable solutes in liquid runoff is discussed in U.S. patent application Ser. No. 10/208,631 (Tyler). Tyler discloses tubular devices that control erosion by inhibiting the flow of water and lowering its velocity in order to allow solids to fall out of suspension. Tyler discloses filling the tubular erosion control devices with permeable reactive media to treat liquid runoff and separately discloses stacking the devices to form a retaining wall to control erosion. There are numerous reasons, however, why a barrier constructed from a stack of the tubular erosion control devices in Tyler would be ill-suited for treatment of liquid runoff.
[0006] First, a barrier constructed out of stacked tubes would necessarily have a pyramid shape and, therefore, a sloped face. Liquid runoff takes the path of least resistance and would tend to flow over the top of the pyramid-shaped barrier rather than through the tubes at the base of the structure. This would result in a significant amount of unfiltered runoff. This also means that the tubes at the base and in the middle of the pyramid do not actually filter a significant amount of liquid runoff whereas the tubes on the outside of the pyramid encounter more runoff than they can adequately filter. This imbalance results in high maintenance costs for the outer tubes, low efficiency and waste from the unused media in the inner tubes, and untreated runoff.
[0007] Second, accessing individual tubes in a barrier constructed according to Tyler in order to change or clean the reactive media in the tubes or to otherwise service the tubular devices would be costly and time consuming. Because most of the tubes in a pyramid-shaped barrier rely on other tubes for support, it would be necessary to destroy the entire barrier when even one tube near the base of the structure needed to removed for maintenance or modification.
[0008] Third, a barrier constructed out of tubes would have significant inter-container voids because tubes lack sides that can mate snugly with adjacent tubes. These voids would reduce the amount of contact between the reactive media in the tubes and the undesired solutes in the runoff, resulting in further untreated liquid runoff.
[0009] Finally, tubular erosion devices tend to roll when placed in the path of rapidly-flowing runoff. This can result in an unstable barrier that requires extensive maintenance and an elaborate and costly system for securing the tubes in the barrier to each other and securing the entire structure to the ground.
[0010] What is needed is a system for treatment of liquid runoff that uses reactive media to immobilize solutes of concern, that is easily assembled, maintained, modified, and augmented, and that has a geometry that enhances contact between the reactive media and the solutes.
BRIEF SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention provides a system and method for the treatment of liquid runoff comprising modularized, self-supporting, aboveground permeable reactive barriers, or media volumes. In certain embodiments, the individual modules, or containers, that form the barriers may have substantially planar or flat sides so that the sides of the modules may fit together snugly with the sides of adjacent modules to form a substantially uniform barrier with no substantial inter-module voids. The modules may be filled with a reactive media chosen to immobilize a particular solute so that, when assembled together, they form a barrier that is essentially a large volume of media.
[0012] In addition to facilitating the construction of a relatively uniform barrier that is free of inter-module voids, the shape of the individual media modules provides further advantages over previous methods. For example, when certain embodiments of modules with substantially planar sides are assembled together, they may create a barrier with generally planar exterior surfaces that can be oriented simultaneously both orthogonal to the flow of the runoff stream to provide uniform flow into the reactive media-through the flat-front face of the modules-and parallel to the runoff stream flow to reduce turbulence in situations where the runoff flows across the exterior surfaces of the barrier. This means that, in these embodiments, substantially all of the portion of liquid runoff stream that comes in contact with the front of the present barrier will flow through it. Modules with planar sides may also allow for the construction of an inherently stable barrier because they do not tend to roll, even in forceful runoff streams.
[0013] The modularity of the present invention provides further advantages. For example, using modules may facilitate construction of a permeable reactive barrier suitable for a variety of drainage-way sites with a wide range of solute species, hydrological parameters, and land forms. Also, modules constructed according to the present invention may have the advantage of being relatively easy to access for maintenance, modification, or augmentation. In certain embodiments, access to an individual module within the barrier can be had simply by moving the few modules that might be on top of it. The rest of the media volume may remain undisturbed in the process. This ability to access individual modules is found in certain embodiments where the modules have relatively planar sides that allow for construction of a self-supporting and stable structure that may retain its shape over time.
[0014] Further advantages derive from the flexibility in the design and application of aboveground permeable reactive barriers constructed according to the present invention. For example a barrier may be designed for a particular drainage-way site to first treat a “first flush” of liquid runoff and then allow much of the following runoff in a rising runoff stream to pass over the media volume without damaging it or the occupied drainage-way site. Additionally, in certain embodiments, modules with differing media compositions may be placed in different sections of an otherwise uniform larger reactive barrier to treat liquid runoff streams with multiple solute species of concern. This may be particularly helpful in situations where two types of reactive media must be kept separate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. The same reference numerals are employed to designate like parts in all Figures.
[0016] FIG. 1 depicts an embodiment of the invention wherein a plot of land is shown containing a substance being first mobilized by liquid (rainfall) runoff and subsequently captured as the runoff stream passes through the aboveground permeable reactive barrier, or media volume, relatively unimpeded.
[0017] FIG. 2 depicts an embodiment of the invention wherein a hexahedron-shaped module with three sets of parallel sides is shown that is constructed of pliable netting with reinforced edges on two opposing sides to facilitate shape retention, anchorage, and assembly with other containers.
[0018] FIG. 3 depicts an embodiment of the invention wherein multiple media containers are shown anchored to the ground surface and assembled together into a larger uniform volume of media comprising a modularized aboveground permeable reactive barrier structure with substantially planar exterior surfaces.
[0019] FIG. 4 depicts an embodiment of the invention wherein a process is shown for removing an individual module from the reactive barrier without the need to disassemble the entire media volume.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] FIG. 1 shows one embodiment of the present invention. The figure depicts a plot of agricultural land 1 containing a substance 2 on the surface and an aboveground permeable reactive barrier structure 6 comprised of individual modules or containers 16 constructed according to the system and method taught in the present invention. Accumulated rainfall mobilizes some of the substance 2 in rainfall runoff 4 whereby substance 2 becomes solute 3 . The rainfall runoff 4 flows along the existing drainage ways to the reactive barrier 6 . The rainfall runoff 4 containing the solute 3 flows substantially unimpeded through the barrier 6 wherein reactive media 12 contained within the modules 16 takes up the unwanted solute 3 . Treated rainfall runoff 10 exits the permeable barrier structure with a substantially reduced solute concentration.
[0021] The reactive media 12 preferably has a surface that reacts with or takes up and holds solutes, and may include zeolites, ion-exchange materials, activated carbon and other organic substances, biological matter, calcium carbonate, or iron filings for example. As used herein, the term “zeolite” means a three dimensional, microporous, crystalline solid that includes aluminum, silicon and oxygen in a regular framework. Natural zeolite material exists that may be mined and crushed into various size pieces. One preferred size of the zeolite pieces is greater than three-eighths of an inch and less than three quarters of an inch in diameter. In one embodiment of the present invention, the natural zeolite species clinoptilolite is utilized because of a high selectivity for ammonium, a common substance found in rainfall runoff from agricultural land.
[0022] After prolonged use, the clinoptilolite media can be maintained within the individual media modules, for example, by washing out accumulated silt, removing accumulated ammonium by washing with an eluant, or bio regenerating with bacteria or algae. In most settings bio regeneration will commence naturally with the native flora present, or additionally the process can be accelerated by inoculating the barrier with a concentrated source of bacteria such as compost tea.
[0023] The modules 16 can be combined to form aboveground permeable reactive barrier structures of various shapes, sizes, and compositions, as required for removing unwanted solutes from runoff streams in a variety of settings. Important considerations for aboveground permeable reactive barriers are proper media selection and a barrier geometry that includes sufficient width, or length of travel through the media 12 for the runoff stream to afford increased contact opportunities between the media and the solutes of concern. It is preferred that the permeable reactive barrier is constructed in such a manner that the transportation of solutes in rainwater drainage is inhibited but the flow of rainwater along the drainage pathway is not inhibited or impeded. A person having ordinary skill in the art will be able to construct a barrier to address the particular requirements of a wide variety of settings.
[0024] FIG. 2 shows one embodiment of an individual module or container 16 . In this embodiment the module 16 is hexahedron-shaped with three sets of substantially parallel sides 8 and is comprised of netting 18 with two reinforced shape-retaining ends 14 and reactive media 12 . The module 16 is shaped so that, when joined together with other modules, the substantially flat adjacent sides 8 match and mate tightly together, eliminating any substantial gaps, holes, or voids that might otherwise be formed where adjacent module sides intersect in an assembled permeable barrier structure 6 . In one embodiment, the netting 18 is formed with material that resists photo-degradation, has apertures small enough to contain the reactive media 12 , sufficient mechanical strength to resist rupture during transportation, installation, and maintenance, and is sufficiently pliable to conform to the shape of the ground surface. Reinforced ends 14 may be comprised of a material with suitable strength to securely close netting 18 , retain the shape of the module 16 , accommodate optional anchorage and attachment holes 20 , and can be either sewn or welded onto the netting, or, in cases where the netting is comprised of thermoplastic, formed with excess netting material at the edges of the joined sides 8 and 14 using heat and pressure.
[0025] In one embodiment, modules 16 are 5 inches tall, 14 inches wide, and 21 inches long, hold approximately 45 pounds of clinoptilolite or other reactive media 12 sized between three-eighths and three-quarters of an inch in diameter, and utilize UV stabilized extruded high density polyethylene plastic netting 18 with 0.25 inch apertures. In this embodiment, excess netting 18 at the junction of sides 8 and reinforced ends 14 is formed with heat and pressure into 0.625 inch wide reinforcements 15 that accommodate punched 0.375 inch diameter anchorage and attachment holes 20 centered and spaced 1 inch from each of the four corners in reinforced ends 14 with additional holes centered and spaced 6 inches from the corner of each long side of said reinforced ends 14 . An advantage of this embodiment is that the individual modules can be handled manually by a single person for installation and maintenance, without the use of machinery.
[0026] Preferably, the sides 8 of the modules 16 are constructed with similar materials and are seamless with no reinforced edges (the module deriving its shape and support from the reinforced ends 14 and the reactive media 12 ). This design allows the sides 8 of the modules 16 to be constructed without obstructions that would impair the otherwise substantially uniform hydraulic conductivity through the reactive media volume.
[0027] FIG. 3 shows another embodiment of the present invention. In this figure, the aboveground permeable reactive barrier structure 22 is comprised of individual media modules 16 attached together with attachment straps 24 through anchorage and attachment holes 20 and anchored to the ground surface with anchorage stakes 28 inserted through anchorage and attachment holes 20 and driven into the ground surface 36 . In one embodiment, attachment straps 24 are UV stabilized high density polyethylene cable ties 8 inches long with 50 lb breaking strength, anchorage stakes 28 are galvanized steel spikes 10 inches long and 0.25 inches in diameter. Sets of the substantially parallel sides 8 and 14 of assembled modules 16 create planar surfaces on the structure 22 simultaneously both perpendicular and parallel to the liquid runoff stream flow 30 so as to promote uniform flow into the media volume through the upstream exterior surface 32 and facilitate substantially laminar exterior flow across top surface 34 when runoff steams rise above the height of upstream exterior surface 32 .
[0028] The embodiment shown in FIG. 3 may be assembled by first placing media modules 16 side by side in a drainage-way, attaching them together and to the ground surface, to form a first media module row orthogonal to the direction of liquid runoff flow that is of sufficient length to accommodate the width of the runoff stream to be treated. Additional rows may then be added to the downstream side of the first row until a first media layer, one module high, is formed with sufficient contacting width to provide immobilization of a solute of concern in the runoff stream as it would flow through the first media layer. Other media layers similar to the first media layer are added and attached to the first layer creating a media volume, or barrier, with sufficient height to accommodate the depth of the runoff stream to be treated.
[0029] FIG. 4 shows another embodiment of the present invention. Specifically, this figure depicts a modular barrier 6 constructed to permit easy removal of a module to be serviced 38 without the need to disassemble the entire barrier 6 . This can be accomplished by locating the module to be serviced 38 within the barrier and removing any modules above it 40 that may be blocking access. Once the module to be serviced 38 is exposed, it can easily be removed from the barrier 6 for repair, modification, or cleaning of the module 38 itself or the reactive media 12 within the module. For example, the reactive media 12 within the module to be serviced 38 may be completely replaced with the same type of media, or a different type of media if the requirements of the barrier 6 change, or it may be cleaned periodically to maintain its ability to treat the runoff. The remaining modules 16 and the barrier 6 remain relatively undisturbed throughout this process.
[0030] A further embodiment of the present invention utilizes a characteristic of sand bags in that the shape of the modules conform to the ground surface and other adjacent bags forming a structure that does not require anchorage or attachment of the individual containers to each other.
[0031] The foregoing description of the preferred embodiments of the present invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above description. The scope of the invention is to be defined only by the claims appended hereto.
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A system and method are disclosed for the treatment of liquid runoff, such as rainfall, irrigation, and waste or produced water, utilizing aboveground, modular, permeable barriers containing reactive media that can immobilize particular solutes of concern, removing them from the liquid runoff. The modular design allows construction of a relatively-uniform barrier, or media volume, that is self-supporting and easily assembled, maintained, modified, and augmented. A permeable reactive barrier constructed according to the present invention provides significant contact between the reactive media and the solutes of concern while allowing the runoff stream to flow through the structure relatively unimpeded.
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This application is a continuation-in-part of U.S. patent application Ser. No. 08/088,823, filed on Jul. 8, 1993 now U.S. Pat. No. 5,443,222.
BACKGROUND OF THE INVENTION
The present invention relates to a belt retractor for vehicle safety belts, comprising a belt pretensioner acting on the belt drum and having a linear drive, and a transmission means for converting the linear movement of the linear drive into a rotary movement.
Such a belt retractor is integrated with the belt pretensioner as a single assembly. In U.S. Pat. No. 4,423,846 a number of designs of such an assembly are described. On tripping the belt pretensioner the movement of the piston of the pyrotechnical linear piston and cylinder drive unit is transmitted via a cable to a pulley whose periphery is engaged by the cable. This pulley is then caused to rotate by the tension exerted by the cable and at the start of such rotation it is drivingly coupled with the belt drum. The cable and the pulley constitute a transmission means for converting the stroke of the piston into rotation of the belt drum. Owing to the rotation of the belt drum there is a tightening of the belt webbing. The angle of rotation necessary for a sufficient tightening of the belt requires a relatively large stroke of the piston. The cylinder of the piston and cylinder unit has to be made with a corresponding length so that the assembly consisting of the belt retractor and the belt pretensioner needs a correspondingly large amount of space in the vehicle.
A primary object of the present invention is to improve a belt retractor of the type referred to above so that a short working stroke of the linear drive is sufficient to achieve the desired pretensioning of the webbing, thus permitting a more compact design of the retractor/pretensioner unit.
SUMMARY OF THE INVENTION
In the belt retractor of the present invention transmission means are provided which are able to be coupled drivingly with said belt drum by the intermediary of a step-up gear transmission. A toothed gearing allows a conversion of a short driving stroke of the linear drive into a rotary movement of the belt drum through an angle of rotation sufficient for tightening the belt. In accordance with a preferred embodiment of the invention, the toothed gearing consists of a first gear wheel following the transmission means and a second gear wheel which meshes with the first gear wheel and is able to be coupled with the belt drum via a freewheel coupling, preferably a locking transmission with rolling elements.
A simple transmission means is constituted by a pulley and a cable which engages the periphery of the pulley and is connected with the linear drive. Particularly low losses are achieved by a transmission means which is constituted by a rack connected with the linear drive and a pinion meshing with the rack.
Various types of linear drives are suitable for use with the invention. By way of example, the linear drive is constituted by a piston and cylinder drive having a gas generator, with the cylinder in particular bearing on the retractor housing. Owing to the short stroke of the piston, the cylinder of the piston and cylinder drive only extends a short distance past the load bearing retractor housing so that the assembly consisting of the belt retractor and the belt pretensioner hardly needs any more space than a belt retractor of the same design but without a belt pretensioner. An especially advantageous structural design results when in accordance with the preferred embodiment the rack which is adapted to be loaded with the thrust is rigidly connected with the piston and is slidably guided in parallelism to the floor of the retractor housing, which is generally U-shaped in cross-section.
Upon a collision of the vehicle, tensioning of the belt takes place firstly, and then the vehicle occupant is thrown forward so that a high strain may be produced in the belt webbing. In order to reduce the risk of injury it is desirable for the strain to be limited and for the peak values of the strain to be decreased by energy conversion. For this to be possible the belt webbing must be able to be pulled off from the belt drum against predetermined holding force. In the case of the preferred working embodiment the second gear wheel is adapted to be coupled via a freewheel coupling with the first end of a torsion rod, whose second end bears on the housing of the belt retractor in such a manner as to prevent relative rotation. When, after tensioning of the belt, the belt webbing is subjected to a high tension load, the belt drum will be turned in the direction of belt webbing pay off and its rotary movement is transmitted via the second gear wheel to the first gear wheel, which is however coupled in such a manner as to prevent relative rotation with the first end of the torsion rod via the freewheel coupling. Since the second end thereof bears on the housing of the belt retractor in such a manner as to prevent relative rotation, on further rotation of the belt drum in the direction of pay off of the belt the torsion rod will be twisted. Owing to the plastic deformation of the torsion rod now occurring the strain in the belt webbing is limited, and the peak energy values are decreased by energy conversion. The danger of injury for the occupant of the vehicle is substantially reduced owing to this design of the belt retractor/belt pretensioner/energy converter combination.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will be apparent from the following description of two preferred working embodiments and from the drawings, to which reference is made and in which:
FIG. 1 is a diagrammatic side elevation of an assembly consisting of a belt retractor and a belt pretensioner according to a first embodiment of the invention, with which an energy converter for limiting strains in the safety belt system has been integrated;
FIG. 2 is a diagrammatic plan view of the design illustrated in FIG. 1;
FIG. 3 is a diagrammatic cross sectional view of the design illustrated in FIGS. 1 and 2;
FIG. 4 is a diagrammatic side elevation of an assembly consisting of a belt retractor and a belt pretensioner according to a second embodiment of the invention; and
FIG. 5 is a diagrammatic sectional view of the design illustrated in FIG. 4, without a belt drum.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A belt drum 12 is rotatably supported in a load bearing belt retractor housing 10 which in cross section is generally U-shaped. The belt webbing 14 wound up on the belt drum 12 emerges from the belt retractor in parallelism to the bottom or floor of the housing 10 of the belt retractor. The belt retractor is provided with a locking mechanism, whose control system, which is conventional and is consequently not described in detail, is accommodated in a housing cover 16 on the one side of the housing 10 of the belt retractor. The locking mechanism consists of locking teeth on the flanges of the belt drum 12, of which in FIG. 1 two teeth 18 will be seen, and at least one ratchet 20 pivoted in a load bearing manner on the housing 10 of the belt retractor and designed for cooperation with the ratchet teeth on the flange of the belt drum.
According to FIGS. 1 to 3, on the side opposite the housing cover, and on the floor of the housing 10 of the belt retractor a pyrotechnical piston and cylinder linear drive is arranged, which is generally referenced 22. It consists of a cylinder 24 projecting partly from the housing 10 of the belt retractor, pyrotechnic gas generator 26 and a hollow piston 28 sliding in the cylinder 24. The hollow piston 28 defines a cylindrical interior space wherein the gas generator 26 is positively fitted, two working chambers 30a and 30b being constituted. The fit between the hollow piston 28 and the gas generator 26 is such that when the hollow piston 28 slides within the cylinder 24, the gas generator 26, being positively fitted within the hollow piston 28, slides with the hollow piston 28.
A rack 32 is rigidly connected with the piston 28. The rack 32 is guided for movement in parallelism to the floor of the housing 10 of the belt retractor. The teeth of the rack 32 mesh with a pinion 34 in the neutral position illustrated in FIG. 1, such pinion 34 being connected permanently with a gear wheel 36 having a larger diameter. The transmission means, which is constituted by the pinion 34 meshing with the rack 32 and which converts the linear movement of the piston 28 into a rotary movement, is rotatably mounted via the gear wheel 36 on the first axial end of a torsion rod 38, whose opposite end is fixed and locked against rotation in the adjacent side wall of the housing 10 of the belt retractor. The gear wheel 36 is able to be coupled via a freewheel coupling in the form of a rolling element locking transmission having rolling elements 40 on the adjacent end of the torsion rod 38. The preferably roller-like rolling elements 40 are received in recesses in the outer periphery of the adjacent end of the torsion rod 38, which are limited respectively by a ramp surface 42.
The gear wheel 36 meshes with a further gear wheel 44 with a smaller diameter. This gear wheel 44 is rotatably bearinged on the outer periphery of an axial coupling projection 46 of the belt drum 12. Between the gear wheel 44 and the coupling projection 46 a freewheel coupling is arranged, which is constituted by a rolling element locking transmission with a roller-like rolling elements 48. The rolling elements 48 are received by recesses 50 delimited by ramp surfaces, of the gear wheel 44.
The rack 32 is able to be shifted between two extreme positions, in which its teeth are out of engagement with the teeth of the pinion 34. By means of the rack 32 a lever 54, which is pivoted on a bearing pin 52 on the housing 10 of the belt retractor, is able to be shifted between a first position shown in continuous lines in FIG. 1 and a position as shown in broken lines. In the resting or neutral position (as illustrated in continuous lines) the lever 54 assumes a position which is oblique in relation to the rack 32. By moving the rack 32 out of the rest position illustrated in FIG. 1 the lever 54 is pivoted into a position parallel to the rack 32, and a headpiece 56 on its end fits over the ratchet 20 so that the same is prevented from coming into engagement with the locking or ratchet teeth 18 on the belt drum 12.
On activation of the gas generator 26 by a control system (not illustrated), the working chambers 30a and 30b are acted upon by gas under pressure and the piston 28 is moved forward in the cylinder 24, the rack 32 also being shifted forward. The rack 32 in mesh with the pinion 34 now causes a rotary movement of this pinion so that the gear wheel 36 is caused to rotate as well. The forward movement of the rack 32 is indicated in FIG. 1 by an arrow F 1 . The rotation of the gear wheel 36 as caused by the forward movement of the rack 32 is indicated by an arrow F 2 . The freewheel coupling arranged between the torsion rod 38 and the gear wheel 36 allows rotation in the direction indicated by the arrow F 2 but locks in the opposite direction of rotation.
The rotation of the gear wheel 36 also causes rotation of the gear wheel 44 in mesh with it. The corresponding direction of rotation is indicated by an arrow F 3 in FIG. 1. On rotation of the gear wheel 44 in the direction of this arrow F 3 the freewheel coupling arranged between the gear wheel 44 and the coupling projection 46 will lock so that the rotation of the gear wheel 44 is transmitted to the coupling projection 46. The belt drum 12 is now caused to rotate, the belt webbing 14 being rolled up so that the safety belt system is freed of belt slack. Since the gear wheel 36 has a substantially larger diameter than the gear wheel 44, the forward or feed movement of the rack 32 is converted by a step-up gear transmission into a large angle of rotation of the belt drum 12. This gear transmission is one having a low loss so that the drive energy available from the pyrotechnical gas generator 26 is effectively employed.
If after tensioning of the belt there is a high tension in the belt webbing 14, the belt drum 12 will tend to rotate in the direction of belt pay off. The relative direction of rotation between the coupling projection 46 and the gear wheel 44 in this case remains the same in relation to the operation of drawing the belt tight so that the freewheel coupling remains locked. The rotation now occurring of the gear wheel 44 is a direction opposite to the direction denoted as F 3 is transmitted to the gear wheel 36, the freewheel coupling between this gear wheel 36 and the adjacent end of the torsion rod 38 now being locked so that the torsion rod will oppose the rotation of the gear wheel 36. However when the strain exceeds a predetermined level the torsion rod 38 will undergo torsional deformation, plastic work of deformation being performed. The torsion rod 38 thus constitutes an energy conversion means, by which the strain in the belt webbing is limited and peak strain values are decreased. Dependent on the opposite force of the belt system to be overcome during the operation of belt tensioning it is possible for the rack 32 to be moved forwards into its extreme position, in which it is out of engagement with the pinion 34 or is even stopped before such extreme position. In the latter case the rack 32 is moved back during the rotation of the gear wheel 36 by the pinion 34 connected with it until it has reached its opposite extreme position, in which its teeth are out of engagement with the pinion 34. The rotation of the gear wheel 36 with simultaneous plastic deformation of the torsion rod 38 is for this reason not impeded by the rack 32, which may not be moved to an unlimited degree in relation to the housing 10 of the belt retractor. The lever 54 remains in its pivoted position after tripping of the belt pretensioner, in which position it holds the ratchet 20 out of engagement with the locking or ratchet teeth 18 of the belt drum 12.
In the case of an alternative working embodiment there is no torsion rod 38 if no conversion of energy is called for. The gear wheel 36 is in this case able to be coupled with a locking element rigidly anchored on the housing 10 of the belt retractor by means of the rolling elements 40, which locking element may be designed in the same manner as the end illustrated in the drawing of the torsion rod 38. After tensioning of the belt the ratchet 20 is in any case kept untripped, since at this point in time a sudden reversal of the direction of rotation of the belt drum occurs and it might be transmitted with such an angular acceleration that reliable engagement of the ratchet would not be certain.
In FIGS. 4 and 5 a further embodiment of a belt retractor cum belt pretensioner is illustrated. It differs from the first embodiment shown in FIGS. 1 to 3 in that the transmission means is not constituted by the pinion 34 and the rack 32 but by a pulley 60 and a cable 62 engaging the periphery of the pulley 60. Further, the linear drive, not shown here, is not disposed at the belt retractor housing 10. The linear drive may consist of a remotely arranged piston and cylinder drive having a gas generator or may be derived from the relative movement of a vehicle unit to the vehicle body by the intermediary of a cable in the event of a collision of the vehicle. The cable 62 is connected with the linear drive via a Bowden cable.
The ratchet 20 may be held in an inactive position in a manner analogous to the first embodiment or for example by a control unit (not shown), which is connected with the cable 62. In other respects, the second embodiment is designed to be in correspondence with the first embodiment.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
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The belt retractor with a belt pretensioner acting on the belt drum (12) has a pyrotechnical piston and cylinder linear drive (22). A rack (32) adapted to be subjected to thrust is connected with the piston (28) of such linear drive (22). The rack (32) is able to be drivingly coupled with the belt drum by the intermediary of a step-up gear wheel transmission (34, 36, 44). After tensioning of the belt, tensions in the safety belt system are limited by plastic deformation of a torsion rod (38), and peak strain values are decreased.
The belt retractor is integrated with the belt pretensioner and the energy converter as a compact assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to German patent application number DE 102009020892.5, filed May 13, 2009, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a method for closing containers, as well as to a packaging machine for carrying out such a method.
BACKGROUND
[0003] Packaging machines for closing already preformed and separated containers are known in the form of so-called tray sealers, for example from DE 10 2006 018 327 A1. Such machines are fed with already preformed and separated trays which are usually stacked and stocked after they have been formed. The containers are individually removed from the stock and placed onto a conveying belt where they are filled with a product from above. In the conventional tray sealer, a sealing foil is subsequently applied onto the trays that are open to the top which closes as well as seals the trays.
[0004] In conventional tray sealers, the sealing foil must not be stretched by the product, as otherwise the sealing foil might tear off. Consequently, the trays must be comparably deep to prevent the products from projecting over the edge of the trays. This excessive height of the trays, however, also involves drawbacks. On the one hand, this leads to an increase in the required amount of material and costs of a package. On the other hand, less preformed or filled trays can be accommodated per volume, so that costs increase for the stock-keeping of the empty trays as well as for the distribution of the filled and closed trays.
SUMMARY
[0005] It is an object of the present disclosure to overcome these drawbacks with structural means that are as simple as possible.
[0006] An embodiment of the present disclosure involves using a deep-drawable foil for closing already preformed and separated containers, and the foil is deep-drawn in a forming means or device of a packaging machine before the containers are closed with the lid foil. This deep-drawing offers the advantage that the package can be much better adapted to the respective product than before, although the containers are already preformed. In particular, products projecting over the container edge can also be accommodated in the containers, without the lid foil stretching over the product. Moreover, there are also esthetic advantages as, in contrast to conventional tray sealers, the upper side of each package does no longer have to be flat, but can be structured.
[0007] The lid foil may be heated upstream of and/or in the forming device to permit deep-drawing. The preheating of the lid foil upstream of the forming device can accelerate deep-drawing and reduce superfluous waiting times of other components of the packaging machine.
[0008] It is conceivable to deep-draw the lid foil towards the side of the lid foil facing the container during closing altogether or at least in sections. In this manner, a lid section which projects into the interior of the container is formed in the lid foil. This is in particular suited for products or regions of a product which are situated at a lower level than the edge of the container.
[0009] As an alternative or in addition, it is conceivable to deep-draw the lid foil towards the side of the lid foil facing away from the container during closing altogether or at least in sections. In this manner, a dome shaped lid section is formed which projects upwards over the container edge and permits the accommodation of projecting products without the lid foil stretching over the product.
[0010] By the method according to the present disclosure, in the deep-drawing process, at least one concave and/or one convex section can be formed on the side of the lid foil facing the container during closing. They can facilitate the placement of complementary formed regions of the products against the lid to prevent, for example, shifting of the products in the containers.
[0011] The forming device can be provided separately from the closing station. The complete packaging machine, however, becomes more compact and the method thereby less complex, if deep-drawing is carried out within the closing station itself.
[0012] As lid foil, a flexible foil or a hard foil could be used, if they can be deep-drawn in a suited manner.
[0013] Depending on the product, it can be advantageous to use a multilayer foil as lid foil. For example, a combination of an outer layer impermeable to oxygen and an inner layer permeable to oxygen would be conceivable to permit oxygen to flow around the products.
[0014] In one variant of the invention, the lid foil or the lid section formed in it, respectively, is only placed onto the respective containers by a form fit in the form of a “slip lid”. The lid section can, for example, snap in at an edge of the container to securely connect the lid to the container.
[0015] In addition or as an alternative, it is possible for the lid foil to be sealed onto the containers, in particular if the interior of the container is to be hermetically sealed.
[0016] If the lid foil is sealed to the containers, the transport of the closed containers connected with the lid foil out of the closing station can cause further lid foil to be drawn behind, which is used for closing following containers. In this manner, one could do without a separate conveyor device for the lid foil.
[0017] The present disclosure also relates to a packaging machine for carrying out a method according to the present disclosure. The packaging machine comprises a forming means or device for deep-drawing the deep-drawable lid foil.
[0018] It is appropriate for the forming device to comprise an exchangeable insert which determines the deformation of the lid foil to a lid section. This insert can be replaced if it is worn down, or if a different shape of the lids for the containers is to be produced.
[0019] Mainly in comparably thick hard foils, the pulling force acting on the lid foil only by the movement of the closed containers still connected to the lid foil might not be sufficient. In this case, it is advantageous to provide, in addition to a transport means for the containers, such as a conveyor belt or any other suitable transport device, a separate conveying means for the lid foil, for example a clamp chain arranged on both sides which can also be used to stretch the lid foil laterally, or any other suitable conveyor device.
[0020] The packaging machine according to the present disclosure may have a tool for placing and/or sealing the lid foil onto the containers. In this tool, the actual closing of the containers is thus accomplished.
[0021] The tool itself can comprise a lower tool and an upper tool which can be moved relative to each other. For example, they can open for receiving the unclosed containers and reduce the space between them for closing and possibly evacuating and/or gassing the containers.
[0022] It is appropriate if the lower tool and the upper tool can be spaced apart by the relative movement at least far enough to correspond to the sum of the height of a container and the height of a lid section of the lid foil. In this manner, the closing tool also permits the accommodation of containers in which the product and the lid project over the edge of the container.
[0023] In the following, two advantageous embodiments of the present disclosure are illustrated more in detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a packaging machine according to the present disclosure;
[0025] FIGS. 2 to 8 show schematic vertical sections through a first embodiment of the packaging machine in different steps of a method according to the present disclosure; and
[0026] FIGS. 9 to 15 show a second embodiment of the packaging machine in different steps of the method according to the present disclosure.
DETAILED DESCRIPTION
[0027] In the Figures, equal and similar components are provided with the same reference numerals.
[0028] FIG. 1 shows a first embodiment of a packaging machine 1 according to the invention in a perspective view. This embodiment is a tray sealer. The packaging machine 1 has a machine frame 2 on which a closing station 3 is arranged for closing as well as possibly evacuating, gassing and/or sealing supplied, tray-shaped containers as well as for cutting a lid foil used for closing. The closing station 3 is located under a cover 4 that can be opened.
[0029] The packaging machine 1 furthermore has a feed belt 5 for feeding the containers, a discharge belt 6 for carrying away the closed containers, a foil feed roller 7 for taking up and feeding a roll of a lid foil, a foil stretching means 8 for stretching the lid foil, as well as a foil residue winder 9 for winding up the foil residues that remain after sealing. A display 10 permits the operator of the packaging machine 1 to check and control the operation of the packaging machine 1 . To this end, operational controls 11 can be provided at the display 10 , for example operator panels or switches to influence the operation of the packaging machine 1 .
[0030] FIG. 2 shows, in a first embodiment of the packaging machine 1 according to the invention, a vertical section through the closing station 3 in a schematic view. The closing station 3 has a tool 12 which in turn comprises an upper tool 13 and a lower tool 14 . The upper tool 13 and the lower tool 14 can be moved in the vertical direction relative to each other. The upper and lower tools 13 , 14 can form a closed chamber 15 between themselves in a closed state (see FIG. 3 ).
[0031] A lifting table 16 is provided at the lower tool 14 which can be traveled in the vertical direction via a lifting rod 17 independent of the lower tool 14 . The lifting table 16 forms a recess or cavity 18 for receiving a prefabricated, tray-shaped container 19 . This container 19 can consist, for example, of hard plastics. After preforming, a plurality of containers 19 are stacked and stocked in this manner. They can be individually removed from this stock and placed onto the feed belt 5 of the packaging machine 1 to be filled there.
[0032] One can see in FIG. 2 that an edge 20 of the container rests on an edge of the lifting table 16 or cavity 18 . One can also see that the container 19 is filled with a product 21 which projects upwards beyond the level formed by the edge 20 of the container 19 .
[0033] In the present embodiment, the upper tool 13 has a more complex design. It has on its part three tool components which can be traveled relatively to each other in the vertical direction within the upper tool 13 independent of each other as well as independent of the outer wall 22 of the upper tool 13 . The innermost tool component is a forming means 23 for forming a lid section in the single- or multilayer lid foil 24 advance by the foil feed roller 7 . In the present embodiment, the forming means 23 may comprise any suitable forming device, such as a forming mold or tool having a concave design on a surface 25 facing the container 19 . The forming means 23 can have vacuum lines (not shown) to create a vacuum between the surface 25 and the lid foil 24 .
[0034] Above the forming means 23 , a sealing plate 26 is arranged which has sealing edges 27 projecting downwards. The sealing edges 27 are shaped such that they can contact the edge 20 of the container 19 when the sealing plate 26 is lowered.
[0035] A cutting means 28 is provided above the sealing plate 26 , between the sealing plate 26 and the outer wall 22 of the upper tool 13 . The cutting means 28 may comprise any suitable cutting device, such as a movable cutting tool having cutting edges 29 projecting downwards which are configured for cutting the lid foil 24 in two. The tool 12 can moreover have means for evacuating and/or gassing the chamber 15 formed between the upper and the lower tool 13 , 14 . For example, the tool 12 may be connected to a vacuum pump, or any other suitable evacuating device, and/or a gas supply system.
[0036] The deep-drawable (e.g., thermoplastic) lid foil 24 passes over a first deflection roller 30 and is there deflected such that it traverses the interior of the tool 12 essentially in parallel to the level formed by the edge 20 of the container 19 . The residual sections of the lid foil 24 remaining after the containers 19 have been closed and the lid sections punched out pass over a second deflection roller 31 to a residual foil winder 9 to be accumulated there. Between the foil feed roller 7 and the tool 12 , a foil stretching means 8 , which is not represented in FIG. 2 for a better overview, can be moreover provided. The foil stretching means 8 may be any suitable device, such as a movable plate or a system of rotatable drums or cylinders that includes one or more cylinders that are movable toward and away from another cylinder.
[0037] Between the foil feed roller 7 and the first deflection roller 30 , a heating means or a preheating means 32 (if a further heating step is performed), respectively, is moreover provided. The heating means 32 can be a heating plate which is heated, for example, via a thermal fluid or an electric heating medium. The heating means 32 is used to heat a given section 33 of the lid foil 24 to a temperature which permits thermoplastic forming of the lid foil 24 during a deep-drawing operation.
[0038] With reference to FIGS. 2 to 8 , a method according to the present disclosure and the operating sequence of the packaging machine 1 , respectively, will now be illustrated.
[0039] FIG. 2 shows the tool 12 of the packaging machine 1 in a state in which a tray 19 filled with a product 21 has been inserted into the cavity 18 of the lifting table 16 and guided into the interior of the tool 12 . For this purpose, the upper and the lower tools 13 , 14 can be removed from each other to such an extent that the distance A between the lower edge of the upper tool 13 and the upper edge of the lower tool 14 is larger than the sum of the height of the container 19 and the projecting part of the product 21 , to permit in this manner the introduction of the filled container 19 into the tool 12 . A certain section 33 of the lid foil 24 is heated under the heating means 32 .
[0040] FIG. 3 shows the tool 12 in a state in which first the lid foil 24 has been conveyed far enough for the heated section 33 to be located underneath the forming means 23 . At this time, the feed of the lid foil 24 is stopped. One can see in FIG. 3 that the upper tool 13 and the lower tool 14 move towards each other until they clamp the lid foil 24 between their edges and form a closed chamber 15 between themselves. As the feed of the lid foil 24 is stopped, now a further section 33 ′ of the lid foil can be brought to the temperature required for forming under or in the heating means 32 .
[0041] It could already be seen in FIG. 3 that the forming means 23 contacts the lid foil 24 when the upper tool 13 is lowered. Arrows 34 in FIG. 4 indicate that now a vacuum is created at the surface 25 of the forming means 23 by suited provisions. In connection with the contact between the forming means 23 and the lid foil 24 , this vacuum takes care that the heated section 33 of the lid foil 24 is pulled against the concave surface 25 of the forming means 23 and in this manner deep-drawn to form a lid section 35 .
[0042] The lid section 35 is represented in FIG. 5 . It has a shape which is complementary to the edge 20 of the container 19 on the outer surface. On the side facing the product 21 , the lid section 35 is concave.
[0043] FIG. 6 shows the tool 12 in a state in which—starting from the state in FIG. 5 —the lifting table 16 was lifted until the edge 20 of the container 19 came into contact with the lid foil 24 . This movement of the lifting table 16 is indicated by arrow 36 . Simultaneously—as indicated by arrow 37 —the sealing plate 26 was lowered until its sealing edges 27 came into contact with the lid foil 24 from above. In this state, the lid foil 24 is now sealed onto the edge 20 of the container 19 .
[0044] Subsequently or simultaneously with the sealing, the cutting means 28 is lowered—as shown in FIG. 7 —, so that its cutting edges 29 cut out the lid foil 24 all around the closed container 19 . This movement of the cutting means 28 is indicated by arrow 38 .
[0045] In FIG. 8 , the tool 12 is opened. This is done by moving the lower tool 14 and the lifting table 16 downwards and the upper tool 13 with the forming means 23 , the sealing plate 26 and the cutting means 28 upwards. The lid section 35 is firmly connected to the rest of the container 19 by the sealing and remains at the container 19 . The filled container 19 can now be removed from the tool 12 . At the same time, the lid foil 24 can be transported forwards, while the rest of the lid foil 24 that remains during cutting is winding up on the foil residue winder 9 . The closing process can now be performed in the same manner for a subsequent container.
[0046] FIG. 9 shows a second embodiment of a packaging machine 1 according to the present disclosure. It differs from the first embodiment in that the forming means 23 for forming the lid sections is now no longer provided in the closing tool 12 , but in the region of the heating means 32 . Apart from that, the upper tool 13 and the lower tool 14 of the closing tool 12 remain unchanged. In particular, the upper tool 13 still comprises a sealing plate 26 and a cutting means 28 , while the lower tool 14 still comprises a lifting table 16 .
[0047] In the second embodiment, the forming means 23 comprises a first forming half 39 and a second forming half 40 . As indicated by the arrows 41 , the two forming halves 39 , 40 can be moved relative to each other perpendicular to the plane of the lid foil 24 , so that they can close around the lid foil 24 or can release the lid foil 24 , respectively.
[0048] In the first forming half 39 , an exchangeable inset 42 is provided. Its surface 43 facing the lid foil 24 defines the shape of the lid section 35 if the section of the lid foil 24 heated by the heating means 32 in the opposite second forming half 40 is pulled closer by applying a vacuum to the surface 43 of the inset 42 to deep-draw the lid foil 24 .
[0049] FIGS. 9 to 15 show various steps of the method according to the present disclosure during the operation of the packaging machine 1 according to the second embodiment. FIG. 9 shows the packaging machine 1 in a state in which a fresh section of the lid foil 24 has been brought into the forming means 23 .
[0050] In FIG. 10 , the two forming halves 39 , 40 of the forming means 23 have been closed. Arrows 44 indicate that a vacuum is created at the inset 42 of the forming means to place the lid foil 24 in this region against the inset 42 of the first forming half 39 and to form a lid section 35 in this manner. The inset 42 can be exchanged if lid sections 35 having a different shape are to be produced.
[0051] FIG. 11 shows the state of the packaging machine 1 after the lid foil 24 has been deep-drawn in the forming means 23 . The lid foil 24 now has a lid section 35 .
[0052] In FIG. 12 , the two forming halves 39 , 40 have been removed from each other. The opening 45 formed between them now must be large enough—at least in the exiting direction out of the forming means 23 —to let the domed lid section 35 pass.
[0053] Between the state in FIG. 12 and the state in FIG. 13 , the lid foil 24 has been moved into the conveying direction 45 far enough for the lid section 35 now to be positioned within the closing tool 12 over the container 19 to be closed. The first deflection roller 30 here only lies against an outer edge of the lid foil 24 , so that it does not collide with the lid section 35 in the central region of the lid foil 24 .
[0054] FIG. 14 shows the packaging machine 1 in a state in which the closing tool 12 has been closed by moving the upper tool 13 and the lower tool 14 towards each other. A contact between the sealing edges 27 of the sealing plate 26 and the edge 20 of the container 19 , that is close by due to the lifting of the lifting table 16 , permits to seal the lid foil 24 to the container 19 . Simultaneously or subsequently, the cutting means 28 has been lowered to cut out the closed container. The forming means 23 has simultaneously closed around a new section of the lid foil 24 to form a further lid section 35 .
[0055] In FIG. 15 , the forming means 23 as well as the closing tool 12 have been opened. The closed container 19 can now be removed from the tool 12 , and the cycle can start anew.
[0056] Starting from the two embodiments described in detail, a method according to the present disclosure and a packaging machine according to the present disclosure can be modified in many ways. It is, for example, conceivable for the lid sections 35 not to be sealed to the edge 20 of the container 19 , but to only be placed onto the container 19 by a form fit in the form of slip lids. It is moreover possible to impart any arbitrary shape to the lid section 35 . In the first embodiment, too, the forming means 23 can have an exchangeable inset 42 . Though it is not shown, several lid sections 35 can be manufactured one after or one next to the other in the forming means 23 , and several containers 19 can be simultaneously closed in the closing station 3 .
[0057] While exemplary embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
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The invention relates to a method for closing already preformed and separated containers ( 19 ), for example trays, with a lid foil ( 24 ) in a closing station ( 3 ). The invention is characterized in that a deep-drawable foil is used as lid foil ( 24 ), that the lid foil ( 24 ) is deep-drawn in a forming means ( 23 ) of the packaging machine ( 1 ), and that the deep-drawing of the lid foil ( 24 ) is accomplished before the containers ( 19 ) are closed with the lid foil ( 24 ). The invention also relates to a packaging machine ( 1 ) suited for carrying out such a method.
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FIELD OF THE INVENTION
This invention relates to laparoscopic surgery in general, and more particularly to apparatus and methods for tying knots inside the body during such surgery.
BACKGROUND OF THE INVENTION
In laparoscopic surgery, access is gained to an interior surgical site by making one or more short incisions in the body which extend down to the interior surgical site, and then inserting a hollow tube or cannula into each incision so that the cannulas can act as liners to hold the incisions open and thereby provide portals leading down to the interior surgical site. A laparoscopic procedure can then be performed by passing instruments (e.g. cutting devices, clamps, viewing apparatus, etc.) down the cannulas so that the distal working ends of the instruments can be positioned and used about the surgical site, while the proximal handle ends of the instruments remain outside the body where they can be grasped by the surgeon.
Laparoscopic procedures frequently involve the repair and/or removal of tissue from the interior surgical site, and often require that some sort of closure be made to the tissue which is being operated upon. Such closure can be effected through the use of conventional needles and suture, surgical clips or staples, or other known closure means. In this respect, it has been found that the use of conventional needles and suture can have significant advantages in many laparoscopic procedures, since they generally allow the tension of the closure to be dynamically adjusted during suture deployment. At the same time, however, the use of conventional needles and suture can also present significant difficulties in laparoscopic surgery, on account of the limited access provided to, and at, the interior surgical site.
One aspect of using conventional needles and suture which can be particularly difficult to accomplish in a laparoscopic setting is that of tying knots. In particular, it has been found that it can be very difficult to properly manipulate the suture ends within the body so as to tie the knots, given the limited space available adjacent the interior surgical site. In addition, it will also be appreciated that the remote nature of the surgical site, and the limited cannula access provided to that site, further complicates this procedure.
Currently, surgeons generally use long straight forceps to reach into the interior surgical site to manipulate the suture ends during knot tying. This tends to be a time-consuming and inconvenient method to tie knots in a laparoscopic setting. In addition, such long forceps tend to offer limited suture control at the surgical site, since there is essentially no tactile feedback to the user when grasping the suture and no reliable way to vary the degree of engagement between the forceps and the suture. Furthermore, with such forceps the outer diameter of the forceps changes according to the positioning of the forceps' jaw members; when the two jaws are opened wide, the forceps will have a relatively large outer diameter, and when the jaws are closed down, the forceps will have a relatively small outer diameter. This characteristic can present problems in certain surgical sites which may be too cramped to permit the forceps' jaws to open fully. In addition, the fact that the outer diameter of the forceps changes according to the positioning of the forceps' jaws means that the surgeon must take care to ensure that nothing is placed adjacent the jaws which might interfere with operation of the forceps' jaws. Thus, for example, suture cannot be coiled tightly about the exterior of the forceps' jaws when the jaws are closed and must thereafter be opened, since the wound suture might inhibit opening of the jaws.
OBJECTS OF THE INVENTION
Accordingly, one object of the present invention is to provide a novel device to facilitate knot-tying inside the body during a laparoscopic surgical procedure.
Another object of the present invention is to provide a novel method for tying knots inside the body during laparoscopic surgery.
And another object of the present invention is to provide a novel device for gripping and manipulating suture at a remote location within the body, wherein the device is capable of alternatively engaging the suture so as to hold it fast to the device or engaging the suture so that it can slip in a controlled manner relative to the device.
Still another object of the present invention is to provide a novel device for gripping and manipulating suture at a remote location within the body, wherein the device will maintain a substantially constant outer diameter at the working end of the device.
Yet another object of the present invention is to provide a novel device for gripping and manipulating suture at a remote location within the body, wherein the device can have suture coiled about its exterior surface at the working end of the device without interfering with the device's suture gripping and manipulating features.
SUMMARY OF THE INVENTION
These and other objects are achieved through the present invention, which comprises the provision and use of a suture manipulating device comprising an outer sheath and an inner rod.
In the preferred embodiment, the outer sheath comprises a straight, rigid distal portion, a flexible intermediate portion, and a straight, rigid proximal portion. The sheath's flexible intermediate portion is formed so that the longitudinal axis of the sheath's distal portion is normally aligned with the longitudinal axis of the sheath's proximal portion; at the same time, however, the sheath's flexible intermediate portion is capable of being elastically deformed so that the longitudinal axis of the sheath's distal portion can be moved out of alignment with the longitudinal axis of the sheath's proximal portion.
In the preferred embodiment, the inner rod comprises a straight, rigid distal portion, a bending intermediate portion and a straight, rigid proximal portion. The rod's bending intermediate portion is formed so that the longitudinal axis of the rod's distal portion normally resides at an acute angle (e.g. approximately 30 degrees) relative to the longitudinal axis of the rod's proximal portion, but is capable of being elastically deformed so that the longitudinal axis of the rod's distal portion can be brought into alignment with the longitudinal axis of the rod's proximal portion. The distal portion of the inner rod comprises a crochet-type hook disposed adjacent the distal tip of the inner rod.
In the preferred embodiment, the outer sheath and the inner rod are formed so that the length of the distal portion of the outer sheath is approximately the same as the length of the distal portion of the inner rod, and the length of the flexible intermediate portion of the outer sheath is approximately the same as the length of the bending intermediate portion of the inner rod. Preferably the length of the proximal portion of the outer sheath is somewhat less than the length of the distal portion of the inner rod so as to facilitate connecting the outer sheath and the inner rod to a preferred form of handle. The outer sheath and the inner rod are also formed so that the inner rod can make a close sliding fit within the interior of the outer sheath.
On account of the foregoing construction, when the inner rod is positioned within the outer sheath, the outer sheath and the inner rod can be moved relative to one another so as to assume:
(1) a first position wherein the distal tip of the inner rod is withdrawn slightly relative to the distal tip of the outer sheath, and the inner rod's bending intermediate portion is positioned within and constrained by the outer sheath's straight proximal portion, whereby the inner rod and the outer sheath will both be substantially straight and in longitudinal alignment with one another;
(2) a second position wherein the distal portion of the inner rod and the bending intermediate portion of the inner rod both project out of the distal portion of the outer sheath, and so that the longitudinal axis of the inner rod's distal portion is disposed at an acute angle to both the longitudinal axis of the inner rod's proximal portion and the longitudinal axis of the outer sheath; and
(3) a third position wherein the distal tip of the inner rod is nearly aligned with the distal tip of the outer sheath and so that the bending intermediate portion of the inner rod is generally aligned with the flexible intermediate portion of the outer sheath, so that the longitudinal axis of the inner rod's distal portion will be aligned with the longitudinal axis of the outer sheath's distal portion, the longitudinal axis of the inner rod's proximal portion will be aligned with the longitudinal axis of the outer sheath's proximal portion, and the longitudinal axis of the inner rod's distal portion will be disposed at an acute angle to the longitudinal axis of the inner rod's proximal portion.
Two identical suture manipulating devices such as the one described above can be used as follows to tie two suture ends into a knot at a remote surgical site.
First, the two suture manipulating devices are picked up by the surgeon so that one device is held in the right hand and one device is held in the left hand. At the same time, the devices are arranged so that they are positioned in their aforementioned first positions, so that the outer sheath and inner rod are both substantially straight and in longitudinal alignment with one another. Then the devices are passed through cannulas down to the surgical site so that the distal end of each device is positioned adjacent the suture ends which are to be tied in a knot.
Next, the left hand device is moved toward its aforementioned second position so that its crochet-type hook is exposed out the distal end of the outer sheath. It will be appreciated that as this occurs the left hand device will move briefly through its aforementioned third position until its hook is exposed the desired amount. Then a first suture end is picked up in the crochet-type hook and the left hand device is positioned in its third position so that the suture is captured between the crochet-type hook of the inner rod and the distal tip of the outer sheath. It will be appreciated that the suture end can be slidably captured by the device if the crochet-type hook is positioned slightly outboard of the outer sheath's distal tip, or the suture end can be fixedly captured by the device if the crochet-type hook is pulled tight against the outer sheath's distal tip. Generally the device will be used to first slidably capture the suture end to the tool, whereby the precise positioning of the tool relative to the suture end can be safely adjusted, and then the crochet-type hook will be moved further inboard to fixedly capture the suture end to the tool.
Next, the right hand device is positioned in its aforementioned third position so that the distal ends of the outer sheath and inner rod are set at an acute angle to the proximal ends of the outer sheath and inner rod. Then the length of first suture end extending between the host tissue and the left hand device is wound around the distal end of the right hand device several times so as to form at least one suture coil about the distal end of the right hand device. Preferably this is accomplished by rotating the right hand device axially about its principal axis while its distal end is disposed adjacent the suture so that its distal tip whips around the extended suture so as to form several suture coils about the distal end of the right hand device; alternatively, this may be accomplished by holding the right hand device relatively steady and winding the extended suture around the distal end of the right hand device using the left hand device.
In this respect it is also to be appreciated that the precise number of suture coils formed about the distal end of the right hand device is determined by the type of knot which is to be formed at the surgical site. For example, one complete coil is used to form a standard suture throw; two complete coils are used to form a so-called "surgeon's throw", which is also known as a locking throw.
Once the suture coils have been formed about the distal end of the right hand device, the right hand device is moved toward its aforementioned second position so that its crochet-type hook is exposed out the distal end of the outer sheath, the second suture end is picked up in the crochet-type hook and the right hand device is positioned in its third position so that the suture is captured between the crochet-type hook of the inner rod and the outer sheath. Again, it will be appreciated that the suture end can be slidably captured by the device if the crochet-type hook is positioned slightly outboard of the outer sheath's distal tip, or the suture end can be fixedly captured by the device if the crochet-type hook is pulled tight against the outer sheath's distal tip. As noted previously, the device will generally be used to first slidably capture the suture end to the tool, whereby the precise positioning of the tool relative to the suture end can be safely adjusted, and then the crochet-type hook will be moved further inboard to fixedly capture the suture end to the tool.
Finally, the right hand device is pulled away from the left hand device so as to draw the second suture end through the several coils of the first suture end, thereby forming a suture throw.
The foregoing procedure may then be repeated one or more times as required so as to form the desired suture knot. In this respect, it is also to be appreciated that by using successive throws formed by coiling the suture about the distal end of the right hand device in alternating directions of rotation, rather than in identical directions of rotation, a square knot can be formed by laying two or more such throws upon one another. Stated another way, if it is desired to form a square knot at the surgical site, a first throw would be formed by coiling the suture about the right hand device in a first (e.g. either clockwise or counterclockwise) direction, and the second throw would be formed by coiling the suture about the right hand device in a second (i.e., either a counterclockwise or clockwise) direction, respectively. A person skilled in the art will readily appreciate that still other types of knots can be formed using the present apparatus as well. In fact, it will be appreciated that the present apparatus can be used to duplicate, in an intracorporeal setting, all of the knots typically utilized in open surgical settings.
Other forms of the suture manipulating device are also contemplated. Thus, for example, in one alternative embodiment the device's outer sheath is formed with a permanent helical spiral and the inner rod is formed out of a material which is resilient at least along the portion of the rod which reciprocates within the helical spiral. Such a construction provides a tool which can be inserted through a surgical cannula so as to reach the interior site, yet still provides an outer sheath which has its distal portion set at an angle to the longitudinal axis of the sheath's proximal portion so that suture can be coiled about the exterior of the sheath's distal portion. Similarly, in another alternative embodiment, the device's outer sheath is formed with one or more permanent bends in a two-dimensional plane, and the inner rod is formed out of a material which is resilient at least along the portion of the rod which reciprocates within the single bend. Again, this construction provides a tool which can be inserted through a surgical cannula so as to reach the interior site, yet still provides an outer sheath which has its distal portion set at an angle to the longitudinal axis of the sheath's proximal portion so that suture can be coiled about the exterior of the sheath's distal portion.
BRIEF DESCRIPTION OF THE DRAWINGS
Still other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the present invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
FIG. 1 is a side view in elevation, in partial section, showing a suture manipulating device formed in accordance with the present invention, wherein the device is shown in its aforementioned first position;
FIG. 2 is a side view in elevation, in partial section, showing the same suture manipulating device shown in FIG. 1, except that the device is shown in its aforementioned second position;
FIG. 3 is a side view in elevation, in partial section, showing the same suture manipulating device shown in FIG. 1, except that the device is shown in its aforementioned third position;
FIG. 4 is a view like that of FIG. 2, showing the distal tip of the suture manipulating device engaging a suture end;
FIG. 4A is an enlarged view of selected portions of FIG. 4, showing the distal portion of the inner rod engaging the suture end, with the apparatus of FIG. 4A having been rotated approximately 90 degrees from the position shown in FIG. 4;
FIG. 5 is a view generally like that of FIG. 3, showing the distal tip of the suture manipulating device engaging a suture end and slidably capturing the suture end to the distal end of the outer sheath;
FIG. 5A is an enlarged view of selected portions of FIG. 5, showing the distal portion of the inner rod slidably capturing the suture end to the distal end of the outer sheath, with the apparatus of FIG. 5A having been rotated 90 degrees from the position shown in FIG. 5;
FIG. 6 is a view generally like that of FIG. 3, showing the distal tip of the suture manipulating device engaging a suture end and fixedly capturing the suture end to the distal end of the outer sheath;
FIG. 6A is an enlarged view of selected portions of FIG. 6, showing the distal portion of the inner rod fixedly capturing the suture end to the distal end of the outer sheath;
FIGS. 7A-7E show how two suture manipulating devices such as those shown in FIGS. 1-6 can be used to tie a knot at an interior surgical site;
FIG. 8 is a side view in elevation showing the distal end of an alternative suture manipulating device also formed in accordance with the present invention; and
FIG. 9 is a side view in elevation of still another suture manipulating device formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Looking first at FIGS. 1-3, there is shown a suture manipulating device 2 formed in accordance with the present invention. Suture manipulating device 2 comprises a preferred embodiment of the present invention, and generally comprises an outer sheath 4 and an inner rod 6.
Outer sheath 4 comprises a straight, rigid distal portion 8, a flexible intermediate portion 10, and a straight, rigid proximal portion 12. Outer sheath 4 terminates in a distal end 14 and a proximal end 16.
The sheath's flexible intermediate portion 10 is formed so that the longitudinal axis of the sheath's distal portion 8 is normally aligned with the longitudinal axis of the sheath's proximal portion 12 (FIGS. 1 and 2); at the same time, however, the sheath's flexible intermediate portion 10 is capable of being elastically deformed so that the longitudinal axis of the sheath's distal portion 8 can be moved out of alignment with the longitudinal axis of the sheath's proximal portion 12 (FIG. 3).
Outer sheath 4 can be formed in a variety of ways well known in the art. For example, sheath 4 can be formed by attaching a somewhat softer, somewhat elastic (e.g. rubber) cannula 18 to the front end of a relatively rigid (e.g. steel) cannula 20, wherein the softer somewhat elastic cannula 18 forms the sheath's distal portion 8, its flexible intermediate portion 10 and the front part of its proximal portion 12, and the relatively rigid cannula 20 forms the rear part of the sheath's proximal portion 12. In such a construction, softer cannula 18 has a sufficient hardness and thickness in the regions where it comprises the sheath's distal portion 8 and proximal portion 12 so as to be substantially rigid, yet has a reduced thickness in the region where it comprises the sheath's intermediate portion 10 so as to be substantially flexible. The precise material chosen to form cannula 18 can vary according to the application, but in general it is preferred that cannula 18 be formed out of a material which is as soft as, or softer, than the material which is used to form the suture, so as to ensure that cannula 18 will deform during suture engagement before the suture deforms, so as to protect the integrity of the suture. Alternatively, other equivalent structures may be used to form outer sheath 4.
Inner rod 6 comprises a straight, rigid distal portion 22, a bending intermediate portion 24, and a straight, rigid proximal portion 26. Inner rod 6 terminates in a distal end 28 and a proximal end 30.
The rod's bending intermediate portion 24 is formed so that the longitudinal axis of the rod's distal portion 22 normally resides at an acute angle (e.g. approximately 30 degrees) relative to the longitudinal axis of the rod's proximal portion 26 (FIGS. 2 and 3), but the bending intermediate portion 24 is capable of being elastically deformed so that the longitudinal axis of the rod's distal portion 22 can be brought into alignment with the longitudinal axis of the rod's proximal portion 26 (FIG. 1).
The distal portion 22 of inner rod 6 comprises a crochet-type hook 32 (see FIGS. 1-4, 4A, 5, 5A, 6 and 6A) which is disposed adjacent the distal end 28 of inner rod 6.
Inner rod 6 may be formed in a variety of ways well known in the art, e.g. inner rod 6 may be formed out of a single piece of steel rod which is bent as required so as to form the rod's bending intermediate portion 24, and worked as required so as to form the rod's crochet-type hook 32.
Outer sheath 4 and inner rod 6 are formed so that the length of the distal portion 8 of outer sheath 4 is approximately the same as the length of the distal portion 22 of inner rod 6, and the length of the flexible intermediate portion 10 of outer sheath 4 is approximately the same as the length of the bending intermediate portion 24 of inner rod 6. Preferably the length of the proximal portion 12 of outer sheath 4 is somewhat less than the length of the distal portion 26 of inner rod 6 so as to facilitate connecting outer sheath 4 and inner rod 6 to a handle of the sort described below.
Outer sheath 4 and inner rod 6 are also formed so that the inner rod can make a close sliding fit within the interior bore 34 of the outer sheath.
On account of the foregoing construction, when inner rod 6 is positioned within outer sheath 4, the outer sheath and the inner rod can be moved relative to one another so as to assume:
(1) a first position (FIG. 1) wherein the distal end 28 of inner rod 6 is withdrawn slightly relative to the distal end 14 of outer sheath 4, and the inner rod's bending intermediate portion 24 is positioned within and constrained by the outer sheath's straight proximal portion 12, whereby the inner rod and the outer sheath will both be substantially straight and in longitudinal alignment with one another;
(2) a second position (FIG. 2) wherein the distal portion 22 of inner rod 6 and the bending intermediate portion 24 of inner rod 6 both project out of the distal portion 8 of outer sheath 4, and so that the longitudinal axis of the inner rod's distal portion 22 is disposed at an acute angle (e.g. approximately 30 degrees) to the longitudinal axis of the inner rod's proximal portion 26, and at the same acute angle to the longitudinal axis of outer sheath 4; and
(3) a third position (FIG. 3) wherein the distal tip 28 of inner rod 6 is nearly aligned with the distal tip 14 of outer sheath 4 and so that the bending intermediate portion 24 of the inner rod 6 is generally aligned with the flexible intermediate portion 10 of outer sheath 4, so that the longitudinal axis of the inner rod's distal portion 22 will be aligned with the longitudinal axis of the outer sheath's distal portion 8, and the longitudinal axis of the inner rod's proximal portion 26 will be aligned with the longitudinal axis of the outer sheath's proximal portion 12, and so that the longitudinal axis of the inner rod's distal portion 22 will be disposed at an acute angle (e.g. approximately 30 degrees) to the longitudinal axis of the inner rod's proximal portion 26.
A handle 36 is provided to telescope outer sheath 4 and inner rod 6 back and forth relative to one another so as to place the suture manipulating device 2 into its aforementioned first, second and third positions. In this respect, it will be appreciated that such telescoping of outer sheath 4 and inner rod 6 relative to one another may be achieved by holding outer sheath 4 fixed in place and moving inner rod 6 back and forth relative to the outer sheath, or by holding inner rod 6 fixed in place and moving outer sheath 4 back and forth relative to the inner rod, or by moving both outer sheath 4 and inner rod 6 back and forth relative to one another.
In the preferred embodiment shown in FIGS. 1-3, it is preferred that the telescoping of outer sheath 4 and inner rod 6 relative to one another be achieved by holding inner rod 6 fixed in place and moving outer sheath 4 back and forth relative to the inner rod. To this end, inner rod 6 is formed slightly longer than outer sheath 4, and handle 36 is formed with two telescoping portions, a distal portion 38 and a proximal portion 40. Distal portion 38 is securely attached to proximal portion 12 of outer sheath 4, and proximal portion 40 is securely attached to proximal portion 26 of inner rod 6. As a result of this construction, the surgeon can grasp the handle's proximal portion 40 with the palm of the hand and manipulate the handle's distal portion 38 toward and away from the handle's proximal portion 40 by using thumb and forefinger, whereby outer sheath 4 and inner rod 6 can be moved between the positions shown in FIGS. 1-3.
If preferred, a detent arrangement may be provided in handle 36 to help maintain outer sheath 4 and inner rod 6 in certain predetermined positions. By way of example, such a detent arrangement might comprise a spring-biased ball 42 mounted to proximal handle portion 40 and adapted to engage one of a plurality of surface openings 44 formed in distal handle portion 38. Alternatively, other equivalent detent arrangements may also be provided.
Looking next at FIGS. 4 and 4A, outer sheath 4 and inner rod 6 are formed so that the inner rod's crochet-type hook 32 can engage a suture end 46 in a sort of grappling hook manner when the inner rod's distal portion 22 is extended relative to the distal portion 8 of outer sheath 4. Furthermore, by thereafter moving outer sheath 4 distally relative to inner rod 6, in the manner shown in FIGS. 5 and 5A, the inner rod's crochet-type hook 32 can coordinate with the outer sheath's distal end 14 to slidingly capture suture end 46 to suture manipulating device 2. Finally, by thereafter moving outer sheath 4 even further distally relative to inner rod 6, in the manner shown in FIGS. 6 and 6A, the inner rod's crochet-type hook 32 can coordinate with the outer sheath's distal end 14 to lockingly capture suture end 46 to suture manipulating device 2. Preferably the outer sheath's distal portion 8 is bevelled slightly where its interior bore 34 meets its distal end 14 so as to minimize any possibility that the suture 46 might be damaged when it is lockingly captured to suture manipulating device 2 in this way. Furthermore, by forming at least the distal tip of outer sheath 4 out of a somewhat soft, somewhat elastic material, i.e., a material which is at least as soft as the material which is used to form the suture, the possibility of damaging suture 46 during locking engagement will be further reduced.
Thus it will be seen that a suture manipulating device 2 can be used to pick up a loose suture end at the interior surgical site using its crochet-type hook, in the grappling hook manner shown in FIGS. 4 and 4A; to remain in engagement with that suture end while it is slid along the length of the suture to reach a desired point of attachment, in the manner shown in FIGS. 5 and 5A; and to securely grasp the suture end to the device at the desired point of attachment, in the manner shown in FIGS. 6 and 6A. Conventional long straight forceps are incapable of providing such suture control.
Two identical suture manipulating devices 2 may be used as follows to tie a knot in a pair of suture ends located within the body during a typical laparoscopic procedure.
More particularly, and looking next at FIG. 7A, there is shown a typical incision 48 formed in a piece of tissue 50 which is located at an interior surgical site. Access to incision 48 and tissue 50 is typically gained by means of one or more surgical cannulas (not shown) which extend from the region outside the body down to the interior surgical site. In a typical laparoscopic procedure, a suture 46 having a first suture end 46' and a second suture end 46" might be deployed across incision 48 and need to have its ends 46' and 46" tied in a knot so as to hold the incision closed. Two identical suture manipulating devices 2 may be used as is hereinafter described to tie a knot in first suture end 46' and second suture end 46".
First, the suture manipulating devices 2 are picked up by the surgeon so that one suture manipulating device 2R is held in the surgeon's right hand and one suture manipulating device 2L is held in the surgeon's left hand. At the same time, each of the suture manipulating devices 2 is arranged so that it is positioned in its aforementioned first position, in the manner shown in FIG. 1, so that the outer sheath 4 and inner rod 6 are substantially straight and in longitudinal alignment with one another. Then the two suture manipulating devices 2R and 2L are passed down the aforementioned cannulas to the surgical site so that the distal ends of suture manipulating devices 2R and 2L are positioned adjacent incision 48.
Next, the suture manipulating device 2L is positioned in (or at least moved toward) its aforementioned second position (see FIGS. 2, 4 and 4A) so that its crochet-type hook 32 is exposed out the distal end of outer sheath 4. It will be appreciated that as this occurs suture manipulating device 2L will move briefly through its aforementioned third position until its hook is exposed the desired amount. Then first suture end 46' is picked up in the crochet-type hook 32 with a grappling hook motion and the suture manipulating device 2L is positioned in its third position (FIG. 3) so that the suture is captured between the crochet-type hook 32 of inner rod 6 and the distal end 14 of outer sheath 4.
More particularly, it will be appreciated that the first suture end 46' can first be hooked by the suture manipulating device's hook 32 by putting the device in the position shown in FIGS. 4 and 4A (or in a position approaching that shown in FIGS. 4 and 4A); then first suture end 46' can be slidably captured to the suture manipulating device 2L by putting the device in the position shown in FIGS. 5 and 5A, whereupon the tool can be safely slid along the length of the suture until the desired point of attachment is reached; and finally the first suture end 46' can be fixedly captured by suture manipulating device 2L by putting the device in the position shown in FIGS. 6 and 6A. See generally FIG. 7B.
Next, the suture manipulating device 2R is positioned in its aforementioned third position (FIG. 3) so that the distal lengths of the outer sheath 4 and inner rod 6 are set at an acute angle (e.g. approximately 30 degrees) to the proximal lengths of the outer sheath 4 and inner rod 6. Then the length of first suture end 46' extending between the host tissue 50 and suture manipulating device 2L is wound around the distal portion 8 of suture manipulating device 2R several times so as to form at least one suture coil about the distal portion of suture manipulating device 2R. See generally FIG. 7C. It is to be appreciated that coiling first suture end 46' around the distal portion 8 of suture manipulating device 2R can be quickly and easily achieved simply by rotating suture manipulating device 2R about its principal axis, i.e., the longitudinal axis of the sheath's proximal portion 4, since the distal portion 8 will be set at an acute angle (e.g. approximately 30 degrees) to the axis of rotation (see FIGS. 3 and 7C). Alternatively, first suture end 46' may be coiled around the distal portion 8 of suture manipulating device 2R by holding suture manipulating device 2R relatively steady and winding first suture end 46' around the distal end of suture manipulating device 2R using suture manipulating device 2L.
In this respect it is also to be appreciated that the precise number of suture coils formed about the distal end of suture manipulating device 2R is determined by the type of knot which is to be formed at the surgical site. For example, one complete coil is used to form a standard suture throw; two complete coils are used to form a so-called "surgeon's throw", which is also sometimes referred to as a locking throw.
Once the suture coils have been formed about the distal end of suture manipulating device 2R, suture manipulating device 2R has its outer sheath 6 retracted so that the device approaches, but does not necessarily reach, its aforementioned second position (FIG. 2). In this way the tool's crochet-type hook 32 is exposed. Then the second suture end 46" is picked up in the exposed crochet-type hook 32. While this is being done, the length of first suture end 46' extending between the host tissue 50 and suture manipulating device 2L remains coiled about the distal portion of suture manipulating device 2R. See generally FIG. 7D.
Next, the suture manipulating device 2R is positioned in its third position (see FIG. 3) so that the second suture end 46" is captured between the crochet-type hook 32 of the inner rod 6 and the outer sheath 4.
More particularly, it will again be appreciated that the second suture end 46" can first be hooked by the suture manipulating device's hook 32 by positioning the device in the position shown in FIGS. 4 and 4A (or in a position approaching that shown in FIGS. 4 and 4A); then second suture end 46" can be slidably captured to the suture manipulating device 2R by putting the device in the position shown in FIGS. 5 and 5A, whereupon the tool can be safely slid along the length of the suture until the desired point of attachment is reached; and finally the second suture end 46" can be fixedly captured by the suture manipulating device 2R by putting the device in the position shown in FIGS. 6 and 6A. Again, all of this is done while the length of first suture end 46' between the host tissue 50 and suture manipulating 2L remains coiled about the distal portion of suture manipulating device 2R.
Next, suture manipulating device 2R is pulled away from suture manipulating device 2L so as to draw the second suture end 46" through the several coils of the first suture end 46' which formerly sat wrapped about the distal portion of suture manipulating device 2R, and so as to thereby form a suture throw. See generally FIG. 7E.
The foregoing procedure may then be repeated one or more additional times as required so as to form the desired suture knot at the surgical site. In this respect, it is also to be appreciated that by using successive throws formed by coiling the suture about the distal end of suture manipulating device 2R in alternating directions of rotation, rather than in identical directions of rotation, a square knot can be formed by laying two or more such throws upon one another. Stated another way, if it is desired to form a square knot at the surgical site, a first throw would be formed by coiling the suture about suture manipulating device 2R in a first (e.g. either clockwise or counterclockwise) direction, and the second suture throw would be formed by coiling the suture about suture manipulating device 2R in a second (i.e., either counterclockwise or clockwise) direction, respectively. It will be appreciated that still other types of knots can be formed using the present apparatus as well. In fact, the present apparatus can be used to duplicate, in an intracorporeal setting, all of the knots typically utilized in open surgical settings.
It is to be appreciated that suture manipulating device 2 maintains a substantially constant outer diameter at substantially all times, regardless of whether it is grappling a piece of suture in the manner shown in FIGS. 4 and 4A, slidably capturing the suture in the manner shown in FIGS. 5 and 5A, or fixedly capturing the suture in the manner shown in FIGS. 6 and 6A. This feature is a major improvement over the prior art forceps devices, which increase or decrease their outer diameters according to the positioning of their jaws. For one thing it means that suture manipulating device 2 can be used more conveniently in tight surgical locations; for another thing it means that lengths of suture (see, for example, FIGS. 7C-7E) can be conveniently wound around the distal end of the tool and then conveniently disengaged from the same, all without fear of inhibiting the suture grasping and manipulating characteristics of the tool, as occurs in the case of forceps tools. Thus it will be seen that suture manipulating tool 2 constitutes a significant improvement over the forceps tools of the prior art.
Furthermore, inasmuch as suture manipulating device 2 is adapted so that its distal portion 8 can be positioned at an acute angle (e.g. approximately 30 degrees) to the major longitudinal axis of the tool (i.e., the longitudinal axis of the sheath's proximal portion 16), coiling a length of suture about the distal portion of the tool can be quickly and easily accomplished simply by positioning the distal portion of the tool adjacent the suture to be coiled and then rotating the tool about the longitudinal axis of its proximal portion.
Numerous modifications may, of course, be made to the apparatus and method disclosed above without departing from the scope of the present invention. Thus, for example, an alternative handle arrangement of the sort well known in the art could be provided for moving outer sheath 4 and inner rod 6 back and forth relative to one another.
Furthermore, it is anticipated that only one suture manipulating device 2 could be used to form the desired intracorporeal knot. In such a situation, the single suture manipulating device would function as the device 2R identified above, and the device 2L could be replaced by conventional forceps or other equivalent means to hold suture end 46' extended away from host tissue 50.
It is also anticipated that other forms of suture manipulating devices may be provided without departing from the scope of the present invention.
Thus, for example, the distal end of such an alternative suture manipulating device 102 is shown in FIG. 8. Suture manipulating device 102 is identical to the suture manipulating device 2 previously described, except as will hereinafter be discussed in detail. More specifically, suture manipulating device 102 has its outer sheath 104 formed out of a tube which is rigid along its entire length, and which has a helical or spiral portion 109 just proximal to its distal end 114. Helical portion 109 is formed so that its distal-most turn 109A will have its longitudinal axis 109B set at an acute angle (e.g. approximately 30 degrees) to the longitudinal axis of the sheath's proximal portion 112, whereby suture can be conveniently coiled about the distal end of sheath 104 when the straight proximal end of sheath 104 is rotated about its longitudinal axis. Helical portion 109 is formed so that the distal end of tool 102 can be passed through the interior passageway of a surgical cannula (shown in phantom as 200 in FIG. 8). Correspondingly, inner rod 106 has at least a portion of its distal end formed out of a flexible material so that inner rod 106 and outer sheath 104 can telescope relative to one another. More specifically, inner rod 106 has a flexible portion 123 set proximal to its distal portion 122 which extends along a sufficiently long portion of inner rod 106 to permit the rod to pass through the outer sheath's helical portion 109. On account of the construction, it will be seen that the inner rod's crochet-type hook 132 can be projected completely out of the sheath's distal end 114 so as to grapple a suture length disposed adjacent the distal end of the tool (in a manner analagous to that shown in FIGS. 4 and 4A), or it can be projected partly out of the sheath's distal end 114 so as to slidingly capture a suture length to the distal end of the tool (in a manner analagous to that shown in FIGS. 5 and 5A), or it can be withdrawn into the sheath's distal end so as to fixedly capture a suture length to the distal end of the tool (in a manner analagous to that shown in FIGS. 6 and 6A).
Suture manipulating device 102 is used in a manner generally analagous to the manner in which suture manipulating device 2 is used, except, of course, that the distal tip of suture manipulating device 102 does not articulate back and forth relative to the proximal portion of the device in the manner that the distal tip of suture manipulating device 2 does. However, in this respect, it will be appreciated that such articulation is provided in the case of suture manipulating device 2 so that the tool's distal tip can be set at an acute angle to the longitudinal axis of the tool's proximal end to facilitate coiling the suture about the exterior of the tool, and such articulation is not necessary in the case of suture manipulating device 102 since the distal tip of the device 102 is permanently set at an angle to the longitudinal axis of the tool's proximal end.
Another alternative suture manipulating device is shown in FIG. 9. More specifically, a suture manipulating device 302 is shown which is identical to the suture manipulating device 102, except as will hereinafeter be described in detail. More specifically, suture manipulating device 302 has a bent portion 309 just proximal to its distal end 314. Bent portion 309 is formed so that it has one or more permanent bends disposed in a two-dimensional plane (as opposed to the several permanent bends of tool 102 which are disposed in a three-dimensional sense), and so that its distal-most extension 309A will have its longitudinal axis 309B set at an acute angle (e.g. approximately 30 degrees) to the longitudinal axis of the sheath's proximal portion 312, whereby suture can be conveniently coiled about the distal end of sheath 304 when the straight proximal end 312 of sheath 304 is rotated about its longitudinal axis. Bent portion 309 is formed so that the distal end of tool 302 can be passed through the interior passageway of a surgical cannula (shown in phantom as 200 in FIG. 9). Correspondingly, inner rod 306 has at least a portion of its distal end formed out of a flexible material so that inner rod 306 and outer sheath 304 can telescope relative to one another. More specifically, inner rod 306 has a flexible portion 323 set proximal to its distal portion 322 and set distal to its proximal portion 326. Flexible portion 323 extends along a sufficiently long portion of rod 306 to permit the rod to pass through the outer sheath's bent portion 309. On account of this construction, it will be seen that the inner rod's crochet-type hook 332 can be projected completely out of the sheath's distal end 314 so as to grapple a suture length disposed adjacent the distal end of the tool (in a manner analagous to that shown in FIGS. 4 and 4A), or it can be projected partly out of the sheath's distal end 314 so as to slidingly capture a suture length to the distal end of the tool (in a manner analagous to that shown in FIGS. 5 and 5A), or it can be withdrawn into the sheath's distal end so as to fixedly capture a suture length to the distal end of the tool (in a manner analagous to that shown in FIGS. 6 and 6A).
Suture manipulating device 302 is used in the same manner as suture manipulating device 102.
These and other changes of their type are considered to be within the scope of the present invention.
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Apparatus and method for tying knots in suture at a interior surgical site. The apparatus comprises an elongated hollow member having a distal portion extending at an acute angle to the major longitudinal axis of the hollow member and terminating in a distal end surface, and a rod being partly flexible along its length and having a J-shaped hook at its distal end, wherein the hook is sized to grapple the suture which is to be manipulated by said device. The rod is received within the interior of the hollow member and adapted to reciprocate relative to the hollow member so that the hook can be moved between (i) an extended position wherein the mouth of the hook is spaced from the distal end surface of the hollow member by more than the thickness of the suture, whereby the suture can be grappled by the hook, (ii) an intermediate position wherein the mouth of the hook is spaced from the distal end surface of the hollow member by less than the thickness of the suture, but the interior base of the hook is spaced from the distal end surface of the hollow member by more than the thickness of the suture, whereby a suture grappled by the hook will be slidably captured to the hollow member, and (iii) a withdrawn position wherein the interior base of the hook is spaced from the distal end surface of the hollow member by less than the thickness of the suture, whereby a suture grappled by the hook will be fixedly captured to the hollow member.
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REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application, Ser. No. 697,286, filed on even date herewith, in the names of Ronald L. McAllister and John H. Freimuth, entitled Twine Wrapper with Spring Supplement for Round Bales.
BACKGROUND OF THE INVENTION
This invention relates to a machine for forming round bales of forage crops and, more particularly, to apparatus for wrapping a strand of binding twine in coiled fashion around a round bale between the opposite ends thereof, said apparatus having mechanism to effect roving of the binding twine around said bale as the bale is being rotated around a horizontal axis prior to discharging the same from the bale forming machine.
It has been the accepted and customary way to harvest and store forage crops for many years by mowing the crop in the field, permitting it to dry to a reasonable extent, forming it into windrows, and compacting the windrows into rectangular shapes of bales by conventional hay-baling machines of customary type. To store rectangular type bales, they must either be conveyed to a shed or barn and stacked, or if they are left in the field, they must be covered with waterproof coverings in order to provide means for shedding rain and other types of moisture in order to prevent the bales from rotting.
In recent years, an innovation has occured in the baling art in the form of machine which handles the windrows in a manner to coil the same into a relatively compact roll, usually of very substantial size and weighing many hundreds of pounds such as of the order of between one thousand and fifteen hundred pounds. One of the principal advantages of roll type bales of forage crops is that they may be much more readily stored as well as fed to herbivorous animals simply by letting the rolls lie on one side in a field or feed lot. In this condition, animals may readily feed upon such rolls until they are gradually consumed. In order to stabilize the rolls, it has become accepted practice to coil a strand of binding twine or the like circumferentially around the rolls and extend the same somewhat in spiral manner between opposite ends of the roll.
For purposes of illustrating typical types of machines for forming round bales, attention is directed to U.S. Pat. No. 3,815,345 that discloses a machine that has been highly successful in the formation of round bales. Also, for purposes of illustrating a typical type of apparatus for disposing a roving type strand of binding twine in spiral manner around a round bale, attention is directed to U.S. Pat. No. 3,910,178, to Eggers et al, and assigned to the assignee of the instant invention. In the latter machine, the application of the binding twine to the roll is at least in part effected manually by an operator sitting, for example, upon the seat of the tractor which propels the round bale forming machine along a field.
In addition to the aforementioned prior art patents, reference is also made to U.S. Pat. No. 3,913,473, to Meiers, dated Oct. 21, 1975 and in which roving of the binding twine is effected by hydrauically-actated mechanism which moves a twine directing arm substantially along a horizontal plane while distributing the twine from the outer end of the arm which moves in an arcuate path beween opposite sides of the bale forming machine.
One problem encountered in previously employed devices for applying a substantially spiral type strand of binding twine around a round bale of forage crop material has been the inability to furnish adequate tension to the twine as it is applied to the bale and particularly to achieve substantially even tension in the twine between opposite ends of the bale. Further, in manually operated twine applying devices, it has been found that when tractors, for example, of substantial horsepower and large size are employed to propel a round bale forming machine along a field, the seat for the operator either is enclosed within a cab or otherwise is sufficiently remote from the bale forming machine that it is difficult or even impossible for the operator to negotiate operation of manually operated means to effect the deployment of the binding twine around a round bale as produced in a round bale forming machine.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
It is the principle object of the present invention to provide in a round bale forming machine apparatus to dispose a strand of binding twine in substantially spiral manner around a round bale of forage crop material by means which is power operated and control of the power is effected from a substantially remote position relative to the apparatus on the bale forming machine and only the control means is actuated manually, whereby such control means may be readily disposed within a cab of a tractor or adjacent the seat which is positioned reasonably remote from the power means of the apparatus which deploys the strand of binding twine around a round bale.
Another object of the invention is to utilize in the twine applying apparatus a twine directing arm which is operated from an upstanding member adjacent the forward end of the bale forming machine, approximately midway between opposite sides of the machine and actuate said arm in a plane which is tilted somewhat forwardly at the top from the vertical, whereby the arm describes an arc which extends from one side of the machine, downwardly and then upwardly toward the opposite side of the machine, the actuating drive for the arm being effected by power means preferably comprising an electric motor and the control for the current delivered to the motor being operated by a manually actuated switch unit mounted adjacent the seat for the operator of the tractor which propels the bale forming machine along a field.
A further object of the invention is to employ speed reduction means associated with the drive shaft of the electric motor for purposes of not only decreasing the speed at which the twine distributing arm operates relative to the speed of the electric motor but also to permit the use of a relatively low horsepower motor which, for example, may be actuated by current supplied by a storage battery carried upon either the tractor or the bale forming machine.
Still another object of the invention is to employ limit switches operated by highly affective and reliable mechanism by which the electric motor is stopped when the outer end of the twine distributing arm respectively reaches one or the other of the sides of the bale forming machine and thereby prevent damage to the apparatus and mechanism.
Ancillary to the foregoing object, it is a related object to provide actuating means for the limit switches which is operated by a threaded shaft which is driven by the aforementioned reduction gear unit, said operating mechanism comprising a threaded sleeve having recesses spaced longitudinally therealong respectively to receive cam members associated with the limit switches, the position of the recesses being precisely located so as to allow for no over-travel of the twine distributing arm respectively adjacent the opposite sides of the machine.
One further object of the invention is to provide in the circuit between the control switch unit and the electric motor quick disconnect means, whereby when it is desired to disconnect the tractor from the baling machine, said circuit also readily may be disconnected in order that the operating means for the twine distributing arm on the baler may remain in its normal location thereon, while the control switch unit and/or the electric energy source, if carried by the tractor, may remain therewith after separation of the tractor from the baling machine.
Details of the foregoing objects and of the invention, as well as other objects thereof are set forth in the following specification and illustrated in the accompanying drawings comprising a part thereof.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation, partly in vertical section, taken along the line 1--1 of FIG. 2. and illustrating a typical machine for forming round bales and upon which the twine wrapping mechanism comprising the present invention is shown in operative position thereon.
FIG. 2 is a substantially front elevation of the bale forming machine shown in FIG. 1 but illustrated on a larger scale than employed therein, the outer portions of the mobile wheel and the upper portion of said machine being omitted in said figure to adapt it to the sheet, the twine directing arm of the wrapping mechanism being shown in one extreme position in full lines and in the opposite extreme position being illustrated in phantom.
FIG. 3 is a fragmentary, and partially sectioned enlarged view of the twine wrapping mechanism embodying the present invention, substantially as seen on the line 3--3 of FIG. 2.
FIG. 4 is a fragmentary, further enlarged side elevation of the driving mechanism for the twine directing arm, said view including the driving motor and speed reduction mechanism as well as the control means for the motor, substantially as viewed on the line 4--4 of FIG. 2.
FIG. 5 is a vertical sectional view of the gear type speed reduction unit which is directly associated with the motor, said view being taken on the line 5--5 of FIG. 4.
FIG. 6 is a fragmentary vertical elevation illustrating details of the limit switch arrangement employed in the control means for the motor of the apparatus, as seen on the line 6--6 of FIG. 4.
FIG. 7 is a horizontal sectional view showing details of the operation of the limit switch unit as seen on the line 7--7 of FIG. 6.
FIG. 8 is a diagrammatic plan view of the limit switch circuit and motor which is mounted on the baling machine and also showing the electric power and control means for the circuit such as carried by the tractor which propels the baling machine and illustrating a diagrammatic quick disconnect provided in said circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the round bale forming machine comprises a sturdy frame 10 which is supported in mobile fashion by a pair of wheels 12 respectively mounted on opposite sides of said frame. The frame 10 also includes a horizontal, transverse front beam 14 from which a tongue 16 projects forwardly for connection by means of a clevis 18 to a tractor, not shown. Illustrated in association with the tongue 16 is a telescoping type drive shaft 20 which is connected at its forward end to a p.t.o. unit of a conventional agricultural tractor of suitable size and power to propel the baling machine along a field for purposes of picking up a swath of dried or semi-dried agricultural crop material such as hay, alfalfa, clover, or otherwise, and coil it into a roll 22 of such product.
The swath of material is picked up at the forward end of the baling machine by rotatable pickup means 24 which delivers the swath to the upper flight of a bottom conveyor apron unit 26, the upper flight of which moves rearwardly as shown by the direction arrow in FIG. 1. Said swath is also engaged by an upper endless apron 28 which is of the type illustrated in said aforementioned U.S. Pat. No. 3,910,178 and consists of a pair of endless chains 30 between which a number of similar rigid, horizontal bars 32 extend as shown in FIG. 2, said bars being spaced apart in the direction of movement of the apron 28. Said apron moves in the direction of the arrows shown in FIG. 1, with respect thereto, whereby it will be seen that the innermost portion of the apron 28 is capable of expansion as the roll 22 of crop material expands in diameter. This is accomplished in a manner also described in detail in said aforementioned U.S. Pat. Nos. 3,910,178, the same being effected by the idler sprockets 34 and 36 being mounted upon arms capable of rotating about a supporting axis 38 which extends between and is supported by a pair of vertical frame members 40 which extend upward from the main frame 10 at opposite sides of the machine as can be seen from FIG. 2. Drive sprockets 42 and additional idler sprockets 44 are supported by curved frame members 46 which are connected at the opposite ends thereof to pivoted frame members 48 which are operated simultaneously by a pair of hydraulic cylinder units 50 when it is desired to discharge the completed roll 22 of crop material which occurs from the rearend of the machine which is at the right hand end as viewed in FIG. 1.
In order that the roll 22 of desired diameter may be stabilized when discharged from the baling machine, said machine is provided with a supply of twine or the like which is arranged in a compact ball stored in twine container 52. As viewed in FIG. 2, it will be seen that the outer end of the twine 54 extends from the container 52 to the inlet end of a pivotally mounted twine directing arm 56 and is discharged from the outer end 58 thereof, as also shown in exemplary manner in FIG. 2. During the formation of the roll 22 of crop material, the outer end of the twine 54 is held loosely substantially in the position shown in FIG. 1 with respect to said roll. Said outer end, under said circumstances, also will be adjacent one end of the roll as can be visualized from FIG. 2 where it will be seen that said outer end of the twine is disposed adjacent the right hand end of the machine as viewed in said figure. No substantial feeding of the twine will occur under such circumstances until it is desired to coil the twine around the completed roll 22 which occurs immediately before discharging the roll from the machine. When the coiling of the twine around the completed roll is to occur, the mechanism comprising the principal object of the present invention then is operated while the roll 22 is continuously rotated about its central horizontal axis through the power derived from drive shaft 20 that is connected to the p.t.o. of the tractor and, by means of suitable gearing, not shown, a drive shaft 60 is rotated to effect operation of various drive shafts connected with the lower and upper aprons 26 and 28 for purposes of actuating the same in the manner also described in detail in said aforementioned U.S. Pat. No. 3,190,178. Such continuous rotation of the roll 22 effects frictional contact with the outer end of the twine 54 in a manner to pull the twine from the twine directing arm 56, pivotal movement for roving operation thereof then being effected by the operator who is seated at that time upon the tractor, not shown. The operation initiates operation of the pivotal movement of the arm 56 by manually operating a switch handle 62, see FIG. 8, connected to a suitable double-throw switch 64, or the equivalent thereof, which is connected in a control circuit 66 shown at the left hand end of the diagrammatic layout in FIG. 8, said circuit continuing through a quick disconnect 68 and extends to an electric motor 70 which furnishes the motive power for oscillating the twine directing arm 56 through apparatus described in detail as follows.
Supported by the front beam 14 of the bale forming machine is an upstanding member 72 which is best shown in detail in FIG. 3. As will be seen from FIG. 2, the member 72 is substantially midway between the opposite sides of the bale forming machine but, in actuality, is lightly offset from the center due to the fact that the tongue 16 is actually disposed in the center of the machine and the member 72 is immediately adjacent one side thereof. An angular extension 74 is provided for purposes of supporting a short shaft 76 within an appropriate bearing and to which a circular disc 78 is fixedly connected to one end of said short shaft which is supported by said angular extension of said post-like upstanding member 72. Said disc comprising mounting means for the tubular twine directing arm 56. As clearly shown in FIG. 3, a pair of clamping hasps 80 extend around the tube 56 adjacent one end thereof and conventional bolts tightly clamp the tube to the mounting disc 78. The periphery of the disc 78 also is grooved for purposes of receiving an endless, flexible driving cable 82, said cable also engaging a pair of idler pulleys 84, one of which is clearly shown in FIG. 3, said pulleys being for purposes of changing the direction of the cable 82 in order that the lower portion 82' may extend for a number of convolutions around a small diameter drivng hub 86.
The purpose of the angular offset or extension 74 of the upstanding member 72 is to dispose the supporting disc 78 and twine directing arm 56 within a plane which slopes downward and rearward from the vertical as can best be seen in FIGS. 1 and 3. Considering this in conjuction with the opposite, extreme positions of the outer end 58 of the distributing arm 56 as shown in FIG. 2, it has been found that such an arrangement affords desired efficiency with respect to tensioning the twine 54 as it is spirally extended around the completed roll of crop material 22 due to the roving action of the twine directing arm 56 as it oscillates from one extreme position to the other. From FIG. 2, it also will be seen that the full line extreme position of the arm 56 is closer to the horizontal than the phantom position thereof shown adjacent the left hand side of the machine as seen in FIG. 2. This is due to the offset of the upstanding post member 72, the necessity for which is explained hereinabove.
DRIVE MECHANISM FOR TWINE positioning ARM
As referred to hereinabove, one of the principal purposes of the present invention is to provide drive means for the twine distributing arm 56 capable of being controlled from a relatively remote position with respect to the roll forming machine and particularly under circumstances where, for example, the actuating means for the control unit is mounted in a cab on a tractor or otherwise is positioned in a way where it is either not possible or highly inconvenient to actuate the oscillation of the twine directing arm 56 by such manually operable means disclosed in said aformentioned U.S. Pat. No. 3,910,178. At the present time, most agricultural tractors of modern design include a storage battery, especially for purposes of operating starting mechanisms for the engine of the tractor. Accordingly, it is one aspect of the present invention to employ an electric motor 70 to effect oscillating movement of the directing arm 56. Details of the drive mechanism actuated by the electric motor 70 are as follows.
Attention is primarily directed to FIGS. 3-8 in which details of the drive mechanism are shown suitable scale to readily comprehend the same. In FIG. 3, it will be seen that diagrammatically illustrated housing 88 encloses the drive mechanism. Two speed reduction units are employed in this mechanism. The first speed reduction unit comprises a circular mounting disc 78 which is of a far greater diameter than the small driving hub 86 around which the lower portion 82' of the cable 82 extends for a limited number of convolutions to provide adequate driving friction between hub 86 and the cable. Hub 86 is driven by the drive shaft 90 which extends through bearing 92 and 94. Drive shaft 90 is driven by a gear type speed reduction unit 96 which comprises the second speed reduction unit referred to above. Said unit is enclosed within an appropriate housing and includes, in addition to shaft 90, an idler shaft 98 and a drive shaft 100. The drive shaft 100 is connected by means of a flexible coupling 102 shown in FIG. 4 directly to one end of the motor shaft 104.
Mounted upon shaft 100 is a small diameter, preferably helical spur gear 106 which meshes with a larger diameter gear 108 which has teeth complementary to those on spur gear 106. These meshing gears drive the shaft 98 upon which is mounted another spur gear 110 of relatively small diameter which meshes with a driven gear 112 of much greater diameter than spur gear 110, driven gear 112 being connected to shaft 90. As a result of said gearing, the speed of rotation of shaft 90, which drives the hub 86 is far less than that of the motor shaft 104 and, due to the first mentioned speed reduction unit comprising disc 78 and driving hub 86, the speed of oscillation of the twine direction arm 56 is sufficiently slow that sucessive convolutions of the twine around the round bale 22, especially in relation to the speed of rotation of said bale, are spaced axially apart appropriate distances, such as of the order of six or eight inches to one foot or more, as required in accordance with the type of material and the degree to which the binding of the bale is desired.
The limit of movement of the outer end 58 of the twine directing arm 56 is controlled by suitable electrical means comprising a pair of limit switches 114 and 116 which are connected in the circuit 118 to the motor 70 as shown in FIG. 8. Said circuit is also innerconnected to the control circuit 66 in which the double throw switch 64 is connected by means of the quick disconnect 68. The circuit 66 also includes an energy source such as a storage battery 120 of the type normally embodied in a modern tractor of the size and power capable of propelling the bale forming machine. Said circuit also preferably includes an overload breaker 122. Without describing each individual circuit conductor of the circuits 66 and 118, the paths of which are obvious from FIG. 8, it is believed to be sufficient to state that when the doublethrow type switch handle 62 is thrown in one direction, it will energize the motor 70 to operate in one direction, and in view of the fact that said motor is of the reversible type, when the handle 62 is thrown in the opposite direction, the first circuit is broken and a second circuit is established to cause the motor 70 to operate in the reverse direction to the first one described. Accordingly, from this, it will be seen that the operation of the twine directing arm is effected to move the outer end thereof from one side of the bale forming machine toward the other when the switch is closed in one direction, whereas a reverse traverse of the arm 56 is effected by closing the switch in the opposite direction. The limit of movement of the outer end of the arm 56 in either direction respectively is controlled by operation of the limit switchs 114 and 116.
The limit switchs 114 and 116 preferably are of the type having an operating plunger which is spring pressed radially inward toward the axis of the screw threaded shaft 124 which is co-axial with and is fixedly connected to drive shaft 90 through an appropriate coupling 126 shown in FIG. 4.
A limit switch actuating member 128 is internally threaded to receive the threaded shaft 124 as is best shown in FIG. 7. The member 128 also is axially movable within a housing 130 which is mounted adjacent the motor 70 and is supported within the housing 88 by an appropriate pair of threaded bolts 132. The acuating member 128, for example, is cylindrical and is slidable within a mating bore in the housing 130. To prevent rotation between the two, a coacting spline and key 134 is provided between the housing and actuating member.
The switch actuating member 128 is provided respectively on opposite ends thereof with recesses or flats 136 and 138. These are provided for purposes of accommodating intermediate actuating members 140 and 142 which specifically comprise hardened balls such as those used in ball bearings which respectively are seated on the inner ends of the switch-actuating plungers of limit switches 114 and 116. Hence, when the control switch 64 is closed at one end to actuate the twine directing arm 56 in one direction, the actuating member 128 will be moved axially in one direction until one of the recesses 136 or 138 is disposed opposite one of the balls 140 or 142 which will then drop into the appropriate recess and open that particular limit switch to which it is connected. Conversely, when the twine directing arm 56 is to be moved in the opposite direction, so as to restore the outer end thereof to the initial starting position, at which time the twine is severed, the control switch 64 is closed at the opposite end to interrupt the first circuit and establish a second circuit which will cause the actuating member 128 to move in the opposite axial direction until the other recess 136 or 138 is disposed opposite the other ball 140 or 142, at which time said ball will drop into the recess and open the opposite limit switch 114 or 116 and thereby stop any further movement of the arm 56.
In the preferred operation of applying the binding twine to a completed round bale, the twine directing arm moves from its initial position shown in full lines in FIG. 2 arcuately to the opposite extreme position shown in phantom in said figure and then returns from the latter position to said initial position, at which time the twine is then severed by knife means, not shown. One type of suitable knife means is shown in said aforementioned U.S. Pat. No. 3,910,178 and such knife may be employed in the present invention.
If desired, and in view of the fact that in the preferred operation of the twine directing arm 56, the initial arcuate excursion of the arm 56 moves the outer end 58 thereof from adjacent one side of the machine to the other and then stops such movement by actuation of one of the limit switchs 114 or 116, followed by shifting of the control switch 64 to effect the return excursion to the initial starting position, it is conceivable within the purview of the present invention that twine severing and knife means may be mounted respectively adjacent opposite sides of the bale forming machine, if desired.
For purposes of facilitating the imposition of adequate tension upon the outer end 58 of the twine directing arm 56 as said outer end approaches the limit of outward movement respectively toward opposite sides of the machine, whereby substantially uniform tension may be applied to the twine being dispensed from said arm during the entire excursion of the outer end thereof between opposite sides of the bale 22, attention is directed particularly to FIGS. 2 and 3 in which it will be seen that a bracket 144 is attached at one end to the uppermost portion of angular extension 74 of upstanding member 72 as shown in FIG. 3, said bracket being curved to provide an opposite end to which a small anchor plate 146 is connected, the same having an aperture receiving one hooked end of a relatively strong, tension spring 148. The opposite end of said tension spring is connected to an eyebolt 150 which is clamped by means of a U-bolt 152 to the twine directing arm 56 intermediately thereof between the outer end 58 and the pivotal axis of the arm provided by shaft 76. By reason of the fact that the upper, anchored end of spring 148 is spaced vertically above the pivotal axis comprising shaft 76, substantial assisting supplemental force is applied to the distributing arm 56 to move the outer end 58 thereof toward one or the other of its extreme positions respectively adjacent opposite sides of the machine and thereby provides additional torque to said arm for purposes of supplementing the drive force of the motor under conditions where twine 58 is being wrapped around the outer end portions of the round bale 22.
From FIG. 3, it also will be seen that the curved arrangement of bracket 144 disposes the spring 148 out of any conflict with the movement of the pivoted end of arm 56 and the supporting disc 78. Also, in the preferred arrangement, spring 148 is under tension in all positions of the arm 56 and particularly as the arm 56 approaches its opposite extreme positions between the sides of the machine. Further, the tension provided by spring 148 may be adjusted due to the fact that the U-bolt 152 may be firmly clamped to the arm 56 at any desired location longitudinally along the arm, whereby the added torque furnished to arm 56 by spring 148 may be varied, as desired.
Further, from FIG. 2, it will be seen that as the outer end of arm 56 is moved toward the extreme, adjacent the right hand side of the machine, the arm will be closer to the horizontal than when it is in the extreme left hand position shown in phantom in FIG. 2. Therefore, it is in regard to movement of the outer end of the arm 56 toward the right hand position viewed in FIG. 2 that the added torque afforded by spring 148 is most needed and during such movement of the arm to the right hand extreme position, the spring 148 will progressively be contracted but the added torque afforded by the spring under such circumstances is fully adequate to supplement the driving force provided by motor 70 and thereby prevents placing any undue burden upon the motor, whereby a motor of only limited horsepower may be used and particularly a motor which is capable of being energized by a storage battery such as one normally provided in a tractor of the type which propels the bale forming machine which embodies the present invention along a field.
The foregoing description illustrates preferred embodiments of the invention. However, the concepts employed may, based upon such description, be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly, as well as in the specific forms shown herein.
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Apparatus on a round bale forming machine for wrapping a strand of binding twine around a round bale of crop material prior to discharging said bale from the machine and including a movable strand directing arm to effect roving of said strand as applied to a bale. Electrically operated power means are connected to said arm to effect movement of the outer end thereof between opposite ends of said bale and control means for said power operated means are mounted remotely therefrom such as adjacent the seat of an operator on a tractor connected disengageably from said bale forming machine.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 102013014571.6 filed Sep. 2, 2013 which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The technical field relates to a hand brake device for a vehicle, which encompasses an electric actuator for activating a brake, an operating element that can be moved between a brake position and release position, and a control unit for triggering the actuator according to the position of the operating element.
BACKGROUND
[0003] Such a hand brake device is known from EP 1 655 190 A1. While the brake is electrically activated in this conventional hand brake device, the operating element resembles the lever in a conventional, purely mechanical hand brake device. The hand brake exhibits a handle to be gripped by the user, and can be locked in a brake position by having a latch engage into a toothed rack. However, while the position of the brake lever in the conventional mechanical hand brake is clearly correlated with the status of the brake, i.e., tightened or released, and the user can read the status of the brake by the position of the lever, there is no such clear correlation for the hand brake device according to EP 1 655 190 A1. When a user pulls up the brake lever, he or she can lock it into the brake position, but if the onboard electrical system of the vehicle is turned off, the actuator cannot respond to lever activation and tighten the brake. In this circumstance, the position of the lever may give the driver the impression that the hand brake device has been activated, when in reality it has not.
SUMMARY
[0004] In accordance with the present disclosure a hand brake device for a vehicle is provided with a brake to be activated by an electric actuator, in which the status of the brake can be reliably read from the position of an operating element.
[0005] In an embodiment of the present disclosure, a hand brake device for a vehicle is disclosed with an electric actuator for activating a brake and an operating element that can be moved between a brake position and release position. A control unit triggers the actuator according to the position of the operating element by having the control unit control a locking device for locking the operating element in the brake position according to the position of the operating element. Since the control unit determines and knows the status of the actuator, it can easily ensure that the position of the operating element correlates with the status of the brake.
[0006] One way to ensure this correlation can be for the control unit to release the operating element locked in the brake position when the actuator has failed to tighten the brake. In particular, this allows it to lock the operating element right away once it has been shifted into the brake position by the driver. The driver can then let go of the operating element even if the actuator has not yet completely tightened the brake, and allow the control unit control the movement of the actuator until it reaches a position corresponding to the operating element position. If the brake has been successfully tightened, the operating element stays in the brake position, and if it has not, for example because the actuator fails to perform an envisaged positioning movement within a prescribed period of time, the operating element is again released, and can return to the release position.
[0007] As an alternative, it can be provided that the control unit locks the operating element in the brake position after the actuator has tightened the brake.
[0008] In order to ensure that the operating element returns to the release position quickly and reliably, a return element, in particular a return spring, can be provided that acts on the operating element in the direction of its release position.
[0009] In order to be able to easily release the brake, it should be possible to manually undo the operating element locked by the locking device. As depicted in EP 1 655 1990 A1, such a locking device can encompass a latch that interacts with a toothed rack. This type of latch can be engaged with the toothed rack via an electric actuator in order to lock the operating element in the brake position, and disengaged from the toothed rack by swiveling the operating element beyond the brake position.
[0010] In one preferred embodiment, the locking device encompasses a brake pad, which when locked frictionally abuts against the operating element. As a result, a user can release the brake just by overcoming the friction between the operating element and brake pad to move the latter back into its release position.
[0011] A user can determine if a brake was successfully tightened by whether the operating element, once released, remains in the brake position or returns to the release position. If the user lets go of the operating element before the actuator has had the time to tighten the brake, and the operating element returns to the release position, it makes sense for the actuator to cease tightening the brake, and move the latter back into the released position. The user must then activate the operating element again, and wait until such time as the actuator has successfully tightened the brake. So as not to lose time by letting go of the operating element too early, it can be provided that the control unit delivers a confirmation to the user once the actuator has tightened the brake. Such a confirmation can take the form of an optical or acoustic signal, but can also be a haptic type, wherein in particular the operating element can be moved by the locking process, and the user holding the operating element in the brake position can feel its movement. This type of haptic feedback can be provided without the need for any additional components, as explained below based upon exemplary embodiments.
[0012] The operating element can be a lever that can be swiveled around an axis between the brake position and release position. In such a lever, the movement by the operating element caused by the locking process can be in particular a translation, preferably transverse to the lever axis.
[0013] Since the force required to tighten the brake is applied by the actuator, and need not be exerted by the user, the lever of the hand brake device according to the present disclosure can be considerably smaller than a conventional hand brake lever. In particular, this makes it possible to embed the lever in a space-saving manner in a plate, especially in a dashboard, the wall of an interior lining of the passenger compartment or the like.
[0014] Because the lever exhibits a flank that is aligned with the plate in a selected brake position or release position, preferably in the release position, the respective other, misaligned position is easily and reliably detected, so that a user can smoothly read the status of the hand brake device. In particular, the lever can be mounted on a location inside the passenger compartment visible through a window of the vehicle, allowing the user to verify the status of the hand brake as needed, without having to open the vehicle.
[0015] In order to make the lever easier to handle, a trough can be molded into the plate, accommodating the lever in the aforementioned selected position and extending beyond an axial end of the lever, which enables the user to reach into the trough and pull out the lever. The width of the trough in the axial direction preferably does not exceed 4 cm, and is in practice dimensioned sufficiently to offer space for precisely one finger of the user.
[0016] The lever can be arranged on a center console or transmission tunnel of the vehicle. Since it requires significantly less space there than the lever of a conventional mechanical hand brake device, there can be space next to the lever for another operating element or a storage compartment, especially if the lever is eccentrically arranged on the center console or transmission tunnel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.
[0018] FIG. 1 is a view depicting the lever of a hand brake device according to the present disclosure, built into the central console of a vehicle;
[0019] FIG. 2 is a schematic section through the lever and its environment; and
[0020] FIG. 3 is a section similar to FIG. 2 according to a second configuration.
DETAILED DESCRIPTION
[0021] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0022] FIG. 1 shows a perspective view of a cutout from the center console of an automobile. Molded into a plate 1 on the upper side of the center console next to an edge 2 of the latter adjacent to the driver's seat is a trough 3 , whose width in the transverse direction of the vehicle is somewhat larger than that of a human finger, e.g., measuring 2 cm, and whose extension in the longitudinal direction corresponds to roughly the length of two finger digits, approx. 5 cm. A lever 4 is pivoted around an axis extending in the transverse direction of the vehicle (not shown on the figure) in a rearward area of the trough 3 relative to the longitudinal direction of the vehicle.
[0023] A larger depression 5 only partially visible on FIG. 1 is tightened in the plate 1 on the side of the trough 3 facing the passenger, e.g., which can be used as a beverage holder.
[0024] FIG. 2 presents a schematic section through the lever 4 and its environment according to a first embodiment of the present disclosure. The lever 4 shown in FIG. 2 is depicted in two positions, one a release position denoted by a solid outline, and the other a brake position denoted by a dashed outline. An upper side of the lever 4 is aligned flush with the enveloping plate 1 in the release position. The swiveling axis of the lever 4 is established by the axle journals 6 protruding from either side of the lever 4 , which are held in lateral walls 7 of the trough extending essentially parallel to the sectional plane.
[0025] An electrical contact 8 is coupled to one of these axle journals 6 below the plate 1 . Together with a fixed contact 9 , it forms an electrical switch that closes with the lever 4 in the brake position. The closing process is detected by a logic circuit 10 , and prompts the latter to supply battery voltage to a first actuator, here an electric motor 11 . The rotation of the electric motor 11 drives a toothed rod 12 , which is coupled to a brake of the vehicle (not shown), and tightens it. Once the brake has reached a sufficiently tightened position, another switch formed by a fixed contact 13 and a contact 14 that can move with the toothed rod 12 closes, after which the logic circuit 10 stops supplying voltage to the electric motor 11 , and outputs a switching pulse to a second actuator 15 for it to extend a latch 16 .
[0026] In the extended position, the latch 16 engages into a tooth system of the lever 4 . Since the deepest points of notches 17 in the tooth system and the tip of the latch 16 do not lie precisely opposite each other when extending the latch 16 , the latch 16 in general exerts a torque on the lever 4 while moving into the notches 17 that can be felt by the user, and tells him or her that the brake is tightened, and that the lever 4 has been locked in the brake position. The lever 4 can now be released, and its position visibly indicates that the brake has been tightened.
[0027] As an alternative, the logic circuit 10 can already start extending the latch 16 as soon as the contacts 8 , 9 touch each other, so as to already lock the lever 4 in the brake position while the electric motor 1 is in the process of displacing the toothed rod 12 . As a result, the driver is given a chance to quickly release the lever 4 again even before the brake has actually been tightened. If the contacts 13 , 14 fail to close within a prescribed period of time after the contacts 8 , 9 have closed, the logic circuit 10 assumes from this that a malfunction has occurred, and retracts the latch 16 once again. Driven by the spring 18 , the lever 4 thereupon returns to the release position, allowing the driver to see that the brake has not been tightened.
[0028] If the axle journals 6 of the lever 4 have been mounted in the walls 7 with a radial clearance, the latch 16 hitting the lever 4 can also cause a slight translation by the lever 4 perpendicular to its swiveling axis within the framework of this clearance that is perceptible to the user.
[0029] By contrast, if the driver lets go of the lever 4 before the latch 16 has been extended, a spring 18 drives the lever 4 back into the release position that is essentially flush with the surface of the plate 1 , the contacts 8 , 9 separate from each other, and the movable contact 8 reaches a second fixed contact 19 in the release position, after which the logic circuit 10 powers the electric motor 11 with the opposite rotational direction until the toothed rod 12 has reached a stop position (not depicted on the figure) in which the brake is completely released.
[0030] In the embodiment shown in FIG. 2 , the user must pull the lever 4 up beyond the brake position to thereby force the latch 16 out of the notch 17 in order to again release the tightened brake. He or she can then let go of the lever 4 , and the spring 18 pulls it back into the release position. The logic circuit 10 in turn responds to the contact between the contacts 8 , 19 by powering the electric motor 11 , so that it displaces the toothed rod 12 into the released position of the brake.
[0031] The embodiment shown in FIG. 3 differs from the one illustrated in FIG. 2 essentially by the type of locking device used to lock the lever 4 in the brake position. While the latter includes the actuator 15 , latch 16 and notches 17 of the lever 4 interacting therewith in the embodiment on FIG. 2 , it also includes a friction body 20 with an allocated actuator 21 in the embodiment on FIG. 3 . In the case being considered here, the actuator 21 is an electric motor, and the friction body 20 is a disk that is eccentrically mounted on the shaft of the electric motor, and can be turned by the latter into a position frictionally touching the lever 4 , marked on FIG. 3 as a dashed outline. The rotatable friction body 20 could also be replaced by a friction body that can move radially to the axis of the lever like the latch 16 , or by a tongue with two brake pads, which are moved axially toward the lever 4 to lock the lever 4 , clamping the latter between them.
[0032] In this embodiment as well, the logic circuit 10 responds to a swiveling by the lever 4 into the brake position and a closing of the contacts 8 , 9 by powering the motor 11 so as to tighten the brake. Once the brake has been tightened and the contacts 13 , 14 have closed, the logic circuit 10 in a first variant activates the actuator 21 so as to press the friction body 20 against the lever 4 . In the position depicted as a dashed outline, the friction body 20 blocks the lever 4 from turning counterclockwise.
[0033] In a second variant, the logic circuit 10 activates the actuator 21 as soon as the contacts 8 , 9 touch each other, so as to thereby lock the lever 4 , but undoes the lock if the contacts 13 , 14 fail to touch each other within a prescribed period of time.
[0034] The following applies to both embodiments: When the user presses the lever 4 back into the release position, this also turns the friction body 20 away from the lever 4 , and the diminished friction allows the spring 18 to pull back the lever 4 into the release position.
[0035] As described above with reference to FIG. 2 , locking the lever 4 can cause a translation of the lever 4 perpendicular to its swiveling axis that is perceptible to the user within the framework of a clearance between the axle journal 6 and the openings in the wall 7 accommodating it. In addition, a marked torque in the direction of the swiveling axis can act on the lever 4 .
[0036] Instead of discrete contacts 8 , 9 or 13 , 14 that each close in precisely one defined position of the lever 4 or toothed rod 11 , a further development can also provide quantitative sensors for detecting a rotational angle of the lever 4 or the displacement of the toothed rod 12 , and the logic circuit 10 can be set up to determine the position of the toothed rod 12 in which it regards the brake has having been successfully tightened and shuts off the electric motor 10 based on the acquired displacement of the lever 4 . This allows the user to shorten the time needed to tighten the hand brake when parking on a slightly sloped surface by selecting only a slight displacement of the lever 4 in this case.
[0037] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment is only an example, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.
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A hand brake device for a vehicle includes an electric actuator for activating a brake and an operating element that can be moved between a brake position and release position. A control unit triggers the actuator according to the position of the operating element. A locking device for locking the operating element in the brake position is controlled by the control unit.
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BACKGROUND
[0001] This invention relates to dehumidification and cooling in an enclosed area, in particular, a method and system for climate control in a motorized vehicle.
BACKGROUND OF THE INVENTION—DESCRIPTION OF PRIOR ART
[0002] This invention relates to dehumidification and cooling in an enclosed area, in particular, a method and system for climate control in a motorized vehicle. There exists a strong need for dehumidification in the enclosed area of a motor vehicle; for safety reasons, i.e. the windshield can fog up during high humidity conditions, resulting in reduced driver visibility; comfort of the passengers; and if the humidity of the cabin can be lowered by thermally activated means, the compressor power consumption and the size of the direct expansion (DX) air-conditioning system can be reduced. If the load on the DX system is reduced through addition of a light component (i.e. a small desiccant rotor), the benefits include; fuel savings, reduced shaft horsepower required to operate the compressor, and possibly weight reduction. With such potential benefits, a design study of such a system is warranted.
[0003] Different methods of systems to dehumidify and cool air in motor vehicles have been previously described. U.S. 2002/0002833 A1 describes an A/C system including an evaporator, a desiccant dryer (located downstream of the evaporator, and a compressor fluidly connected to the evaporator.) The desiccant dehumidifier in this system is of the carousel type. This patent explicitly states that the only sufficient heat source existing in a motorized vehicle for the regeneration of the desiccant is from the engine exhaust air, and states that this heat source is undesirable due to safety reasons. The safety concerns are founded: If the catalytic converter and the seals separating the process and regeneration air on the desiccant dryer were to simultaneously fail, the result would be unburned hydrocarbons and carbon monoxide entering the cabin. However, the statement that this is the only sufficient heat source is not true for U.S. 2002/0002833 A1 or for the present invention due to the configuration of these systems. The other sufficient sources of regeneration heat for systems of these configurations (desiccant dryer downstream of evaporator) are the engine coolant leaving the engine block (185-200 deg F.) and the hot air leaving the radiator (estimated to be approximately 130 deg F.). These sources of heat, while unacceptable for systems requiring regeneration temperatures in excess of 200 deg F. (where the desiccant dryer is upstream of the evaporator), are acceptable for U.S. 2002/0002833 A1 or for the present invention since the regeneration temperature requirements are estimated to be approximately 100-130 deg F.
[0004] U.S. 2002/0092419 A1 describes an air desiccant system for climate control in a motor vehicle. This system uses a vacuum method for desiccant regeneration. The desiccant dryer in this system is of the cartridge type. The only heat source that this patent mentions in a motorized vehicle for the regeneration of the desiccant is from the exhaust, and states that this heat source is undesirable. This patent overlooks the other sources of heat for desiccant regeneration, as previously stated. Furthermore, there are disadvantages to using a vacuum for the regeneration of the desiccant. They will be presented in the following paragraph.
[0005] In any desiccant system that uses low pressure regeneration air and ambient pressure process air, the seals that separate the process side from the regeneration side have to be very sturdy, well-mated to the dryer face and also wear resistant over time. If the seals don't have these characteristics then the potential exists for unacceptable amounts of higher ambient pressure air to leak into the low pressure regeneration side. In other words, there has to be an excellent seal mating or the desiccant performance will suffer adversely.
[0006] Another disadvantage of the vacuum from engine method is that such a system will require redesign of the engine's intake manifold in order to gain access to the required low pressure air.
[0007] U.S. Pat. No. 5,514,035 describes a desiccant based windshield defog system including an evaporator, a desiccant dryer (located upstream of the evaporator), and a compressor fluidly connected to the evaporator. The desiccant dryer in this proposed system is a rotor. This system is not optimized because the desiccant dryer is located upstream of the evaporator. A model was developed to simulate these systems and identify the optimum configuration. The results are shown in FIG. 1 . FIG. 1 shows that the compressor power consumption reduction is overall larger and more uniform when the desiccant dryer is placed after the evaporating coil.
BRIEF SUMMARY OF THE INVENTION
[0008] This invention presents a method and apparatus for dehumidification and cooling in an enclosed area. In particular, it is a method and system for climate control in a motorized vehicle. The air conditioning system includes an evaporator and desiccant dryer located downstream of the evaporator, and a compressor fluidly connected to the evaporator. The desiccant dryer in this system is of the rotor type, and the heat source used to regenerate the desiccant is the excess heat generated by the motor. The engine heat can be used to regenerate the desiccant by one of the following 3 methods:
1. Hot air coming off the radiator routed directly into the rotor housing (approx. 130 deg F.) 2. Engine coolant, exiting the engine block (approx 190 deg F.), routed to a liquid-to-air heat exchanger to heat the regeneration air. 3. Hot engine exhaust, after catalytic conversion, routed to an air-to-air heat exchanger.
[0012] The advantages of this system include:
1. As FIG. 1 shows, placing the desiccant rotor upstream of the evaporator will not necessarily reduce shaft power to the compressor. But for the present invention, electric energy requirements are uniformly displaced with “free” thermal energy requirements. Thus the cooling efficiency, measured by electric power consumption, is higher. 2. The present invention is simple, and reduces compressor power consumption and cooling load on the evaporator. Reduced cooling load on the evaporator means that compressor, condenser and evaporator coils will be smaller and lighter. Note that the desiccant rotor itself is very light, weighing on the order of two pounds. Some additional fan power to drive process and regeneration air through the desiccant dryer is required, but this amount is more than offset by the reduced power consumption of the compressor. 3. The temperature method of desiccant regeneration provides a simpler, less problematic solution to desiccant regeneration than the vacuum method: The sealing system will be less expensive and require little or no maintenance. In addition, upon failure, the system performance changes are expected to be small since the similar pressures on the process and regeneration side will result in minimal leakage rates. 4. In contrast with the systems where the desiccant rotor is upstream of the evaporator, there is sufficient excess heat produced in a motor vehicle for the present invention. 5. If the system is so designed, the additional dehumidification capability provided by the desiccant rotor will improve comfort to the passengers and the defog capacity of the air-conditioning system.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 2 depicts the preferred embodiment of the invention.
REFERENCE NUMERALS IN DRAWINGS
[0019]
11 —Intake air (from cabin or ambient)
12 —After filter and fan, entering evaporator coil
13 —Leaving evaporator coil, entering desiccant rotor
14 —Leaving evaporator coil (to cabin)
15 —Regeneration air inlet
16 —Regeneration air outlet
17 —Discharge air
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 2 is an illustration of the configuration of the invention where the desiccant rotor is downstream of the evaporator coil. The air being processed passes through the filter, the fan, and the evaporator coil where the air is cooled and dehumidified, then through the desiccant rotor where the air is dried and heated.
[0027] An analysis was performed on the configuration of this invention (evap-rotor) vs. a configuration where the desiccant is placed upstream of the evaporator (rotor-evap).
[0028] A model developed by Chant and Jeter (1995) for rotary desiccant wheels was used to simulate the desiccant rotor. In addition to the validation performed on the model described in the paper, the model was adapted to the Engelhard HexCore rotor and validated with data collected at the National Renewable Energy Laboratory in 1998. The model's latent capacity predictions for HexCore's hexagonal passage, Nomex core coated with titanium silicate desiccant were within +/−10% and the outlet dry bulb agreement followed the latent agreement. The model was used in the HexCore selection software until Engelhard Corporation closed the HexCore business in 2001. Since then, the model has been adapted by NovelAire technologies for design work and eventual integration into their selection software for their wound silica gel and molecular sieve series desiccant rotors. The model's predictions for Novelaire's rotor were also validated with NREL data and gave agreement of latent capacity errors between +/−10%. The NREL data is confidential.
[0029] Two rotor-evaporator coil configurations were under study. For each system, the rotor type, size and operating conditions were selected. These design selections are merely typical operating conditions for commercial desiccant wheels, with no optimization involved. The source of regeneration air is not addressed.
[0030] For the performance calculations included in this report, the inlet air state was constant at 95 deg F., while the inlet humidity was varied (117, 100, 80, and 67 grns/lb). For each of the four inlet humidities considered, the integrated systems were operated to supply 70 deg F., 60 grns/lb air to the cabin. The vapor compression system's capacity and the desiccant rotor's regeneration temperature and wheel speed were varied to produce the desired supply condition. Thus the performance calculations were performed for a constant sensible load and varying latent load. This approach was used in order to produce some parametric results with which to demonstrate the systems' characteristics.
[0031] In the case of the Rotor-evap system, the rotor was operated to remove the entire latent load, while the DX system performed only the sensible cooling. Thus the latent and sensible loads are handled independently. The VC system must remove the original sensible load plus the heat of adsorption. For Case 1—where the ambient humidity is 1117 grns/lb—this sensible load on the DX system is greater than the conventional system load and DX system tonnage required is more than the conventional system. Thus the Rotor-evap system will result in increased power consumption during periods of high humidity. Note that this is a typical summer operating condition for many regions of the United States, such as the entire East Coast and much of the Midwest. FIG. 3 shows a psychrometric plot for the rotor-evap system.
[0032] The rotor in the Evap-rotor system serves to handle a portion of the latent load, heating the air in the process and eliminating the need for reheat. The desiccant rotor's capacity increases with process inlet relative humidity, so the desiccant rotor's performance is well served by this configuration. The VC system was operated in each case to bring the air to a 58.5 deg F. dew point. The desiccant rotor's capacity was roughly constant since it was bringing the air from 58.5 deg F., 71 grns/lb to 70 deg F., 60 grns/lb. FIG. 4 shows a psychrometric plot for the rotor-evap system.
[0033] A rotor comprised of silica gel desiccant in a high temperature fiber substrate, was simulated. The rotor is 12 inches in diameter, and 4 (Evap-rotor system) or 6 (Rotor-evap system) inches deep. The wheel's rotation speed is between 12 and 45 revs/hour. A 50/50 face split, balanced flow design was used. The particular rotor simulated, excluding the housing, is estimated to be 2 to 3 lbs. However, there are similarly performing, light-weight rotors that could be evaluated for this application which would weigh about 1 lb. The regeneration temperature ranged from 110 to 205 deg F. In an actual installed system, these parameters would not be varied, but set at design time to handle a pre-defined extreme load. The system components would then be cycled as needed during part-load conditions.
[0034] Evaporator performance was estimated based on “typical” cooling coil performance. Latent cooling was initiated at about 80% RH.
[0035] The latent capacity (amount of dehumidification cooling performed) characteristics of a desiccant rotor as a function of regeneration temperature and relative humidity are shown in FIG. 5 . FIG. 5 shows that the latent capacity of the rotor increases with increasing regeneration temperature and increasing process inlet relative humidity. For the system where the rotor is upstream of the evaporator, the rotor will need high capacity (in order to handle the entire latent load) and will be processing air at moderate relative humidities. Thus such a system, using thermal reactivation, requires regeneration temperature in the range of 220 deg F. This quality of thermal energy is only available from the engine's exhaust air. In the case of the system where the rotor is downstream of the evaporator and only handling a portion of the latent load, the rotor requires only moderate capacity and—since it is downstream of the evaporator—is processing nearly saturated air.
[0036] Thus results of the analysis completed so far have shown that the current invention is a good match with the low grade, safe thermal energy available from the engine coolant and radiator exhaust air. The results also indicate that compressor power consumption reduction is higher and more uniform when the desiccant dryer is placed after the evaporating coil.
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An air-conditioning system for a cabin of a motorized vehicle comprising of an evaporator and desiccant, where said desiccant is downstream of evaporator, and said desiccant is a rotor that uses nearby excess heat to regenerate the desiccant.
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This invention relates to a method of and apparatus for detecting and measuring low levels of chloride, sulfate, phosphate and nitrate in high pressure feedwater at atmospheric boiling temperatures.
BACKGROUND OF INVENTION
The capability of detecting and continuously measuring low levels of chloride, sulfate, phosphate and nitrate has been needed for water treatment control in the power industry for many years. The available titration or colorimetric procedures are not continuous measurements and have not possessed the necessary sensitivity or accuracy. So-called cation conductivity procedures have been used in the past as an indication of condensate leakage (inorganic comtamination) but, as with many such procedures, the errors involved with their use have not been fully recognized nor have corrective measures been applied to obtain precise results.
The use of once-through and supercritical boilers, pressurized water reactor (PWR) nuclear and cogeneration systems has brought to light problems of corrosion and deposits on surfaces of steam boilers and generators as a result of which stress-corrosion cracking of turbine blades and circulation troubles in the system occur, as in the denting (cracking) of Iconnel 600 in PWR heat exchangers. Chloride, sulfate, phosphate and nitrate in the high temperature feedwater, normally found in water, are responsible for this corrosion, for the harmful deposits, and for the deterioration of auxiliary equipment. Resulting mechanical failure, such as boiler tube eruption, may cause injury to operating personnel and serious economic disruption for the public.
The foregoing problem of stress corrosion cracking of turbine blades in large steam turbines has revealed an urgent need for reexamination of the allowable upper limits of steam purity. Heretofore, a maximum of 10-30 μg/l (micrograms per liter) sodium (as Na + ), equivalent to 15-45 μg/l chloride (as C1), was considered allowable. Recently, turbine manufacturers have specified chloride ions plus sulfate ions (C1 - +SO 4 = ) limits of 5 μg/l or less.
Corrosion studies have recognized the importance of C1 - and SO 4 = ions in promoting the corrosion of metals in water. The measurement of the Na - (sodium) ion may not provide a correct estimate of anion contamination, as other cations such as potassium, calcium and magnesium may be present in combination with C1 - and SO 4 = rather than Na + alone. Heretofore, the deleterious effect of calcium and magnesium impurities associated with chloride and sulfate has not been recognized or considered important in steam purity measurement. The recognition of such effect is important in the determination of feedwater contaminants, and is taken into account by the present invention.
So far as applicants are aware, the present invention achieves for the first time a greater sensitivity and accuracy of conductivity measurements based on chlorides, sulfates, and nitrates in feedwater than heretofore possible. The present invention is able to detect and continuously measure extremely low levels of 1 to 5 μg/l (micrograms per liter) chlorides, sulfates and nitrates (equivalent to 0.6 to 3 μg/l sodium). Heretofore, there has been no procedure for detecting chlorides, sulfates and nitrates at this very low level; still less, on a continuous measuring basis.
The apparatus of the present invention is designed to fill an analytical and operational need for control of contaminants and water treatment in large fossil fueled boilers, particularly once-through type or PWR (pressurized water reactor) nuclear systems. Up to the present time there has been no satisfactory method of continuous sampling and measuring the purity of saturated and superheated steam generated by these systems, due to the physical characteristics of the boiler design and the superheated steam used. Hence there is a present need to monitor the feedwater influent rather than the steam or steam condensate effluent. The present invention satisfies such need.
U.S. Pat. No. 3,158,444 granted Nov. 24, 1964 describes a method of and apparatus for determining steam purity. Although the apparatus illustrated therein bears a superficial resemblance to the apparatus of the present invention hereinafter illustrated and described it should be understood that the apparatus disclosed in the aforementioned patent is not designed for nor can it be used to test high temperature feedwater (approx. 350° F. and above) in place of steam. In using the apparatus of U.S. Pat. No. 3,158,444 for the determination of steam purity, it was found that the superheated steam deposits insoluble salts, such as sodium chloride and sulfate on the sampling line to the measuring instrument and in the instrument itself. This problem is described in an article entitled "The Prevention of Errors in Steam Purity Measurement Caused by Deposition of Impurities in Sampling Lines," by R. V. Cobb and E. E. Coulter published by the American Society for Testing Materials, Philadelphia, PA., Proc. ASTM61, 1386--1395(1961). The technique for avoiding these errors described in the foregoing article is complicated and has never been used practically, so far as applicants are aware. This problem does not exist in the practice of the present invention.
OBJECTS AND FEATURES OF INVENTION
An object of the present invention is to enable the continuous detection of low level chloride, sulfate, phosphate and nitrate of the order of 1-5 μg/l in high pressure feedwater at atmospheric boiling temperatures from high pressure boiler systems and pressurized water reactor nuclear systems.
Another object is to improve the safety of high pressure steam generator systems that utilize high temperature, high pressure feedwater by detecting contaminating impurities in the feedwater which cause mechanical failures in the system.
A further object is to achieve accurate, sensitive and continuous measurements of chloride, sulfate and other anions in high temperature, high pressure feedwater at lower levels than heretofore possible.
A feature of the invention is the arrangement of a pair of conductivity cells in the flow paths of the water in the system which in cooperation with a recording instrument provides an indication of the effectiveness of the hydrogen exchange resin bed, thereby indicating to operating personnel when the resin should be replaced.
Another feature lies in the use of individually adjustable stainless steel valves having small orifices of approximately two-onehundredths of an inch for separately supplying the high pressure feedwater at atmospheric boiling temperature to coils in both the condenser and the reboil chamber. The metal from which the valves are made prevents possible contamination of the feedwater, such as may occur if copper or brass were used.
An advantage of the invention is that the apparatus can be used in the field where the power generating parts of the whole system are located, and does not require time consuming laboratory analytical methods involving huge samples by evaporation processes.
Other objects, features and advantages will appear from a reading of the following detailed description of the invention which is given in conjunction with a drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of the apparatus of the invention, and
FIG. 2 graphically illustrates the effect of flow rate through the condensate analyzer on the conductivity of the effluent from the hydrogen exchange resin bed.
DETAILED DESCRIPTION
The apparatus of the invention comprises an elongated structure comprising tubular stainless steel sections 10, 12, 14 and 16 placed end-to-end to form a single integral structure. Section 10 is a water cooling condensing unit supported from section 12 by suitable metal braces or arcuate-shaped metal trusses. All sections are preferably of the same diameter. Upper section 10 contains a multi-turn cooling coil 11 and a disc-like baffle 13. Section 12 is a reboil chamber which is separated from section 14 by a screen 18 through which effluent from the section 14 may pass. Section 14 contains a hydrogen exchange resin bed 15. Bed 15 is, for example, a strong acid type cation exchange resin such as polystyrene material in hydrogen form sold by Rohm & Haas under the trade-name IR-120. This bed is of suitable depth to insure substantially complete exchange of the cations in the condensate to hydrogen ions. The metals used for sections 10, 12, 14 and 16 and the tubing therein are materials, such as stainless steel, which will not add contamination to the high temperature, high pressure sample feedwater supplied to the apparatus over sample inlet 20. The reboil chamber 12 and the screen 18 may suitably be clamped by collars or flanges to the lower chamber 14.
The cooling chamber 16 at the bottom of the apparatus contains a cooling coil 17, the upper end of which is in fluid communication with a perforated distributor plate 19.
A feedwater sample inlet pipe or tube 20 supplies high temperature feedwater under high pressure through a manually controllable valve V1, to a path divider arrangement 22, 24. Tubes 22 and 24 are provided with separate small orifice stainless steel manually controllable valves, V2 and V3 respectively, through which the high pressure, high temperature feedwater passes. These two valves which have orifices in the range of 0.01 "to 0.02" are important in the practice of the invention. The temperature of the feedwater in chamber 10 is reduced to atmospheric boiling temperature.
Manually controllable valve V1 regulates the total flow of feed-water sample to the apparatus. Valve V3 regulates the amount of sample feedwater which passes to coil 21 in the reboil chamber 12, thereby regulating the heat which takes place in the reboil chamber. Manually controllable valve V2 serves a dual purpose, viz, (a) to by-pass some of the input feedwater sample into the coil 23 located within the condensing section 10 to maintain the temperature of the water of pond 25 at atmospheric boiling temperature, and (b) enables proper reboil without excessive boiling of the water 26 in the reboil chamber 12 due to the presence of coil 21 which receives high temperature feedwater through tube 24 and valve V3. Violent boiling of the water of pond 26 will cause a change in the water level of this pond and disturb the smooth constant flow of water through the tube 35. This constant flow is required for proper performance of the instrument. Thus both valves V2 and V3 together judiciously adjusted, regulate the operating temperatures of the water 25 and 26 in both condenser 10 and reboil chamber 12 at the same atmospheric boiling temperature despite variations in temperature and pressure in the input feedwater through valve V1, and maintain the flow of liquid through the resin bed constant.
The water 26 is at atmospheric boiling point, approximately 98.5° C., and is maintained at a constant level by the judicious adjustment of valves V 2 and V 3 to assure a constant flow of the water through conductivity cell C 2 at a rate of 250 ml/min to 1000 ml/min as described hereinafter. The constant level of the water 26 in the reboil chamber 12 is manually adjustable by raising or lowering waste or overflow tubing 28 which is attached to and communicates with the interior of cell C 2 . It should be noted that the top of tube 28 is on the same horizontal line as tube 35. Cells C 2 and C 1 are flow-type conductivity cells which are well known in the art. An adjustable screw 27 passes through an opening in tubing 28 to prevent siphoning. The screw 27 may be replaced by an open-ended tube inserted into the top of tubing 28 to serve as a siphon breaker.
The feedwater exiting from valve V2 in the direction of the arrow over tube 22 and which is under pressure at a temperature of about 350° F. and higher, passes through coil 23 and discharge nozzle 29. The hot feedwater exiting from valve V3 in the direction of the arrow over tube 24 passes through coil 21 in the reboil chamber 12 and through an upwardly extending tube 47 to the discharge nozzle 30 in the section 10. Manually adjustable valves V1, V 2 and V 3 are important in the practice of the invention and have orifices in the range of 0.01" to 0.02" to prevent too much feedwater from passing therethrough. Both nozzles 29 and 30 serve to discharge their steam jets, if any steam is present therein, vertically for impingement upon the stainless steel baffle plate 13. Impingement baffle place 13 is slightly spaced from the wall of section 10 to permit an upward flow of discharged steam and gas which then pass out of section 10 through vent 32. Baffle 13 is supported by the bottom tubing of multi-turn coil 11. Coil 11 is supplied with cooling water from inlet 31 which communicates with tube 33 through an open and shut valve V5. An outlet tube 34 discharges the cooling water from the cooling coil 11. The coil 11 is suitably suspended from a closure plate 31'. Vent 32 in the closure plate serves to release any non-condensable gases such as CO 2 separated from the water in pond 25 and any steam exiting from nozzles 29 and 30 which pass by the baffle. This vent also helps to maintain the constant level of the water in pond 25 by preventing air finding. A tube 35 has an open end at the constant level of the water 26 in the reboil chamber. This pipe is in flow communication with the bottom of conductivity cell C 2 , as shown. A tube 36 has an open end at the bottom of pond 25 for abstracting water therefrom and passing it through conductivity cell C 1 . A short length of vertical tubing 37 supports a thermometer T at its upper end and has an overflow opening 38 placed at the constant level of pond 25. Any excess water from pond 25 passes out over overflow pipe 28. The level of the water in condensing section 10 (pond 25) must always be constant as determined by the level of the overflow pipe 38 which is at the same level. The flow rate of the feedwater in the sample inlet is such as to always produce an overflow in pipe 38 which maintains a constant level for pond 25. The constant level of pond 25 achieves a constant flow rate of liquid, via tube 40, into the coil 17 in the cooling chamber 16. In practice, the feedwater supplied by the sample inlet over tube 22 is mostly water which accumulates as pond 25 at the bottom of condensing section 10, although a small portion (about 5-10%) will produce flash steam from nozzle 29 and will be condensed by baffle 13 and fall back as water into pond 25.
The vertical tubing 40 conducts the water flowing through the conductivity cell C 1 into the bottom end of coil 17 contained within the cooling chamber 16. A manually controlled open and shut valve V4 regulates the flow rate of hot water from the cell C 1 which passes through tube 40. The cooled water, cooled to a temperature below 65° C. and preferably between 20° C. and 40° C., is passed through the distributor plate 19 into the hydrogen exchange resin bed 15. The perforated distributor plate 19 serves not only to pass the upward flow of the cooled water into the section 14 but also for supporting the bed of ion exchange material 15. The screen 18 above the resin bed 15 serves to prevent any particles from the resin bed from rising in the effluent therefrom beyond the level of said screen into the reboil chamber 12.
A vent 39 leading to the reboil chamber is for the same purpose as the vent 32, namely to permit the escape of any non-condensable gases such as carbon dioxide, released by the reboiling of the condensate or by the heating thereof to the atmospheric boiling point. Vent 39 also serves to allow the steam produced by reboiling in the reboil chamber 12, an escape path to atmosphere, thereby preventing fluctuating sample flow rates and assisting in the flushing of the non-condensable gases from the reboil chamber. The coil 21 in the reboil chamber 12 provides the heat necessary to drive off substantially all of the carbon dioxide that may be dissolved in the condensate. Coil 21 and reboil chamber 12 are of sufficient size to reheat the effluent from the hydrogen ion exchange bed 15 back to atmospheric boiling temperature.
The cooling chamber 16 is supplied with constant temperature cooling water from the cooling water inlet 31. Valves V6 and V7 regulate the volume of the cooling water passing into and out from the cooling chamber 16. The water in inlet 31 may be in the range from near zero to 30° C. and should cool the hot feedwater in tube 40 to 20°-65° C., preferably in the range of 20°-40° C., approximately.
In some instances, such as when there is little flash steam or if the temperature of the water in pond 25 is less than atmospheric boiling temperature the cooling or condensing coil 11 in the section 10 can be eliminated entirely in which case the vent 32 will permit the passage of any steam exiting from nozzle 29. The elimination of coil 11 will make unnecessary the use of the cooling water feedback tube 33 together with the thermometer T located at the top of coil 11. Alternatively, two cooling inlets can be used, one for the lower chamber 16 and the other for the upper chamber 10 with separate shut off valves in each cooling inlet.
Flow type conductivity cells C 1 and C 2 are electrically connected to a conductivity recording instrument 41 via electrical connections 42 and 43 respectively. During normal operating conditions the difference in conductivities in the cells is an indication of the ammonia and/or amine concentrations as well as CO 2 in the feedwater sample (influent). This difference is an indication of the extent of removal of the substances in the feedwater sample which interfere with accurate and sensitive measurements of chloride and sulfate. When the difference in conductivities of the cells C 1 and C 2 approaches zero as indicated on the recorder 41, then the hydrogen exchange resin bed 15 should be replaced. The two valves V, V and the tubing 44 and 45 associated therewith and connected to the interior of section 14 are for the purpose of fast removal and replacement of the resin by means of water flow. The open funnel 46 aids in the replacement of resin. The recorder 41 can be of a type which prints out both conductivity values of the cells C 1 and C 2 , or, if desired, the recorder can be of a type which subtracts the conductivity of pure water (0.82 μS/cm at 98.5° C.) from the conductivity measurement of cell C 2 , thereby indicating the chloride and sulfate content. The recorder 41 may be provided with an alarm which becomes actuated in the presence of excessive contents of chloride and sulfate in the feedwater.
Suitable recording instruments and flow type cells useful in the practice of the present invention are manufactured and sold by Beckman Instruments of Fullerton, Calif. Valves V1, V2 and V3 used in the practice of the invention are type "Whitey Series 21" manufactured by Whitey Company of Oakland, Calif. These valves are made of stainless steel, resistant to erosion or corrosion by high velocity, high pressure, high temperature feedwater, and have limited dimension orifices of approximately 0.02" inner diameter. These valves are micro-regulating valves designed to handle a flow capacity of 250 ml/min to 1000 ml/min at pressures of from 500 to 3,000 psig (lbs per square inch gauge) or higher at temperatures from 250° F. to 600° F.
The effect of flow rates through the condensate analyzer of the invention on the conductivity of the effluent from the hydrogen resin bed is shown in the graphical representation of FIG. 2. We have satisfactorily operated the apparatus of the invention at a flow rate through the resin bed between 250 and 1000 ml/min at 20° C.-40° C. Higher flow rates can be used. Lower flow rates are less satisfactory because of higher background conductivity due to undesired resin leaching, as indicated on the graph. Other dimensions than those indicated in FIG. 2 and other conditions, such as temperature, will give other graphs, but all will show that at higher flow rates the conductivity will decrease.
In an embodiment of the invention built and successfully tested the apparatus was a circular construction with an overall height of approximately 41/2 feet and with an outer diameter of approximately 4 inches. The stainless steel outer tube was approximately one-eighth (1/8") thick. A tubular brace eight and one-half inches (81/2") long fastened the upper section 10 to the reboil chamber section 12. Upper section 10 had a height of eleven inches (11"); reboiler chamber 12 had a height of seven inches (7"); the resin chamber 14 was thirteen and three-quarter inches (133/4") high and the lower cooler section was eleven and one-quarter inches (111/4") high. Coil 11 in the condenser section had six turns, while coil 17 in the cooler section 16 had thirteen turns. The analyzer of the invention (the outer metal tubing) was surrounded by 1/2 inch fiber glass insulation to reduce heat losses and to maintain a constant control of temperature. It is preferred that the apparatus not be exposed to cold drafts. Beckman Instrument flow type conductivity cells and a Beckman Instrument recorder were used. The valves V1, V2 and V3 were Whitey Series 21 stainless steel of approximately 0.02" inner diameter. Stainless steel parts and "Mirprene" tubing have demonstrated their superior properties after adequate rinsing. By means of the invention, cell C 2 has been able to measure the conductivity of the chlorides and sulfates in the converted acid form (converted by the hydrogen exchange resin) as a precise determination of the degree of contamination of chlorides and sulfates in the feedwater sample. The analyzer of the invention is sensitive to 1-5 μg/l of C1 -1 or SO 4 = . This is equivalent to 0.6 to 3.0 μg/l sodium, as contrasted to the results achieved in the aforementioned U.S. Pat. No. 3,158,444 used for determining steam (not feedwater) and restricted to a detection of approximately 3 μg/l sodium.
The feedwater analyzer of the invention was tested at Kincaid Station, a mine mouth power station which is generally operated as a base load plant to supply electricity to the Chicago area. Its facilities include two once-through boilers operated at a pressure of 2620 psig (lbs per square inch gauge) and a temperature of 1005° F. and two 600 MW (megawatt) turbines. Cooling water is supplied by a man-made lake, Lake Sangchris. The apparatus of the invention was installed in a vertical position sampling feedwater from the economizer inlet of unit 1. The feedwater was passed to the top section 10 of the apparatus of the invention to relieve pressure and to reduce the 400° F. feedwater temperature to atmospheric boiling temperature. Part of the feedwater flow passed through the reboil chamber 12 to heat the entering resin-treated feedwater which had been cooled to reduce contamination from resin leaching. The effluent 26 from the resin bed 15 after being heated in the reboil chamber to atmospheric boiling water temperature to boil off carbon dioxide of the acidic feedwater resulting from passage through the hydrogen exchanger and to maintain constant atmospheric boiling temperature was then passed through conductivity cell C 2 mounted in the effluent line 35 from this reboil chamber, at which time the conductivity was recorded. In passage through the hydrogen exchanger, the ammonia and alkaline amines are removed and the cations of the feedwater salts (such as sodium of sodium sulfate) are replaced by hydrogen ions. The conductivity of ammonia and the amines is thereby eliminated by their removal. The mineral chlorides, sulfates and phosphates are converted to the respective mineral acids. Since the conductivity of hydrogen ions is about seven times that of metallic ions, the sensitivity of this conductivity measurement for minerals is significantly increased by measurement at constant boiling water temperature and by elimination of carbon dioxide and amine interference.
By using the present invention and assuming a 3 million lbs/hr feedwater flow (6000 gpm) at Kincaid Station, a detection of 0.1 gpm (gallons per minute) condenser leak (0.0016%) of lake cooling water would be indicated by a 0.033 μS/cm increase in conductivity over that of purewater at 98.5° C. Even less than 0.033 μ5/cm, for example 0.01 μS/cm, can be indicated by our analyzer apparatus. So far as we are aware, no other known instrumentation can achieve these results in a continuous measurement in a once-through boiler. The tests at the Kincaid Station with the apparatus of the invention achieved sensitive observations at low levels of chloride, sulfate, phosphate and nitrate which could not be as accurately detected by heretofore known instrumentation. We are thus able to detect and record anion levels as low as 1 μg/l.
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Apparatus of high sensitivity and accuracy for detecting and measuring very low levels of chlorides, sulfates, phosphates and nitrates in high pressure, high temperature feedwater present in once-through and supercritical boilers, nuclear reactors and cogeneration systems. A sample of feedwater at 350° F. and above is maintained near atmospheric boiling point in a vented chamber where volatile gases, mainly carbon dioxide, are removed by venting. The effluent from this chamber passes through a flow-type conductivity cell, is cooled to 20°-40° C. and flows upward through a hydrogen exchange resin bed at a flow rate of approximately 250 and 1,000 ml/min and higher. Subsequent reboiling of the condensate in a reboil chamber with the help of a small orifice valve through which a part of the hot feedwater sample passes provides constant temperature control of the condensate at or near atmospheric boiling and at a constant level prior to flow through another flow-type conductivity cell. This last cell measures the conductivity of the chlorides, sulfates, phosphates and nitrates in the converted acid form and indicates the extent of the contaminants of the foregoing substances in the feedwater. A recorder electrically connected to both cells enables observation of the difference in conductivity between the two cells, thereby providing an approximation of the amine or ammonia content in the high pressure, high temperature feedwater. Individual small orifice valves control the volume and rate of flow of the feedwater supplied to both the vented and reboil chambers.
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BACKGROUND OF THE INVENTION
The present invention concerns a semiconductor memory. More particularly, the present invention relates to a cell array structure for a ferroelectric semiconductor memory adapted for constructing a highly integrated circuit, and a method for sensing data from the same.
Generally, semiconductor memory fabrication technology has been developed to minimize chip size by increasing the integration density of a memory cell device while enhancing the capacity of the device. A ferroelectric semiconductor memory device improves the device capacity by using capacitors comprised of a ferroelectric material with electrical non-volatility. Conventional dynamic random access memories (DRAMs) use a non-ferroelectric dielectric material between the upper and lower electrodes of their storage capacitors. Ferroelectric semiconductor memory devices, e.g., ferroelectric random access memories (FRAMs) employ ferroelectric capacitors that use a ferroelectric material between the upper and lower electrodes. This ferroelectric material eliminates the data loss problem caused by current leakage. As a result, a ferroelectric semiconductor memory does not require a refresh operation.
In addition, ferroelectric semiconductor memories store information by exploiting invertible and residual polarization properties of the ferroelectric material, so that the read/write operation may be carried out at a high speed. Since the inversion of polarization is made by the spins of the electric dipoles in the ferroelectric material, the operating speed of the ferroelectric semiconductor memory is several thousand times faster than other nonvolatile semiconductor memory such as electrically erasable and programmable read only memories (EEPROMs) and Flash-EEPROMs. The operating speed of these devices may be further increased by optimizing their design, thus making them comparable to conventional DRAMs in speed. Furthermore, the voltage required for the inversion of polarization is about 2 to 5 V, making it possible for the memory to operate at a relatively low voltage.
FIG. 1 illustrates an equivalent circuit of a unit cell of a conventional ferroelectric semiconductor memory. As shown in FIG. 1, the unit cell comprises an access transistor 1 and a ferroelectric capacitor 2. The drain D of the access transistor is connected to a corresponding bit line B/L and the gate G of the access transistor 1 is connected with a word line W/L. One plate of the ferroelectric capacitor 2 is connected to the source S of the access transistor 1, while the other plate of the ferroelectric capacitor 2 is connected with a plate line PL.
The unit cell is generally fabricated on a single semiconductor substrate. The access transistor 1 is formed in the active region between the field oxide layers on the substrate by means of the conventional process for fabricating n-channel MOS transistors. The ferroelectric capacitor 2 is formed over the field oxide layer with an insulating layer between them. The ferroelectric capacitor 2 generally includes a lower electrode layer, a ferroelectric layer and an upper electrode layer deposited in sequence over the insulating layer. The three layers may be respectively composed of Pt, PZT (lead zirconate titanate) and Pt or Al. The upper electrode layer is connected to the plate line PL, and the lower electrode layer to the source of the transistor 1, as shown in FIG. 1. An example of the capacitor cell structure composed of an access transistor and PZT ferroelectric layer is disclosed in U.S. Pat. No. 5,189,594, issued to Kazuhiro Hoshiba, the contents of which are hereby incorporated by reference.
It is well known in this art that a ferroelectric capacitor stores data by exploiting the characteristics of the hysteresis loop, as illustrated in FIG. 2, where the horizontal axis represents the electric field intensity or voltage V, and the vertical axis represents the polarization or the amount of charge. In FIG. 2, V c represents a coercive voltage to invert the direction of polarization. The points on the hysteresis loop labeled "a" and "d" represent the storage of binary data "0" and "1," respectively.
In operation, if a positive saturation voltage greater than the coercive voltage V c is initially applied to the node DN of FIG. 1, the polarization or the amount of charge is increased from a starting point at point "a" (representing binary data "0"), through point "b" to point "c" along the loop, as shown in FIG. 2. Then, once the voltage at the node DN is returned to 0 V, the amount of charge decreases from point "c" only to point "d" along the loop. At this point, the data stored in the capacitor 2 then represents binary data "1" via the stabilized polarization or charges. In other words, from a starting point where binary data "0" is stored in the ferroelectric capacitor, the plate line PL is applied with 0 V and a positive pulse is applied to the node DN to store data "1" in the ferroelectric capacitor. Thereafter, the polarization is maintained at point "d" according to the characteristics of the hysteresis loop of the ferroelectric material and the binary data "1" remains stored in the ferroelectric capacitor.
Alternatively, if a negative saturation voltage lower than the coercive voltage -V c is applied to the node DN of FIG. 1, the polarization or the amount of charges is increased from a starting point at point "a" (representing binary data "0"), through point "e" to point "f" along the loop, as shown in FIG. 2. Thereafter, the amount of the charges is decreased from point "f" only to a point "a" along the loop with the voltage cut off from the node DN, so that the data stored in the capacitor 2 represents binary data "0", stabilized in the polarization or charges. In other words, from a starting point where binary data "0" is stored in the ferroelectric capacitor, the plate line PL is applied with a positive pulse and the node DN with -V c in order to store binary data "0."
In order to replace data "1" already stored in the capacitor 2 with data "0", the negative saturation voltage greater than the coercive voltage -V c is applied to the node DN of FIG. 1. In this situation, the polarization or the amount of charge changes from point "d" (representing binary data "1"), through points "e" and "f," back to point "a" along the loop (representing binary data "0").
In order to replace binary data "0" already stored in the capacitor 2 with binary data "1", the positive saturation voltage greater than the coercive voltage V c is applied to the node DN of FIG. 1. The polarization or the amount of charge then changes from point "a" (representing binary data "0"), through points "b" and "c," back to point "d" along the loop (representing binary data "1"). The ferroelectric capacitor 2 may then store stable binary data "1" or "0" without an additionally applied voltage.
Detection of the stored data is made by applying a voltage equal to or greater than the positive saturation voltage between both electrodes of the capacitor 2. The difference between the polarization or the amount of charge at point "d" (representing data "1") and that at point "c" is considerably smaller than the difference between the polarization or the amount of charges at point "a" (representing data "0") and that at point "c." These differences may be easily detected by the sensing circuit provided in the ferroelectric memory. The sense amplifier compares the reference voltage supplied from the reference cell with the voltage supplied from the memory cell to determine the logical state of the stored data as "1" or "0."
FIG. 3 illustrates a conventional semiconductor memory which comprises a plurality of sense amplifiers 300 and 310, a plurality of reference cell groups 20 and 21, a plurality of main cell groups 30 and 31, and a plurality of precharge and equalization circuits 10 and 11. This conventional semiconductor memory has an open bit line structure symmetrically arranged with respect to the sense amplifiers.
The plurality of reference cell groups 20 and 21 each comprise a plurality of reference cells and pass gates. The plurality of main cell groups 30 and 31 each comprise a plurality of main cells for storing data. The plurality of precharge and equalization circuits 10 and 11 act to precharge and equalize the bit lines. The precharge and equalization circuit 10, for example, comprises an equalizing transistor Q 1 for connecting the bit lines BL a1 and BL a2 , and precharging transistors Q 2 and Q 3 . In this case, the reference cells and main cells are fabricated using the same process as for the ferroelectric capacitors 2 included in the reference cell RC 1 and main cell MC 1 , and have the same polarization.
If a memory arranged in one side of a sense amplifier 300 is selected to read data, the reference voltage is supplied to the corresponding bit line BL b1 by the operation of the reference cells RC 11 and RC 21 arranged in the other side of the sense amplifier.
The operation of the conventional semiconductor memory will now be described with reference to FIG. 3, and using the example of reading the data stored in the memory cell MC 1 of the main cell group 30 arranged in one side of the sense amplifier 300. In this operation, the reference cells RC 1 an RC 2 are cut off while the reference cells RC 11 and RC 21 arranged in the other side of the sense amplifier 300 are operated to provide the bit line BL b1 with the reference voltage. To this end, the reference cell data input terminals PFPRS*, PFPRS, RDIN*, and RDIN are provided respectively with logically high, low, high, and low signals.
In addition, the reference cell plate line RPL 2 is applied with 0 V.
Assuming the logically high signal has the level of about 5 V, and the low signal is 0 V, the pass gate PG 11 of the reference cell group 21 generates a positive voltage of about 5 V and the pass gate PG 21 generates a voltage of 0 V. If both of the reference cells RC 11 and RC 21 have the same polarization corresponding to point "a" in FIG. 2, the reference cell RC 11 changes the direction of polarization approaching point "c" along the loop of FIG. 2. Meanwhile, the reference cell RC 21 undergoes no change maintaining the same polarization at point "a."
The reference cell word line RWL 2 is then enabled to load the bit line BL b1 with the voltage induced by the polarization change, e.g., about 5 V, and the adjacent bit line BL b2 with 0 V. Then, the transistor Q 1 of the precharge and equalization circuit 11 is enabled by applying the equalization signal EQ at a high level to equalize the bit lines BL b1 and BL b2 to the same voltage level. In this case, the voltage level becomes 2.5 V which is in the middle of 0 V and 5 V so that the bit line BL b1 is provided with about 2.5 V, which is applied as the reference voltage to the reference voltage input terminal of the tense amplifier 300.
Meanwhile, the word line MWL 1 and the plate line MPL 1 of the main memory cell MC 1 are applied with a logically high signal. If the memory cell MC 1 stores data "1," the direction of polarization is reversed, and the corresponding voltage of about 5 V is developed in the precharged upper bit line BL a1 . The corresponding voltage is then applied to the data input terminal of the sense amplifier 300 which compares the voltages of the two input terminals to amplify the voltage of the bit line BL a1 . The amplified voltage is transmitted through the data line D/01 when the transmission transistor S 1 is enabled by the logically high signal C data . Hence, the data "1" is read from the memory cell MC 1 .
Such conventional memory device suffers the drawbacks that a plurality of reference cells must be driven in order to read data from the main cells, and the reference cell bit lines must be equalized by applying external data to the reference cells. This results in a lagging of the operating speed. In addition the plurality of the precharge and equalization circuits connected with the reference cells and the pass gates comprising P-type and N-type MOS transistors complicate the structure of the semiconductor memory. Moreover, a peripheral logic circuit is required to apply external data to the plurality of reference cells. This serves as a limiting factor in reducing the chip size.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a ferroelectric semiconductor RAM with a cell array structure adapted to increase the integration density of the chip, and method for sensing data in such RAM.
It is another object of the present invention to simplify the structure of a Ram cell array.
It is still another object of the present invention to provide a ferroelectric semiconductor memory having a simple structure to speed up the read operation, and method for forming the corresponding reference cells.
It is a further object of the present invention to provide a ferroelectric semiconductor memory without the precharge and equalization circuits and pass gates
According to an aspect of the present invention, a ferroelectric semiconductor Ram comprises a memory cell array having a plurality of memory cells arranged in a matrix, each of the memory cells consisting of against access transistor-and a ferroelectric capacitor, a plurality of bit lines of open bit line structure connected with corresponding sense amplifiers, and a plurality of reference cells arranged symmetrically against the sense amplifiers for providing reference voltage to the reference input terminals of the sense amplifiers to sense the logical states of the data stored in the memory cells, characterized in that the reference voltage is provided from one of the reference cells 11a.
According to another aspect of the present invention, a ferroelectric semiconductor memory comprises a plurality of sense amplifiers connected with corresponding bit lines of open bit line type, a plurality of ferroelectric memory cells arranged symmetrically against the sense amplifiers and connected between the bit lines and plate lines, a pair of reference cells arranged symmetrically against each of the sense amplifiers and connected with the bit lines so as to be outside the memory cells, each of the reference cells having a capacitor with a capacitance equal to half the polarization capacitance of the ferroelectric capacitor of the memory cell, characterized in that the reference voltage for the sense amplifier to sense the data of a selected memory cell in data read mode is supplied at the half level of a binary data from the reference cell opposite to the selected memory cell with respect to the sense amplifier. The reference cells may consist of ferroelectric capacitors or conventional MOS capacitors. In case of using the ferroelectric capacitor, the aperture size of the barrier layer between the ferroelectric layer and the upper electrode layer is adjusted to provide the reference voltage level.
Thus, the present invention provides a semiconductor memory without the precharge and equalization circuits and pass gates, increasing the integration density. Furthermore, the data input and equalization for the reference cells are not necessary, speeding up the data read/write operation.
The present invention will now be described more specifically with reference to the drawings attached only by way of example. In the drawings, same reference numerals are used to represent same functional elements. Detailed descriptions of the conventional part unnecessary for grasping the inventive concept arc omitted for convenience's sake.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the equivalent circuit of a typical cell structure of a conventional ferroelectric semiconductor memory;
FIG. 2 is a diagram for illustrating the general hysteresis loop representing the characteristics of a ferroelectric material;
FIG. 3 illustrates the core of a conventional ferroelectric semiconductor memory;
FIGS. 4 and 5 illustrate the cores of ferroelectric semiconductor memories according to a preferred embodiment of the present invention;
FIGS. 6 and 7 are cross sectional views for illustrating the fabrication of the reference cell capacitors shown in FIGS. 4 and 5; and
FIG. 8 is a diagram illustrating an example of a sense amplifier applied to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 4 illustrate the core of ferroelectric semiconductor memories according to a first preferred embodiment of the present invention. As shown in FIG. 4, sense amplifiers 300 and 301 connected with the bit lines of open bit line type memory. The sense amplifier 300 is connected between an upper bit line BL a1 and a lower bit line BL b1 .
FIG. 8 discloses a preferred sense amplifier 300 and 301 to be used in the circuit of FIG. 4. The sense amplifiers 300 and 301 each have the same structure, which comprises, for example, a pair of cross-coupled P-type and N-type MOS transistors P 1 and N 1 and P 2 and N 2 to achieve the sensing scheme of a conventional inverter latch type, as shown in FIG. 8. The cross-coupled P-type and N-type MOS transistors function as an inverter. The reference symbols SAPEN and SANEN in FIG. 8 represent externally applied signals to enable data sensing.
Ferroelectric memory cells MC 1 and MC 11 of FIG. 4 are arranged symmetrically with respect to the sense amplifier 300, connected between the bit lines and the plate lines MPL 1 and MPL 2 . Each of the main cells MC 1 , MC 2 , MC 11 , and MC 21 making up the main cell groups 200 and 210 comprises an access transistor 1 and a ferroelectric capacitor 2, having the same polarization. The reference cells RC 1 , RC 2 , RC 11 , and RC 21 of the reference cell groups 100 and 110 are arranged symmetrically against corresponding sense amplifiers and are connected with the bit lines so as to be outside the memory cells as shown in FIGS. 4 and 5. The ferroelectric capacitor 3 of each of the reference cells RC 1 , RC 2 , RC 11 , and RC 21 is fabricated to have a capacitance equal to half the polarization capacitance of the ferroelectric capacitor 2 of the memory cell. This allows the reference cell RC 11 opposite to a selected memory cell MC 1 with respect to the sense amplifier 300 to supply the reference voltage to the bit line BL b1 at the half level of a binary data for the sense amplifier 300 to sense the data of the selected memory cell in a data read mode.
Such difference in capacitance between the reference cell capacitor and the main cell capacitor serves to eliminate the conventional precharge and equalization circuits 10 and 11 the and pass gates PG 1 , PG 2 , PG 11 , and PG 21 used in the conventional circuit of FIG. 3. As a result, the data input and equalization for the reference cell is not required, and the read/write operation is sped up.
The ferroelectric capacitor 3 of the reference cell RC 1 , RC 2 , RC 11 , and RC 21 is fabricated in the same way as the ferroelectric capacitor 2 of the main cell, but the aperture size "D" formed in the barrier layer 35 is different, as shown in FIG. 6. The difference of the aperture size makes for a difference in the contact area between the ferroelectric layer 33 and the upper electrode layer 37, resulting in difference in polarization. The aperture size "D" should be adjusted for the capacitor 3 to have a polarization half the polarization of the capacitor 2.
As shown in FIG. 6, when the lower electrode layer 30 is formed by platinum with a thickness of about 3200 Åon the substrate 3, the ferroelectric layer 33 may be formed by PZT, preferably with a length of about 3.5 μm, and more preferably with a length of about 3.48 μm. The ferroelectric layer preferably has a thickness of about 2800 Å. The barrier layer 35 is a dielectric layer to protect the ferroelectric layer 33, and has the aperture to adjust the polarization. The upper electrode layer 37 is formed by platinum with a length of preferably to about 3 μm, and more preferably with a thickness of about 3.08 μm. The upper electrode layer preferably has a thickness of about 21 Å.
When reducing the aperture size, the capacitor 3 achieves a polarization of half the polarization of the capacitor 2 by applying data for inverting the data stored in the reference cell from "1" to "0" or vice versa to the reference input terminals RDIN 1 and RDIN 2 . In this case, the invertible polarization of the reference cell is half the invertible polarization of the capacitor 2. The invertible polarization of the reference sell is set to have about 2.5 V. Alternatively, when increasing the aperture size of the capacitor 3 greater than that of the capacitor 2, the capacitor 3 achieves a polarization half the polarization of the capacitor 2 by applying data for maintaining the data stored in the reference cell to the reference input terminals RDIN 1 and RDIN 2 of FIG. 4. In this case, the polarization produced in the curve interval between point "d" and point "c" is only employed to obtain 2.5 V.
FIG. 5 illustrate the core of ferroelectric semiconductor memories according to a second preferred embodiment of the present invention. FIG. 5 has a similar structure as FIG. 4 except that the reference cell comprises a conventional MOS transistor N 1 and a conventional capacitor. As with the first preferred embodiment, the reference cell RC 1 is fabricated to have a capacitance half the polarization of the ferroelectric capacitor 2 of the main cell by adjusting the size and thickness of the gate oxide layer 6, as shown in FIG. 7. In this case, a direct bias should be applied to the gate 1, source 4 and drain 5 for a given time. The MOS transistor of FIG. 7 is fabricated substantially in the same way as a conventional MOS transistor.
The read operation for the memory device shown in FIG. 4 will now be described for reading data from the memory cell MC 1 of the memory cell group 200 arranged in one side of the sense amplifier 300. In this example, the reference cell has a reduced aperture size compared to the memory cell. During the read operation, the reference cells RC 1 and RC 2 are cut off while the reference cell RC 11 arranged in the other side of the sense amplifier 300 is only driven to supply the sensing reference voltage to the bit line BL b1 . Accordingly, the reference cell signal RDIN 2 of the reference cell group 110 becomes logically high. The reference cell word line RWL 2 is enabled for the bit line BL b1 to have a voltage induced by the inverted polarization, e.g., about 2.5 V. In this way, the polarization of the capacitor 3 is half that of the capacitor 2. Therefore, the logical state of the main cell data, i.e., 2.5 V, which is the middle value between 0 V and 5 V, is supplied without equalization. Thus, the sensing reference voltage of about 2.5 V is supplied through the bit line BL b1 to the reference level input terminal of the sense amplifier 300.
Meanwhile, the word line MWL 1 and plate line MPL 1 of the main memory cell MC 1 is applied with a high signal. If the memory cell MC 1 stores data "1", the direction of polarization is inverted to develop the corresponding voltage in the precharged upper bit line BL a1 . The corresponding voltage, for example, 5 V is applied to the data input terminal of the sense amplifier 300, so that the sense amplifier 300 compares the two input voltages to amplify the voltage of the bit line BL a1 . In this way, the sense amplifier 300 amplifies the difference between the reference voltage level and the data voltage level, as illustrated in FIG. 8. The amplified voltage is transmitted through the data line D/01 when the signal C data for enabling the transmission transistor S 1 becomes high. Consequently, the operation for reading the data "1" from the memory cell MC 1 is sped up.
As described above, the present invention provides means for simplifying the semiconductor memory by eliminating the precharge and equalization circuits and pass gates, thereby increasing the integration density of the memory. In addition, the data read/write operation is sped up.
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A ferroelectric semiconductor random access memory (RAM) is disclosed, which comprises a memory cell array having a plurality of memory cells arranged in a matrix, each of the memory cells having an access transistor and a ferroelectric capacitor, a plurality of bit lines of open bit line structure connected with corresponding sense amplifiers, and a plurality of reference cells arranged symmetrically against the sense amplifiers for providing reference voltage to the reference input terminals of the sense amplifiers toe sense the logical states of the data stored in the memory cells. In this device, the reference voltage is provided from one of the reference cells.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part of our previously filed application, Ser. No. 048,202 filed June 13, 1979, now abandoned.
DETAILED DESCRIPTION OF THE INVENTION
In most instances involving commercial metal-cutting, the use of a cutting fluid is required. A cutting fluid is an aqueous system containing an additive, the cutting oil, which serves as a heat transfer agent, corrosion inhibitor and lubricant in the cutting operation. Cutting oils may be either emulsifiable oils, straight oils or synthetic oils. They are added to water at ratios of 1-5 parts by volume to 100 parts water. Large volumes of such fluids are required to serve properly as a heat transfer fluid, and for reasons of economy and potential pollution problems resulting from its discharge, recirculation of this fluid is required. This, in turn, requires that the fluid does not spoil due to biological attack during use or during storage.
While metal deposits can easily be removed from the recirculating fluid by mechanical means, bacterial and fungal contaminants represent more serious difficulties; they could easily ruin an entire system of recirculating cutting fluid which otherwise could be used for months. In order to prevent microbial degradation, the metal cutting industry requires additives that inhibit the growth of bacteria and/or the growth of fungi in the aqueous environment of this fluid. Such an additive is preferably available as a concentrated stock liquid which dissolves or disperses easily in the metal cutting fluid; it must not be corrosive to the metallic environment of its storage, circulation and operating area.
It has now been found that a combination of one part of the known fungicide, 1,1-diiododimethyl sulfone (hereinafter called DIDS) and 0.5-250 parts by weight of a chelating agent of the formula: ##STR1## wherein R is hydrogen, an alkali metal cation or ammonium, and n is 0 or 1, inhibits, at low concentrations, both industrial bacterial and fungal growth for extended periods of time. These new mixtures are not corrosive and can be stored as concentrated aqueous codispersions. The new combination is useful in all of the above-named types of cutting oils. Typical representatives of the above chelating agents are the disodium salt of ethylenediamine tetraacetic acid (hereinafter named EDTA), disodium salt, Versene (=EDTA tetrasodium salt), diethylenetriaminepentaacetic acid (DTPA), or the corresponding ammonium or potassium salts and the like.
The new combination fungicide has unique advantages over a chelating agent alone or DIDS alone, for instance, EDTA or its salts alone are essentially inactive and high concentrations are required to produce biocidal effects while DIDS is costly and quite toxic. EDTA and DTPA and their salts have been found to be unique and surprisingly outstanding potentiators for the desirable and useful protective activity of DIDS in cutting fluids. By their addition, the necessary amount of DIDS can be cut to 50% to produce equal or better biocidal effects than DIDS alone.
The components used in the present invention are well known materials: The above chelating agents have been known for decades and DIDS is known from U.S. Pat. No. 3,615,745. The named patent mentions the fungicidal and bactericidal activity of DIDS with reference to certain substrates. However, prevention of bacterial or fungal growth in metal cutting fluids is a much more difficult task. It has been recognized for many years that only very few biocides are suitable in metal working fluids and that only very few chelating agents have the ability to potentiate the activity of selected biocides.
The activity of the new combination of DIDS/chelate against industrial micro-organisms is particularly unusual, as only an extremely small number of compounds tested in metal working fluids prove to be active against both bacteria and fungi and most biocides useful in other industrial or agricultural substrates fail in cutting fluids.
In order to show the use of the above combination of materials, reference is made to the following examples which, however, serve only as illustration and are not meant to limit the invention in any respect.
EXAMPLE 1
To establish the activity of the above combination against various industrial bacteria and fungi, the minimum inhibitory concentrations (MIC) were determined in various cutting fluids. A bacterial and fungal mixture containing Pseudomonas, E. coli, Paracolobactrum, Proteus, Klebsiella and Aerobacter (the more common bacteria found in cutting fluids) and Fusarium, Cephalosporium and Cladosporium (the most common fungi found in cutting fluids) was used in this test. The bacteria-fungi mixture was placed in a test tube in two industrial cutting oils and then diluted with water to the commercially used oil/water ratio of 1:40. The oils used were A a petroleum-based coolant (Sun-Seco, marketed by the Sun Oil Co.) and B a synthetic coolant (Trim Regular, marketed by Master Chemical Co.). The results are tabulated in Table I.
TABLE I______________________________________Materials Tested MIC(A) MIC(B)______________________________________DIDS 15 ppm 7 ppmEDTA >125 ppm >125 ppmDIDS/EDTA 8/48 ppm 4/24 ppm______________________________________
These figures show that only about half of the amount of DIDS is required when it is used in combination with a typical chelating agent.
EXAMPLE 2
In a synergism study, using the standardized microtiter technique, Aerobacter and Pseudomonas were added to the nutrient broth at 10,000 colony-forming units/ml. of each. The MIC (in ppm) of various chelators and their combinations with DIDS were determined and tabulated below:
TABLE II______________________________________ MIC of MIC of Chelate CombinationChelate Alone (DIDS/Chelate)______________________________________Versene powder 500 ppm 1.5/100 ppmVersene liquid 1000 ppm 6/400 ppmEDTA . 2Na 1000 ppm 6/100 ppmDPTA 2000 ppm 0.8/200 ppm 1.5/100 ppm 3/100 ppmEDTA . 2NH.sub.4 >2000 ppm 3.9/500 ppm______________________________________
Since DIDS alone has an MIC of 12.5 ppm, the above results indicate 1/2 to 1/8 of DIDS can be used with the appropriate amount of a chelating agent.
EXAMPLE 3
DIDS/chelate mixtures were also tested at various concentrations and ratios in oils A and B (identified in Example 1) under simulated industrial use conditions. The results expressed in days of protection are given in Table III.
TABLE III______________________________________Concentrations (ppm/Days) of InhibitionDIDS EDTA . 2Na in Trim in Sun-Seco______________________________________1020 35 >105 (1)510 7 >105 (1)382.5 28 42255 42 35127.5 35 2863.75 21 210 0 0765 250 28 >105 (1)510 500 56 >105 (1)255 750 63 >105 (1)0 1000 28 14______________________________________ (1) Test was terminated after 105 days.
In this test, DIDS was used as a 51% solution in DMF and the chelating agent was simultaneously added to the cutting fluid as a solid. Results with other organic solvents for DIDS are found to be similar. Also, the use of DIDS plus chelates in other oils gives similar results, e.g., cutting oils sold by Shamrock, Norton, Quaker, Texaco or those sold as Do All, IRMCO, Polar Chip, Shercool, etc.
EXAMPLE 4
The following tests were carried out in the fashion of Example 3 using 1 volume of a commercial cutting oil in 40 volumes of aqueous cutting fluid. The oils are identified only as to their commercial source; the biocides are made up using the following ingredients (by weight):
I. 40% EDTA.2Na+14.5% DIDS
II. 42.32% DTPA+5.28% DIDS
III. 48% DIDS alone
Table IV shows the number of weeks the above mixtures provide protection at the concentrations listed. Again, the tests were discontinued after 15 weeks (105 days).
TABLE IV______________________________________Oil For- Quaker Vantrol Sun-Seco Texaco-591mulation I II III I II III I II III I II III______________________________________150 ppm 7 1 2 2 300 ppm 9 3 3 5 450 ppm 5* 9 2* 3 5* 5 2* 5 600 ppm 15 5 6 7 800 ppm 15 5 6 7 1000 ppm 5 7 15 4 9 10 15 15 6 15 9 7 1500 ppm 15 15 9 15 15 15 7 2000 ppm 15 15 15 15 15 15 15 15 15______________________________________ 15 15 8 *500 ppm instead of 450 ppm.
The results listed in Table IV clearly show that with a chelate, the actual concentration of DIDS to get biocidal protection is far below the amount required when DIDS is used alone.
It is easily seen from the tables that the combination of a chelating agent with DIDS greatly improves the performance of DIDS. For instance, 255 ppm of DIDS protects Trim and Sun-Seco oils in cutting fluids for only 6 or 5 weeks, respectively, while the addition of potentiator disodium EDTA produces protection for 9 to 15 weeks, respectively.
Compositions most practical for use by the consumer are the above described concentrates containing between 10 and 60% by weight of the combination of DIDS and a chelating agent. An excellent concentrate can be prepared by combining 12 parts of DIDS, 36 parts of a chelating agent, 5.33 parts of silica, 1 part of a wetting agent, 4 parts ethylene glycol, 3 parts of a nonionic surfactant, a trace of a defoamer and 39.3 parts of water. These materials are first mixed and then dispersed in a roller mill, a ball, pebble or sand mill, or a kinetic-energy disperser. Such liquid compositions are easily dispersed in water, they are stable for extended storage periods, and they are compatible with cutting oils commercially used on a large scale. However, other water soluble, organic, noncorrosive liquids may sometimes be added because of other beneficial properties they may have. Typical examples thereof are DMF, DMAc or N-methylpyrrolidone, which in some instances add to the lubricating qualities of the cutting fluid. Others may be more compatible with the one or the other of the frequently used commercial cutting oils. Where the above chelating agent is a salt of DTPA, a particularly stable composition is obtained.
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The addition of a combination of CH 3 SO 2 CHI 2 and certain chelating agents to cutting fluid prevents bacterial and fungal growth. Concentrated aqueous co-dispersions thereof are particularly useful.
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BACKGROUND
[0001] This disclosure generally relates to a post insert for reinforcing hollow-fence components. This disclosure also relates to reinforced fence structures and methods for reinforcing fence structures.
[0002] Fence structures or railings made of wood or plastic such as, for example, polyvinyl chloride (PVC) are well-known in the art. PVC fencing systems are susceptible to warping, flexing, sagging, or swaying due to environmental conditions such as high winds because, PVC material in elongate, hollow fencing structures, may not withstand strong forces.
[0003] Some fence installers pour concrete into the fence post to prevent sway. However, the concrete-spill on the outside of the post, causes discoloring and scratching. Further, such concrete-filled posts are subject to cracking and splitting of the fence material due to dissimilar expansion or contraction and other damages to the post and the cosmetic surface. Some installers use wood inserts, but wood is relatively expensive.
SUMMARY
[0004] The current disclosure, relates to a system and apparatus for reinforcing hollow-fence components. In one embodiment, a stiffening insert for reinforcing fence components includes an elongate portion that resembles a “Z-shape” and fits inside a hollow cavity defined by the fence component, for example, a fence post. The hollow fence components are formed of a plastic or a resin material, such as PVC or other vinyl fencing materials. The angled design of the “Z-shaped” portion enables simpler manufacturing in an economical way and, yet offers substantial resistance to vertical fence post structures against forces, general wear and tear or any other stress.
[0005] In one embodiment, the stiffening insert is formed with openings through which horizontally attached rails can be inserted. The openings may be configured sufficiently elongated along the central axis of the structure to accommodate a range of positions relative to corresponding openings in the hollow fence post structure to allow for horizontal rails to secured to the insert. In one embodiment, the insert is solid without any openings.
[0006] A method to reinforce preexisting fence components includes installing the stiffening component inside the post while mounting the post in the ground. A portion of the stiffening component can extend from the buried end of the post. The extending component may interface with soil, sand, stone, gravel, cement or any other material in which the post is mounted.
[0007] In one embodiment, the stiffening component may not extend the entire length of the vertical post and may extend only a partial distance, for example, three feet in a six-foot post. The stiffening component can be formed of any number of materials, including but not limited to rolled steel. Suitable metal material may be roll formed into the desired shape that resembles a “Z-shape”. The ends of the stiffening component, along the length of the edges, can be beveled so as to engage an internal surface of the post for retaining it in position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings are provided to illustrate some of the embodiments of the disclosure. It is envisioned that alternate configurations of the embodiments of the present disclosure maybe adopted without deviating from the disclosure as illustrated in these drawings.
[0009] FIG. 1 shows a perspective view of a fence structure having two fence posts with stiffening inserts and three rails. The inserts buried below the surface are shown in phantom.
[0010] FIG. 2 shows a partial fragmentary perspective view of an elongate stiffening insert having a plurality of openings inside the stiffening insert corresponding to openings in the post.
[0011] FIG. 3 shows a top plan view of a stiffening insert and a fence post.
[0012] FIG. 4 shows a top plan view of a stiffening insert with beveled edges and a fence post.
DETAILED DESCRIPTION
[0013] While the present disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, embodiments with the understanding that the present description is to be considered an example of the principles of the disclosure and is not intended to be exhaustive, restrictive in character, or to limit the disclosure to the details of construction, the arrangements of components and methods set forth in the following description or illustrated in the drawings, and that all changes and modifications are incorporated herein.
[0014] FIG. 1 shows a fence structure 10 . The fence structure 10 has a fence post 12 with an upper end 14 and a lower end 16 . The post is generally hollow having a wall 13 defining a cavity 15 . The fence post 12 has a stiffening insert 20 positioned inside the cavity 15 . The upper end 14 of the fence post 12 may be capped or removably covered to allow access for reinforcement. Rails 38 may be associated with the fence post 12 and the stiffening insert 20 through the openings 28 in the fence post 12 . The fence structure 10 is mounted on a surface 40 . The fence post 12 may be a corner post or an end post or an intermediary post in the fence structure 10 . The fence structure 10 may be by way of example, but not limitation, any form of vinyl fence, a picket fence, ornamental fence, and privacy fence.
[0015] As shown in FIG. 2 , the fence post 12 includes the hollow shell 13 defining the cavity 15 . The stiffening insert 20 has a first portion 22 having a first end 24 and a second end 26 . The second portion 30 of the stiffening insert 20 also has a first end 32 and a second end 34 . The first portion 22 and the second portion 30 are generally parallel to each other. The third portion 36 of the stiffening insert 20 intersects the first portion 22 at its second end 26 and the second portion 30 at its first end 32 . The third portion 36 need not be at right-angle to the first portion 22 and the second portion 30 . For example, the third portion 36 may intersect the first portion 22 at its second end 26 and the second portion 30 at its second end 32 , at an acute angle that is less than 90° (e.g., 75° as in a “Z-shape”) or at an obtuse angle that is slightly more than 90° (e.g., 100°) with respect to generally parallel surfaces.
[0016] The stiffening insert 20 may be formed or configured to provide a snug-fit against an inside surface 17 of the fence post 12 defining the cavity 15 . Alternatively, stiffening insert 20 may be retained inside the fence post 12 with a securing device including, but not limited to latch, brace, nut and bolt, screw, pin, flange, sleeve, collar, adhesive, and adhesive tape. The securing device may be installed externally or can be designed into the fence post 12 or the stiffening insert 20 during manufacturing.
[0017] In an embodiment shown in FIG. 3 , in an embodiment, the first end 24 of the first portion 22 and the second end 34 of the second portion 30 are beveled 46 and 50 respectively, to generally engage the stiffening insert 20 inside the corners 44 and 48 of the shell 13 defining a cavity 15 . The angled edges 46 and 50 are beveled such that they fit inside the corners 44 and 48 to provide at least some degree of interference or gripping and to at least help retain the stiffening insert 20 in the post 12 and generally prevent or at least resist movement within the cavity 15 . Generally, the beveled edges 46 and 50 can be configured to fit the contours of standard fence posts. Such designs can be integrated into the stiffening inserts 20 during manufacture or can be implemented externally through post-manufacture tooling and designing. Additionally, the insert 20 may be configured with some degree of flexion between the members 22 , 30 , 36 so as to provide some degree of adjustment. Such adjustability allows the insert 20 to be used with posts having different internal dimensions or shapes. As such, one configuration of insert 20 may be used with a range of post dimensions and/or configurations. This feature also allows the insert to adjust to irregularities in the post as well as variations in manufacturing tolerances in the post.
[0018] In the embodiment shown in FIG. 4 , the stiffening insert 20 may be provided with multiple openings 54 positioned along a central axis 19 of the third portion 36 . These openings 54 can be aligned with the openings 28 present in the fence post 12 to engage rails 38 positioned horizontally as shown in FIG. 1 . The openings 54 are of sufficient dimension to allow a range of access for engaging the rails 38 . Instead of multiple openings 54 on the stiffening insert 20 , a single opening that extends longitudinally along the central axis 19 and is large enough to engage multiple rails 38 can also be designed in to the stiffening insert 20 . This configuration is tolerant of variations in the placement and dimensions of the openings 28 in the post such that the elongated openings 54 along the central axis 19 will be able to align with at least one of the openings 28 in the shell 13 .
[0019] The plurality of openings 54 in the insert 20 may enable securing the insert into a mounting surface 40 such as concrete. The openings 54 may also prevent damages to the insert 20 and/or the shell 13 due to expansion and contraction or any other impediments due to temperature fluctuations. An insert 20 without any openings 54 or a single opening may also withstand expansion and contraction issues due to temperature fluctuations.
[0020] The fence post 12 having a hollow shell 13 defining a cavity 15 may be made of polyvinyl chloride (PVC) and may be manufactured by extrusion molding or by any other standard manufacturing techniques for PVC fence components. Manufacturing of PVC and other plastic components for fence structures are well known in the art. Other suitable fence materials include but are not limited to plastic, chlorinated polyvinyl chloride (CPVC), acrylic, vinyl polymers, and polyethylene. The fence post 12 may have a length and width that generally conform to industry standards for fence components.
[0021] As shown in FIG. 1 , the insert 20 may be provided with a formed leading end 21 . The leading end 21 is the end which will be imbedded in the construction material, as shown, the ground 40 . The leading end 21 as shown is formed with tapered sides so as to form a point which will help facilitate imbedding the insert 20 into the ground 40 . Other variations of the leading end 21 are envisioned and fully within the scope of this application.
[0022] The stiffening insert 20 may be made of steel. Other suitable materials include but are not limited to galvanized steel, iron, cast iron, aluminum, or an alloy thereof. The stiffening insert of suitable thickness can be manufactured by casting, rolling, or by any other standard metal manufacturing processes. Other suitable materials include for example, reinforced polymer resin, composite material, or any other material that provides resistance to forces. The multiple openings 54 can be provided in the material that is formed into the insert or may be formed into the stiffening insert 20 during the manufacturing. The dimensions of the openings 54 and the spacing of the openings 54 conform to industry standard for fence components or can be determined depending upon the number of horizontal rails 38 desired and their dimensions. The stiffening insert 20 may also be coated with a protective layer such as, for example but not limited to, paint, powder coating, galvanizing, rubber, vinyl coating, or any other protective coating, treatment or layer to prevent corrosion or rust formation.
[0023] A method for reinforcing the fence structure 10 includes the steps of providing fence post 12 having an elongate shell 13 having an upper end 14 and lower end 16 with a plurality of openings 28 . The method further includes providing a stiffening insert 20 having a plurality of openings 54 in the third portion 36 and providing a plurality of rails 38 . The stiffening insert 20 is positioned inside the shell 13 of the post 12 , such that the plurality of openings 28 of the fence post 12 and the plurality of openings 54 of the stiffening insert 20 align. The plurality of rails 38 , through the plurality of openings 28 and 54 in the shell 13 and in the stiffening insert 20 respectively, are engaged to form a reinforced fence structure 10 .
[0024] In an embodiment, the stiffening insert 20 can extend below the mounting surface 40 to provide additional support as shown in phantom in FIG. 1 . The depth of extension below the ground may depend upon the total height of the fence post 12 , the dimensions of the stiffening insert 20 , the prevailing environmental conditions, and the nature of the mounting surface 40 . For example, in high-wind environments and in a soil-laden back yard, the stiffening insert 20 can extend below ground up to one-third of the height of the fence post 12 that is exposed above the surface. In a paved mounting surface such as, for example, asphalt, the depth of extension may be less. The mounting surface 40 may be soil, gravel, cement, concrete, asphalt, wood, brick, or any other composite material. The fence post 12 along with the stiffening insert 20 can be mounted using standard techniques such as, for example, by burying the post, using a spiked support, using a foundation socket, or a socket with a base plate.
[0025] In an embodiment, the stiffening insert 20 may not extend to the full length of the fence post 12 . For example, the stiffening insert 20 may extend up to three feet in a six-feet long fence post 12 . The length of extension may depend upon the total height of the fence post 12 , the dimensions of the stiffening insert 20 , the prevailing environmental conditions, and the nature of the mounting surface 40 . The length of extension may also depend upon the alignment of openings 54 with the openings of the fence post 28 for engaging horizontal rails 38 .
[0026] Another method for reinforcing a fence structure includes the steps of providing the stiffening insert 20 and manufacturing the shell 13 of fence post 12 , such that the shell 13 encloses the stiffening insert 20 . For example, the first portion 22 and the second portion 30 of the stiffening insert 20 may be molded into the shell 13 .
[0027] In an embodiment, the stiffening insert 20 may also be used to reinforce other fence components such as, for example, rails 38 . As disclosed herein for the fence post 12 , the stiffening insert 20 can be installed inside the rails 38 .
[0028] While embodiments have been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. The applicant has provided description and figures which are intended as illustrations of embodiments of the disclosure, and are not intended to be construed as containing or implying limitation of the disclosure to those embodiments. There are a plurality of advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiments of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods, without undue experimentation, that incorporate one or more of the features and/or steps of the disclosure and fall within the spirit and scope of the present disclosure and the appended claims.
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Disclosed is a system and apparatus for reinforcing a fence structure for example, to resist the potentially detrimental forces caused by wind and other environmental factors. An elongate stiffening insert for reinforcing a fence structure is configured to appear in cross section to generally resemble a Z-shape. The stiffening insert fits inside a fence post to reinforce the fence structure. The stiffening insert generally extends below the ground to provide support.
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FIELD OF THE INVENTION
This invention relates to compounds useful as antiretroviral agents. More particularly, this invention relates to pyridine and quinoline derivatives which inhibit replication of the retroviruses HIV-1, HIV-2 and human cytomegalovirus (HCMV).
BACKGROUND OF THE INVENTION
There are currently about seven nucleoside reverse transcriptase (RT) inhibitors (NRTIs), about three nonnucleoside RT inhibitors (NNRTI) and about six protease inhibitors (PI) officially approved for the treatment of HIV-infected individuals. Reverse transcriptase and protease are virus-encoded enzymes. The clinical efficacy of the individual drugs varies depending on the nature and the molecular target of the drugs.
U.S. Pat. No. 5,268,389 describes certain thiocarboxylate ester compounds that are said to inhibit replication of HIV. It is alleged that the selectivity of these compounds for HIV-1 is due to a highly specific interaction with HIV-1 RT.
U.S. Pat. No. 5,696,151 is directed to certain carbothioamides that inhibit replication of HIV-1 and reverse transcriptase mutants thereof.
The rapid emergence of HIV-1 strains resistant to several HIV-1 -specific RT inhibitors in cell culture and in AIDS patients has caused concern for further development of these inhibitors in the clinic. See, e.g., Balzarini et al, J. Virology 67(9): 5353-5359 (1993) (“Balzarini I”) and Balzarini et al, Virology 192: 246-253 (1993) (“Balzarini II”).
Failure of long-term efficacy of known drugs can be associated with the appearance of dose-limiting and/or long-term side-effects, or more importantly, with the emergence of drug-resistant virus strains. Both RT inhibitors and protease inhibitors tend to select for virus strains that show a reduced susceptibility for the particular drugs. Moreover, a considerable cross-resistance exists between drugs that act against the same target.
Attempts have been made to combine various HIV-1 RT inhibitors to eliminate virus resistance. See, e.g., Balzarini I, supra. However, there is still a need for new compounds for the treatment of HIV that act at a target (either viral or cellular) that is different from those at which the existing drugs act.
It is the purpose of this invention to provide compounds which, by themselves, can inhibit or suppress the emergence of HIV-1, HIV-2 and HCMV.
SUMMARY OF THE INVENTION
This invention relates to the novel compounds 2-[[1-(5-amino-2-methylphenyl)ethyl]sulfonyl]pyridine-N-oxide [compound 1],1,4-xylyl-bis-2-sulfonyl pyridine-N-oxide [compound 23], 1,4[1,2,4,5-tetramethylbenzyl]-bis-(2′-sulfonylpyridine-N-oxide) [compound 25], 2-(4′-tert-pentylphenylmethylsulfonyl)pyridine-N-oxide [compound 40], 2[1-(9-anthryl)methylsulfonyl]pyridine-N-oxide [compound 51], ethyl-N-[4-(pyridyl-N-oxide-2-sulfonylmethyl)phenylcarbonyl]carbamate [compound 60], 2-[(3-methoxy-4-benzyloxy)phenylmethylsulfonyl]pyridine-N-oxide [compound 61], 2-[[(2-nitro-5-methylphenyl)methyl]sulfonyl]pyridine-N-oxide [compound 62], 2-[[[2,5-bis(1-methylethyl)-4-bromophenyl]methyl]sulfonyl]pyridine-N-oxide [compound 63], 2-[[(3-nitro4-chlorophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 64], 2-[[(3,5-dinitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 65], 2-[[(3-methyl-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 66], 2-[[(3-nitro-4-methylphenyl)methyl]sulfonyl]pyridine-N-oxide [compound 67], 2-[[(2-chloro-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 69], 2-[(2,5-dimethylphenyl)chloromethylsulfonyl]-6-methylpyridine-N-oxide [compound73], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-6-chloropyridine-N-oxide [compound 76], 2-(2,5-dimethylphenylmethylsulfonyl)-6-chloropyridine-N-oxide [compound 77], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-4,6-dimethylpyridine-N-oxide [compound 81], 2[(2,5-dimethylphenyl)chloromethylsulfonyl]pyridine [compound 106], 8-ethyl-4-methyl-2-[(1-phenylethyl)sulfonyl]quinoline [compound 107], 2-[[1 -(2,5-dimethylphenyl)-2-methoxyethyl]sulfonyl]pyridine [compound 123], 3-chloro-2-[[1-(2,5-dimethylphenyl)ethyl]sulfonyl]pyridine-N-oxide [compound 124], 3-chloro-2-[[chloro-(2,5-dimethylpbenyl)methyl]sulfonyl]pyridine-N-oxide [compound 125], 3-chloro-2-[(phenylmethyl)thio]pyridine-N-oxide [compound 132], 3-chloro-2-[[(2,5-dimethylphenyl)methyl]thio]pyridine-N-oxide [compound 133], 4-(1,1 -dimethylethyl)-2-[(4-methoxyphenyl)methylthio]pyridine-N-oxide [compound 134], 3-chloro-2-[(phenylmethyl)sulfinyl]pyridine-N-oxide [compound 136], 2-[[(2,6-dichlorophenyl)methyl]thio]-3-methyl-pyridine-N-oxide [compound 137], 2-[[(2,6-dichlorophenyl)methyl]sulfinyl]-3-methyl-pyridine-N-oxide [compound 138], 2-[[(2,6-dichlorophenyl)methyl]sulfonyl]-3-methyl-pyridine-N-oxide [compound 139], 2[[(2,5-dimethylphenyl)methyl]thio]-1-methylpyridinium chloride [compound 142], 2-benzylthio-3-nitropyridine [compound 146], 2-((2,5-dimethylphenyl)methylthio) pyridine [compound 148], 6-chloro-(2-benzylthio)pyridine-N-oxide [compound 149], 2-(2,5-dimethylbenzylsulfonyl)pyridine [compound 150], 5-chloro-2(benzylthio) pyridine-N-oxide [compound 151], 2-(N-methyl-3-piperidylmethylthio)pyridine-N-oxide [compound 156], 2-(2,5-dimethylphenylmethylthio)pyridine hydrochloride [compound 157], 2-(1-cyano-2-phenylethenethio) pyridine-N-oxide [compound 158], 2-[1-cyano-2-(p-methoxyphenyl)ethenethio]pyridine-N-oxide [compound 159], 2-[1-cyano-2-(3,4,5-trimethoxyphenyl)ethenethio]pyridine-N-oxide [compound 160], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]pyridine [compound 161], 2-[[1-(2,5-dimethylphenyl)ethyl]thio]-4-methylquinoline [compound 162] and 2-(2,5-dimethylphenyl)methylsulfinyl)pyridine [compound 163], and pharmaceutically acceptable salts thereof
The compounds of this invention are useful for inhibiting replication of HIV-1, HIV-2 and HCMV in vitro and in vivo. The compounds are also useful in the therapeutic or prophylactic treatment of diseases caused by these viruses.
This invention additionally relates to pharmaceutical compositions containing one or more of the above recited compounds and a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the following novel compounds: 2-[[1-(5-amino-2-methylphenyl)ethyl]sulfonyl]pyridine-N-oxide [compound 1], 1,4-xylyl-bis-2-sulfonyl pyridine-N-oxide [compound 23], 1,4[1,2,4,5-tetramethylbenzyl]-bis-(2′-sulfonylpyridine-N-oxide) [compound 25], 2-(4′-tert-pentylphenylmethylsulfonyl)pyridine-N-oxide [compound 40], 2[1-(9-anthryl)methylsulfonyl]pyridine-N-oxide [compound 51], ethyl-N-[4-(pyridyl-N-oxide-2-sulfonylmethyl)phenylcarbonyl]carbamate [compound 60], 2-[(3-methoxy-4-benzyloxy)phenylmethylsulfonyl]pyridine-N-oxide [compound 61], 2-[[(2-nitro-5-methylphenyl)methyl]sulfonyl]pyridine-N-oxide [compound 62], 2-[[[2,5-bis(1-methylethyl)4-bromophenyl]methyl]sulfonyl]pyridine-N-oxide [compound 63], 2-[[(3-nitro-4-chlorophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 64], 2-[[(3,5-dinitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 65], 2-[[(3-methyl-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 66], 2-[[(3-nitro-4-methylphenyl)methyl]sulfonyl]pyridine-N-oxide [compound 67], 2-[[(2-chloro-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide [compound 69], 2-[(2,5-dimethylphenyl)chloromethylsulfonyl]-6-methylpyridine-N-oxide [compound73], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-6-chloropyridine-N-oxide [compound 76], 2-(2,5-dimethylphenylmethylsulfonyl)-6-chloropyridine-N-oxide [compound 77], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-4,6-dimethylpyridine-N-oxide [compound 81], 2[(2,5-dimethylphenyl)chloromethylsulfonyl]pyridine [compound 106], 8-ethyl-4-methyl-2-[(1-phenylethyl)sulfonyl]quinoline [compound 107], 2-[[1-(2,5-dimethylphenyl)-2-methoxyethyl]sulfonyl]pyridine [compound 123], 3-chloro-2-[[1-(2,5-dimethylphenyl)ethyl]sulfonyl]pyridine-N-oxide [compound 124], 3-chloro-2-[[chloro-(2,5-dimethylphenyl)methyl]sulfonyl]pyridine-N-oxide [compound 125], 3-chloro-2-[(phenylmethyl)thio]pyridine-N-oxide [compound 132], 3-chloro-2-[[(2,5-dimethylphenyl)methyl]thio]pyridine-N-oxide [compound 133], 4-(1,1-dimethylethyl)-2-[(4-methoxyphenyl)methylthio]pyridine-N-oxide [compound 134], 3-chloro-2-[(phenylmethyl)sulfinyl]pyridine-N-oxide [compound 136], 2-[[(2,6-dichlorophenyl)methyl]thio]-3-methyl-pyridine-N-oxide [compound 1371, 2-[[(2,6-dichlorophenyl)methyl]sufionyl]-3-methyl-pyridine-N-oxide [compound 138], 2-[[(2,6-dichlorophenyl)methyl]sulfonyl]-3-methyl-pyridine-N-oxide [compound 139], 2[[(2,5-dimethylphenyl)methyl]thio]-1-methylpyridinium chloride [compound 142], 2-benzylthio-3-nitropyridine [compound 146], 2-((2,5-dimethylphenyl) methylthio)pyridine [compound 148], 6-chloro-(2-benzylthio)pyridine-N-oxide [compound 149], 2-(2,5-dimethylbenzylsulfonyl) pyridine [compound 150], 5-chloro-2(benzylthio)pyridine-N-oxide [compound 151], 2-(N-methyl]-3-piperidylmethylthio)pyridine-N-oxide [compound 156], 2-(2,5-dimethylphenylmethylthio)pyridine hydrochloride [compound 157], 2-(1-cyano-2-phenylethenethio) pyridine-N-oxide [compound 158], 2-[1-cyano-2-(p-methoxyphenyl)ethenethio]pyridine-N-oxide [compound 159], 2-[1-cyano-2-(3,4,5-trimethoxyphenyl)ethenethio]pyridine-N-oxide [compound 160], 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]pyridine [compound 161], 2-[[1-(2,5-dimethylphenyl)ethyl]thio]-4-methylquinoline [compound 162] and 2-(2,5-dimethylphenyl)methylsulfinyl)pyridine [compound 163] and pharmaceutically acceptable salts thereof.
It will be apparent to those of skill in the art that certain compounds herein may have at least one asymmetrical carbon atom and therefore all isomers, including diastereomers and rotational isomers of such compounds are contemplated as being part of this invention. The invention includes (+)- and (−)-isomers in both pure form and in admixture, including racemic mixtures. Isomers can be prepared using conventional techniques, either by reacting optically pure or optically enriched starting materials or by separating isomers of a compound herein. Those skilled in the art will appreciate that for some compounds herein, one isomer may show greater pharmacological activity than other isomers.
It will also be apparent to those of skill in the art that certain compounds herein can exist in unsolvated and solvated forms, including hydrated forms. In general, the solvated forms, with pharmaceutically acceptable solvents such as water, ethanol and the like, are equivalent to the unsolvated forms for purposes of this invention.
It will also be apparent to those of skill in the art that certain compounds herein with a basic group can form pharmaceutically acceptable salts with organic and inorganic acids. Examples of suitable acids for salt formation are hydrochloric, sulfuric, phosphoric, acetic, citric, oxalic, malonic, salicylic, malic, fumaric, succinic, ascorbic, maleic, methanesulfonic and other mineral and carboxylic acids well known to those in the art. The salt is prepared by contacting the free base form with a sufficient amount of the desired acid to produce a salt. The free base form may be regenerated by treating the salt with a suitable dilute aqueous base solution such as dilute aqueous sodium bicarbonate. The free base form differs from its respective salt form somewhat in certain physical properties, such as solubility in polar solvents, but the salt is otherwise equivalent to its respective free base forms for purposes of the invention.
It will also be apparent to those of skill in the art that certain compounds herein may be acidic (e.g., compounds containing a carboxyl group). Acidic compounds according to the present invention can form pharmaceutically acceptable salts with inorganic and organic bases. Examples of such salts are the sodium, potassium, calcium, aluminum, lithium, gold and silver salts. Also included are salts formed with pharmaceutically acceptable amines such as ammonia, alkyl amines, hydroxyalkylamines, N-methylglucamine, and the like.
Compounds such as those disclosed herein may be prepared by a variety of methods known to those skilled in the art. For example, U.S. Pat. Nos. 3,960,542, 4,019,893, 4,050,921, and 4,294,970 the contents of each being incorporated herein by reference, describe methods of preparing 2-thio-, 2-sulfinyl-, and/or 2-sulfonyl-pyridine N-oxide derivatives. For example, the parent 2-thiopyridine N-oxides may be prepared, e.g., by two procedures: (1) the reaction of 2-chloropyridine N-oxide with the appropriate mercaptan in the presence of an acid acceptor such as an alkaline earth hydroxide; (2) reaction of the sodium salt of 2-mercaptopyridine N-oxide with a suitable halide preferably of, but not limited to, the benzyl type. The yields of the two procedures are comparable.
The aryl (or heteroaryl) alkylthiopyridines produced above may be oxidized by methods well known to those skilled in the art. The oxidation involves the conversion of both the sulfur and nitrogen to their higher oxidative states in a single preparative step. In this case the products are sulfones as the sequence of oxidation proceeds from sulfide→sulfoxide→sulfone→sulfone N-oxide. The oxidant most generally employed, but not limited to, is 30-50% hydrogen peroxide in glacial acetic acid. In excess of three equivalents of peroxide is necessary. The conversion of the aryl (or heteroaryl) alkylthiopyridine-N-oxides to analogous sulfinyl or sulfonyl compound may be accomplished by employing one or two equivalents of an oxidizing agent selected from, but not necessarily limited to, hydrogen peroxide, peracetic acid, and the aromatic peroxy acids. The ratio of peroxide to substrate varies with the desired product.
The solvents employed may vary with the oxidant as described in the literature (Katritsky and Lagowski, Chemistry of the Heterocyclic N-Oxides, Academic Press, 1971). Glacial acetic acid and water are preferred when hydrogen peroxide is used and a nonpolar solvent such as chloroform is preferred for use with the aromatic peroxy acids. When water is employed as a solvent, a catalyst of the nature of a tungsten, vanadium, zirconium or molybdenum salt (U.S. Pats. Nos. 3,005,852, 3,006,962, and 3,006,963 and British Pat. No. 1,335,626; the contents of each being incorporated by reference herein) is generally used. Temperature and time are a function of the sulfide employed with the range varying from about 50° C. to reflux in the case of water and acetic acid to about 0° to about 60° C. with chloroform.
The synthesis of 2-(alpha-aryl-alpha-chloromethyl sulfonyl) pyridine-N-oxides is also known and described in U.S. Pat. No. 4,360,677 the contents of which are incorporated by reference herein. The types of starting materials generally employed in the preparation of these compounds arc known to those skilled in the art. These parent 2-aryl methylsulfonylpyridine-N-oxides may be prepared by methods described in U.S. Pat. No. 3,960,542. Their subsequent conversion to (alphachloromethylsulfonyl)pyridine-N-oxides may be carried out using a modification of a known procedure. (C. Y. Meyers, et al., J. Org. Chem., 91,7510 (1969); C. Y. Meyers, et al., Tetrahedron Lett., 1105 (1974); the contents of each being incorporated by reference herein).
The solvent, N,N-dimethylformamide, is used without drying. Sodium hydroxide (97 -98%) is freshly ground to a powder before use, care being taken to avoid prolonged exposure to moisture. Temperature may generally be maintained from about −5° to about +5° C., with reaction times between about 25 and about 35 min.
The synthesis of substituted pyridine N-oxide compounds is described in U.S. Pat. No. 4,394,155 and foreign patent publication EP 36388 the contents of each being incorporated by reference herein. The substituted pyridine N-oxide compounds are generally prepared, e.g., by first preparing the appropriate thio compound. An essentially equimolar amount of an alkali metal alkoxide is added with stirring at room temperature under an atmosphere of nitrogen to the substituted or non-substituted benzylmercaptan dissolved in a suitable solvent (such as a C 1 to C 4 aliphatic alcohol, preferably methanol). The resulting solution is added slowly to a solution of a substituted pyridine N-oxide hydrochloride, which has been treated with an essentially equimolar amount of alkali metal alkoxide. The molar ratio of mercaptide anion to pyridine N-oxide is maintained at about 1, and stirring, nitrogen atmosphere and reaction at room temperature are also maintained throughout the complete reaction. After all the reactants have been combined, the reaction mixture is refluxed from about one to about six hours. The thio product which precipitates when the reaction mixture is poured into a large excess of ice water is filtered, washed several times with water, air dried and recrystallized from an alcohol such as wet ethanol.
The thio compound may be oxidized to the desired sulfinyl or sulfonyl compound by known means, e.g. the thio compound dissolved in excess chloroform is stirred into a chloroform solution of m-chloroperbenzoic acid at about −10° to about 10° C. The reaction vessel is stoppered and kept at about 0° C. for about 24 hr. The by-product, m-chlorobenzoic acid, is removed by filtration and the remaining chloroform solution washed thoroughly with aqueous sodium bicarbonate solution, then water. The chloroform solution is dried (e.g. with anhydrous magnesium sulfate) and the solvent evaporated. The final product may be recrystallized from a suitable solvent (e.g. lower alcohol).
The compounds of the present invention can be administered in any conventional dosage form known to those skilled in the art. Pharmaceutical compositions containing the compounds herein can be prepared using conventional pharmaceutically acceptable excipients and additives and conventional techniques. Such pharmaceutically acceptable excipients and additives include non-toxic compatible fillers, binders, disintegrants, buffers, preservatives, anti-oxidants, lubricants, flavorings, thickeners, coloring agents, emulsifiers and the like. All routes of administration are contemplated including, but not limited to, parenteral, transdermal, subcutaneous, intramuscular, sublingual, inhalation, rectal and topical.
Thus, appropriate unit forms of administration include oral forms such as tablets, capsules, powders, cachets, granules and solutions or suspensions, sublingual and buccal forms of administration, aerosols, implants, subcutaneous, intramuscular, intravenous, intranasal, intraoccular or rectal forms of administration.
When a solid composition is prepared in the form of tablets, e.g., a wetting agent such as sodium lauryl sulfate can be added to micronized or non-micronized compounds herein and mixed with a pharmaceutical vehicle such as silica, gelatine starch, lactose, magnesium stearate, talc, gum arabic or the like. The tablets can be coated with sucrose, various polymers, or other appropriate substances. Tablets can be treated so as to have a prolonged or delayed activity and so as to release a predetermined amount of active principle continuously or at predetermined intervals, e.g., by using ionic resins and the like.
A preparation in the form of gelatin capsules may be obtained, e.g., by mixing the active principle with a diluent, such as a glycol or a glycerol ester, and incorporating the resulting mixture into soft or hard gelatin capsules.
A preparation in the form of a syrup or elixir can contain the active principle together, e.g., with a sweetener, methylparaben and propylparaben as antiseptics, flavoring agents and an appropriate color.
Water-dispersible powders or granules can contain the active principle mixed, e.g., with dispersants, wetting agents or suspending agents, such as polyvinylpyrrolidone, as well as with sweeteners and/or other flavoring agents.
Rectal administration may be provided by using suppositories which may be prepared, e.g., with binders melting at the rectal temperature, for example cocoa butter or polyethylene glycols.
Parenteral, intranasal or intraocular administration may be provided by using, e.g., aqueous suspensions, isotonic saline solutions or sterile and injectable solutions containing pharmacologically compatible dispersants and/or solubilizers, for example, propylene glycol or polyethylene glycol.
Thus, to prepare an aqueous solution for intravenous injection, it is possible to use a co-solvent, e.g., an alcohol such as ethanol or a glycol such as polyethylene glycol or propylene glycol, and a hydrophilic surfactant such as Tween® 80. An oily solution injectable intramuscularly can be prepared, e.g., by solubilizing the active principle with a triglyceride or a glycerol ester.
Topical administration can be provided by using, e.g., creams, ointments or gels.
Transdermal administration can be provided by using patches in the form of a multilaminate, or with a reservoir, containing the active principle and an appropriate solvent.
Administration by inhalation can be provided by using, e.g., an aerosol containing sorbitan trioleate or oleic acid, for example, together with trichlorofluoromethane, dichlorofluoromethane, dichlorotetrafluoroethane or any other biologically compatible propellant gas; it is also possible to use a system containing the active principle, by itself or associated with an excipient, in powder form.
The active principle can also be formulated as microcapsules or microspheres, e.g., liposomes, optionally with one or more carriers or additives.
Implants are among the prolonged release forms which can be used in the case of chronic treatments. They can be prepared in the form of an oily suspension or in the form of a suspension of microspheres in an isotonic medium.
The daily dose of a compound as described herein for treatment of a disease or condition cited above is about 0.001 to about 100 mg/kg of body weight per day, preferably about 0.001 to about 10 mg/kg. For an average body weight of 70 kg, the dosage level is therefore from about 0.1 to about 700 mg of drug per day, given in a single dose or 2-4 divided doses. It is contemplated that any range of the aforementioned doses may be administered at intervals greater than daily, e.g., one of four times per week over a period of several weeks or for greater periods. The exact dose, however, is determined by the attending clinician and is dependent on the potency of the compound administered, the age, weight, condition and response of the patient.
The therapeutically effective amount of the compounds of this invention that can be combined with the pharmaceutically acceptable carrier to produce a single dosage form will vary depending upon the age and condition of the host treated and the particular mode of administration. In general, the compounds of this invention are most desirably administered at a concentration level that will generally afford antiretrovirally effective results without causing any medically unacceptable harmful or deleterious side effects.
While the compounds of this invention can be administered as the sole active pharmaceutical agents, the compounds can also be used in combination with one or more other pharmaceutical agents which are not deleterious to the activity of the compounds of this invention or whose combination with the compounds will not have a deleterious effect on the host treated. Indeed, it is also contemplated that compounds of this invention may be combined with other antiviral agents or other agents useful in the treatment of conditions resulting from viral infection.
The following examples are provided to merely illustrate certain aspects of the present invention and should not be construed as a limitation thereof.
EXAMPLE 1
Preparation of 2-[[1-(5-amino-2-methylphenyl)ethyl]sulfonyl]-pyridine-N-oxide
To a stirred room temperature solution of 3.0 g (0.01 mole) of 2-[[1-(5-acetylamino-2-methylphenyl)ethyl]thio]-pyridine-N-oxide in 10 ml of methanol were added 0.12 g of Na 2 WO 4 followed by 1 g of 35% hydrogen peroxide added over 20 minutes. The exothermic reaction was cooled using a room temperature water bath. The mixture was stirred for 20 minutes, and then treated dropwise with another 1.3 g of 35% H 2 O 2 . The mixture was warmed to 35-43° C. for two hours, and then left to stir at room temperature overnight. The mixture was then treated with 5 ml of ethanol, 10 ml of water, and 5 ml of concentrated HCl and heated on a steam cone for one hour. The mixture was cooled, diluted with 20 ml of water and filtered to remove a solid. The filtrate was made basic with concentrated aqueous ammonium hydroxide to give a tacky solid. This solid was taken up in 30 ml of water and 3 ml of concentrated HCl and some insoluble material was filtered off. The filtrate was basified to give a solid precipitate that was filtered off, washed with water, and left to dry overnight. The dry solid weighed 0.85 g and melted at 165-170° C. Recrystallization gave a solid with a melting point of 184-188° C. and having infrared and NMR spectra consistent with the proposed structure.
EXAMPLE 2
Preparation of 1,4-xylyl-bis-2-sulfonyl pyridine-N-oxide
To a mixture of 14 g of 1,4-xylyl-bis-2-thio-pyridine-N-oxide in 175 ml of glacial acetic acid was added 20 ml of H 2 O 2 (30% in water). The mixture was stirred over a weekend and then a further 8 ml of 30% H 2 O 2 was added and the mixture was heated to 50-60° C. for 2 hours. The mixture was cooled and evaporated to dryness. Chloroform was then added and the mixture was brought to boiling and then cooled and let stand overnight. The insoluble product was filtered off, washed with ethanol, and then with chloroform. 13.6 g of final product was obtained, having a melting point of 233-235° C. Analysis calculated for C 18 H 16 N 2 S 2 : C=51.42; H=3.84; N=6.66. Found: C=47.39; H=4.10; N=6.74.
EXAMPLE 3
Preparation of 1,4[1,2,4,5-tetramethylbenzyl]-bis-(2′-sulfonylpyridine-N-oxide)
To a mixture of 1,4[1,2,4,5-Tetramethylbenzyl]-bis-(2′-thiopyridine-N-oxide) in 175 ml of glacial acetic acid was added 25 ml of 30% aqueous H 2 O 2 . The reaction mixture was allowed to stir overnight, then an additional 25 ml of 30% aqueous H 2 O 2 was added, and the mixture was heated at 50-60° C. for 4 hours. Then, 600 ml of water and 100 g of ice was added. The white solid was filtered off and dried at room temperature, having a melting point of 242-244° C. Recovery was 2.2 g. An infrared spectrum was consistent with the structure.
EXAMPLE 4
Preparation of 2-(4′-tert-pentylphenylmethylsulfonyl)pyridine-N-oxide)
A mixture of 2.9 g (0.01 mole) of 2-(4′-t-pentylphenylmethylthio)pyridine-N-oxide) with 50 ml of chloroform and 80 ml of pH 7.5 phosphate buffer was maintained at 40° C. while 4 g (0.02 mole) of 85% metachloroperbenzoic acid (MCPBA) dissolved in 50 ml of chloroform was added. The mixture was stirred overnight, and the chloroform phase was then separated, washed with sodium bicarbonate, decanted and dried over anhydrous Na 2 SO 4 . The chloroform was filtered from the Na 2 SO 4 and evaporated to leave 2.5 g of an oil which did not crystallize. An infrared spectrum was consistent with the structure.
EXAMPLE 5
Preparation of 2[1-(9-anthryl)methylsulfonyl]pyridine-N-oxide
A mixture of 14.27 g (0.045 mole) of 2-[1-(9-anthryl)methylthio-pyridine-N-oxide in 250 ml of chloroform was cooled to 10° C. and stirred. Then 18 g (0.09 mole) of metachloroperbenzoic acid dissolved in 250 ml of chloroform was added slowly, and the reaction mixture was allowed to warm to room temperature and held at that temperature overnight. The reaction mixture was washed with NaHCO 3 solution in water, the chloroform layer was separated, and then dried with anhydrous sodium sulfate. The chloroform solution was filtered and the solvent removed. The residue was recrystallized from ethanol to give 10 g (66%) of a solid having a melting point of 213-215° C. Calculated for C 20 H 15 N 3 S: C=68.76; H=4.33; N=4.01. Found: C=67.32; H=4.25; N=3.89.
EXAMPLE 6
Preparation of ethyl-N-[4-(pyridyl-N-oxide-2-sulfonylmethyl)phenylcarbonyl]carbamate
To 5.86 g (0.020 mole) of 4[((1-oxo-2-pyridyl)sufonyl)methyl]benzoic acid in 50 ml of methylene chloride was added 2 g of triethylamine. The mixture was stirred at room temperature for 10 minutes and then 1.9 ml of ClCO 2 Et was added at 0° C., and the mixture was stirred at 0° C. for 30 minutes. To this mixture was added 1.78 g of urethane (H 2 NCO 2 Et) and the mixture was refluxed for 60 minutes. The reaction mixture was evaporated under reduced pressure, dissolved in ethanol, and poured into water. The solid was filtered off, washed with ether, and air-dried to give 2 g of product having a melting point of 90-92° C. An NMR spectrum was consistent with the structure.
EXAMPLE 7
Preparation of 2-[(3-methoxy-4-benzyloxy)phenylmethylsulfonyl]pyridine-N-oxide
A mixture of 6.0 g (0.017 mole) of 2-[(3-Methoxy-4-benzyloxy) phenylmethylthio]-pyridine-N-oxide, 0.02 g of Na 2 WO 4 and 10 ml of glacial acid was prepared and brought to 40° C. To the above mixture was added 4.25 ml (0.017 mole) of 35% hydrogen peroxide. The whole mixture was then brought to 85° C. for one hour, cooled and then poured into ice water. The solid product was filtered off and dried to give 7.1 g of crude material. This crude material was recrystallized from ethanol to give 3.0 g of pure product having a melting point of 137-139° C.
EXAMPLE 8
Preparation of 2-[[(2-nitro-5-methylphenyl)methyl]sulfonyl]pyridine-N-oxide
Five grams [5.0 g (0.02 mole)] of 2-[[(5-Methyl-2-nitrophenyl) methyl]sulfinyl]pyridine-N-oxide, was slurried in 30 ml of glacial acetic acid. The slurry was stirred while 3.6 g of 40% peracetic acid (1.11 mole) was added dropwise. After addition, the mixture was heated to 60° C. for 4 hours, allowed to cool and stirred at room temperature overnight. Excess peracetic acid was destroyed using NaHSO 3 . The mixture was neutralized with K 2 CO 3 solution, and the solid was filtered and washed with water. After drying, the solid melted at 178-183° C. and had an NMR consistent with the proposed structure.
EXAMPLE 9
Preparation of 2[[[2,5-bis-(1-methylethyl)-4-bromophenyl]methyl] sulfonyl]pyridine-N-oxide
A solution of aqueous hydrogen peroxide (1.6 g) was added dropwise to a mixture of 3.0 g (0.0079 mole) of 2[[[2,5-bis-( 1-Methylethyl)-4-bromophenyl]-methyl]thio]-pyridine-N-oxide, 50 ml of methanol, and 0.1 g of Na 2 WO 4 . The suspension was heated at reflux for 2 hours and everything dissolved. About 25 ml of methanol was removed from the mixture, and the remaining solution was allowed to crystallize at room temperature. The crystalline material, having a melting point of 161-175° C., was filtered off and recrystallized from methanol with a resulting melting point of 171-174° C. The infrared and NMR spectra were consistent with the proposed structure.
EXAMPLE 10
Preparation of 2-[[(3-nitro-4-chlorophenyl)methyl]sulfonyl]pyridine-N-oxide
To a mixture of 14.0 g (0.0426 mole) of 2-[[(4-chloro-3-nitrophenyl) methyl]sulfinyl]-pyridine-N-oxide in 35 ml of acetic acid was added 10.1 g of peracetic acid (40% in acetic acid) dropwise over one hour. The temperature of the reaction mixture rose to 27° C. before a water bath was placed on the flask to hold the temperature at 25° C. After addition, the mixture was heated to 70° C. for five hours. The mixture was cooled, and 20 ml additional acetic acid and solid sodium bisulfate and water were added to destroy the excess peracetic acid. The aqueous mixture was neutralized with potassium carbonate and chilled in an ice bath to precipitate an almost white solid. This solid was filtered off, washed with water, dried under vacuum overnight, and had a melting point of 162-164° C. Infrared and NMR spectra were both consistent with the proposed structure. The product was recrystallized from ethanol to give needle-like white crystals having a melting point of 168-170° C. C,H,N calculated for C 12 H 9 ClN 2 O 5 S: C=43.85%; H=2.76%; N=8.52%. Found: C=43.27% H=2.65%; N=8.21%.
EXAMPLE 11
Preparation of 2-[[(3,5-dinitrophenyl)methyl]sulfonyl]pyridine-N-oxide
To 14.0 g (0.043 mole) of 2-[[(3,5-dinitrophenyl)methyl]sulfinyl]-pyridine-N-oxide in 35 ml of glacial acetic acid was added, dropwise over 0.5 hours with stirring, 8.2 g of 40% peracetic acid in acetic acid. After addition was complete, the mixture was heated to 70° C. for 4.5 hours. The mixture was cooled to room temperature, and then an additional 2.0 g of 40% peracetic acid was added, and the mixture heated to 45-50° C. for three hours while stirring. The mixture became quite thick, so 20 ml of glacial acetic acid was added to enable better stirring and heating was continued at 70° C. for one more hour, followed by stirring at 30° C. overnight. Workup of a small aliquot indicated some sulfoxide to still be present, so heating was continued at 65-70° C. for 4 more hours. The excess peracetic acid was then destroyed by adding 100 ml of water and sodium bisulfite. After neutralizing the mixture to pH 4 with potassium carbonate, the white solid was filtered off, and then dried under vacuum. Yield was 11.5 g or 79%, having a melting point of 198-201° C. This material was recrystallized from ethanol to give a white solid, melting point 202-204° C. Infrared and NMR spectra were consistent with the proposed structure.
EXAMPLE 12
Preparation of 2-[[(3-methyl-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide
To a mixture of 9.5 g of 2-[[(3-methyl-4-nitrophenyl)methyl]sulfinyl]-pyridine-1-oxide in 50 ml of acetic acid was added, dropwise with stirring at room temperature, 9.17 g of 40% peracetic acid in acetic acid. After addition, a short period of heating was required to complete the reaction. Excess peracetic acid was then destroyed by the addition of sodium bisulfite and this was followed by the addition of 200 ml of water and potassium carbonate to neutralize the acidic solution. The white solid was filtered off and washed with water. Yield 9.7 g, melting point of 160-162° C. Infrared and NMR spectra supported the proposed structure.
EXAMPLE 13
Preparation of 2-[[(3-nitro-4-methylphenyl)methyl]sulfonyl]pyridine-N-oxide
To a mixture of 12.1 g (0.042 mole) 2-[[(4-methyl-3-nitrophenyl)methyl]sulfinyl]-pyridine-1-oxide in 35 ml of acetic acid was added, dropwise at room temperature over one-half hour, a solution of 9.2 g (1. 16 mole) of 40% peracetic acid in acetic acid. The reaction mixture was heated to 70° C. for two hours, and then allowed to cool and stir at room temperature overnight. An additional period of heating at 70° C. for five hours was instituted after which time work-up of a small portion of the mixture indicated some starting material to still be present. Heating and stirring at 70° C. for two more hours, and then standing at room temperature over the weekend completed the reaction. Excess peracetic acid was then destroyed with sodium bisulfite followed by the addition of 100 ml of water and neutralization with potassium carbonate. The aqueous mixture was chilled in an ice bath to precipitate yellow/white crystals. These were filtered off, washed with water and dried. Recrystallization from ethanol gave 2.9 g of white fluffy needles, having a melting point of 154-156° C. Infrared and NMR spectra were in agreement with the proposed structure.
EXAMPLE 14
Preparation of 2-[[(2-chloro-4-nitrophenyl)methyl]sulfonyl]pyridine-N-oxide
To a mixture consisting of 16.1 g (0.055 mole) of 2-[[(2-chloro-4-nitrophenyl)-methyl]sulfinyl]-pyridin-1-oxide and 60 ml of acetic acid was added, dropwise at room temperature over 0.5 hours, 13.5 g (1.3 mole) of peracetic acid in acetic acid (40%). The mixture was heated at 70° C. for six hours. The reaction was worked up in the usual fashion, but the product proved to be a mixture of the starting material and desired sulfone. The isolated material (10 g), estimated to contain about 16% sulfoxide, was subsequently redissolved in 40 ml of acetic acid and 1.33 g of 40% peracetic acid in acetic acid was added. The mixture was heated for seven hours at 70° C. and then stirred at room temperature overnight. The excess peracetic acid was destroyed with sodium bisulfite, the mixture was then poured into ice water and then neutralized with potassium carbonate. The solid was filtered off and dried, having a melting point of 199-201 ° C. An NMR spectrum supported the proposed structure.
EXAMPLE 15
Preparation of 2-[(2,5-dimethylphenyl)chloromethylsulfonyl]-6-methylpyridine-N-oxide
a) Preparation of 2-[(2,5-dimethylphenyl)methylthio]-6-methylpyridine-1-oxide
A mixture of 4.48 g (0.020 mole) of 2-bromo-6-methylpyridine hydrochloride, 3.34 g (0.022 mole) of 2,5-dimethylbenzylmercaptan and 0.88 g (0.022 mole) of powdered sodium hydroxide were stirred together at room temperature in 35 ml of DMF for 3.5 hours. The reaction mixture was poured into water and the precipitate filtered off and washed with water. Yield 1.96 g or 38%.
b) Preparation of 2-[(2,5-dimethylphenyl)methylsulfonyl]-6-methylpyridine-1-oxide
The sulfide isolated in step (a) above was dissolved in 15 ml of glacial acetic acid and then 2 ml of 30% hydrogen peroxide was added along with 50 mg of sodium tungstate. The reaction mixture was heated at 40° C. for two hours, cooled, and poured into water to percipitate the product. Yield, 1.53 g.
c) Preparation of 2[(2,5-dimethylphenyl)chloromethylsulfonyl]-6-methylpyridine-N-oxide
The sulfone (1 .53 g or 0.0053 mole) prepared in step (b) above, was added to a mixture of 0.24 g (0.006 mole) of NaOH, 1.1 g (0.007 mole) of carbon tetrachloride and 15 ml of DMF at −10-0° C. After 30 minutes of stirring, the reaction mixture was quenched with water and the precipitate was filtered off, washed with water, and dried. Yield 1.67 g, melting point 177° C., with decomposition. An NMR spectrum supported the proposed structure.
EXAMPLE 16
Preparation of 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-6-chloropyridine-N-oxide
To a stirred and cooled solution of 5.44 g (0.018 mole) of 2-[1-(2,5-dimethylphenyl)ethylthio]-6-chloropyridine-N-oxide in 100 ml of chloroform was added 12 g (0.05 mole) of metachloroperbenzoic acid in 150 ml of chloroform. The reaction mixture was kept cold in a refrigerator for one day. The precipitated metachlorobenzoic acid was removed and the reaction mixture was washed with sodium bicarbonate, and then water. The chloroform phase was dried, and the chloroform then removed using a vacuum. The solid product (5.0 g) had a melting point of 190° C. to 198° C. which was recrystallized from ethanol/ethyl acetate (95/5) to give 3.2 g (55%) of product. Melting point was 197-200° C. Analysis for C 15 H 16 NO 3 SCl Calc: C=55.27, H=4.95, N=4.30, S=9.84, Cl=10.88. Found: C=55.20, H=4.95, N=3.98, S=9.47, Cl=10.83.
EXAMPLE 17
Preparation of 2-(2,5-dimethylphenylmethylsulfonyl)-6-chloropyridine-N-oxide
To a stirred solution of 3.5 g (0.01 25mole) of 2-(2,5-dimethylphenyl)-methylthio)-6-chloropyridine-N-oxide in 75 ml of acetic acid was added 150 mg of sodium tungstate and then 10 g of 30% hydrogen peroxide over a period of 10 minutes. The reaction mixture was heated at 45° C. for 2 hours and allowed to stand overnight. The solid product was recrystallized from ethanol/water (75/25). Melting point was 208 to 209° C. The product showed JR bands at 1340 and 1180 cm−1 ascribed to SO 2 .
EXAMPLE 18
Preparation of 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]-4,6-dimethylpyridine-N-oxide
To a stirred and cooled solution of 2.88 g (0.01 mole) of 2-(1-(2,5-dimethylphenyl)ethylthio)-4,6-dimethylpyridine-N-oxide in 50 ml of chloroform was added 7.5 g (0.043 mole) of 80% active metachloroperbenzoic acid. The reaction mixture was kept cold in a refrigerator for 2 days. The precipitated metachlorobenzoic acid was removed and the reaction mixture was washed with sodium bicarbonate, and then water. The chloroform phase was dried, and the chloroform then removed using vacuum. The solid product (3.0 g or 98%) was recrystallized from ethanol/water. Melting point was 201-204° C. Analysis for C 17 H 21 SO 3 N Calc: C=64.08,H=6.62, N=4.38, S=10.03 Found: C=62.53,H=7.09, N=4.16,S=9.64.
EXAMPLE 19
Preparation of 2-[(2,5-dimethylphenyl)chloromethylsulfonyl]pyridine
A mixture of 2.0 g (0.0064 mole) of 2-[(2,5-dimethylphenyl)-chloromethylsulfonyl]-pyridine N-oxide, 3.5 g (0.026 mole) of PCl 3 and 15 ml of chloroform was refluxed for one hour. Addition of ethanol to destroy excess PCl 3 and evaporation of the solvents left 2.6 g of crude product. The crude material was recrystallized from ethanol to give 1.5 g (79%) of crystalline material having a melting point of 117-119° C. Infrared and NMR spectra were in agreement with the structure. Analysis calculated for C 14 H 14 ClNO 2 S: C=56.85; H=4.77; N=4.74. Found: C=56.67; H=4.78; N=4.81.
EXAMPLE 20
Preparation of 8-ethyl-4-methyl-2-[(1-phenylethyl)sulfonyl]-quinoline
To a mixture of 4.5 g of 8-ethyl-4-methyl-2-[(1-phenylethyl)thio]-quinoline in 40 ml of acetic acid was added slowly 17.3 g of 40% peracetic acid in acetic acid. The mixture was stirred for three hours in an ice bath, brought to room temperature, and then stirred at room temperature overnight. A white precipitate formed, which was filtered off and recrystallized from ethanol, having a melting point of 146.5-147.5° C. Yield was 2.7 g. An NMR spectrum supported the structure. C,H,N,S calculated for C 22 H 25 NO 2 S: Theoretical: C=71.91; H=6.86; N=3.81; S=8.73; Found: C=71.73; H=7.00; N=3.53; S=6.46.
EXAMPLE 21
Preparation of 2-[[1-(2,5-dimethylphenyl)-2-methoxyethyl]sulfonyl]pyridine
The starting material (0.1 g) was placed in 2 ml of methanol and 10 drops of 40% Triton B were added. The mixture was heated at 40° C. for two hours, and the methanol was then allowed to evaporate. An NMR spectrum was consistent with the proposed structure, and the compound had a melting point of 91-93° C.
EXAMPLE 22
Preparation of 3-chloro-2-[[1-(2,5-dimethylphenyl)ethyl]sulfonyl]pyridine-N-oxide
A solution 3.0 grams of 3-chloro-2-[[1-(2,5-dimethylphenyl)methyl]sulfonyl pyridine-N-oxide in 15 ml of dimethylformamide was cooled to 5° C. and then treated with 0.5 g of NaOH. The mixture was stirred for five minutes and then 0.75 ml of methyl iodide was added. The mixture was stirred for two more hours, and then allowed to stand overnight. Cold water was added to precipitate the product. The solid was filtered off, washed with water and dried, yield 2.4 g, melting point of 148-1 54° C. An infrared spectrum and the elemental analysis for CH&N confirmed the structure.
EXAMPLE 23
Preparation of 3-chloro-2-[[chloro(2,5-dimethylphenyl)methyl]sulfonyl]pyridine-N-oxide
To a suspension of 2.2 g (0.01 mole) of 3-chloro-2-[[1-(2,5-dimethylphenyl)-methyl]sulfonyl]pyridine-N-oxide in 10 ml of dimethylformamide (DMF) was added 2 g (0.013 mole) of carbon tetrachloride. The mixture was cooled to 15° C. and then treated with 0.5 g (0.013 mole) of NaOFl. The mixture was stirred and allowed to warm to room temperature for two hours. It was then poured into cold water and the solid was filtered off, having a melting point of 125-127° C. Infrared and NMR spectra were consistent with the proposed structure.
EXAMPLE 24
Preparation of 3-chloro-2-[(phenylmethyl)thio]pyridine-N-oxide
A mixture of 5 g of 2,3-dichloropyridine-N-oxide, 4 g of sodium sulfide, and 30 ml of water was heated to 70° C. for three hours. The mixture was cooled and then 3.8 g of benzyl chloride was added dropwise. The resulting mixture was heated to 70° C. for four hours and then cooled and extracted with toluene. The toluene solution was dried with Na 2 SO 4 and the toluene then removed. 10 ml of toluene was then added back and the crystalline precipitate was filtered off and washed with 5 ml of cold toluene. 1.4 g of white crystals were obtained, having a melting point of 70-73° C. The elemental analysis for CH&N, the infrared spectrum and the NMR spectrum were all consistent with the proposed structure. A second (1.8 g) and third (0.1 g) crop could be obtained from the toluene mother liquors and these crops were recrystallized from ether to give a further 1.5 g of pure material having a melting point of 70-74° C.
EXAMPLE 25
Preparation of 3-chloro-2-[[(2,5-dimethylphenyl)methyl]thio]pyridine-N-oxide
2,3-Dichloropyridine N-oxide (4.3 g, 0.026 mole) (prepared according to U.S. Pat. No. 3,850,939) and sodium sulfide (3.4 g, 0.026 mole) were mixed with 25 mL of water and then heated to 70 degrees for two hours. The resulting mixture was cooled to room temperature and treated with 2,5-dimethylbenzyl chloride (4.3 g, 0.026 mole) drop wise. After the addition, the mixture was heated to 70 degrees for four hours, then cooled in an ice bath. The precipitated solid was filtered and washed with cold toluene leaving 3.5 g of product. Recrystallization from toluene afforded pure product having a melting point of 77-80° C. The compound was identified by its NMR spectrum. NMR data (CDCl 3 ): 2.3 (s, 6H); 4.5 (s, 2H); 7.1-8.0 (m, 6H).
EXAMPLE 26
Preparation of 4-(1,1-dimethylethyl)-2-[(4-methoxyphenyl)methylthio]pyridine-N-oxide
Under nitrogen, to a solution of 10 g (0.065 mole) of 4-methoxybenzyl ercaptan in 50 ml of methanol were added 2.6 g of NaOH dissolved in 5 ml of water and 40 ml of methanol. To the above mixture was slowly added 12 g (0.065 mole) of 2-chloro-4-t-butylpyridine-N-oxide dissolved in 50 ml of methanol. The mixture was refluxed under nitrogen with stirring for about 3 hours, and then allowed to stir at room temperature overnight. Then 400 ml of water was added and the mixture was stirred and warmed slightly to digest. Saturated NaCl solution and chloroform (400 ml) was added and the phases separated. The chloroform layer was washed with 400 ml of water, dried over Na 2 SO 4 , filtered, and the chloroform removed on a rotovap to leave an amber viscous oil, which slowly crystallized. This was taken up in petroleum ether, filtered and dried, to give 8.7 g of crude product having a melting point of 134-143° C. It was recrystallized from 125 ml of ethyl acetate to give 5.4 g of a white crystalline solid having a melting point of 144.5-146° C. The infrared and NMR spectra were consistent with the structure.
EXAMPLE 27
Preparation of 3-chloro-2-[(phenylmethyl)sulfinyl]pyridine-N-oxide
To 4.7 g of the starting sulfide (Sec Example 24 above) dissolved in 25 ml of methanol were added a pinch of Na 2 WO 4 followed by 1.5 g of 50% aqueous hydrogren peroxide. The mixture was stirred at room temperature for four hours, filtered, and the solid was washed with NaHSO 3 solution, followed by water. The dried solid 2.2 g, melting point of 119-122° C., gave an NMR which indicated mostly the desired sulfoxide but some contamination by the sulfone and sulfide. A second crop of 1.1 g, melting point 118-123° C., was also obtained. Attempts to recrystallize from toluene and from ethyl acetate gave material still contaminated by sulfone, so the mixture was finally separated by preparative HPLC and then recrystallized from ethyl acetate, having a melting point of 124-126° C. The elemental analysis for C,N&N, the infrared spectrum, and the NMR spectrum were all consistent with the proposed structure.
EXAMPLE 28
Preparation of 2-[[(2,6-dichlorophenyl)methyl]thio]-3-methyl-pyridine-N-oxide
A solution consisting of 8.0 g of Na 2 S and 2.8 g of NaOH in 100 ml of water was treated with 10.8 g of 2-chloro-3-methylpyridine-N-oxide. The mixture was heated at 80° C. for three hours, cooled to room temperature, and then treated dropwise with 12.0 g of 2,6-dichlorobenzylchloride. The reaction mixture was heated back to 80° C. for three more hours, and then allowed to stand at room temperature overnight. The mixture was then extracted with two 200 ml portions of methylenechloride. The methylenechloride phases were dried, and solvent then removed to give a solid. The solid was taken up in ether and filtered to give 6.6 g of material having a melting point of 85-90° C. An NMR suggested a mixture of the desired product and the disulfide of the 3-methylpridine-N-oxide starting material. The mixture was separated with a preparative HPLC silica column and ethyl acetate as eluant. The desired product had a melting point 135-138° C., and NMR and infrared spectra supported the proposed structure.
EXAMPLE 29
Preparation of 2-[[(2,6-dichlorophenyl)methyl]sulfinyl]-3-methyl-pyridine-N-oxide
To 10.5 g (0.035 mole) of 2-[(2,6-dichlorophenyl)methylthio]-3-methyl-pyridine-N-oxide (See Example 28 above) dissolved in 100 ml of methanol were added a pinch of sodium tungstate and then dropwise 4.2 ml (0.4 mole) of 50% hydrogen peroxide. The temperature was maintained at 25° C. for four hours, and then a cold solution of NaHSO 3 was added slowly to destroy residual H 2 O 2 . The solid was filtered and air-dried, having a melting point of 178-181° C., yield 10 g. The elemental analysis for C,H,N; the infrared spectrum, and the NMR spectrum all supported the proposed structure.
EXAMPLE 30
Preparation of 2-[[(2,6-dichlorophenyl)methyl]sulfonyl]-3-methyl-pyridine-N-oxide
To 8.0 g (0.03 mole) of 2[(2,6-dichlorophenyl)methylsulfinyl]-3-methyl-pyridine-N-oxide (See Example 29 above) in 150 ml of chloroform were added 10 g (0.05 mole) of metachloroperbenzoic acid. The mixture was stirred at room temperature for 24 hours, and then was washed with 20% K 2 CO 3 , and then with aqueous NaHSO 3 until no peroxides were present. The chloroform layer was dried with Na 2 SO 4 and then the mixture was filtered and the solvent removed on a steam bath. The residue was taken up in ether and filtered to give 2 g of solid, having a melting point of 215-218° C. The elemental analysis for C,H,N; the infrared, and the NMR all supported the proposed structure.
EXAMPLE 31
Preparation of 2-[[(2,5-dimethylphenyl)methyl]thio]-1-methyl-pyridinium chloride
A mixture of 5.0 g of 1-methyl-2(1H)-pyridinethione and 6.2 g of 2,5-dimethylbenzyl-chloride in 40 ml of toluene was heated for five hours at 70° C. A pale yellow solid was filtered from the cooled mixture. Yield was 5 g having a melting point of 130-137° C. NMR and infrared spectra were consistent with the structure.
EXAMPLE 32
Preparation of 2-benzylthio-3-nitropyridine
To a stirred solution of 35 ml of ethanol, 1 ml of water, and 2.0 g (0.025 mole) of 85% KOH pellets was added 3.2 g (0.025 mole) of benzyl mercaptan. To this mixture was added 4 g (0.025 mole) of 2-chloro-3-nitropyridine. After complete addition (20 minutes), the reaction mixture was warmed to 55° C. and held at that temperature for 25 minutes. It was then allowed to cool to room temperature over the next hour. The solid was filtered off (KCl) and the ethanol was removed from the filtrate. The residue was treated with 40 ml of acetone by warming, cooling and then filtering to remove more KCl. The filtrate was evaporated to leave an oil which solidified. The solid was recrystallized from 40 ml of ethanol to give 2.3 g of crystals, having a melting point of 57-59° C. The infrared spectrum was consistent with the structure. A second crop of 1.3 g of impure product was also obtained.
EXAMPLE 33
Preparation of 2-((2,5-dimethylphenyl)methylthio) pyridine
A mixture of 5.6 g (0.05 mole) of 2-mercaptopyridine, 3.3 g (0.05 mole) of potassium hydroxide (85% pellets), 35 ml of ethanol and 5 ml of water was prepared. To this mixture was added 7.8 g (0.05 mole) of 2,5-dimethyl-benzylchloride, while maintaining good stirring. The mixture was stirred and heated to 40° C. for 45 minutes, cooled to room temperature, and then added to 150 ml of water. The aqueous mixture was extracted with 150 ml of diethyl ether; the ether phase washed with 150 ml of water. Finally, the ether phase was dried with anhydrous sodium sulfate. Removal of the ether left a green oil. An infrared spectrum was consistent with the structure of 2-((2,5-dimethylphenyl)methylthio) pyridine.
EXAMPLE 34
Preparation of 6-chloro-(2-benzylthio)pyridine-N-oxide
A solution of 2 g (0.03 mole) of KOH in 50 ml of ethanol and 0.5 ml of water was prepared. To this solution was added a mixture of 5 g (0.03mole) of 2,6-dichloropyridine-N-oxide and 3.8 g (0.03 mole) of benzylmercaptan. The resulting mixture was stirred and heated for 2 hours, and then evaporated to dryness. The residue was treated with 100 ml of chloroform and the insoluble portion (KCl) was filtered off. The chloroform was dried with sodium sulfate, filtered, and evaporated to dryness to leave a white solid having a melting point of 78 to 90° C. This solid was recrystallized from ethyl acetate, to give 5.8 g (77%) of product having a melting point of 112-115° C. Analysis calculated for C 12 H 10 NSClO: C=57.26, H=4.00, N=5.57. Found: C=57.03, H=3.00, N=4.32.
EXAMPLE 35
Preparation of 2-(2,5-dimethylbenzylsulfonyl)pyridine
To a well-stirred and cooled (−10° C.) solution of 6.9 g (0.03 mole) of 2-(2,5-dimethyl-benzylthio)pyridine in 75 ml of chloroform was added portion-wise a solution of 12 g (0.06 mole) of metachloroperbenzoic acid dissolved in 100 ml of chloroform. The mixture was kept at −10° C. for 10 minutes and then allowed to warm to room temperature over the next six hours. It was stirred at room temperature overnight. Water was then added and the phases separated. he chloroform phase was washed with aqueous sodium bicarbonate and then again with water. he chloroform phase was dried with anhydrous sodium sulfate, filtered, and the chloroform removed using a rotary evaporator to give 8 g of an oil. The oil was crystallized from a small amount of ethanol, with a melting point of 77-78° C., and a yield of 3 g (30%). IR spectrum showed the presence of SO 2 at 1160, 1310 cm −1 .
EXAMPLE 36
Preparation of 5-chloro-2(benzylthio)pyridine-N-oxide
A solution consisting of 1.1 g (0.016 mole) of 85% KOH pellets, 50 ml of ethanol, and 0.5 ml of water was prepared. To this solution was added slowly, with stirring at room temperature, a mixture of 3.3 g (0.02 mole) of 2,5-dichloropyridine-N-oxide and 2.5 g (0.02 mole) of benzylmercaptan dissolved in 25 ml of ethanol. The reaction mixture was heated to about 60° C. for 2 hours and then evaporated to dryness. The residue was taken up in water and chloroform, the phases separated and the chloroform phase was dried over Na 2 SO 4 . The Na 2 SO 4 was filtered off and the chloroform evaporated to leave a solid. The solid was recrystallized from ethanol to give 3.0 g of material, having a melting point of 130-133° C. Recovery was 2.2 g. The structure was confirmed by its IR spectrum.
EXAMPLE 37
Preparation of 2-(N-methyl-3-piperidylmethylthio)pyridine N-oxide
To 24.5 g (0.0675 mole) of sodium omidine (40% aqueous solution) dissolved in 50 ml of ethanol were added 10 g (0.0675 mole) of 3-chloromethyl-1-methylpiperidine. The mixture was stirred and warmed in a water bath at 58° C. for two hours and then allowed to stir overnight at room temperature. She mixture was then filtered to remove NaCl and the filtrate was evaporated on a rotovap. The remaining oil solid was treated with 50 ml of acetone and filtered to remove residual NaCl. Evaporation of the acetone left 15 g of oil. This was treated with dilute aqueous sodium hydroxide and chloroform. The phases were separated, the chloroform layer dried, and the chloroform then removed to leave 6 g of an amber liquid. An infrared spectrum was consistent with the structure of the product.
EXAMPLE 38
Preparation of 2-(2,5-dimethylphenylmethylthio)pyridine hydrochloride
To 25 ml of water were added 10 ml of concentrated hydrochloric acid and then 4.6 g (0.02 mole) of 2-(2,5-dimethylphenylmethylthio)pyridine. The mixture was swirled and the water was then evaporated to leave a solid. The solid was taken up in ethanol and ether was then added to precipitate a yellow-colored solid. The solid was filtered off and then treated with boiling acetone and filtered while hot. Obtained 4 g of pale-yellow solid having a melting point of 83-85° C. An infrared spectrum indicated a pyridine hydrochloride by the broad peak at 2500 cm −1 , and peaks at 740 cm −1 and 815 cm −1 consistent with a pyridine ring.
EXAMPLE 39
Preparation of 2-(1-(cyano)-2-(phenylethenethio)pyridine-N-oxide
Ethanol (60 ml) and 0.5 g of sodium metal were added to a three-neck flask fitted with a magnetic stirrer, thermometer and condenser. The sodium was allowed to completely react with the ethanol to form sodium ethoxide. Then 4.2 g (0.025 mole) of 2-(1-cyanomethylthio)-pryridine-N-oxide was added followed by 2.7 g (0.025 mole) of benzaldehyde. The solution immediately turned orange, then red, and a precipitate formed. There was also a slight temperature increase from 27-36° C. After 15 minutes the batch was filtered to give a yellow solid having a melting point of 171-173° C. An NMR was consistent with the structure. Yield 2.9 g or 46%.
EXAMPLE 40
Preparation of 2-[1-cyano-2-(p-methoxyphenyl)ethenethio]pyridine-N-oxide
To a 125 ml erlenmeyer flask fitted with a magnetic stirrer and thermometer were added 4.2 g (0.025 mole) of 2-(2-cyanomethylthio)-pyridine-N-oxide, 3.4 g (0.025 mole) of 4-methoxybenzaldehyde, 60 ml of ethanol and 3 ml of sodium ethoxide solution in ethanol. The mixture was stirred at room temperature overnight and was then filtered to give 4.3 g (64.2%) of a white solid having a melting point of 169-172° C. The infrared spectrum was consistent with the structure, showing a CN absorption at 2200 cm −1 .
EXAMPLE 41
Preparation of 2-[1-cyano-2-(3,4,5-trimethoxyphenyl)ethenethio]pyridine-N-oxide
To a 125 ml erlenmeyer flask fitted with a thermometer and magnetic stirrer were added 4.2 g (0.025 mole) of 2-(1-cyanomethylthio)-pyridine-N-oxide, 4.9 g (0.025 mole) of 3,4,5-trimethoxybenzoldehyde, 60 ml of ethanol, and 3 ml of sodium ethoxide in ethanol. The batch developed a yellow, then orange color with the production of a very heavy precipitate within 10 minutes. A few ml of ethanol were added and the batch stirred for one hour before filtering. There was a temperature increase of only 3° C. (24-27°) during the reaction. A yellow solid was isolated having a melting point of 141-158° C. The crude material was recrystallized from ethanol to give a yellow solid having a melting point of 176-179° C., whose IR spectrum supported the proposed structure. There were 2.0 g isolated (23.2% yield).
EXAMPLE 42
Preparation of 2-[1-(2,5-dimethylphenyl)ethylsulfonyl]pyridine
A mixture of 4.7 g (0.017 mole) of 2-[1-(2,5-Dimethylphenyl)-ethylsulfonyl]-pyridine-N-oxide, 60 ml of chloroform, and 7.5 g (0.055 mole) of PCl 3 were placed in a 100 ml round bottom flask equipped with a magnetic stirrer and reflux condenser. The mixture was refluxed for one hour, and then the solvent was removed under reduced pressure using a rotovap. To the residue was added 25 ml of ethanol, followed by a second evaporation. The residue crystallized to give a white solid, which was recrystallized from ethanol. Obtained were 3.0 g of product having a melting point of 95-96° C. The IR, NMR and mass spectra were consistent with the proposed structure.
EXAMPLE 43
Preparation of 2-[[1-(2,5-dimethylphenyl)ethyl]thio]-4-methylquinoline
a) Preparation of 2-thio]-4-methylquinoline(starting material)
A mixture of 15.9 g of 2-hydroxy-4-methylquinoline and 24.4 g of P 2 S 5 were heated together in an oil bath at 150° C. to give a homogeneous melt. The melt was cooled and then 100 ml of hydrochloric acid (90ml of concentrated HCl and 10 ml of 10% HCl) were added and the mixture was refluxed for two hours. The mixture was then filtered hot through a large buchner funnel using coarse filter paper. The yellow/orange solid was dried in a vacuum oven, melting point 250-253° C. An NMR spectrum indicated that it was the desired thiol.
b) Preparation of 2-[[1-(2,5dimethylphenyl)ethyl]thio]-4-methyl-Quinoline
Sodium (1.2 g) was dissolved in 50 ml of ethanol and then 9.5 g of 2-thiol-4-methylquinoline (prepared in accordance with step (a) above), and 11.6 g of 2,5-dimethylphenyl(2-bromoethyl)benzene were added while stirring. An additional 50 ml of ethanol was then added and the reaction mixture was heated on a steam bath for five minutes, and then it was filtered hot to remove some light brown precipitate. A reddish precipitate deposited in the cooled filtrate. This was filtered off and then taken up in carbon tetrachloride and water to remove sodium bromide. There was some material that was insoluble in both the organic and the water layer, and this was removed by filtration. The layers were separated and the carbon tetrachloride removed from the organic layer. The residue was crystallized from ethanol and then recrystallized from isopropanol, melting point of 84-85° C. An NMR spectrum was in agreement with the proposed structure. C,H,N calculated for C 20 H 21 NS: %C=78.14; %H=6.89; %N=4.56; Found: %C=78.13; %H=6.85; %N=4.46.
EXAMPLE 44
Preparation of 2-(2,5-dimethylphenyl)methylsulfinyl)pyridine
To a stirred and cooled solution (−10° C.) of 4.6 g (0.02mole) of 2-(2,5-dimethyl-phenyl)methylthio)pyridine in 50 ml of chloroform was added 4.1 g (0.02 mole) of 85% active metachloroperbenzoic acid in 50 ml of chloroform over a period of 30 minutes. The reaction mixture was stirred at 0° C. for 2 hours and then at ambient temperature overnight. The reaction mixture was washed with sodium bicarbonate, and then water. The chloroform phase was dried with magnesium sulfate, and the chloroform then removed using vacuum. A solid product (4.85 g or 98.5%) was obtained; melting point 77-79° C. It showed IR bands at 1050 and 1060 cm −1 (S—O).
EXAMPLE 45
Activity against HIV
The cell type used to determine activity of the compounds of the invention herein, i.e., the test compounds, against HIV was human T-lymphoblast (CEM) cells obtained from the American Tissue Cell Culture Collection (Rockville, Md.). HIV-1 (III B ) was originally obtained from the culture of persistently HIV-1 infected H9 cells and was provided by R. C. Gallo and M. Popovic (National Cancer Institute, National Institutes of Health, Bethesda, Md.). HIV-2 (ROD) was originally obtained from L. M. Montagnier (Pasteur Institute, Paris, France).
To determine the antiviral activity of the test compounds, CEM cells were suspended at a cell density of approximately 300,000 cells per ml of culture medium and infected with approximately 100 CClD 50 (100 CClD 50 being the 50% cell culture infective dose) of HIV-1 (IIIB) or HIV-2 (ROD)). Then 100 μl of the infected cell suspensions was added to 200 μl micro titer plate wells containing 100 μl of appropriate serial (5-fold) dilutions of the test compounds. The inhibitory effect of the test compounds on HIV-1 or HIV-2 syncytium formation in CEM cells was examined microscopically on day four post infection. The 50% effective concentration (EC 50 ) was defined as the test compound concentration that inhibits syncytium formation in the HIV-1 or HIV-2 infected cell cultures by 50%.
In some cases, the compounds had considerable cytotoxicity to CEM cells which made determination of the EC 50 difficult. In these cases, the percent protection of the cells against virus-induced cytopathicity by the test compounds at the indicated compound concentration in the previous column is given.
The results are summarized in Table 1.
EXAMPLE 46
Activity against HCMV
Confluent HEL cells grown in 96-cell microtiter plates were inoculated with CMV at an input of 100 PFU (plaque forming units) per well. After a one to two hour incubation period, residual virus was removed and the infected cells were further incubated with MEM (Minimal Essential Medium) (supplemented with 2% inactivated Fetal Calf Serum (FCS), 2 μM L-glutamine, and 0.3% sodium bicarbonate) containing varying concentrations of the test compounds. Antiviral activity was expressed as EC 50 (50% effective concentration), or test compound concentration required to reduce virus-induced cytopathicity after seven days by 50% compared to the untreated control.
In some cases, the compounds had considerable cytotoxicity against HEL cells, which made determination of the EC 50 's difficult. In these cases, an estimate of the percent protection at the compound concentration indicated in the previous columns is given. The results are summarized in Table 1.
TABLE 1
Antiviral
Antiviral %
Compound
EC50 (μg/ml)
HIV-1 %
EC50 (μg/ml)
HIV-2 %
IC50 (μg/ml)
Inhibition
No.
HIV-1
Protection
HIV-2
Protection
Davis strain
Davis strain
1
20.00
41.0
>50
0.0
23
20
37.5
20
37.5
>20
20.0
25
10.00
20
37.5
16.0
40
3.10
3.4
1.5
51
>.8
0.0
>.8
0.0
1.3
60
40.00
17.0
>50
0.0
61
>4
0.0
>4.0
6.0
14.0
62
1.90
5.0
>5
20.0
63
2.30
2.5
3.7
64
1.50
1.9
>5
10.0
65
2.80
3.5
5.0
66
3.10
2.5
5.0
67
2.30
2.4
>50
20.0
69
2.90
2.9
>5
20.0
73
2.80
>100.0
0.0
>20
40.0
76
0.90
2.4
>9.1
77
0.70
>0.8
0.0
11.0
81
20
37.5
>20.0
0.0
8.6
106
0.90
>4.0
0.0
20.0
107
0.65
>100
>20
0.0
123
60.00
>100
0.0
>50
40.0
124
>.8
0.0
>0.80
0.0
>5
10.0
125
>4
0.0
>4.0
0.0
31.5
132
2.40
>20.00
0.0
>50
0.0
133
0.14
>20.00
0.0
25.0
134
>20
0.0
>100.0
0.0
>50
136
1.50
>4.0
0.0
4.7
137
>20
0.0
>20.00
0.0
28.0
138
>100
0.0
>100.0
0.0
>50
20.0
139
>20
0.0
>20.00
0.0
43.0
142
>4
0.0
>4
0.0
3.4
146
2.30
20
37.5
40.0
148
>20
>20
0.4
149
9.00
16.0
20.0
150
3.25
20.0
>50
20.0
151
>20
0.0
>20.00
0.0
>20
20.0
156
16.00
>100
0.0
>50
0.0
157
6.00
20
37.5
>50
0.0
158
>4
0.0
>4
0.0
3.6
159
>20
0.0
>20
25.0
10.0
160
>20
0.0
>20
0.0
7.0
161
9.50
>100
0.0
38.0
162
>.8
0.0
>.16
0.0
1.6
163
3.25
>100
0.0
>50
0.0
Means greater or equal to
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Certain pyridine and quinoline derivatives' which inhibit replication of the retroviruses HIV-1, HIV-2 and human cytomegalovirus (HCMV) are provided. Pharmaceutical compositions useful in methods of treating or inhibiting certain retrovirus infections are described.
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[0001] The present application is based on and claims priority of Japanese patent applications No. 2003-339644 filed on Sep. 30 , 2003 and No. 2004-54289 filed on Feb. 27, 2004, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a liquid crystal television receiver in which a television receiver body equipped with a liquid, crystal panel and a control unit is pivotally supported on a leg portion in a tiltable fashion.
[0004] The present invention is described using a liquid crystal television receiver as an example of the preferred embodiment of the invention, but it is applicable to liquid crystal displays of desk top personal computers and the like. It is also obviously applicable to any type of hinge structure bearing a pivoting movement.
[0005] 2. Description of the Related Art
[0006] Liquid crystal television receivers or liquid crystal displays of desk top personal computers etc. are pivotally supported to enable tilting movement thereof so that a viewer (user) can select the most suitable viewing angle. The pivoting means for such equipment generally adopts a structure in which a stand portion and a swing portion are pivotally supported via a pin.
[0007] Such pivoting means suffered the drawback of the hinge portion being loosened after long termuse of the equipment during which the tilting operation is repeated, and in some cases it became impossible to stably support the image display portion in a static manner.
[0008] Patent document 1 discloses a tilt hinge in which the hinge portion is riveted to strengthen the fixture of the tilt movement portion, but according to this disclosure, the riveting operation is performed from the side face of the hinge portion, and since the rivet pin and washer remain on the side face, the width of the hinge portion is inevitably increased.
[0009] As an alternative, it is possible to constitute the hinge portion with a pair of spaced-apart members and to perform the riveting operation from the inner sides thereof. However, this will not reduce the width of the hinge portion, and since the rigidity in the twisting direction of the pair of independent hinge members is weak, stable tilting movement cannot be performed if a twisting force is added when tilting the equipment.
[0010] Patent document 2 also discloses an art related to a similar hinge structure.
[0011] Patent Document 1:
Japanese Patent Laid-Open No. 2000-213526
[0013] Patent Document 2:
Japanese Registered Utility Model No. 3069339
SUMMARY OF THE INVENTION
[0015] In order to solve the problems of the prior art, the present invention aims at providing a liquid crystal television receiver or a liquid crystal display of a desk top personal computer etc. having a pivoting means capable of statically supporting the image display portion in a stable manner since the hinge portion will not be loosened after long term use of the equipment and repeated tilting operation. Further, the present invention aims at providing an equipment equipped with a hinge portion having a small width and a strong structure.
[0016] According to a first aspect of the present invention, the liquid crystal television receiver comprising a television receiver body equipped with a liquid crystal panel and a control unit, which is pivotally supported on a leg portion so as to enable tilting of the television-receiver body in front and rear directions comprises a hinge portion for pivotally supporting the television receiver body in a tiltable manner which is formed of a pair of left and right hinge portions, the left and right hinge portions each respectively composed of a stand portion attached to the leg portion and a swing portion attached to the television receiver body, and the left and right hinge portions are assembled to form an integral hinge portion.
[0017] According to a second aspect of the present invention, the liquid crystal television receiver according to the first aspect of the invention characterizes in that the left and right hinge portions are formed to have plane symmetric shapes, and the left and right hinge portions are assembled and screwed together to form the hinge portion.
[0018] According to a third aspect of the present invention, the liquid crystal television receiver according to the second aspect of the invention characterizes in that the stand portions of the left and right hinge portions are respectively shaped to have an angulated U-shape cross-section, and the stand portions are assembled by having the openings of the U-shapes oppose one another to form a square column shape.
[0019] According to a fourth aspect of the present invention, the liquid crystal television receiver according to any one of the above aspects characterizes in that the hinge portion having an assembled rectangular column shape is formed so that side surface portions of the left and right hinge portions disposed in front and rear directions of the liquid crystal television receiver constitute a double layered structure.
[0020] According to a fifth aspect of the present invention, the liquid crystal television receiver according to any one of the above aspects characterizes in that the stand portion and swing portion of the left and right hinge portions are pivotally supported via a pin, and the pin is riveted to pivotally fasten the stand portion and the swing portion together in a tiltable manner.
[0021] According to a sixth aspect of the present invention, the liquid crystal television receiver according to any one of the above aspects characterizes in that a biasing means for biasing the swing portion is attached to the stand portion, and the biasing means biases the swing portion rearward when the television receiver body is tilted to the frontward direction.
[0022] According to a seventh aspect of the present invention, the liquid crystal television receiver according to the sixth aspect of the invention characterizes in that the biasing means is composed of a fixing plate fixed to the stand portion and an engagement portion integrally formed with the mounting plate and engaged to the swing portion.
[0023] The present invention forms a hinge portion from a pair of left and right hinge portions which are assembled together to form an integral hinge portion, according to which the formed hinge portion has a simple structure and improved strength. Therefore, the present invention provides a liquid crystal television receiver in which the direction of the liquid crystal panel can be adjusted appropriately to any viewing angle with freedom.
[0024] Since the shapes of the left and right hinge portions are plane symmetric, it is possible to form the front and rear directions of the equipment with two layered members by assembling the left and right hinges together, according to which a hinge portion of a liquid crystal television receiver having high strength can be provided.
[0025] Since the hinge portion is composed by assembling a pair of left and right hinge portions, the left and right hinge portions can be easily riveted (fastened for example by pressing and widening an end of a pin) from the inner side of the pivoting portion and the flat-head portion of the pin can be disposed on the outer side of the pivoting portion, so the width of the hinge portion can be formed small. Furthermore, by pivotally fastening the pivoting portion via riveting, the television receiver body can be tilted more freely within larger tilt angles and statically held at any desired angle.
[0026] Moreover, since a biasing means for biasing the swing portion is attached to the stand portion so as to bias the swing portion rearward by the biasing means when the television receiver body is tilted frontward, the rotational forces required for tilting the television receiver body frontward and rearward can be substantially equalized, and the television receiver body can be tilted in a stable fashion. Thus, the present invention enables to provide a liquid crystal television receiver having an advantageous quality and capable of preventing the receiver from turning over when the tilting operation of the television receiver body is performed by a rapid motion.
[0027] Furthermore, since the biasing means is composed of a mounting plate fixed to the stand portion and an engagement portion formed integrally with the mounting plate and engaged with the swing portion, the present invention enables to provide a liquid crystal television receiver that is cost-effective without having to use expensive coil springs and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a side view of a liquid crystal television receiver according to the present invention in which a hinge cover (illustrated in dotted lines) is removed to show the hinge portion clearly;
[0029] FIG. 2 is a perspective front view of the liquid crystal television receiver according to the present invention;
[0030] FIG. 3 is a perspective back view of the liquid crystal television receiver according to the present invention;
[0031] FIG. 4 is a partial detailed view of a hinge portion;
[0032] FIG. 5 is a six-side view of a left hinge portion;
[0033] FIG. 6 is a six-side view of a right hinge portion;
[0034] FIG. 7 is a four-side view of the hinge portion in which the left and right hinge portions are assembled;
[0035] FIG. 8 is a cross-sectional view showing the riveted state of the left and right hinge portions;
[0036] FIG. 9 shows A-A and B-B cross-sections of the left and right hinge portions;
[0037] FIG. 10 is a perspective view showing the state in which the hinge portion is attached to a leg portion;
[0038] FIG. 11 is a detailed view showing the state in which the hinge portion is attached to the device body;
[0039] FIG. 12 is a perspective view showing the hinge portion of Embodiment 2;
[0040] FIG. 13 is an exploded perspective view showing the state in which a biasing means is removed according to Embodiment 2;
[0041] FIG. 14 is an explanatory view showing the liquid crystal television receiver of Embodiment 2; and
[0042] FIG. 15 is an enlarged cross-sectional view showing the main portion of the hinge portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] Now, the present invention will be described according to the preferred embodiments. FIG. 1 is a side view showing the present invention applied to a liquid crystal television receiver, shown with a hinge cover removed (illustrated by dotted lines) so as to clearly illustrate the hinge portion.
[0044] As shown in FIGS. 1 through 3 , the liquid crystal television receiver comprises a television receiver body 10 equipped with a liquid crystal panel display 11 and a control unit 12 , which is pivotally supported by a leg portion 90 via a hinge portion 20 .
[0045] In FIG. 1 , the television receiver body 10 is capable of being tilted in the left and right directions with respect to the leg portion 90 pivoting around a pivot axis of the hinge portion 20 . According to the television receiver body 10 , the visual angle of the liquid crystal panel display 11 can be changed freely to face the operator (viewer) by simply holding an appropriate portion of the body 10 and tilting the body 10 to the desired direction.
[0046] FIG. 4 is a partial detailed view for explaining the tilting operation around the hinge portion 20 , illustrating the hinge portion from the opposite direction of FIG. 1 , showing the state in which the hinge is capable of being tilted for 5 degrees toward the front and 15 degrees toward the back. This range of movement is merely a matter of design and can be selected appropriately according to the status of use of the equipment to which the present invention is actually applied. In some applications, it is possible to set the range of movement to exceed 180 degrees.
[0047] The hinge portion 20 is constructed of a pair of left and right hinge portions 30 and 50 , the details of which are illustrated in FIGS. 5 and 6 . FIG. 5 is a six-side view of the left hinge portion 30 , in which (a) is a right side view, (b) is a back view, (c) is a left side view, (d) is a front view, (e) is a bottom view and (f) is an upper view. FIG. 6 is a six-side view of the right hinge portion 50 , in which (a) is a right side view, (b) is a back view, (c) is a left side view, (d) is a front view, (e) is a bottom view and (f) is an upper view.
[0048] The left and right hinge portions 30 and 50 are respectively formed of main members, which are stand portions 31 and 51 and swing portions 32 and 52 . In the present application, the stand portion in the drawing is illustrated by heavy lines and the swing portion is illustrated by thin lines, in order to clearly distinguish the stand portion and swing portion. The swing portions 32 and 52 are respectively pivotally supported via pins 33 and 53 on the stand portions 31 and 51 . FIGS. 5 and 6 illustrate states in which the swing portions 32 and 52 are pivotally supported via pins 33 and 53 on the stand portions 31 and 51 , and washers 34 , 35 and 54 , 55 are inserted thereto, but pins 33 and 53 are not yet riveted.
[0049] The stand portion 31 of the left hinge portion 30 is equipped with an upright surface 39 that is raised in upright form from a leg portion attachment surface 36 to form an L-shape, and the surface 39 is connected to a substantially circular pivot surface 40 . In front of and behind the upright surface 39 are formed front and rear engagement surfaces 37 and 38 formed by bending, which constitute an angulated U-shaped cross-section together with the upright surface 39 . An embossment engagement hole 41 and a screw engagement hole 42 are formed on the front engagement surface 37 , and embossments 44 , 44 , an embossment engagement hole 41 and a screw engagement hole 42 are formed on the rear engagement surface 38 . In the drawings, in order to visually clearly distinguish the holes and embossments, the embossments are illustrated with three slant lines.
[0050] On the other hand, the stand portion 51 of the right hinge portion 50 is equipped with an upright surface 59 that is raised in upright form from a leg portion attachment surface 56 to form an L-shape, and the surface 59 is connected to a substantially circular pivot surface 60 . In front of and behind the upright surface 59 are formed front and rear engagement surfaces 57 and 58 by bending, which constitute an angulated U-shaped cross-section together with the upright surface 59 . On the front engagement surface 57 , an embossment 61 is formed at a position capable of engaging with the embossment engagement hole 41 on the front engagement surface 37 of the left hinge portion 30 , and a screw engagement hole 62 is formed at a position corresponding to the screw engagement hole 42 on the front engagement surface 37 of the left hinge portion 30 . On the rear engagement surface 58 , an embossment 61 is formed at a position capable of engaging with the embossment engagement hole 41 on the rear engagement surface 38 of the left hinge portion 30 , and a screw engagement hole 62 is formed at a position corresponding to the screw engagement hole 42 on the rear engagement surface 38 of the left hinge portion 30 . In FIG. 6 , similar to FIG. 5 , in order to visually clearly distinguish the holes and embossments, the embossments are illustrated with three slant lines.
[0051] According to such structure, upon assembling the left hinge portion 30 and the right hinge portion 50 , positioning is assured by the embossments engaging with the embossment engagement holes.
[0052] A swing portion 32 is pivotally supported via a pin 33 by the stand unit 31 of the left hinge portion 30 in a freely tiltable manner. The swing portion 32 is equipped with a body attachment surface 45 for attaching the television receiver body 10 and an engagement surface 46 . Body attachment screw holes 47 and 47 are formed on the body attachment surface 45 of the swing portion 32 of the left hinge portion 30 , and a screw engagement hole 48 is formed on the engagement surface 46 .
[0053] Screw engagement holes 42 , 42 , 42 and 42 are formed on the leg attachment surface 36 of the stand portion 31 of the left hinge portion 30 .
[0054] A swing portion 52 is pivotally supported via a pin 53 by the stand unit 51 of the right hinge portion 50 in a freely tiltable manner. The swing portion 52 is equipped with a body attachment surface 65 for attaching the television receiver body 10 and an engagement surface 66 . Body attachment screw holes 67 and 67 are formed on the body attachment surface 65 of the swing portion 52 of the right hinge portion 50 , and a screw engagement hole 68 is formed on the engagement surface 66 .
[0055] Screw engagement holes 62 , 62 , 62 and 62 , and an embossment 61 (not shown) to be used for positioning with the leg portion 90 , are formed on the leg attachment surface 56 of the stand portion 51 of the right hinge portion 50 .
[0056] Thus, upon assembling the left hinge portion 30 and the right hinge portion 50 , the engagement surface 46 of the left hinge portion- 30 and the engagement surface 66 of the right hinge portion 50 are superposed and positioned appropriately, the screw engagement hole 48 and the screw engagement hole 68 are matched and screwed together, by which the swing portion 32 of the left hinge portion 30 and the swing portion 52 of the right hinge portion 50 are fastened securely in an integral manner.
[0057] The pivot surface 40 of the stand portion 31 of the left hinge portion 30 and the swing portion 32 are pivotally supported via a pin 33 , wherein washers 34 and 35 are inserted before the pin 33 is riveted from direction A of FIG. 8 , so as to pivotally fasten the stand portion 31 and the swing portion 32 to allow tilting thereof.
[0058] The pivot surface 60 of the stand portion 51 of the right hinge portion 50 and the swing portion 52 are pivotally supported via a pin 53 , wherein washers 54 and 55 are inserted before the pin 53 is riveted from direction A of FIG. 8 , so as to pivotally fasten the stand portion 51 and the swing portion 52 to allow tilting thereof.
[0059] Thus, since the pivoting portions of the left and right hinge portions 30 and 50 are riveted, the bearing will not be loosened even through repeated tilting movement, and maintain a constantly stable fixed condition. Further, since the hinge portion 20 is constructed by assembling the left and right hinge portions 30 and 50 which are plane symmetric, the hinges can be riveted from direction A (inner direction), according to which the washer and riveted portions can be disposed inside the hinge portion 20 and the width of the whole hinge portion 20 can be reduced.
[0060] Further, since left and right hinge portions 30 and 50 are assembled together to form one integral hinge portion 20 , the obtained hinge portion has high strength even with a small width and is strong against twisting.
[0061] The riveted left hinge portion 30 and the similarly riveted right hinge portion 50 have, as shown in FIG. 7 , the stand portions 31 and 51 of two members assembled together to form a stand portion 71 having a substantially rectangular cross-section, and the swing portions 32 and 52 of the two members assembled to form an integral swing portion 72 .
[0062] FIG. 7 shows a four-side view of the integral hinge portion 20 formed by riveting pins 33 and 53 and assembling the left and right hinge portions 30 and 50 , wherein (a) is a back view, (b) is a right side view, (c) is a front view and (d) is an upper view. In FIG. 7 , the left hinge portion 30 is illustrated using heavy lines, the right hinge portion 50 is illustrated using thinner solid lines (stand portion) and dotted lines (swing portion), and further in (a) and (c), screws are illustrated in perspective to show how the left and right hinge portions 30 and 50 are screwed together.
[0063] As shown in FIG. 7 , the integral swing portion 72 formed by assembling two members constitutes a hinge portion 20 with high strength, since double layered members are disposed on the front and rear sides of the equipment. Moreover, the bottom surface portions 36 and 56 are designed to have sizes that differ by the thickness of the bottom plate, so that two surface portions can be superposed by placing one above the other.
[0064] FIGS. 9 ( a ) and 9 ( b ) respectively show the A-A cross-section of the left hinge portion 30 and the B-B cross-section of the right hinge portion 50 . An embossment 61 formed on a rear engagement surface 58 of the stand portion 51 of the right hinge portion 50 is fit to the embossment engagement hole 41 formed on the rear engagement surface 38 of the stand portion 31 of the left hinge portion 30 , by which screw engagement holes 42 and 62 are matched and connected via a screw.
[0065] Thus, the integrally formed hinge portion 20 (screw engagement holes etc. are not shown) can be attached to a leg portion 90 with appropriate means (not shown) as illustrated in FIG. 10 .
[0066] FIG. 11 illustrates a state in which the hinge portion 20 is attached via a screw on the television receiver body 10 .
[heading-0067] [Embodiment 2]
[0068] Next, Embodiment 2 of the present invention will be described. FIG. 12 is an exploded perspective view showing a hinge portion according to Embodiment 2 of the present invention. FIG. 13 is an exploded perspective view showing the state in which a biasing means removed. FIG. 14 is an explanatory view showing a liquid crystal television receiver. FIG. 15 is an enlarged cross-sectional view showing the main part of the hinge portion.
[0069] The present embodiment is equivalent to Embodiment 1 except for the biasing means, so the same members as Embodiment 1 are denoted with the same reference numbers and the detailed descriptions thereof are omitted. The television receiver body 10 according to Embodiment 2 is large sized and heavy, equipped with a large liquid crystal panel display portion 11 having a screen size of 20 inches or larger.
[0070] The biasing means is composed of a mounting plate 80 for fixture to a stand portion 71 , and an engagement portion 82 formed integrally with the mounting plate 80 , which is formed of metal and has elasticity. The mounting plate 80 is placed so that a hole 81 formed thereto is matched with screw engagement holes 42 and 62 formed to the rear engagement surfaces 38 and 58 , and while it is in contact with the rear surface of the stand unit 38 , it is attached using a screw and the like. The upper portion of the mounting plate 80 is bent toward the front, having formed integrally thereto an engagement portion 82 to be engaged with either the engagement surfaces 46 or 66 of the hinge portion 20 .
[0071] As shown in FIG. 14 , the center of gravity a of the television receiver body 10 is placed substantially at the center in the front-rear direction, in other words, the center of gravity a of the television receiver body 10 is placed frontward than the pivot point b of the hinge portion 20 , so that the pivoting force for tilting the television receiver body 10 with respect to the hinge portion 20 differs in the front and rear pivoting directions (directions shown by arrows of FIG. 14 ).
[0072] Next, the operation of the liquid crystal television receiver formed as above will be described.
[0073] When an operator tilts the television receiver body 10 forward from the maximum backward tilt position, as shown in FIG. 15 , the swing portion 72 of the hinge portion 20 follows the pivoting movement and pivots forward (counterclockwise direction shown in FIG. 15 ). Then, since the engagement portion 82 is fixed to the engagement surfaces 46 or 66 of the hinge portion 20 , the engagement portion 82 follows this pivoting movement and flexibly bends forward. In other words, by tilting the swing portion 72 forward from the maximum backward tilt position, the engagement portion 82 flexibly bends forward, and the television receiver body 10 can be pivoted and stopped at a desired position resisting against the biasing force caused by the bending of the engagement portion 82 .
[0074] On the other hand, when the operator tilts the television receiver body 10 rearward from the frontward tilted state (clockwise direction shown in FIG. 15 ), the swing portion- 72 follows this pivoting movement and pivots rearward. During this operation, the operator can smoothly and easily tilt the television receiver body 10 rearward by the biasing force of the leaf spring member 80 in addition to the operator's own force.
[0075] Thus, by attaching a biasing means formed of a mounting plate 80 and an engagement portion 82 to the hinge portion 20 and biasing the television receiver body 10 rearward by the resilience of engagement portion 82 , it is possible to prevent the backlash caused by the gap in the movable area of the hinge portion 20 , and the pivoting force for tilting the television receiver body 10 forward and backward can be substantially equalized. Therefore, it becomes possible to tilt the television receiver body 10 in a stable manner, and even if the tilting operation of the television receiver body 10 is performed rapidly, tipping of the body can be prevented. Thus, the present invention can provide a high-quality liquid crystal television receiver.
[0076] Moreover, since the mounting plate 80 can easily be attached to the rear of the stand portion 38 of the hinge portion 20 in a detachable manner via a screw or the like, there is no need to provide a large assembly space as in the case of a coil spring, and the size of the hinge portion can be reduced. Furthermore, the cost of the biasing means composed of the mounting plate 80 and engagement portion 82 is low compared to the cost of a coil spring, so the costs of the required components can be cut down. Thus, the present invention enables to provide a cost-effective liquid crystal television receiver.
[0077] Further, since the thickness and the like of the biasing means can be varied so as to easily change the biasing force of the engagement portion 82 to correspond with the size or weight of the television receiver body 10 attached above the hinge portion 20 , the liquid crystal television receiver according to the present invention has advantageous compatibility and is highly cost effective.
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The invention provides a liquid crystal television receiver, a liquid crystal display of a desktop computer and the like, which is equipped with a pivoting means capable of statically maintaining the image display portion stably with the hinge portion prevented from being loosened even after performing tilting operation repeatedly for a long period of time. The invention provides a liquid crystal television receiver comprising a television receiver body equipped with a liquid crystal panel and a control unit, which is pivotally supported on a leg portion so as to enable tilting of the television receiver body, wherein a hinge portion pivotally supporting the television receiver body in a tiltable manner is composed of a pair of left and right hinge portions, the left and right hinge portions are respectively composed of a stand portion attached to the leg portion and a swing portion attached to the television receiver body, and the left and right hinges are assembled to form an integral hinge portion.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. Ser. No. 10/503,901 filed Aug. 9, 2004, which is a 371 of PCT/AU03/00170, all of which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to electronic devices having an internal printer and to a charging assembly for replenishing the internal ink reservoir of the printer.
[0003] This application refers to the following co-pending applications of the present applicant, the entire contents of which are duly incorporated herein:
CO-PENDING APPLICATIONS
[0004] Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention simultaneously with the present application:
PCT/AU03/00154 PCT/AU03/00151 PCT/AU03/00150 PCT/ AU03/00145 PCT/AU03/00153 PCT/AU03/00152 PCT/AU03/00168 PCT/ AU03/00169 PCT/AU03/00170 PCT/AU03/00162 PCT/AU03/00146 PCT/ AU03/00159 PCT/AU03/00171 PCT/AU03/00149 PCT/AU03/00167 PCT/ AU03/00158 PCT/AU03/00147 PCT/AU03/00166 PCT/AU03/00164 PCT/ AU03/00163 PCT/AU03/00165 PCT/AU03/00160 PCT/AU03/00157 PCT/ AU03/00148 PCT/AU03/00156 PCT/AU03/00155
[0005] The disclosures of these co-pending applications are incorporated herein by cross-reference. Each application is temporarily identified by its file reference. This will be replaced by the corresponding PCT Application Number when available.
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BACKGROUND OF THE INVENTION
[0006] Historically, printers have been desktop devices and have thus been large and immobile. Printers have had large capacity ink cartridges requiring seldom replacement. Replacement ink cartridges are typically kept on hand so that when the current ink cartridge is exhausted it can be replaced with little interruption to the printer operation.
[0007] Recent developments have seen printers being incorporated into portable telecommunications devices such as mobile telephones. Examples of such applications can be found in the present applicant's co-pending applications listed above. However, with a portable printer, there is a problem that a replacement ink cartridge will not always be at hand if the ink supply is exhausted. To overcome this problem the ink cartridge will be replaced before it is absolutely necessary resulting in a wastage of ink otherwise there will be a risk that the ink supply will run out, rendering the printer useless until a replacement ink cartridge is found.
SUMMARY OF THE INVENTION
[0008] In accordance with a first aspect of the invention, there is provided a charging stand for a mobile telecommunications device having an internal printer, the charging stand including:
[0009] a base;
[0010] a receptacle formed in said base and adapted to releasably receive a mobile telecommunications device;
[0011] a power connection for receiving power with which to provide recharging power to a mobile telecommunication device;
[0012] an ink reservoir storing at least one type or color of ink;
[0013] a power transmission arrangement for providing the recharging power to a mobile telecommunications device when positioned in the receptacle; and
[0014] at least one ink connection adapted to engage complimentary ink receiving connections of a mobile telecommunications device, for providing ink from the at least one ink reservoir to the ink telecommunications device when the telecommunications device is positioned in the receptacle.
[0015] Preferably, the power transmission arrangement includes one or more conductive contacts configured to engage complementary conductive contacts on a mobile telecommunications device placed within the receptacle. An electrical circuit can thereby be established for recharging a battery of the telecommunications device.
[0016] Alternatively, the power transmission arrangement can include a magnetic field generator for generating an inductive coupling between the stand and a suitable inductive current generation device within the mobile telecommunications device for recharging a battery of the telecommunications device, configured such that the telecommunications device automatically recharges the battery when placed in the receptacle.
[0017] Preferably, the power connection is an external power connection for receiving power from a remote source.
[0018] It is particularly preferred that the ink reservoir be a removable ink cartridge. In this case, the ink connection includes at least one cartridge connection for engaging at least one corresponding complementary formation on said ink cartridge.
[0019] Preferably, the ink reservoir includes a plurality of ink chambers storing distinct ink colours and/or types, each of said chambers including at least one of said ink connections. More preferably, the cartridge includes one or more ink chambers each including an outlet, wherein the cartridge connection includes one or more cartridge pins adapted to be received by said chamber outlets respectively. It is preferred that each of the cartridge outlets include an elastomeric seal.
[0020] Preferably, an elastomeric pad surrounds the cartridge pins, or each of said cartridge pins. The pad or pads are compressible to expose the cartridge pins.
[0021] In a preferred form, the ink cartridge is configured for reception in said receptacle.
[0022] In one embodiment, the charging stand further includes an ink connector including: the ink connections; the ink cartridge connections; and an ink conduit connecting each cartridge connection with a respective ink connection. In this case, the ink connector can be located within the charging stand such that the ink connections and the cartridge connections are disposed in the receptacle.
[0023] Preferably, the ink connections include one or more device pins adapted to be received in one or more inlets of said telecommunications device. More preferably, the stand includes an elastomeric pad around the device pins, the pad being compressible to expose the device pins.
[0024] In a preferred embodiment, the ink reservoir is disposed on the charging stand such that when a telecommunications device including an internal printer is received in the receptacle, gravity causes ink to flow from the ink reservoir to the printer of the telecommunications device.
[0025] In a second aspect, the present invention provides a charging stand for a mobile telecommunications device having an internal printer, the charging stand including a base, a receptacle formed in said base and adapted to receive a mobile telecommunications device therein, an external power connection, a removable ink cartridge storing one or more inks and adapted to be received in said receptacle, one or more power contacts adapted to engage complimentary contacts on said mobile telecommunications device to provide for recharging a battery of said mobile telecommunications device from said external power connection, and an ink connector including one or more cartridge connections adapted to engage complimentary connections on said ink cartridge, one or more device connections adapted to engage complimentary formations on a mobile telecommunications device and one or more ink flow conduits connecting said cartridge connections and said device connections.
[0026] In a third aspect, the present invention provides a mobile telecommunications device having an internal printer, the mobile telecommunications device including a power recharge interface and an ink supply interface for accepting recharging power and ink from a charging stand in accordance with any one of the preceding claims.
[0027] In a fourth aspect, the present invention provides a recharging device for providing a mobile telecommunications device having an internal printer with recharging power and ink, the recharging device including an ink supply output for releasable connection to a complementary ink supply input of the mobile telecommunications device, and a power recharging output for providing recharging power to the mobile telecommunications device when it is connected to the ink supply output.
[0028] Preferably, the recharging device further includes a power supply connection for connecting an external power supply that provides, in use, power to the power recharging output.
[0029] More preferably, the power recharging output includes a conductive power supply contact for engaging a corresponding conductive power receiving contact of the mobile telecommunications device.
[0030] Alternatively, the power recharging output includes an inductive coupling arrangement for inductively coupling with a corresponding inductive arrangement in the mobile telecommunications device, in use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0032] FIG. 1 is a perspective view of a charging stand, in accordance with the invention;
[0033] FIG. 2 is a perspective view of a charging stand with a mobile telephone positioned therein;
[0034] FIG. 3 is an exploded view of the charging stand;
[0035] FIG. 4 is an assembled view of the charging stand of FIG. 3 ,
[0036] FIG. 5 is a perspective view of a removable ink cartridge;
[0037] FIG. 6 is a perspective view of a mobile telephone adapted for use with a charging stand of the invention; and
[0038] FIG. 7 is a cross section of a charging stand and mobile telephone, in accordance with the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0039] A charging stand according to the invention is shown generally at 10 in FIG. 1 . The stand 10 receives a mobile telecommunications device 20 , e.g. a mobile telephone, as depicted in FIG. 2 . The stand 10 includes a base 11 with a receptacle 12 that receives the mobile telephone. A set of ink contacts 13 and power contacts 14 are disposed in the base receptacle 12 . The base 11 also receives an ink cartridge 50 .
[0040] Reference is now made to FIG. 3 , which is an exploded view of the charging stand 10 illustrating the internal features. The charging stand 10 includes a base moulding 31 and base plate 32 . A power cord 33 passes through an aperture in the base moulding 31 and connects to a Printed Circuit Board (PCB) 34 within the base moulding 31 . The opposite end of the power cord 33 includes a standard plug for connection with mains power, which will usually be alternating current (AC). In this case, the power will need to be rectified if it is to be fed to the battery of the mobile telecommunications device in a direct current (DC) form. Alternatively, the charging stand is configured for connection with an alternative power source such as through the cigarette lighter connection of a car, which will usually be direct current (DC). In either case, the power will typically need to be stepped down to provide compatible voltage and current to a battery of the mobile telecommunications device.
[0041] The PCB 34 supports components including a power-in plug 35 , a speaker plug 36 connected to a speaker 37 and charging contacts 38 . The power-in plug 35 , speaker plug 36 and charging contacts 38 protrude through the base moulding 31 into the receptacle 12 .
[0042] The base moulding 31 also houses ink connections 39 that include hollow cartridge connection pins 40 and device connection pins 41 connected through a conduit in an ink connection base 42 . Four pins are shown in FIG. 3 that provide an ink flow path for three colour inks and black ink. The cartridge pins and device pins protrude through the base moulding 31 into the receptacle 12 . Elastomeric pads 43 are formed around the pins 40 , 41 for protection but compress to the configuration depicted in FIG. 3 during loading of an ink cartridge or telephone device into the receptacle, thereby exposing the pins for use. The device pins may be fitted with a cap or seal that prevents ink flow when no device is received in the receptacle but are removed prior to, or in the act of, loading a device into the charging stand.
[0043] FIG. 4 demonstrates the resilience of the elastomeric pads 43 once the ink cartridge and telephone have been removed. The pads return to their uncompressed state thereby providing protection to the ink cartridge pins and device pins when the pins are not in use. In addition to providing protection, the elastomeric pads 43 also act to seal the ink flow path through the ink connector 40 thereby preventing any ink trapped within the connector 40 from drying out and potentially causing a blockage. As can be seen from FIG. 4 the power-in plug 35 , speaker plug 36 and charging contacts 38 remain exposed.
[0044] The charging stand receives a removable ink cartridge 50 of the type illustrated in FIG. 5 . The ink cartridge 50 includes an ink reservoir sized to fit into the receptacle 12 of the charging stand. Internally the ink cartridge is divided into four separate chambers for the four different types of ink. Four apertures 51 formed in the end of the cartridge 50 provide an outlet for each of the four chambers and are located on the cartridge 50 so as to receive the cartridge pins 41 of the charging stand when the cartridge is loaded into the receptacle of the charging stand. A seal 53 , for example an elastomeric seal, is disposed within each ink chamber about the outlet 51 to seal the respective chamber when the cartridge is removed from the charging stand.
[0045] The cartridge 50 may be provided with a QA chip and contacts 52 that communicate with similar contacts 45 ( FIG. 4 ) on the charging stand to ensure that only compatible cartridges 50 are used with the charging stand.
[0046] The charging stand 10 receives a mobile telephone 20 or like device equipped with an internal printer and battery. As shown in FIG. 6 , the telephone 20 includes a series of ink inlet ports 60 that lead to the ink supply systems of the printer, a power socket 61 , hands free jack 62 and charging contacts 63 leading to a battery or like charge storage device of the telephone. When the telephone 20 is loaded onto the charging stand receptacle 12 as depicted in FIG. 2 , the ink inlets, power socket, hands free jack and charging contacts align with and engage respectively the device pins, power-in connection, speaker plug and charging contacts of the charging stand. Power is then supplied to the telephone both to allow operation of the telephone and to re-charge the telephone batteries in a known manner.
[0047] FIG. 7 shows a reverse cross section of the loaded charging stand of FIG. 2 illustrating the connection from the printer of the telephone to the ink cartridge 50 . As shown in FIG. 7 , the ink cartridge 50 is disposed in the receptacle such that the cartridge pin 40 has penetrated the seal 53 and protrudes into one of the ink chambers of the cartridge. Similarly, the ink inlet ports of the telephone have engaged the device pins of the charging stand. Thus the ink connector 39 provides a conduit from the ink cartridge 50 to the ink reservoirs of the printer. Pressure, gravitational or osmotic effects between the ink chambers of the cartridge and the ink reservoir of the printer causes ink to flow to the printer reservoir.
[0048] While the embodiments of the invention have been described with particular reference to mobile telephones, it will be apparent to the skilled addressee that the invention is equally suitable to other types of mobile telecommunications devices such as Wireless Internet Access Devices (WIADs), in particular Wireless Applications Protocol (WAP) terminals, pagers etc.
[0049] The charging stand of the present invention allows the battery and ink supplies of a mobile telephone with printer to be re-charged simultaneously. Furthermore, using a charging stand as herein described, it is unlikely that ink supplies of the printer would ever be exhausted as by the time this event occurred, there would be insufficient power in the battery to operate the printer.
[0050] The invention has also been described with reference to a four colour printer where the ink cartridge of the charging stand has four chambers for three colour inks and black ink. The configuration of the ink cartridge and the number of pins of the ink connector will depend on the type of printer employed in the mobile telecommunications device. For example the cartridge may store only black ink. Alternatively or in addition, the ink cartridge may include a chamber and ink connection for supplying infra-red ink or some other ink type to a printer.
[0051] It will be appreciated that although the preferred embodiment of the invention takes the form of a stand, an alternative embodiment (not shown) is a plug that interfaces with corresponding ink and power sockets in a phone or communications device. An ink reservoir and power supply are still provided, but there is no stand or cradle for the phone to sit in. Rather, once the plug is plugged into the corresponding socket, the phone is simply laid in a suitable place such as a benchtop or desk. A potential advantage of this embodiment is that the ink reservoir (which might be relatively bulky if of high capacity) can be located remotely from the mobile phone charging point, such as on the floor or on a shelf out of the way. In some cases, this can avoid the reservoir being bumped, or at least diminishes the amount of clutter in a work area. The reservoir in this case can also be mounted in the same housing as, or adjacent to, a transformer for rectifying AC mains power for supply to the mobile phone.
[0052] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. It will further be understood that any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates.
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A portable electronic device and associated charging stand assembly where the portable electronic device has an inbuilt printer and the associated charging stand recharges the device battery and refills the printer.
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FIELD OF THE INVENTION
The invention relates to a static electrical converter, particularly for high voltage DC, including at least one valve assembly with one or more valves electrically connected in series, each having a plurality of valve modules which are carried by a support means included in the assembly and formed for dependent mounting.
BACKGROUND OF THE INVENTION
In electrical converters for high voltages it has previously been customary to build the valve assemblies included in the converter as vertical columns resting on a sub-structure with the valves in a valve assembly placed one on top of the other. This requires a plurality of vertical support insulators which are subjected to very large forces, particularly with large valve assemblies and during earthquakes, for example. In an improved embodiment according to U.S. Pat. No. 4,318,169 such a converter has been given greater resistance to earthquakes by mounting its valve assemblies dependently and by including resilient members in the suspension means for a valve assembly, these members allowing relative vertical movement between the valve assembly and the supporting structure in which it is suspended. However, such an embodiment requires the building or corresponding carrying structure in which suspension takes place to be specially implemented so that space is made from the start for the resilient members.
OBJECT OF THE INVENTION
The object of the invention is to provide a converter which can be more simply mounted dependent in different types of carrying structures but which can even so well withstand forces such as those from earthquakes.
This is achieved in accordance with the invention in that the valve modules are joined to the carrying means with the aid of resilient members allowing vertical relative movement between the valve modules and the upper part of the carrying means, this part being formed for suspension.
By implementing the converter in this way, it will be possible later on simply to supplement and alter a converter which was not initially provided with resiliency, for example. Furthermore, it will also be possible to give a softer suspension than previously to the valve modules included in the converter, thus reducing stresses on the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained, by way of example, with reference to the appended drawings, wherein
FIG. 1 is a side view of a static electrical converter in accordance with the invention,
FIG. 2 is an end view of the converter illustrated in FIG. 1,
FIG. 3 is a side view of a valve assembly,
FIGS. 4 and 5 illustrate two fundamentaly different variants of resilient members included in a valve assembly, and
FIGS. 6, 7, 8, 9a, 9b and 10 illustrate embodiments of the type of resilient members illustrated in FIG. 4.
DETAILED DESCRIPTION
FIGS. 1 and 2 illustrate a static electrical converter 1 made in accordance with the invention, as seen from two mutually perpendicular directions. There are six valves V1-V6 included in the converter, forming in pairs the valve assemblies V1-V4, V3-V6 and V5-V2 of the converter 3. Each valve assembly comprises a vertical column with the valves in the assembly situated under each other. A carrying means 2 is included in each valve assembly, this means having an upper part via which the assembly can be mounted dependent in a carrying structure in a fixed or movable object, e.g., the ceiling or roof of a building.
The upper ends of the valve assemblies are electrically connected with the aid of conductors 5 and 6. In the same way, the lower ends of the valve assemblies are electrically connected with the aid of conductors 7 and 8. A conductor 9 is connected to the valve V5, this conductor constituting one DC terminal of the converter. The other DC terminal of the converter is a conductor 10 connected to the valve V2. The converter has three AC connections 11, 12, 13 each being connected via a conductor to a converter transformer (not shown), and of these only the conductor 14 connected to the connection 13 is shown in FIG. 2. The electrical construction of converters of the type intended here is well-known to those skilled in the art and therefore does not need to be described in detail. Reference is made to the U.S. Pat. No. 4,318,169 mentioned in the introduction, should further details be of interest.
The more specific construction of the valve assembly V1-V4 will be seen from FIG. 3. A plurality of valve modules M11-M16, separated in height, are included in the valve V1, each of these modules constituting a mechanically self-supporting unit including necessary electrical equipment. In turn, these valve modules can be built up from the requisite number of sub-modules and can possibly have masses of different sizes. Each of the valve modules M11-M16 is connected to the carrying means 2 by a suitable number of resilient members allowing vertical mutual movement between the valve module and the upper part 3 of the carrying means, this part being formed for suspension. For example, the valve module M14 is suspended on either side from the carrying means 2 with the aid of resilient members 15 and 16. The valve V4 is built up in a corresponding way. The implementation of the carrying means 2 may of course be varied in a multitude of different ways depending on the size and implementation of the valves and valve modules it is to support. What is vital, however, is that good electrical insulation be obtained between adjacent valve modules and of course between the valve assembly and the carrying structure 4 in which it is suspended.
The resilient members 15 and 16 can be made in many different ways, depending on what resiliency properties are desired. Two fundamentally different embodiments are shown in FIGS. 4 and 5. In the embodiment illustrated in FIG. 4 there is included in the carrying means 2 a vertical elongate carrier member 17 which is substantially rigid in its vertical direction. Via a spring device 18, each valve module can move individually in a vertical direction relative to the carrier member 17 and of course also relative the upper part 3 in the carrying means 2 connected to the support structure 4. Via a first support 19, the spring device 18 is connected to the carrier member 17, and via a second support 20 it is connected to the valve module. The support 19 is included in the carrier member 17 where it joins together insulating links 21, 21'. There is of course nothing to prevent the carrier member 17 from being insulating along its entire length and it could, for example be made from a threaded rod of suitably electrically insulating material.
In FIG. 5, the spring device 18 is instead solely connected to the insulating link 21 via a first support 22 and to a valve module via a second support 10. In this case, the second support 20 is coupled to the insulating link 21'. In this way the spring device 18 will not only be loaded by its own valve module but also by all underlying valve modules with associated parts included in the carrying means 2. In this case it is suitable to give the upper spring devices 18 a larger spring constant than the lower spring devices 18.
Starting from the fundamentally different solutions illustrated in FIGS. 4 and 5, the resilient members 15 can be varied in many different ways, all according to need and desire. Some different embodiments based on the principle illustrated in FIG. 4 are shown in FIGS. 6 to 10 by way of clarification. In FIG. 6, the spring device 18 comprises rubber cushions 18' and 18" mounted on the first support 19 and situated on either side of the second support 20. In FIG. 7, the spring device 18 comprises a conical disc spring confined between the upper end of the second support 20 and the lower end of the first support 19. In FIG. 8, the spring device 15 has a construction similar to that of FIG. 6, the difference being that the resilient means is of the conical disc spring type and that between the first support 19 and the second support 20 there is mounted a shock absorber 23, e.g., of hydraulic type. FIGS. 9a and 9b show a spring device 15 seen from two directions at right angles to each other. The first support 19 and the second support 20 are here formed to allow mounting of parallel helical springs included in the spring device 18. In FIG. 10, the first support 19 and the second support 20 are articulatedly joined to each other so that relative movement between them is counteracted by the spring device 18.
The execution of different embodiments of the fundamental solution illustrated in FIG. 5 for a resilient member 15 should not cause one skilled in the art any difficulties, taking into account the embodiments discussed above for the principal solution according to FIG. 4.
In order to prevent undesired, undamped oscillations (spring movements) in the resilient members, it would appear to be suitable in practice that the resilient members be either movement-damping resilient means such as conical disc springs, rubber springs etc., and/or parallel-coupled special movement-damping means.
It has been illustrated hereinbefore that substantially each tier of the valve assemblies has been mounted resiliently. There is of course nothing to prevent several valve module tiers being cumulated for example, so that larger units are obtained, thus enabling the reduction of the number of resilient members, but in return they would have to be made more substantial. In any case, it is possible, with the aid of the technique illustrated here, and without any great interference in the carrying structure, to alter the vertical springing capacity for units included in a static electrical converter in accordance with the invention. It should be noted here that equipment for preventing lateral oscillation of the valve assemblies has not been included in this connection, since such equipment is well-known to those skilled in the art.
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A static electrical converter for high voltage DC is provided with at least one valve assembly which has one or more valves electrically connected in series. Each of these valves includes a plurality of valve modules carried by a carrier for dependent mounting. The valve modules are connected to the carrier with the aid of resilient members allowing vertical spring movement between the valve modules and the upper portion formed for suspension of the carrier.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/641,393, filed Aug. 13, 2003, now U.S. Pat. No. 7,590,613, which is a CIP of application Ser. No. 10/639,291, filed Aug. 11, 2003, which are incorporated herein by reference in their entirety for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
NOT APPLICABLE
BACKGROUND OF THE INVENTION
This invention relates to the field of database software generally, and specifically to software applications for analyzing data in a database. A database is typically one or more large sets of structured data. A database is usually associated with a software application adapted to query and update data in the database. A common type of database structure is a relational database. A relational database organizes data and the relationships between data in a set of tables, typically two-dimensional tables organized into rows and columns. SQL, a programming language defining the creation and manipulation of tables, is typically used by database applications to create, update, and query the database.
Relational databases are well suited large databases and for quickly processing database queries. Because of this, relational databases are often used for on-line transaction processing (OLTP) applications, which often require handling millions of transactions a day, with each transaction being processed in real-time or near real-time.
In addition to processing transactions, databases can also be used to perform complex data analysis tasks. Although relational databases perform transaction processing applications efficiently, they are typically very inefficient at transforming or processing large amounts of raw data with analytical functions used for data analysis. Because of this, another type of database structure, known as On-Line Analytical Processing (OLAP), is used for data analysis applications.
OLAP databases enable users to analyze the data and look for patterns, trends, and exceptions. Whereas relational databases use tables and columns to organize their data, OLAP databases generally use dimensions and cubes as their central data structures. Cubes are simply datapoint items (e.g. Profit, Cost). Dimensions are data structures that can specify a hierarchy of items. Examples of dimensions can include things like “Time” and “Geography,” for which “Time” might include a hierarchy of (Year, Quarter, Month) and “Geography” might specify a hierarchy of locations, such as (Country, Region, City).
Dimensions are well adapted to allow users to define these analytic calculations. An OLAP database or analysis tool can directly support many types of calculations because it knows the relationship between the items specified by dimensions. For a relational database, analysis is more difficult because data is stored as a group of unrelated columns.
In order provide better analytical capabilities in relational databases without sacrificing performance, data analysis software, such as Oracle Discoverer, have been developed. The data analysis software provides a graphical user interface for analyzing data in a relational database. Users can quickly create, modify, and execute ad-hoc queries, reports, and graphs, using the data analysis software. The data analysis software translates user input from the graphical user interface into specially-created SQL analytic functions, such as those enabled in Oracle 8i. The SQL analytic functions generically partition rows based on columns and compute the functions within those row sets. The SQL statements formulated by the data analysis application are then processed by the database, and the results are displayed in the data analysis application. In this manner, the data analysis application provides relational databases users with “OLAP-type” analysis capabilities.
The functionality introduced by the SQL analytic functions do not, in and of itself, solve the calculation requirements for data analysis software. It is essential that the data analysis tools are easy to use and understand by business users, who do not typically understand the usage of SQL. Data analysis software can present data to users in the form of tables or sheets having cells arranged into rows and columns. User can rearrange the cells on a sheet, or perform filtering or pivot table operations to create different view of data in the database.
A layout specifies the relationship between the cells of the sheet and the data in the database. Typically, SQL statements are associated with the cells for retrieving and processing data from the database. As users change the layout on a sheet, the associated SQL statements often “break” from their intended functionality. This occurs most often with SQL analytic functions, which rely on complicated data partitioning to perform computations. This results in data results that is either invalid or does not reflect the intentions of the user.
Thus, it is desirable for the data analysis software to form correct SQL statements regardless of the layout of cells on a sheet. It is further desirable that users be able to specify complex analytical function on a sheet without having to understand SQL.
BRIEF SUMMARY OF THE INVENTION
The present invention takes into account the layout of a sheet to form analytic database functions. In an embodiment of the invention, a method for analyzing data from a database using an analytic database function comprises receiving a selection of measured items from a user, receiving a placement item from the user, and determining a partitioning of the selection of measured items from the placement item. In one embodiment, the placement item is a column. In another embodiment, the placement item is an axis.
In another embodiment of the invention, a template is associated with the analytic database function and is adapted to define at least one partitioning relative to the placement item. In a further embodiment, the template is further adapted to define an ordering parameter for the analytic database function. One of a set of ordering parameters can be received from the user. In yet a further embodiment, the template is further adapted to define an aggregation level for the analytic database function. One of a set of aggregation levels can be received from the user.
In yet another embodiment, the method further comprises creating a database query including the partitioning. In one embodiment, this database query includes an SQL statement.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be discussed with reference to the drawings, in which:
FIG. 1 is a block diagram of a system for implementing an embodiment of the invention;
FIG. 2 illustrates the partitioning of a set of rows for an analytical function;
FIG. 3 illustrates a sheet having a layout aware calculation according to an embodiment of the invention;
FIGS. 4A , 4 B, and 4 C illustrate the results of an example layout aware calculation in response to changes in a layout according to an embodiment of the invention;
FIGS. 5A and 5B illustrate different aggregation levels of the results of an example layout aware calculation according to an embodiment of the invention; and
FIG. 6 illustrates a sheet having a layout aware calculation according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention takes into account the layout of a sheet to form the SQL statements associated with cells. In this embodiment, these SQL statements, referred to as layout aware calculations, inherit their partitioning from the layout of a sheet. As user rearrange the cells of a sheet, the layout is changed and the SQL statements are updated appropriately. This enables the SQL analytic functions associated with cells to produce valid data calculations that reflect the intent of the user. Additionally, users are able to specify complex analytical functions merely by rearranging cells, without any knowledge of SQL.
FIG. 1 is a block diagram of a system 100 for implementing an embodiment of the invention. System 100 includes user computers 105 , 110 , and 120 . User computers 105 , 110 , and 120 can be general purpose personal computers having web browser applications. Alternatively, user computers 105 , 110 , and 120 can be any other electronic device, such as a thin-client computer, Internet-enabled mobile telephone, or personal digital assistant, capable of displaying and navigating web pages or other types of electronic documents. Although system 100 is shown with three user computers, any number of user computers can be supported.
A web server 125 is used to process requests for web pages or other electronic documents from user computers 105 , 110 , and 120 . In an embodiment of the invention, the data analysis software operates within a web browser on a user computer. In this embodiment, all user interaction with the data analysis software is via web pages sent to user computers via the web server 125 .
Web application server 130 operates the data analysis software. In an embodiment, the web application server 130 is one or more general purpose computers capable of executing programs or scripts in response to the user computers 105 , 110 and 115 . The web application can be implemented as one or more scripts or programs written in any programming language, such as Java™, C, or C++, or any scripting language, such as Perl, Python, or TCL.
In an embodiment, the web application server 130 dynamically creates web pages for displaying the data analysis software. The web pages created by the web application server 130 are forwarded to the user computers via web server 125 . Similarly, web server 125 receives web page requests and input data from the user computers 105 , 110 and 120 , and forwards the web page requests and input data to web application server 130 .
The data analysis application on web application server 130 processes input data and user computer requests and can be stored or retrieved data from database 135 . Database 135 stores data created and used by the enterprise. In an embodiment, the database 135 is a relational database, such as Oracle 9i, that is adapted to store, update, and retrieve data in response to SQL format commands.
An electronic communication network 120 enables communication between computers 105 , 110 , and 115 , web server 125 , web application server 130 , and database 135 . In an embodiment, network 120 may further include any form of electrical or optical communication devices, including wireless and wired networks. Network 130 may also incorporate one or more local-area networks, such as an Ethernet network; wide-area networks, such as the Internet; and virtual networks, such as a virtual private network.
The system 100 is one example for executing a data analysis software according to an embodiment of the invention. In another embodiment, web application server 130 , web server 125 , and optionally database 135 can be combined into a single server computer system. In alternate embodiment, all or a portion of the web application functions may be integrated into an application running on each of the user computers. For example, a Java™ or JavaScript™ application on the user computer is used to retrieve or analyze data and display portions of the data analysis application.
Many SQL analytic functions rely on an ordered set of rows. As part of the function syntax, users define partitions, which are subsets of the ordered set of rows. The partitioning of rows determines the inputs to an SQL analytic function, and consequently, the output of the SQL analytic function as well. Previously, the partitioning of data for a SQL analytic function is determined independently of the layout of the sheet and is fixed. Because the partitioning of the SQL analytic function is independent of the layout, as users change the layout, the partitioning no longer matches the layout, and the SQL analytic function produces incorrect results.
FIG. 2 illustrates the partitioning of a set of rows for an analytical function. FIG. 2 illustrates how a change in layout leads to incorrect results from an SQL analytic function. Example sheet 210 shows a layout for calculating the profit of a quarter in the previous year with the profit in the same quarter of the current year. The SQL analytic function, “Lag,” locates the appropriate profit values and displays the results in the “Lag by Year” column. In sheet 210 , the SQL analytic function uses its partitions to define the location of its inputs. An example of an SQL analytic function used in sheet 210 is “LAG (Profit SUM,1) OVER(PARTITION BY Quarter ORDER BY Year).”
As discussed above, the data analysis software enables users to graphically manipulate the arrangement of cells on a sheet. In sheet 210 , for example, a user has added a new column for “Months.” In this example, sheet 210 displays profit values by quarter and month. Because the position of cells has changed in sheet 210 from their original positions in sheet 205 , the “Lag” function computes incorrect values in sheet 210 . For example, cell 215 displays the profit from the previous month of the same year, rather than the profit of the same month of the previous year. The example of FIG. 2 illustrates how the addition of a column of information “breaks” previously implemented SQL analytic functions. Similar problems with SQL analytic functions can result from many other modifications to a sheet, such as pivots, drills, or change in cell locations.
To resolve these problems with SQL analytic functions, an embodiment of the present invention specifies calculations in a way that they can inherit their partitioning from the layout of the sheet. As users change the layout, the partitioning of the SQL analytic functions changes as well, so that the calculations remain correct.
FIG. 3 illustrates a sheet 300 having a layout aware calculation according to an embodiment of the invention. Layout aware calculations are any calculations that inherit part of their semantic from the layout of a sheet. SQL analytic functions are one class of calculations that can use layout aware calculations. Any other functions that depend on the positioning of input can also use layout aware calculations.
Example sheet 300 shows a profit values for regions and for cities with in each region. For example, the “East” region includes the cities of “Boston,” “Miami,” and “New York.” A detail item is defined as the lowest level of classification for a set of data values. In this example, the detail item on the Y-axis is the “City” column 305 . As discussed below, the detail item is used to create a layout aware calculation.
Additionally, a layout aware calculation defines a measure item as the datapoint or measure that is being used for the calculation. In example sheet 300 , the measure item for the “Rank” calculation is “Profit SUM.” In this example, the Rank calculation will rank cities or regions by the value of its “Profit SUM.” The resulting Rank calculation is displayed in the appropriate “Rank” column in sheet 300 .
In example sheet 300 , users may want to use the rank function to rank profit values either by individual city, by region, or by city within each region. This partitioning of the input data is determined by selecting a placement item. A placement item is used to define the partitioning, or “bucketing” of the analytic function, such as the rank function. In the example of sheet 300 , the region column 310 is selected as the placement item. As a result, the layout aware calculation computes the rank of each cities' profit within its region.
For example, “Boston” has a rank of “2” within the “East” region in the year 1900, as shown in cell 315 . Similarly, “Denver” has a rank of “2” within the “West” region, as shown in cell 320 . Alternatively, if the “City” column 305 had been selected as the placement item, then the cities would have been ranked against each other regardless of region. In this alternate example (not shown in FIG. 3 ), the cities of “Boston” and “Denver” would be ranked against each other, with “Boston” having a rank of “3” and “Denver” having a rank of “4.” (In this example, profits are ranked from lowest to highest).
The data analysis software uses the placement item to determine the appropriate partitioning of the measured items and formats the analytic function accordingly. In an embodiment, the data analysis software creates a SQL statement defining the partitioning of the measured items, the desired analytic function or functions to be performed on the measured items, and the location of the cells containing the results of the function or functions. In an embodiment of the invention, a generic pseudo SQL statement for defining a Layout Aware Calculation looks like:
Compute <function> within <placement item>
based on <measure item>
[at aggregation level <calculated item>]
In this pseudo SQL statement, the function can be any analytical function, such as Rank, Lag, or Cumulative Sum, and the other items are defined above. The optional “[at aggregation level <calculated item>]” allows for the selection of a specific “sublevel” and is discussed in more detail below.
For each analytic function, a function template is defined that determines the partition according to the placement item. Table 1 illustrates example function templates for several analytic functions.
TABLE 1
Function Templates for Determining Partition from Placement Item
Function
Partition By
Order By
Rank
All items “above” the placement item;
Measure,
All items on the opposite axis.
Ascending or
Descending Rank
chosen by the
user.
Lag/Lead
All items except the placement item.
The placement
item, ascending/
descending
inherited from
the display
Cumulative
All items “above” the placement item;
All items “below”
Sum
All items on the opposite axis.
the placement
item; ascending/
descending
inherited
from the display
In Table 1, the partition is selected according to the rule defined by the function template associated with an analytic function. In an embodiment, these function templates are built into the data analysis software and are based on generalizations of typical layouts associated with the usage of analytic functions. In an embodiment, the “Order By” and “Partition By” are parameters of analytic functions. For many types of analytic functions, such as Cumulative Sum and Lag/Lead, the placement item determines the value of the “Order By” and “Partition By” elements and use the measure item to determine the measure of the analytic functions.
However, there may be exceptions to this, for example an embodiment of the Rank function, which determines the “Order By” parameter from the measure item. In this embodiment, the user directly selects whether items are ranked in ascending order or descending order.
Analytic functions can be constructed in a number of different ways by users. In an embodiment, the user can selects the placement item on a sheet. Following the selection of the placement item, this embodiment of the data analysis software presents a window, dialog box, or other user interface element to the user that enables the user to specify the “Order By” parameter. In a further embodiment, a set of alternate “Order By” parameters are presented to the user in this window. The user selects one of the “Order By” parameters. The data analysis software determines the set of alternate “Order By” parameters from the function template.
The following example illustrates the construction and operation of an analytic function according to an embodiment of the invention. Assuming a layout as shown in sheet 300 of FIG. 3 , a user may want to add a template calculation: “Cumulative SUM” within “Region” based on “Profit SUM”
Applying the example templates defined in Table 1 to the layout of FIG. 3 , the following SQL analytic function can be generated:
“SUM(Profit SUM) OVER(PARTITION BY Region, Year ORDER BY City)”
Table 2 illustrates a hypothetical database table associated with the layout sheet 300 of FIG. 3 .
TABLE 2
Example Database Table
Region
City
Year
Profit SUM
East
Miami
1998
9208.69
East
Boston
1998
23742.91
West
Denver
1998
21275.33
East
New York
1998
101063.3
West
Los Angeles
1998
9921
East
Miami
1999
9230.9
East
Boston
1999
24558.58
West
Denver
1999
26494.93
East
New York
1999
107215.5
West
Los Angeles
1999
10907.49
East
Miami
2000
5610.31
East
Boston
2000
16912.2
West
Denver
2000
16440.34
East
New York
2000
71507.43
West
Los Angeles
2000
4490.07
Applying the example generated SQL analytic function to the database table of Table 2, the example SQL analytic function partitions the database table by Region, Year combinations, as shown in Table 3.
TABLE 3
Example Database Partitioning
Region
Year
City
Profit SUM
East
1998
Miami
9208.69
East
1998
Boston
23742.91
East
1998
New York
101063.3
East
1999
Miami
9230.9
East
1999
Boston
24558.58
East
1999
New York
107215.5
East
2000
Miami
5610.31
East
2000
Boston
16912.2
East
2000
New York
71507.43
West
1998
Denver
21275.33
West
1998
Los Angeles
9921
West
1999
Denver
26494.93
West
1999
Los Angeles
10907.49
West
2000
Denver
16440.34
West
2000
Los Angeles
4490.07
Following the partitioning of the database table by Region and Year, the cells within each partition are sorted in the order of the ‘Order By’ paramter, which in this example is City, so that within each partition the rows are cumulatively added up in the same order. The results of this sorting is shown in Table 4.
TABLE 4 Example Database Table Sorting Region Year City Profit SUM East 1998 Boston 23742.9 East 1998 Miami 9208.6 East 1998 New York 101063.3 East 1999 Boston 24558.5 East 1999 Miami 9230.9 East 1999 New York 107215.5 East 2000 Boston 16912.2 East 2000 Miami 5610.3 East 2000 New York 71507.4 West 1998 Denver 21275.3 West 1998 Los Angeles 9921.0 West 1999 Denver 26494.9 West 1999 Los Angeles 10907.4 West 2000 Denver 16440.3 West 2000 Los Angeles 4490.0
Finally the Cumulative SUM is computed within each partition.
TABLE 5
Example Cumulative SUM results
Profit
Region
Year
City
SUM
Cum SUM
East
1998
Boston
23742.91
23742.9
East
1998
Miami
9208.69
32951.6
East
1998
New York
101063.3
134014.9
East
1999
Boston
24558.58
24558.5
East
1999
Miami
9230.9
33789.4
East
1999
New York
107215.5
141005.0
East
2000
Boston
16912.2
16912.2
East
2000
Miami
5610.31
22522.5
East
2000
New York
71507.43
94029.9
West
1998
Denver
21275.33
21275.3
West
1998
Los
9921
31196.3
Angeles
West
1999
Denver
26494.93
26494.9
West
1999
Los
10907.49
37402.4
Angeles
West
2000
Denver
16440.34
16440.3
West
2000
Los
4490.07
20930.4
Angeles
The result of the Cumulative sum calculation can then be displayed in the revised layout 600 of FIG. 6 .
FIGS. 4A , 4 B, and 4 C illustrate the results of an example layout aware calculation in response to different placement items according to an embodiment of the invention. FIG. 4A illustrates example sheet 405 . On example sheet 405 , the “Rank” columns, such as column 420 , use the rank analytic function. In conjunction with the rank function in column 420 , a user has selected the “Region” column 410 as the placement item. In accordance with the function template associated with the rank function, the data analysis software partitions the measured items in the “Profit SUM” column of sheet 405 by region.
In FIG. 4A , this partitioning is indicated by the alternating shaded regions. For example, partition 415 represents the “Profit SUM” in the “East” region, and partition 425 represents the “Profit Sum” in the “West” region. In response to the division of the measured items in this column into partitions 415 and 425 , the rank analytic function will rank cities within each region separately.
FIG. 4B illustrates example sheet 430 . Example sheet 430 also uses the rank function. On sheet 430 , the entire Y-axis is selected as the placement item. In accordance with the function template associated with the rank function, the data analysis software creates a single partition of the measured items in each column, such as partition 435 . In response to the creation of a single partition of measured items in each column, the rank analytic function will rank all of the cities across all of the regions together.
FIG. 4C illustrates example sheet 450 . Like sheets 405 and 430 , sheet 450 also uses the rank function. On sheet 450 , the entire X-axis is selected as the placement item. In accordance with the function template associated with the rank function, the data analysis software creates a partition of the measured items in each row, such as partitions 455 and 460 . In response to the partitioning by row, the rank analytic function will rank the profits along the x-axis from each city separately.
FIGS. 5A and 5B illustrate different aggregation levels of the results of an example layout aware calculation according to an embodiment of the invention. The aggregation level is the level of classification used to compute the calculated items. As discussed above, the detail item is the lowest level of classification for a set of data values. Some layouts can have one or more higher levels of classification. In the examples of FIGS. 4A-4C , data items can be classified by city, which is the detail item, or by region, which represents a higher level of classification. As shown in the pseudo SQL statement above, the result of an analytic function can be affected by the choice of an aggregation level. For example, a rank function can be used to rank profits from cities within a region, or to rank regions based on their total profits.
The user can select an aggregation level for a layout aware calculation. In one embodiment, the data analysis software presents a window or a dialog box to the user that enables the user to specify the aggregation level. This window is presented to the user following the selection of the placement item. In a further embodiment, the data analysis software presents a set of alternate aggregation levels to the user, from which the user selects the desired aggregation level. The data analysis software determines the set of alternate aggregation levels from the function template and the placement item.
FIG. 5A illustrates an example sheet 505 using the city column 510 as the aggregation level. In sheet 505 , the rank function ranks cities within each region. FIG. 5B illustrates an example sheet 520 using the region column as the aggregation level. In sheet 520 , the rank function ranks regions based on their total profits.
Although the invention has been discussed with respect to specific embodiments thereof, these embodiments are merely illustrative, and not restrictive, of the invention. For example, although the invention is discussed with reference to SQL analytic functions, the invention can be used to analyze data using any type of database function expressed in any format. Thus, the scope of the invention is to be determined solely by the claims.
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A method for analyzing data from a database using an analytic database function includes receiving a selection of measured items from a user, receiving a placement item from the user, and determining a partitioning of the selection of measured items from the placement item. A placement item can be a column, a row, or an axis. A template associated with the analytic database function is adapted to define at least one partitioning relative to the placement item. The template is further adapted to define an ordering parameter for the analytic database function and optionally an aggregation level for the analytic database function. A database query is created with the partitioning. The database query can be an SQL statement.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to stairs structure, particularly supports to position the steps and risers along a stringer.
2. Description Of The Prior Art
Certain patents particularly drew our attention:
U.S. Pat. No. 6,088,977 Lawrence, Jul. 18 th , 2000, illustrates a method and an apparatus to build staircases. It comprises a support to build steps supported by a longitudinal beam. Several holes allow different heights and lengths, that is the tread of the steps. The support is made of a central block with legs that overlap the stringer. A total of four (4) parts is required. The external sheet is visible and must be covered.
U.S. Pat. No. 5,899,032, Buzby, May 4, 1999, illustrates a staircase structure. It shows supports for steps. The horizontal side has a flared portion 8 , which allows adjusting the height. The step run cannot vary.
U.S. Pat. No. 4,709,520, Vochatzer, has sides comprising two lower brackets 42 , 48 screwed in place, without means to control height or length. Top strip 29 is positioned lengthwise onto a dotted stringer thanks to a return 32 . The same applies to the flanges 59 , 58 . Locating flanges are measured beforehand to correspond to a desired slope, for instance 7 inch rise and 11 inch length. Such a system cannot be adapted to various slopes unless designed at the time of stamping of bracket 41 .
OBJECTS OF THE INVENTION
It is a general objective of the invention to provide a support for steps that can be used for all types of staircases and be easy to install. This support includes a horizontal side, which supports the steps on the stringer while allowing a variation of angle of the stringer. At the same time a vertical side allows fixing the riser.
Another objective is to provide a support for steps including a corner plate whose ends include wider parts intended to overlap, when installed. These sides, horizontal and vertical, have reinforcements to fix the steps and risers. Moreover, the wide part of the horizontal side may include a horizontal adjustment slit and the wide part on the vertical side includes a series of holes among which at least one will coincide with the slit at the time of the installation. Each wide part comprises a second series of fixing holes, sufficiently spaced apart to secure the contact with the stringer. Instead of a slit one may use a pair of overlapping rulers.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. 1 is a perspective of a support for steps.
FIG. 2 is a perspective of an alternative to the support of FIG. 1 .
FIG. 3 shows the support of FIG. 1, installed on top of a stringer.
FIG. 4 is a side view of the support of FIG. 3 .
FIG. 5 shows the support of FIG. 2, installed against a stringer.
FIG. 6 shows the support of FIG. 3, installed as an alternative.
FIG. 7 is a perspective for the foot of a staircase.
FIG. 8 is a top view of the support of FIG. 1 in mirror image.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the invention is illustrated in the drawings wherein the same numbers identify the same characterising elements.
FIG. 1 shows a support for steps 20 identified by an arrow. The support for steps 20 is a metal piece at right angles defining a set-square, with a horizontal side 24 and a vertical side 26 , which widen out to create an upper wide part 28 and a lower wide part 30 . Each side is folded to make an L-shaped section, that is a horizontal fold 32 and a vertical fold 34 . The upper wide part 28 includes some close holes 46 close with respect to the centre of the support 20 and some further apart 48 and a series of horizontal 58 and vertical holes 60 . The lower wide part 30 has a series of holes, some closer 52 and some farther apart 54 . The wide part 30 of the vertical side 26 is graduated 55 to measure a step rise of the support 20 . A ruler 55 ′ is placed on the horizontal side 24 to measure a step run of the support 20 . This ruler 55 ′ can be fixed, removable, flexible or magnetised.
FIG. 2 shows an alternative identified by an arrow as “French” support 120 . The French support 120 is adapted to be installed on the inner side of a stringer, that is to support steps and risers according to the method known as “French”. There is a horizontal side 124 and a vertical side 126 , a horizontal fold 132 and a vertical fold 134 . There also are horizontal 158 and vertical holes 160 .
FIG. 3 shows the support of FIG. 1 installed on top of a stringer, according to a method known as “English”, that is fixed on the inner side of the stringer and straddling the stringer. A tread 36 will be fixed to the horizontal fold 32 by screws 59 (see FIG. 4 ). A riser 38 is fixed on the vertical fold 34 . The horizontal part of a step, known as the step run of the tread, must be of at least 8¼″ to comply with certain building codes such as the Canadian national building Code. A short support allows a step run between 8¼″ and 10½″. The shorter step run corresponds to the length of the horizontal fold, providing a maximum of resistance. A larger support provides step runs from 10¼″ to 12½″. The same applies to the height known as step rise of the riser, which generally varies from 6″ to 8″. The horizontal 32 and vertical 34 folds have a series of holes for step 40 and riser 42 to fix them in place. In upper wide part 28 two screws are installed one in closer holes 46 and another screw in remote holes 48 . There also is a ruler 55 ′ on the horizontal part. Graduations 55 are drawn on the end of the vertical part. In lower wide part 30 two screws are installed, one in close hole 52 and another screw in remote hole 54 .
FIG. 4 shows the coupling of supports for step 20 inferior and 21 superior. Upon installation one positions the upper support 21 first, followed by the next lower support 20 The ruler 55 ′ of support 20 is placed so it gives the step run and the graduations 55 of support 20 are positioned according to the desired step rise then the support is screwed to the stringer. The lower wide part 30 of the support for steps 21 is under the rule 55 ′ of the support for steps 20 just above. First, the support is fixed on the stringer with series of holes that are closer together 52 and 46 . Then with the series of holes that are farther apart 48 , 54 when the step run of tread and the step rise are determined with the graduations 55 . The series of holes that are further apart 54 forms a line of three holes, one of which will be used. This hole becomes a point of coupling 57 and receives a screw # 8 . One sees such a screw 59 used to hold steps. The metal of the support 20 is thin enough to be sawed with the stringer 22 . This makes the completion of the staircase much easier, as it is possible to cut the stringer 22 and support 20 at the foot of the staircase. In the present drawing, the support 20 is installed according to the method known as “English”, the support 20 being above the stringer 22 .
FIG. 5 illustrates another method that can be used with the support of step 120 that is known as “French”. It shows the support of FIG. 2 installed against the inner side of the stringer 122 . The support for steps is fixed with a series of horizontal 158 and vertical holes 160 located on the horizontal 124 and vertical 126 sides. To install, one draws horizontal 161 and vertical 163 lines on the inner side of the stringer according to step run and step rise.
FIG. 6 shows the support of FIG. 3 installed on the inner side of a stringer. This is an alternative to the “English” method. It differs from that of FIG. 3 in that the horizontal 32 and vertical 34 folds, although the support 20 is fixed on the inner side of the stringer 22 , are directed towards the outer side of the stringer while being above the stringer. The disadvantage of this alternative is the difficulty in screwing steps and risers from the outer side of the staircase.
FIG. 7 shows a foot support 23 at the foot of the staircase that was cut in its vertical side 70 . The horizontal side 72 is fixed on the inner side of the stringer. One sees a base 25 , ending with a strip 27 that folds on the back 29 of the stringer. To install, one fixes the base 25 at the foot of the stringer with screws 74 . The builder then fixes the strip with screws 76 . One fastens the staircase to the floor with a screw into the heel 25 through a floor hole 77 and positions a first step by means of a step hole 79 .
FIG. 8 indicates a ruler offset 141 of the thickness of the wide part away from the bearing face 132 .
METHODS OF INSTALLATION
The measurements mentioned in the description are the reflection of the standards of Quebec and Canada. These will vary in accordance with the country where the support for steps is used. For example, the minimal step run, stated as 8¼″ in description, will be 9″ if the support for steps is adapted to the American market.
The support for steps is fixed on the stringer. The horizontal and vertical folds form a right angle. The wide parts on the horizontal and vertical sides are important for the strength of the supports.
It is possible to use adjustment slits. However graduations allows adjusting a support in relation with the support directly over or above. Horizontal graduations can be on parts that are removable, flexible or even replaceable. Some characteristics of the steps themselves must be taken into consideration. The staircase may be of the “French” type where the steps are installed inside the stringer. The staircase can be of the so-called “English” type, where the steps are installed over the stringer. The English type may also be referred to as “rack” when the stringer is cut, the stringer being made of wood. When the stringer is not cut, the type may nevertheless be referred to as “rack” as the supports are fixed on the stringer by their wide parts. FIG. 6 shows the “English” type and FIG. 5 shows the “French” type. The French support is similar to the English support but for the wide parts that are not necessary as the support is fixed against the sides both horizontally and vertically. It suffices to draw an outline with a pencil and a set-square. The supports are aligned on the outline and screwed in this position. In the case of the “English” type, the support is positioned with the vertical and horizontal rulers and fixed through the wide part.
SUMMARY Upper and lower wide parts provide a structure for firmly fixing such as by screws the adjustable supports to a stringer. The supports are separate and do not overlap, in order to prevent torsion. In addition the horizontal ruler projecting from the side of the support is offset from the base plane of the support and extends to cover the vertical side of a neighbouring support to match the neighbouring vertical ruler. After screwing a support the horizontal ruler may be cut off because it is no longer needed. The vertical ruler may be simply painted onto the vertical side of the support and need not be erased.
It is clearly understood that the mode of realisation of this invention which was described above, in reference to the annexed drawings, was given as an indication and is by no means restrictive, and which modifications and adaptations can be brought without the object deviating from all that the framework of this invention.
Other embodiments are possible and limited only by the scope of the appended claims.
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A support for steps, having the shape of a triangular corner plate to be installed one after the other along a stringer. The sides of this support are reinforced, horizontally and vertically by a 90 degree fold, to fix the steps and risers. The ends are wider and possess a number of fixing holes to provide more stability when fixed against a stringer. The horizontal side is ended by a projecting horizontal rule. The wide part of the vertical side is flanked by vertical graduations. The horizontal rule is set against a stringer at a desired step run and the vertical graduations are set against the stringer at a desired step rise. The horizontal rule overlaps the vertical graduations of the preceding support.
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BACKGROUND OF THE INVENTION
The present invention relates to frames for supporting tracks of track-laying tractors and more particularly relates to portions of such frames which are adapted to prevent undue damage to the tracks. When track-laying vehicles such as those commonly used in forestry and excavating are operated, it sometimes happens that the track passes over obstructions such as bumps, logs and rocks or the like resulting in single track shoe loading which is sometimes in the nature of bending loads that cause damage to the track shoes and/or the remainder of the track.
SUMMARY OF THE INVENTION
According to the present invention there is provided a novel frame for supporting a track of a track-laying vehicle and more particularly there is provided structure for minimizing damage to the track and track shoes during single track shoe loading.
A broad object of the invention is to provide track-laying structure for supporting one or more of the track shoes after the track has undergone a predetermined amount of twist.
A further object of the invention is to provide a track-laying support structure which will prevent the track from sliding sideways from rollers of the track assembly.
Another object of the invention is to provide track protecting structures which may be easily connected to and removed from the track support frame.
These and other objects will become apparent from a reading of the ensuing description taken in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic left side elevational view of a typical track-laying vehicle with which the present invention is particularly adapted for use.
FIG. 2 is an enlarged view of a track support assembly shown in FIG. 1.
FIG. 3 is an enlarged sectional view taken along the lines 3--3 of FIG. 2 with parts omitted for the sake of simplicity.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, therein is shown an industrial vehicle 10 of a type commonly used for excavating or forestry harvesting work and with which the present invention is particularly adapted for use. Specifically, the vehicle 10 includes a superstructure 12 rotatably supported, in a manner conventional in the art, on an undercarriage 14.
The superstructure 12 includes a frame 15 which supports an engine (which is not shown) in an engine compartment 16 located at the rear of the frame. Supported at the forward end of the frame 15 is an operator's cab 18 located along the side of the rear end portion of a boom structure 20 having its rearend connected to the frame 15. The boom structure 20 would normally support excavating or forestry harvesting attachments (not shown) as is conventional.
The undercarriage 14 includes a main frame or carbody 22 including longitudinally extending right and left track support frames 24 of which only the left frame is shown and described herein for the sake of brevity.
As can best be seen in FIGS. 2 and 3, the track support frame 24 includes a longitudinally extending, inverted U-shaped main frame member 26 including right and left transversely spaced vertical walls 28 and 29, respectively, the walls 28 and 29 having lower horizontal edges 30 and 32, respectively. Right and left longitudinal mounting bars 34 and 36, respectively, are fixed, as by welding, to respective inner surfaces of the walls 28 and 29 and extend downwardly below the edges 30 and 32. A plurality of track support roller assemblies 38 are disposed centrally between the vertical walls 28 and 29 and are mounted on the bars 34 and 36 at longitudinally spaced locations. Supported at the rear of the main frame member 26 is a drive sprocket 40 and supported at the forward end of the frame member 26 is an idler wheel 42.
An endless track assembly 44 is entrained about the drive sprocket 40 and idler wheel 42 so as to define upper and lower runs 46 and 48. The track assembly 44 comprises an articulated link assembly including a plurality of links 50 hingedly or pivotally interconnected by pivot pin and bushing assemblies 52 and a plurality of track shoes 54 fixed to the links in a conventional manner, the shoes 54 extending transversely beyond the vertical walls 28 and 29 of the main frame member 26. As is conventional in the art, the pivot pin and bushing assemblies 52 are engaged by the respective teeth (not shown) of the drive sprocket 40 when the track 44 passes thereover. Further, it is to be noted that the pivot pin and bushing assemblies 52 of the lower run 48 of the track 44 engage the track support roller assemblies 38.
It is to be noted that the structure heretofore described is largely conventional and that the instant invention concerns the cooperation of structure to be described below with that which has already been described.
For the purpose of preventing damage to the track 44 when the latter is flexed by passing over a rock, stump, or other obstacles of that nature, right and left track guide and support members 56 and 58, respectively, are mounted on the track support frame 24. Specifically, the members 56 and 58 comprise welded structures respectively including vertical sections 60 and 62 having upper end portions disposed in embracing relationship to outer surface portions of the vertical walls 28 and 29 and having lower ends welded to respective horizontal sections 64 and 66, respectively, the horizontal sections 64 and 66 having respective inner edges 68 and 70 disposed adjacent to the ends of the pivot pin and bushing assemblies 52 of the lower run 48 of the track 44. Respectively welded to the vertical sections 60 and 62 at locations above the horizontal sections 64 and 66 are a plurality of horizontal tabs 72 and 74 which embrace downwardly facing horizontal mounting surfaces of the longitudinal mounting bars 34 and 36 and are secured to the bars 34 and 36 through means of a plurality of screw fasteners 80. For the purpose of rigidifying and maintaining parallelism between the track guide and support members 56 and 58, there is provided a plurality of spacer assemblies, the spacer assemblies each comprising a bolt 82 extending through the vertical sections 60 and 62 of the members 56 and 58 and having a tubular spacer member 84 received thereon and engaged with the inner surfaces of the vertical sections 60 and 62.
It will be appreciated that, during the operation of the vehicle 10, the tendency of track 44 to shift sideways relative to the support frame 24 is resisted by the pivot pin and bushing assembles 52 coming into engagement with the inner edges 68 or 70 of the track guide and support members 56 and 58. Further it will be appreciated that when the tracks of the vehicle 10 pass over an obstacle, such as a rock or log, individual loading of the track shoes 54 will occur and if an end portion of one of the track shoes 54 engages an obstacle being passed over by the vehicle 10, the engaged shoe 54 will rise only as far as permitted by the lower surfaces of the horizontal sections 64 and 66 of the track guide and support members 56 and 58, the forces imposed on the track then being transmitted to the frame 24 so as to prevent undue loading of the track shoe and damage that might occur as a consequence of such loading.
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A frame for supporting a track of a track-laying vehicle includes a pair of lower longitudinally extending members having surfaces disposed to prevent sideways movement of the track and for supporting the track shoes in the event that the track begins to twist from working loads imposed thereon.
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RELATED APPLICATIONS
This application contains subject matter common to that contained in U.S. application Ser. No. 08/496,775, filed on Jun. 29, 1995, entitled INTERNAL PRESSURE SLEEVE FOR USE WITH EASILY DRILLABLE EXIT PORTS, in the names of Larry Comeau, et al.
RELATED APPLICATIONS
This application contains subject matter common to that contained in U.S. application Ser. No. 08/496,775, filed on Jun. 29, 1995, entitled INTERNAL PRESSURE SLEEVE FOR USE WITH EASILY DRILLABLE EXIT PORTS, in the names of Larry Comeau, et al.
BACKGROUND OF THE INVENTION
This invention relates generally to apparatus used in drilling lateral wells from vertical wells, for purposes of producing oil and gas from subsurface formations.
Since its usage began, horizontal drilling has offered dramatic reservoir-exposure improvements. Lately, a new trend has developed towards drilling multiple laterals, thus further increasing production. Until recently, laterals typically were not cased and tied back, which meant when workovers or cleanouts were required, re-entry was difficult and completions were virtually impossible.
Now, the technology allows multiple laterals to be cased and tied back. Multilaterals may be drilled into predetermined producing-formation quadrants at any time in the productive life cycle of wells and can be used in vertical, directional or horizontal applications.
Minimizing the distance hydrocarbons must travel to the wellbore is an important goal. One surface hole installation can now incorporate an integral casing drainage system that takes the wellbore to the hydrocarbons in place.
The same directional bottomhole assembly used to initiate the kickoff is used to drill the build or turn portion of the lateral wellbore. Once a lateral has been drilled, a secondary liner and hanger system is placed into the newly drilled wellbore and mechanically tied back to the main casing string, allowing future re-entry into the new leg. The deflection device can immediately be moved to the next window joint upon installation of the lateral string.
Either the drilling cycle can commence on the next lateral, or the deflection device can be retrieved to surface, enabling access to all casing strings. The deflection device can, alternatively, be left on bottom, to be available if additional laterals are drilled at some other time, to further improve reservoir recovery based on performance of the original wellbore and its added lateral or laterals.
Additional benefits are that the system creates a natural separator for oil and gas production in vertical applications, and it creates the opportunity to drill, complete and produce from several different formations tied to one surface-hole casing string.
An integral part of the system for drilling either a single lateral well, or a multiple lateral well scenario, is the so-called casing window joint, a joint of steel casing having a pre-cut or pre-formed window which is easily drillable. The casing window system is available in various oilfield-tubular material grades. The completed casing window is the overwrapped with composite materials (similar to fiberglass).
PRIOR ART
As noted in U.S. Pat. No. 4,415,205, indexing mechanisms for locating and orienting tools for formation of lateral well bores are well known in the prior art. Typically, such designs use internally projecting keys formed on the internal wall of the surrounding pipe which engage the downhole tool to establish correct lateral or axial tool positioning. U.S. Pat. No. 4,415,205 describes a typical application which employs an internally projecting key which extends radially inwardly from the casing wall for orienting and positioning a whipstock.
While providing adequate precision for their intended purpose, these keys restrict the internal clearance through the casing. Where large forces are to be encountered, one or more relatively large projections may be required to withstand the applied loads further obstructing the internal clearance of the casing. These internal restrictions, whether, one or many, can interfere with work to be performed within the well pipe. Moreover, projections extending into the casing are subject to being damaged or destroyed by tools working in the casing rendering the projections useless for their intended purpose.
The use of projecting keys also limits the type of equipment which may be passed through the well pipe. Full drift tools obviously may not be lowered below such projections. Where the well casing is equipped with multiple setting keys at different axially spaced locations, relatively complex setting tools are required for selectively placing or operating the subsurface assembly at the lower locations.
From the foregoing, it will be appreciated that a primary object of the present invention is to provide a means for physically holding and orienting a subsurface device such as a whipstock within a surrounding well pipe without the use of clearance restricting projections extending inwardly from the pipe wall.
Another object of this invention is to provide a system for anchoring and orienting a subsurface assembly within a well bore by the use of only axial and one-way rotational movement of a surface operated setting tool.
An important object of the present invention is to provide an assembly which may be set at a subsurface location and confirmed to be set properly by monitoring axial and rotational forces exerted by the setting tool.
It is also an object of this invention to provide a subsurface assembly which can selectively be axially moved past one or more subsurface anchoring recesses without being set.
An object of the invention is to provide an assembly with biased latches which reach full outward extension only when each and every latch is properly aligned with its own corresponding recess in the casing wall.
It is also an object of the invention to provide a keyless anchoring and orientation system which allows surface confirmation that the assembly is at a desired subsurface depth location and that the circumferential orientation of the assembly is correct.
SUMMARY OF THE INVENTION
The keyless latch assembly of the present invention cooperates with circumferentially spaced recesses formed on the internal surface of a well pipe to locate, anchor and orient the assembly and any tool attached thereto. The design of the recesses and latches on the assembly function together to ensure that, when fully anchored, the assembly is properly positioned axially as well as circumferentially relative to the surrounding well pipe.
The assembly may be moved axially past any set of recesses without setting by rotating the setting string so that the latches are not aligned with their corresponding recesses as they traverse the recessed area. When the assembly has been set, a direct, nonrotational lifting force on the setting string causes release of the assembly from its surrounding recesses. Upward release movement of the assembly is permitted due to the engagement of tapered shoulders between the latches and their recesses. Downward movement of the anchored assembly is prevented by the engagement of square shouldered surfaces on the latches and recesses. The amount of force required to release the tool can be altered as required by changing the spring forces acting to extend the latches outwardly into their recesses or by altering the surface contact areas between the latches and recesses.
An important feature of the present invention is its ability to confirm proper anchoring and orientation of the assembly by simple right hand rotation of the setting string. An increase in axial forces required to move the string up or down confirms engagement of the assembly with the recess area. A sharp increase in the torque normally required to rotate the assembly confirms proper orientation of the assembly as well as anchoring.
These and other objects, features and advantages of the present invention may be more fully appreciated and understood by reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will be more readily appreciated from a reading of the detailed specification, in conjunction with the drawings, in which:
FIG. 1 is a simplified, elevated, diagrammatic view, partly in cross-section, of an internal pressure sleeve according to the present invention, in place in the interior of a casing having a pre-cut, easily drillable hole therein;
FIG. 2 is an elevated, cross-sectional view of the internal pressure sleeve according to the present invention;
FIG. 3 is an elevated, cross-sectional view of the internal pressure sleeve of FIG. 2, in place in the interior of a casing having a pre-cut, easily drillable hole therein;
FIG. 4 is an enlarged, elevated, cross-sectional view of the upper coupling portion of the internal pressure sleeve according to FIG. 2;
FIG. 5 is an elevated, cross-sectional view of the upper coupling illustrated in FIG. 4, in place in a section of casing;
FIG. 6 is an enlarged, elevated, cross-sectional view of the center sleeve portion of the internal pressure sleeve illustrated in FIG. 2;
FIG. 7 is an enlarged, elevated, cross-sectional view of the lower coupling portion of the internal pressure sleeve according to FIG. 2;
FIG. 8 is a generalized schematic view, partially cut away, illustrating the assembly of the present invention being used to locate, anchor and orient a whipstock within a specially recessed casing joint;
FIG. 9 is a detailed elevation, in cross-section, illustrating the assembly of the invention in its sliding configuration within a recessed casing coupling of the invention;
FIG. 10 is a view similar to FIG. 9 illustrating the assembly of the invention in its latched and oriented configuration within the receiving recesses of the surrounding casing coupling;
FIGS. 11a, 11b, and 11c are isometric views illustrating details in the profiles of the latches employed in one form of the invention;
FIG. 12 is a cross-sectional view of the assembly illustrating the configuration of the latches as the assembly is moved through the casing to the area of the receiving recesses;
FIG. 13 is a cross-sectional view illustrating the latches of the assembly partially extended as they are initially latched in the casing coupling recesses;
FIG. 14 is a cross-sectional view of the latches of the assembly rotated into their fully extended, latched and oriented positions;
FIG. 15 is a partial vertical cross-sectional view of the latch housing sleeve portion of the assembly of the present invention;
FIG. 16 is a view taken along the line 16--16 of FIG. 15 showing details in the latch housing sleeve;
FIG. 17 is a detailed elevation, in cross-section, illustrating details in the internal coupling recesses; and
FIG. 18 is an isometric view illustrating the circumferential spacing and axial positioning of internal recess slots formed on the inner surface of the casing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a tubular, steel casing 10 is illustrated as having a pre-cut or pre-formed hole 12 therein. The outer surface of the casing 10 is wrapped with one or more layers of fiberglass 14, thus providing the easy exit port 12 through the casing 10.
The tubular sleeve 16 is located within the interior of the casing 10, held in place by a plurality of set screws 18 which pin the sleeve 16 to the casing. O-rings 20, 22, 24 and 26 prevent any liquids or gasses from passing along the annular space between the casing 10 and the tubular sleeve 16 coming from the exit port 12. A conventional muleshoe 28 is located at the upper end of the tubular sleeve for rotating the casing 10 and the sleeve 16 as appropriate.
In the operation of the system diagrammatically illustrated in FIG. 1, the internal sleeve 16 is pinned in place at the earth's surface. The combined casing 10 and sleeve 16 is then run into an earth borehole, already drilled by conventional methods, until the exit port 12 is located at the desired vertical depth, within the region of interest 30 in the earth formation. The orientation of the exit port 12 is determined by causing survey instruments to land on the muleshoe 28. By rotating the casing string from the earth's surface, the exit window is thus oriented. Once the exit port 12 is correctly oriented, the casing is typically cemented in place, in the earth borehole, after which a conventional fishing tool is run from the earth's surface, down through the casing 10, the internal sleeve 16, and out the lower end of the sleeve 16. Although the fishing tool (not illustrated) can take various forms, a typical fishing tool for this operation can have one-way dogs, which spring up upon exiting the lower end of the sleeve 16, and actually grapple the lower end of sleeve 16. By pulling up on the fishing tool, the set screws 18 will shear out and the internal pressure sleeve can be retrieved to the earth's surface.
Following retrieval of the internal pressure sleeve 16, a conventional whipstock, such as is illustrated in FIG. 8 is lowered through the casing 10, and once oriented with the orientation of the exit port 12, for example, through the use of a conventional key lug on the interior of the casing 10, is anchored immediately below the exit port 12. With the whipstock anchored in place and its running tool retrieved from the borehole, a conventional drilling operation is commenced, in which a drill bit at the lower end of a drillstring is lowered down to the whipstock and caused to drill off the whipstock, through the fiberglass covered exit port 12, any cement outside the exit port, and into the formation of interest 30. To replace the conventional key lug, the present invention contemplates that a keyless orienting and latching system as described hereinafter be used.
Those skilled in the art will recognize that this system can function without the use of the fiberglass layer or layers 14. However, the preferred embodiment makes use of the fiberglass layer to keep debris in the borehole from entering the exit port into the annulus between the casing 10 and sleeve 16, in between the O-ring 22 and the O-ring 24.
As an additional feature of the invention, a generally incompressible oil or grease is placed in the exit port 12 prior to wrapping the casing 10 with the fiberglass, thus preventing the fiberglass layer 14 from deforming into the exit port 12 when exposed to high pressures external thereto.
Referring now to FIG. 2, the preferred embodiment of an internal pressure sleeve assembly 40 illustrated in greater detail than that of the schematic representation of sleeve 16 in FIG. 1. The sleeve assembly 40 has a muleshoe 42 at the upper end of an upper coupling 44. A lower coupling 46, at the lower end of the sleeve assembly 40, has a pair of wrench slots 48, indexed at 180°, for tightening the parts of the assembly 40. Intermediate the upper coupling 44 and the lower coupling 46 is a sleeve 47.
The tapped holes 49 in the upper coupling 44 receive the set screws (not illustrated in this drawing figure) which are used for attaching the sleeve assembly 40 to the casing, illustrated together in FIG. 3.
Referring now to FIG. 3, the sleeve assembly 40 is illustrated as being pinned to a casing joint 50 having a window (exit port) 52, prior to the casing 50 being wrapped with a composite material, for example, fiberglass.
Referring now to FIG. 4, the upper coupling portion 44 of the sleeve assembly 40 is illustrated in greater detail. The muleshoe 42, used for determining the orientation of the exit port in the casing, is a 44.000 lead taper, single muleshoe. The O-ring receptacles 66 and 62 are formed on opposing sides to the tapered holes 49 which receive the set screws for attaching the sleeve assembly 40 to the casing joint 50. The upper coupling 44 has a female-threaded portion for being threadedly connected to the sleeve illustrated in FIG. 6.
Referring now to FIG. 5, the upper coupling 44 is illustrated as being pinned to the casing 50 through the use of set screws threaded into the casing holes 60 and the holes 49 in the upper coupling 44.
Referring now to FIG. 6, the sleeve 48 is illustrated in greater detail, having a first pin end (male threads) 62 for threadedly engaging the upper coupler 44 and a second box end (female threads) 64 for threadedly engaging the lower coupling 48.
Referring now to FIG. 7, the lower coupling 46 is illustrated in greater detail. Although only a single O-ring receptacle 70 illustrated, a pair of such receptacles for housing a pair of O-rings such as O-rings 24 and 26 of FIG. 1 can be used if desired.
In the course of practicing the invention, it is contemplated that the following method may be used:
1. Windowed casing joints are placed in the main wellbore casing string and rotated at precise locations, to a predetermined orientation, to allow drilling of multilateral sections through predetermined paths.
2. The main casing string is cemented in place using primary cementing techniques. Alternatively, it may be hung off as a slotted-liner completion.
3. Because the window joint contains an inner-pressure sleeve, securely held in place with O-rings, it can withstand more than normal weight buildup and thus maintain pressure integrity; plus, it also prevents cutting debris from entering the window opening.
4. After cementing the main casing string, the inner-pressure sleeve is retrieved using a standard fishing spear. The cavity created between internal sleeve and composite material is filled with a non-compressible fluid medium and balanced to the external annulus.
5. The retrievable deflection tool (whipstock) is then landed and installed into the casing window joint.
6. The lateral section is drilled using conventional directional drilling techniques--from rotary assemblies to articulated short-radius assemblies, depending on desired wellbore path profile.
7. At TD of the lateral section, the drilling assembly is retrieved (while the whipstock is left in place), and the hole is cleaned to ensure that lateral liner and additional completion equipment can be installed.
8. Next, a lateral liner is run in the hole, to the top of which a lateral hanger assembly and specialized running tool are attached. The entire assembly is run into the wellbore on the end of a drillstring.
9. The running tools are run to depth and the lateral hanger assembly is landed within the window joint.
10. A hydraulic gate closing is activated to close a mechanical gate around the hanger, providing a mechanical seal. Surface pressure-recording equipment monitors the gate-travel and gate-closing process.
11. Next, a hydraulic collet is activated for release, and running tools are released and retrieved to surface.
12. With the retrievable deflection tool (whipstock) still there, the lateral is cemented in place using a cementing re-entry guide tool that allows the liner to be cemented using a dual-plug cement procedure.
13. The retrievable deflection tool (whipstock) is either moved to the next window to aid in drilling another lateral or removed from the wellbore.
14. Now, if needed, the lateral section can be re-entered by landing a completion whipstock in the windowed joint for subsequent operations.
FIG. 8 illustrates a well casing 10 extending down a vertical bore ho into the earth. A preformed exit port or window 12 in the casing opens to a region of drilling interest 30 situated laterally away from the vertical well bore.
A laterally extending bore hole may be drilled to the region 30 using a whipstock assembly W indicated within the casing string 10 which deflects a drill bit B away from the vertical bore through the casing window 12. This basic technique for forming lateral well bores is well established and described in the prior art.
The whipstock assembly W includes an anchoring, positioning and orienting assembly 100 of the present invention secured to the bottom of a whipstock tool 102. The assembly W is suspended from a drill string 103 which extends to the surface. The string 103 is used in conventional fashion as a setting string to raise and lower the assembly as well as to rotate the drill bit B.
Specially configured recesses 105 formed along the interior surface of the casing 10 below the window 12 are designed to align with and receive movable, spring loaded, latches 106 extending radially from the assembly 100. When the latches 106 are properly aligned axially and circumferentially with appropriate recesses in the well casing, the spring loading on the latches forces the latches to move radially outwardly into mating forms in the recesses. By selecting a unique pattern of mating latch and recess dimensions, circumferential orientation as well as axial positioning of the whipstock assembly may be achieved.
Once the assembly W has been anchored and oriented, the drillstring 103 is lowered and simultaneously rotated causing the bit B to advance along the inclined whipstock guide surface and through the window 12 to drill laterally into the surrounding formation in a conventional manner.
Details in the construction and operation of a preferred form of the invention may be seen with reference to FIGS. 9 and 10 showing the assembly 100 in its unset or non-anchored configuration (FIG. 9) and its set, oriented configuration (FIG. 10).
Referring jointly to FIGS. 9, 12, and 16, the assembly 100 includes a tubular latch housing 107 through which are formed three circumferentially spaced latch windows, 108, 109, and 110. Latches 111, 112, and 113 (FIGS. 11a, 11b, and 11c) are positioned for radial movement through their respective coinciding latch windows as best illustrated in FIG. 12. For clarity, only latch 108 is illustrated in FIGS. 12, 13 and 14.
As illustrated best in FIGS. 9 and 12, the latches are positioned on a latch carrier 114 which holds each latch segment in its respective housing window. The ends of the latches engage spring loaded latch rings 115 and 116 (FIG. 9) which are urged toward each other by two sets of Bellville springs 117 and 118. Tapered surfaces 115a and 116a on the latch tings 115 and 116, respectively, engage oppositely tapered surfaces such as the surfaces 111a and 111b (FIG. 11a) on the latch segments, to force the latch segments to move radially outwardly.
The assembly 100 is dimensioned to fit snugly against the internal surface of the pipe within which it is to operate so that the latches 111, 112 and 113 are in firm sliding engagement with the internal pipe surface. The amount of force urging the latches outwardly is determined by selecting the appropriate number and strength of elements in the spring assemblies 117 and 118 and by selecting appropriate inclined surfaces for engagement between the latches and the recess contours.
A bull nose nut 119 threadedly engaged to the bottom end of the assembly 100 may be adjusted as required to accommodate different spring configurations. A bull nose spacer 120, having the desired axial length, is positioned between the nut 119 and the housing 107 to permit the nut to be securely tightened onto the housing.
FIG. 16 illustrates protective pads 107a positioned about the outer circumference of the housing 107. These pads assist in centering and protecting the latch elements in the assembly as it is lowered through the well pipe.
FIG. 9 illustrates the assembly in its normal "running-in" position as it would be with the latches riding against the nominal (un-recessed) internal surface of the well casing.
FIG. 10 illustrates the assembly in position within a specially recessed casing coupling 121. The coupling 121 is internally threaded at its ends to mate with corresponding external threads formed at the ends of casing joints. The coupling 121 is positioned in the well bore at a known depth and with a known circumferential orientation to function with the assembly 100 in anchoring and orienting a subsurface well tool attached to the upper end 107a of the housing 107.
As illustrated in FIG. 17, the coupling 121 is provided with an internally recessed area indicated generally at R which has a series of grooves and slots developed radially outwardly from the coupling's central axis. The result is a specially contoured area where the internal casing diameter is increased relative to the normal internal diameter of the connected casing.
The recessed area R includes slotted sections, S1, S2, and S3 which are only partially developed circumferentially about the internal recessed area R. These slotted sections and their placement are schematically illustrated in FIG. 18. The slots S cooperate with annular grooves G in the recessed area R to provide the unique anchoring and orienting features of the present invention.
As best seen by reference to FIG. 17, the slots S are deeper (extend radially further from the coupling axis) than the grooves G. Additionally, the grooves G extend entirely around the internal surface of the coupling while the slots have limited circumferential development. Each slot set, S1, S2, and S3 also has different axial positioning relative to any other slot set. As may be seen by reference to FIG. 11a, 11b, and 11c, the sliding latch surfaces of the latches 111, 112 and 113 also have profiles which are different from each other.
In operation, when the assembly 100 is lowered into the coupling 121, the latches 111, 112 and 113 partially extend radially into the recess area R as the grooves G are aligned with opposing projecting contours on the latch profiles. When the assembly is rotated, the latches fully extend radially once the latches meet their appropriate slots. Because of the unique match of slots with latches, this occurs at only one circumferential orientation of the assembly 100 within the recessed area R.
As illustrated in FIG. 10, full extension of the latches places square shouldered sections 111c, 111d, 112c, 112d, 113c, and 113d (FIGS. 11a, 11b, and 11c) into engagement with square shoulders formed in the recessed area R to prevent further downward movement of the assembly 100.
During the time the assembly 100 is within the recessed area R but with the latches partially extended but before they have engaged their slots, the assembly 100 can be moved up or down through the coupling by increasing the force exerted through the drill string. The increased force is required to overcome the engagement of the grooves G with the mating projections on the spring loaded latches. This increase in force is measurable at the well surface and provides an indication to the operator that the assembly is in the coupling 121.
Rotation of the drill string 103 to the right aligns the slots and appropriate latches, permitting the latches to spring fully outwardly into the slots. This engagement of slots and latches prevents further rotation of the assembly 100 relative to the coupling 121. The anchored, oriented position is detected at the surface by a sharp increase in the amount of torque being applied to rotate the drill string. Further confirmation of anchoring and orientation is obtained by confirming that the assembly 100 does not move down in response to a downward drill string force equivalent to that which was capable of moving the assembly through the recessed area before orientation.
In an example of a practical application of the invention, the assembly 100 is lowered by the drill string into a well casing until it is in the vicinity of the coupling 121. The operator observing a surface weight indicator notes a decrease of approximately twenty thousand pounds in the string weight coinciding with the latches springing out approximately 1/8" into initial engagement with the recess area R. An upward pull on the drill string is exerted to release the assembly 100. This release force will be seen to exceed the normal, non-engaged weight of the string by approximately 20,000 pounds. This provides confirmation that the assembly has been engaged with the recess area R.
The string is then relowered until the weight indicator again shows a string weight loss of 20,000 pounds. The drill string is rotated to the right until the latches engage and fully expand radially into their respective slot sets. This prevents further assembly rotation which in turn produces a sharp increase in reaction torque which is noted at the surface. This provides confirmation that the assembly has been properly anchored and oriented within the coupling 121. Further confirmation is obtained by resting another 20,000 pounds of string weight on the assembly to ensure that the assembly does not move downwardly. Release of the tool is effected by lifting approximately 40,000 pounds which removes the 20,000 pound test weight and provides the additional 20,000 pounds of force to free from the recesses.
While the preferred embodiment of the invention has been described for use with three latches, it will be appreciated that fewer or more latches may be used without departing from the spirit of the invention. Similarly, the recesses may be formed within the casing itself, a sub assembly or other string component and need not necessarily be formed within a casing coupling.
It will further be understood that various means may be provided to produce the biasing force which urges the latches outwardly. Also, while slots and grooves and matching latch contours have been described in the preferred form of the invention, other techniques for ensuring that only specific elements of the assembly 100 will mate with corresponding elements of the coupling 121 to produce a two step radial expansion and a non-rotatable orientation may be employed.
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A keyless latch assembly automatically aligns and fixes the axial and circumferential position of a whipstock within a surrounding casing joint. Alignment and fixing of the whipstock ensures proper engagement and orientation of a drill bit relative to an access window formed in the casing wall. Spring loaded latches in the assembly register with and extend into corresponding receiving recesses formed on the inner surface of the casing joint. The recesses, which are spaced circumferentially around the interior of the casing joint, contain differing profiles that uniquely mate with corresponding profiles on the latches. The position of the latches relative to the recesses determines the amount of radial latch movement which controls the anchoring and orientation of the assembly within the casing. Confirmation of correct axial location and proper circumferential orientation may be made by surface monitoring of the setting string weight and turning torque. The spring loaded latches release from anchored, oriented position in response to an upward axial force exerted by the drill string to provide a straight pull release of the assembly.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/088,236 filed Dec. 5, 2014, the contents of which are hereby incorporated by reference for all purposes as if set forth in their entirety herein.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] This disclosure relates, in general, to improvements in flush valves for toilets, urinals, and other plumbing equipment. More particularly, this disclosure relates to an improved diaphragm for use in flush valves.
[0004] Flush valves in toilets, urinals, and other plumbing devices may utilize a flexible diaphragm to both establish and seal off the connection between the inlet and outlet within a hollow brass body. In some flush valves, a barrel forms the connection between the inlet and outlet and the top of the barrel may include an annular main valve seat. This main valve atop the barrel may be normally closed by a flexible diaphragm which may extend across the hollow body of the flush valve and define an upper chamber. The flexible diaphragm may be clamped in place by an annular clamping rim on the flush valve body. The center of the flexible diaphragm may connect the upper chamber with the outlet, and a relief valve may be located in the center of the flexible diaphragm to normally seal off the upper chamber from the outlet.
[0005] Diaphragm assemblies may include the diaphragm, a relief valve, a stem, a guide member, wing members, a retaining disc, and a flow ring. The guide member in the barrel may move with the diaphragm and include outwardly extending radial wing members, which engage the inner surface of the barrel to guide the guide member and attached diaphragm. The guide member may be attached to the diaphragm with a retaining disc using brass threading. The diaphragm may be formed of rubber which may be bonded to the brass parts in order obtain acceptable seating surfaces.
[0006] In general, a normally closed flush valve may operate to seal off the upper chamber from the outlet using the water pressure from the inlet. The water under pressure at the inlet may communicate with the upper chamber of the flush valve through a bypass in the flexible diaphragm. Since the upper side of the diaphragm has a greater surface area, the water pressure forces the diaphragm down onto the valve seat on top of the barrel, thus preventing water from flowing into the outlet from the upper chamber. When a user moves a handle of the flush valve, a plunger may move inwardly toward the axis of the barrel and tilt a stem of the relief valve. This may break the seal the relief valve has established and allow water to flow through a guide member within the barrel and to the outlet. The opening of the relief valve may relieve the pressure within the upper chamber and the water pressure from the inlet may force the diaphragm upward and off of the main valve seat, allowing water to flow from the inlet through the barrel to the outlet. When moving upward, the diaphragm may reset the relief valve located in its center such that it again seals off the upper chamber from the outlet. Water from the inlet may then flow through the bypass into the upper chamber until the diaphragm is again forced against main valve seat, thereby closing the valve.
SUMMARY
[0007] According to one aspect, a one-piece unitary diaphragm assembly for use in a flush valve is disclosed. The one-piece unitary diaphragm assembly includes an elongated barrel member, an annular flexible diaphragm, a radial support, and a relief valve seat. Constructed of a first predetermined material, the elongated barrel member has a body defining a passageway and the annular flexible diaphragm disposed about it. Constructed of a second predetermined material different from the first, the annular flexible diaphragm has a mounting portion at its peripheral edge for mounting the diaphragm assembly within the flush valve. Extending along some longitudinal length of the barrel member, the radial support is positioned circumferentially around the outer surface of the barrel member. The relief valve seat is located at the upper end of the barrel member and adapted for receiving a relief valve. In some forms, the assembly may further include a relief valve having a stem with a sealing member disposed at its upper end. The lower surface of the sealing member may have a sealing material disposed it, adapted for sealing against said relief valve seat.
[0008] According to another aspect, a flush valve diaphragm kit for use in a flush valve is disclosed. The diaphragm kit includes a one-piece unitary diaphragm assembly, an annular flexible diaphragm, a radial support, relief valve seat, and a relief valve, which are all arranged and constructed as described above.
[0009] The assembly and the kit may vary in form. In some forms, a flow control ring may be positioned about the barrel member and configured to be supported by the radial support. In some forms, a bypass orifice may be disposed through the annular flexible diaphragm.
[0010] According to yet another aspect, a method of molding a one-piece unitary diaphragm assembly is disclosed. The method includes first, heating a first thermoplastic material until molten, and then delivering the first molten thermoplastic material to a mold's first cavity having an elongated tube shape. The method then includes heating a second thermoplastic material until molten, and delivering the second molten thermoplastic material to the mold's second cavity, having an annular shape and fluidly communicating with the first cavity. The next step in the method is holding the first and second thermoplastic materials in the mold for a predetermined period of time to form a one-piece unitary diaphragm, and finally, ejecting the one-piece unitary diaphragm from the mold. In some forms, the first and second cavities may fluidly communicate at an interface between the exterior of the elongated tube shape and the interior of the annular shape. In other forms, the exterior of the elongated tube shape may fluidly communicate with a ring-shaped third cavity positioned about the elongated tube shape via a radial passage, which may be configured to form a radial support. The radial support may be configured to support a flow control ring formed from the ring-shaped third cavity.
[0011] The first and second predetermined materials forming an integral unitary diaphragm assembly may vary according to different forms. In some forms, the first and second predetermined materials may be co-formed. In other forms, the second predetermined material may be overmolded onto the first. In some forms, the first and second predetermined materials may be different thermoplastics. In other forms, the first and second predetermined materials may be acrylonitrile butadiene styrene (ABS) and a thermoplastic elastomer (TPE).
[0012] There are many potential benefits of a one-piece unitary diaphragm assembly as described herein. A one-piece unitary diaphragm assembly may control the flow parameters of a flush valve which may flush, rinse, and refill toilets and urinals in a consistent, quiet, quick and effective manner. A diaphragm assembly may be designed as a unitary diaphragm molded from thermoplastic and thermoplastic elastomer resins. Using thermoplastic elastomer materials for a diaphragm assembly may combine the compressibility and sealing characteristics of rubber with the moldable and rigid structural characteristics of plastic, which may meet and exceed the performance required in flush valves. A unitary diaphragm assembly may be interchangeable with older multi-part diaphragm assemblies used in common valve assemblies, flush valves, and flushometer valves. The unitary diaphragm design of the disclosure may improve the consistency, reliability, and expected life of the diaphragm unit by reducing the number of parts and eliminating parts which cause undesirable wear and corrosion. The unitary diaphragm assembly may extend the life of the product by preventing both the separation of the diaphragm tab from the diaphragm rubber and the creation of rubber particles which may clog parts of the assembly, including the bypass. A unitary diaphragm may allow for reduced unit costs due to a decrease in part manufacturing costs and the elimination of assembly costs. A unitary diaphragm may allow for improved control of tolerances which may result in improved performance valve to valve, as well as reduced part scrappage. Finally, lower inventory costs may result due to a reduction in the total number of parts for a unitary diaphragm design.
[0013] These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows an example of a common flush valve assembly.
[0015] FIG. 2 shows a perspective view of an example of a unitary diaphragm assembly design and a relief valve extending through the center of the diaphragm assembly.
[0016] FIG. 3 shows a cross sectional view of another example unitary diaphragm assembly as it would be seen along line L-L of the assembly of FIG. 2 with the sealing relief valve in an open position.
[0017] FIG. 4 shows a cross sectional view of the unitary diaphragm assembly of FIG. 3 with the sealing relief valve in a closed position.
DETAILED DESCRIPTION
[0018] FIG. 1 shows an example of a flush valve and diaphragm assembly. This type of flush valve may have a hollow body 10 , generally made of brass, which may include an inlet 12 , an outlet 14 , and a handle connection 16 . A barrel 18 may be located within the flush valve such that the connection between inlet 12 and outlet 14 is through the barrel 18 . An annular main valve seat 20 may be formed on the top of the barrel 18 . The annular main valve seat 20 may be normally closed by the diaphragm 22 which may extend across the hollow body 10 and define an upper chamber 24 . The diaphragm 22 may have a bypass 26 which provides fluid communication between the inlet side of the flush valve and the upper chamber 24 . The diaphragm 22 may be attached at its outer edge to the valve body and may be clamped in place by an annular clamping rim on the outer cover 28 of body 10 . The center of the diaphragm 22 may have an opening 30 which allows for fluid communication between upper chamber 24 and the outlet 14 . A relief valve 32 may normally close the opening 30 at the center of the diaphragm 22 .
[0019] In general, a normally closed flush valve may operate to seal off the upper chamber 24 from the outlet using the water pressure from the inlet 12 . The water under pressure at the inlet 12 may communicate with the upper chamber 24 of the flush valve through a bypass 26 in the flexible diaphragm. Since the upper side of the diaphragm 22 may have a greater surface area, the water pressure from the inlet 12 may force the diaphragm 22 down onto the valve seat 20 on top of the barrel 18 , thus preventing water from flowing into the outlet 14 from the upper chamber 24 . When a user actuates a handle 34 of the flush valve, a plunger 36 may move inwardly toward the axis of the barrel 18 and tilt a stem 38 of the relief valve 32 . This may break the seal the relief valve 32 has established and allow water to flow through a guide member 40 within the barrel 18 and through to the outlet 14 . The opening of the relief valve 32 may relieve the pressure within the upper chamber 24 and the water pressure from the inlet 12 may force the diaphragm 22 upward and off of the main valve seat 20 , allowing water to flow from the inlet 12 through the barrel 18 to the outlet 14 . When moving upward, the diaphragm 22 may reset the relief valve 32 located in its center such that the relief valve 32 may again seal off the upper chamber 24 from the outlet 14 . Water from the inlet 12 may then flow through the bypass 26 into the upper chamber 24 until the diaphragm 22 is again forced against main valve seat 20 , thereby closing the valve.
[0020] The guide member 40 may move with the diaphragm 22 and may include outwardly extending radial wing members 42 . The radial wing members may engage the inner surface of the barrel 18 to guide the guide member 40 and attached diaphragm 22 as the diaphragm 22 moves up and down.
[0021] FIG. 2 shows an example of a unitary diaphragm assembly 50 which may be designed to be utilized in flush valves of the type illustrated in FIG. 1 , which may replace the complicated diaphragm assemblies of older devices. The unitary diaphragm assembly 50 may be molded as a single piece from a thermoplastic and a thermoplastic elastomer. The unitary diaphragm assembly 50 may include an integral diaphragm 52 which has a mounting portion 54 at the outer peripheral edge.
[0022] Referring to FIGS. 2-4 , a sealing surface 56 may be located on the underside of the integral diaphragm 52 at a position radially inward relative to integral diaphragm 52 , so as to cooperate with the main valve seat 20 of a flush valve. An integral retaining disc 58 may extend upward from the diaphragm 52 above the portion of the diaphragm 52 having the sealing surface 56 . The retaining disc 58 may include a relief valve seat 60 , which may be configured to receive a sealing relief valve 62 . The sealing relief valve 62 may include a valve stem 64 projecting downward and a sealing material 66 disposed on the underside of the sealing relief valve 62 . The sealing material 66 may form an annular lip configured to establish a seal with the relief valve seat 60 . Alternatively, the sealing material 66 may cover the entire underside of the sealing relief valve 62 rather than only an annular lip. Radial supports 68 may extend from a barrel member 70 to support a flow ring 72 and to maintain the diaphragm assembly 50 in the proper alignment as it moves up and down inside the barrel 18 .
[0023] The relief valve seat 60 may be positioned on the upper end of barrel member 70 . The barrel member 70 may cooperate with the barrel 18 of a flush valve and may extend substantially coaxially along the length of the barrel 18 . The flow ring 72 may control the flow of water when the diaphragm assembly 50 is in the open position.
[0024] The unitary diaphragm assembly 50 may also include a bypass orifice 74 positioned within the diaphragm 52 . The unitary diaphragm assembly 50 may operate in an analogous manner to the diaphragm assembly of FIG. 1 .
[0025] The unitary diaphragm assembly 50 may be molded as a single piece from a thermoplastic and a thermoplastic elastomer via plastic injection molding. The two materials may be co-molded according to known techniques. Alternatively, a first material may be overmolded onto a second material to construct the unitary diaphragm assembly 50 . As an example, the barrel member 70 , retaining disc 58 , radial supports 68 , and flow ring 72 may be molded from a thermoplastic, such as acrylonitrile butadiene styrene (ABS), and the integral diaphragm 52 may be overmolded or co-molded from a thermoplastic elastomer to the thermoplastic making up the barrel member 70 , integral retaining disc 58 , radial supports 68 , and flow ring 72 . In this way, the unitary diaphragm assembly 50 may be constructed as a single piece from two different materials.
[0026] The unitary diaphragm assembly 50 may be constructed from more than two different thermoplastic materials by using multi-shot plastic injection molding methods, where different parts may be constructed from different materials. As an example, the barrel member 70 , radial supports 68 , and flow ring 72 may be molded from a thermoplastic, such as acrylonitrile butadiene styrene (ABS). While the retaining disc 58 and the diaphragm 52 may be overmolded or co-molded from a first thermoplastic elastomer and a second thermoplastic elastomer, respectively, to the thermoplastic of the barrel member 70 , radial supports 68 , and flow ring 72 . In this way, the unitary diaphragm assembly 50 may be constructed as a single piece from three different materials.
[0027] It should be appreciated that various other modifications and variations to the preferred embodiments can be made within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.
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Disclosed are systems and methods for a unitary diaphragm assembly is for use in flush valves. The diaphragm assembly may have a flexible diaphragm which includes a seating portion and a mounting portion at the outer peripheral edge. A flow ring may be positioned adjacent to the seating portion of the diaphragm. An elongated barrel member may extend from the diaphragm in a longitudinal direction and may include a plurality of radial supports positioned circumferentially around the outer surface of the barrel member and along a portion of the length of the barrel member.
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FIELD OF THE INVENTION
This invention relates to vehicle brake actuators, including spring brake actuators, having an improved piston assembly which eliminates welding, reduces cost and results in an improved piston.
BACKGROUND OF THE INVENTION
Brake actuators are conventionally used on heavy vehicles having pneumatic braking systems, including trucks, buses and tractor trailers. Conventional brake actuators include a cup-shaped flexible diaphragm, which is supported in the housing, and a piston having a piston plate which is spring biased against the diaphragm. Upon actuation of the pneumatic braking system, air pressure drives the flexible diaphragm and the piston rod or push rod of the piston to actuate the braking system of the vehicle. Conventional brake actuators generally also include an emergency chamber, which may be mounted on the service chamber, having a power spring, which actuates the piston of the service chamber when the pneumatic pressure of the vehicle braking system fails or when the vehicle is turned off, providing an emergency braking system for the vehicle and a parking brake.
The piston of a brake actuator includes a piston rod or push rod, which is generally welded to the piston plate. The welding of the piston rod to the piston plate, however, creates several problems. First, the heat of welding removes any protective coating which may be applied to the parts, requiring a rust protecting paint to the weld area. Rust may still occur, particularly at the weld area, reducing the strength and durability of the assembly. Second, the butt weld of the piston rod to the piston plate may fail, particularly under the bending load and the extreme conditions encountered with brake actuators for heavy vehicles of the type which utilize brake actors. As will be understood by those skilled in this art, brake actuators are mounted under the carriage of the vehicle or tractor adjacent the axles, wherein the brake actuator is subject to extreme temperature variations and road debris including water, salt and ice.
A primary object of the brake actuator piston assembly of this invention is to improve the integrity of the joint between the piston plate and piston rod. A further object is to reduce cost by eliminating the welding of the piston rod to the piston plate, the subsequent coating or painting of the welded joint and permitting the use of a protective finish, such as zinc dichromate finishes. Another object would be to reduce the weight of the piston assembly which requires a piston plate having sufficient thickness to prevent burn-through when the piston rod is butt welded to the piston plate.
SUMMARY OF THE INVENTION
The improved piston of the type used in vehicle brake actuators of this invention is best described by the method of making the piston assembly. A piston of the type used in vehicle brake actuators includes a generally flat piston plate and a piston rod or push rod which extends generally perpendicular to the piston plate from a mid-portion of the piston plate. In the method of making a piston of this invention, a cylindrical opening is formed in a mid-portion of the piston plate. In the most preferred embodiment of the method of this invention, the piston plate is pierced and extruded, forming an annular upstanding rim portion having a flat free end and a generally cylindrical internal surface defining the opening through the piston plate.
The method of this invention further includes forming a piston rod having a shank portion and a generally cylindrical head portion preferably having a diameter slightly greater than the opening through the piston plate. In the most preferred embodiment and method of this invention, the external surface of the cylindrical piston rod head portion includes a plurality of radially extending teeth having a circumferential crest diameter greater than the internal diameter of the piston plate opening. The piston rod head portion further includes a longitudinally projecting annular rim portion on a free end of the head portion, opposite the shank portion. In the most preferred embodiment, the rim portion on the free end of the piston rod is spaced from the radially extending teeth and the internal surface of the rim portion is cylindrical, defining a cylindrical opening or cavity in the free end of the piston rod.
The method of this invention then includes driving the free end of the piston rod head portion into the opening in the piston plate, preferably forming an interference fit between the piston rod head portion and the piston plate. In the preferred embodiment, where an upstanding rib or rim portion is formed in the piston plate, the head portion of the piston rod is driven into the opening in the piston plate from the free end of the upstanding rim or rib on the piston plate and the radial teeth bite into the generally cylindrical internal surface of the opening through the plate providing an interference fit.
The free end of the longitudinal annular rim on the piston rod is then deformed radially outwardly, preferably by swaging, forming a flush mounting of the piston rod to the piston plate which receives the diaphragm in the brake actuator. In the most preferred embodiment, the head portion of the piston plate includes a radial rib adjacent the teeth, opposite the rim portion, which is driven against the flat free end of the radial rim of the piston plate, forming a very secure and accurate assembly. As will be understood by those skilled in this art, the overall length of the piston must be accurately controlled and the radial flange on the piston rod head portion assures that the overall length of the piston is constant for each assembly.
The brake actuator of this invention includes a housing defining a service chamber, a flexible diaphragm is supported within the housing chamber and a piston including a piston rod and a generally flat piston plate is biased against the flexible diaphragm, generally by a return spring. In the most preferred embodiment, the piston plate includes an upstanding annular rim portion, preferably having a generally flat free end and a generally cylindrical internal surface defining an opening through the piston plate. A piston rod including a shank portion and a generally cylindrical head portion is disposed within the piston plate rim portion opening from the free end, forming an interference fit, and an annular rim portion on the free end of the piston rod, opposite the shank portion, is deformed radially outwardly into the internal surface of the piston plate, permanently attaching the piston plate to the piston rod and forming a flush assembly.
The method of making a piston of the type used in a vehicle brake actuator of this invention thus eliminates the requirement for welding the piston rod to the piston plate, permitting the use of pretreated components, such as a zinc dichromate coating on the piston plate and piston rod. The piston rod is preferably cold headed from steel equivalent to a Grade 2 cold headed bolt. The push rod head portion is firmly secured in the extruded longitudinal rim portion of the piston plate, reducing bending of the push rod as the push rod reciprocates in an arcuate motion to actuate the braking system of the vehicle. Further, the thickness of the piston plate may be reduced without sacrificing the integrity of the joint, thereby reducing the overall weight of the piston.
The improved piston and method of forming a piston assembly for a brake actuator of this invention thus significantly improves the integrity of the joint between the piston rod and the piston plate while reducing cost and weight. Other advantages and meritorious features of this invention will be more fully understood from the following description of the preferred embodiments, the appended claims, and the drawings, a brief description of which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a conventional dual diaphragm spring brake actuator having the improved piston assembly of this invention;
FIGS. 2A and 2B are cross-sectional views of the piston plate illustrating the preferred method of forming the piston plate;
FIG. 3 is a side perspective view of the improved piston plate and piston rod of this invention prior to assembly;
FIG. 4 is a side partially cross-sectioned view of the piston plate during assembly; and
FIG. 5 is a side partially cross-section view of the improved piston following assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a dual diaphragm spring brake actuator 20 of the type disclosed in U.S. Pat. No. 4,960,036, assigned to the assignee of the present application, having the improved piston assembly of this invention. The illustrated dual diaphragm spring brake actuator includes a service chamber 22 , which normally actuates the vehicle braking system as described below, and an emergency chamber 24 which actuates the vehicle braking system when the vehicle pneumatic pressure drops below a predetermined pressure in an emergency situation or as a parking brake when the vehicle is turned off. As will be understood, however, the improved piston assembly of this invention may be utilized with any type of brake actuator, such as a separate service chamber, a piston-type brake actuator, and the like.
The dual diaphragm spring brake actuator 20 illustrated in FIG. 1 includes a service chamber 22 and an emergency chamber or spring chamber 24 . The disclosed embodiment of the brake actuator 20 includes a flange case 26 which may, for example, be formed of cast aluminum, having a central web portion 27 which separates the service chamber 22 from the emergency chamber 24 . The flange case includes radial flanges 28 and 30 for attachment of the cover 32 or head of the emergency chamber and the service chamber housing 34 . The spring chamber 24 includes a cup-shaped flexible diaphragm 36 and a power spring 38 which actuates the brake of the braking system when the pneumatic pressure falls below a predetermined pressure as described below. The power spring 38 reacts against the head 32 and spring piston 40 . The emergency chamber further includes a piston 42 having a piston rod 44 and a piston head 46 . In the disclosed embodiment, the peripheral edge 48 of the cup-shaped flexible diaphragm 36 is received on the flange 28 of the flange case 26 and secured in place by the skirt portion 50 of the head 32 by crimping or the like as disclosed in the above-referenced U.S. patent. The flange case 26 includes a pneumatic port 52 connected to the pneumatic braking system of the vehicle (not shown). During normal operation of the brake actuator, the emergency chamber 24 is pressurized through port 52 , biasing the diaphragm 36 upwardly as shown in FIG. 1, compressing the power spring 38 . When the pressure in the emergency chamber 24 falls below a predetermined pressure or when the vehicle is turned off, the power spring 38 expands against the spring piston 40 , inverting the diaphragm 36 and driving the piston rod 44 through opening 54 in the flange case and driving the piston assembly 58 to actuate the brakes as described below.
The service chamber also includes a cup-shaped flexible diaphragm 60 having a peripheral edge 62 which is received on the flange 64 of the service chamber housing and the clamp 68 secures the flange 64 of the service chamber housing 34 to the flange 30 of the flange case 26 in sealed relation with the peripheral edge 62 of the diaphragm 60 located therebetween. The flange case 26 includes a service chamber port 70 which receives air pressure from the pneumatic braking system upon actuation of the vehicle brakes. The pneumatic pressure inverts the cup-shaped flexible diaphragm 60 , driving the piston plate 72 downwardly in FIG. 1, which drives the piston rod 58 through opening 76 in the service chamber housing 34 , actuating the braking system of the vehicle (not shown). The free end of the piston rod is connected to a clevis 78 and the clevis 78 is connected to the braking system of the vehicle by clevis pin 80 . The service chamber housing 34 is mounted on a bracket (not shown) under the vehicle carriage by mounting bolts 82 , lock nuts 84 and washers 86 . Upon release of the brake by the vehicle operator, the pneumatic pressure from the vehicle through port 70 returns to zero and the return spring 88 returns the piston 58 and the diaphragm 60 to the position shown in FIG. 1 .
Thus, the operation of the brake actuator 20 illustrated in FIG. 1 may be briefly described as follows. During normal operation of the vehicle, when the brake is actuated in the vehicle by the operator, air pressure is delivered to port 70 in the flange case 26 , inverting the cup-shaped flexible diaphragm 60 which drives the piston rod or push rod 58 through opening 76 in the service chamber housing 34 , actuating the brake. Upon release of the brake pedal, the pressure through port 70 returns to zero and the return spring 88 returns the piston 58 to the position shown in FIG. 1 . The air pressure through line 52 retains the pressure in emergency chamber 24 , maintaining the compression of power spring 38 as shown in FIG. 1 . However, when the pneumatic pressure in emergency chamber 24 falls below a predetermined pressure when the vehicle is turned off or when the pneumatic braking system fails, the power spring 38 expands, driving the piston rod 44 through opening 54 in the web 27 of the flange case 26 , driving the piston rod 58 of the emergency chamber through opening 76 in the service chamber housing 34 , actuating the brake. The dual diaphragm spring brake actuator 20 thus operates during normal braking of the vehicle and during emergency situations to stop a runaway truck.
The clevis 78 may be connected directly to the vehicle brake or more commonly to a slack adjuster, such as an automatic slack adjuster commonly used in vehicles of the type having brake actuators. Thus, the clevis 78 must follow the free end of the slack adjuster (not shown), which is an arcuate motion, subjecting the piston assembly 58 to substantial bending forces. That is, the piston rod 74 will rock in an arcuate motion during braking of the vehicle, which results in a bending force between the piston rod 74 and the piston plate 72 . Further, as will be understood by those skilled in the art, the brake actuator 20 will be subject to extreme conditions. As described above, brake actuators are normally mounted beneath the vehicle chassis where the brake actuator is subject to extreme vibrational loads, temperature variations and road debris, including water, salt, ice and dirt. Although most manufacturers of brake actuators include a stone shield which partially seals the opening 76 in the service chamber housing 34 , moisture will still enter the service chamber 22 requiring protection of the components. In a conventional brake actuator of this type, the piston rod 74 is welded to the piston plate 72 and later coated with a protective coating, such as a protective paint. Nevertheless, failures still occur in the weld between the piston rod 58 and the piston plate 72 .
FIGS. 2-5 illustrate an improved piston assembly 58 and a method of making the piston assembly. In the preferred method of making the piston assembly of this invention, an opening 90 is pierced in the piston plate as shown in FIG. 2A and the area around the opening is then extruded as shown in FIG. 2 B. The extrusion step forms an upstanding annular rib or rim portion 92 , preferably having a generally cylindrical internal surface 94 and a generally flat free end 96 . The piston rod 74 in the preferred embodiment of the piston assembly and method of this invention includes an enlarged generally cylindrical head portion 98 having relatively sharp radially projecting teeth 100 , a radial flange 102 adjacent the shank portion 97 and a longitudinal annular rim 104 surrounding a cylindrical cavity or recess 106 as best shown in FIG. 3 . In the preferred embodiment, the diameter of the head portion 98 is selected to form an interference fit with the internal surface 94 of the piston plate 72 . In the most preferred embodiment, the interference fit is provided by the radially projecting teeth 100 , wherein the circumference defined by the crest diameter is greater than the internal diameter of the generally cylindrical opening 94 in the piston plate 72 . In a typical application, the crest diameter of the teeth 100 will be approximately 0.03 inches greater than the internal diameter of the generally cylindrical internal surface 94 of the piston plate. However, the diameter of the annular longitudinal rim 104 may be equal to or slightly less than the diameter of the internal cylindrical surface 94 .
After forming the piston plate 72 and the piston rod 74 as shown in FIGS. 2 and 3, the generally cylindrical head portion 98 is driven into the opening in the piston plate from the upstanding rim 92 , as shown in FIGS. 3 and 4. Because of the interference fit between the head 98 of the piston rod 74 and the cylindrical surface 94 of the piston plate, the teeth 100 bite into the cylindrical surface 94 as shown in FIG. 4 . As the head 98 is driven into the opening in the piston plate 72 , the radial flange 102 on the piston head engages the relatively flat free end 96 of the upstanding rim 92 , accurately locating the piston rod in the piston plate and very accurately controlling the overall length of the piston assembly 58 . As best shown in FIG. 4, the end of the longitudinal lip 104 of the piston rod head extends slightly above the adjacent surface 73 of the piston plate 72 . The final step in the assembly of the piston rod to the piston plate is to radially deform the longitudinal rim 104 as shown in FIG. 5 as by swaging. This forms a very secure assembly as discussed more fully hereinbelow.
The piston rod and piston plate assembly 58 shown in FIG. 5 has several important advantages over the prior art methods of attaching the piston rod to the piston plate by welding as described above. Where the piston rod is welded to the piston plate, the welding operation will remove any finish applied to the components. The piston rod 74 of this invention may be formed by conventional cold heading techniques and may include a protective finish, such as zinc dichromate. Similarly, the piston plate 72 may include a protective finish, such as zinc dichromate, which will protect the components from corrosion due to salt and moisture. The piston assembly 74 of this invention is also able to withstand bending loads, particularly where the piston plate 72 includes an upstanding annular rim portion 92 . Further, as discussed above, the overall length of the piston assembly 58 may be very accurately controlled. As will be understood by those skilled in this art, the overall length of the piston must be accurately controlled because the piston actuates the brakes. The shank portion 97 of the piston rod may include indicia, such as grooves 108 and 110 , which indicate an overstroke condition as is presently conventional in this art. Further, the end of the shank portion may be threaded as shown at 112 for attachment of the piston to the yoke 108 shown in FIG. 1 . As will be understood, the yoke 78 includes an internally threaded bore (not shown) and the yoke is fixed to the threaded portion 112 by nut 114 . The piston assembly 58 is also less expensive than a welded assembly because of the elimination of the welding step. Thus, the piston assembly 58 and method of forming the piston has several significant advantages over the prior art.
As will be understood by those skilled in this art, various modifications may be made to the brake actuator and method of forming a piston of this invention within the purview of the appended claims. For example, as described above, the improved piston assembly 58 may be used with any brake actuator, particularly in service chambers of the type described herein. As will be understood, the piston 42 in the emergency chamber 24 is not subject to the bending loads described above. Therefore, the piston head 46 may be conventionally secured to the piston rod 44 with a screw (not shown). However, the piston assembly 42 may also be replaced by the improved piston assembly of this invention. Further, the configuration of the piston plate 72 and the shank portion 97 may be modified as required by the particular application. Other protective finishes other than zinc dichromate may also be used and various steels may be used to form the piston plate and piston rod. Finally, as described above, the thickness of the piston plate may be reduced because the welding step has been eliminated, thereby further reducing the weight of the piston assembly. Having described the preferred embodiments of the invention, the invention is now claimed as follows.
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A vehicle brake actuator including an improved piston assembly having a piston plate including an upstanding annular rim portion and a piston rod including a shank portion having a generally cylindrical head portion and an annular rim portion on a free end of the piston rod head portion which is deformed radially into a cylindrical internal surface of the piston plate upstanding rim portion, permanently attaching the piston plate and rod. The method includes piercing and extruding the upstanding rim portion of the piston plate and forming radially projecting teeth on an external surface of the head portion of the piston rod, driving the head portion of the piston rod into the upstanding rim portion of the piston plate, preventing relative rotation of the piston rod and head. The improved piston assembly of this invention eliminates welding, permitting finishing of the piston rod and plate prior to assembly and reduces cost.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/330,310, filed Dec. 8, 2008, now U.S. Pat. No. 8,028,526, which claims the benefit of U.S. Provisional Application 60/992,958, filed Dec. 6, 2007, both of which are hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] High pressure boilers of the type used by electrical generating plants operate at a water pressure generally in the range of 2,000-4,000 psi. Before such a high pressure boiler can be fired up, it must be supplied with water under pressure, for example, on the order of 500 to 1,000 psi, depending upon the boiler design. Water under pressure is supplied by a series of feed pumps, one feeding the other. Initially, the boiler and the series of feed pumps are usually filled with condensate from a condenser using only the condensate pump. In normal operation, the condensate pump usually takes water from a condenser and increases the pressure to about 150 psi and supplies a condensate booster pump which boosts the pressure to approximately 300-600 psi. In turn, the condensate booster pump supplies water to a boiler feed pump which increases the pressure to 1,000 to 4,000 psi depending upon boiler design and the operating condition, such as start-up, part load, or full load.
[0004] A very conventional arrangement for boiler feed pumps is to have two boiler feed pumps, one being a start-up pump that is limited in size and driven by a constant speed motor, without a fluid drive, and a second separate main “full-size” pump that is used for normal operation and is driven by a variable speed power source, either (a) a mechanical drive steam turbine, (b) a variable speed fluid drive that is in turn driven by the main turbine-generator, (c) a variable speed fluid drive that is driven by a large constant speed electric motor, or (d) a motor driven by a variable frequency power source based on solid state electronics. When a pump is used for boiler feed pump service and it operates a constant speed, the water flow is controlled by a discharge flow control valve (sometimes called a pressure control valve).
[0005] For boiler feed pump service, it is common to use a two-pole motor, and for 60 hz systems, such motors rotate generally at 3600 rpm if it is a synchronous motor, or between 3575 to 3585 rpm if it is an induction motor (3000 rpm for 50 hz systems). Another motor design that is also commonly used is a four-pole motor, and for 60 hz systems, such motors rotate at or near 1800 rpm (1500 rpm for 50 hz systems), but these motors typically use a step-up gear to increase the pump speed to the 3600 rpm range, or higher, depending upon the pump design.
[0006] Another conventional arrangement is to have two main pumps “usually approximately 60% capacity each”, that are each driven by mechanical drive steam turbines, wherein for start-up, steam from another boiler, either a dedicated start-up boiler, or a boiler of another operating unit, is used to provide steam to drive one or both of these mechanical drive steam turbines during the start-up phase of this unit. In some of these plants where there are two main boiler feed pumps each driven by a mechanical drive steam turbine, a smaller boiler feed pump with discharge flow control valve is driven by a constant speed motor for start-up, for a total of three pumps. The advantage of this arrangement is that the boiler and turbine-generator can be started using electric power either from the grid or from a “black-start” generator, so that no steam source is needed. Clearly, there are advantages to being able to start using a motor driven by a “black-start” generator located at the plant.
BRIEF SUMMARY OF THE INVENTION
[0007] An object of the geared differential drive arrangement of this invention is to use one constant speed motor in series with a variable speed fluid drive to start-up a “full-size” boiler feed pump and to operate this pump in a limited speed range requiring corresponding limited power, yet adequate to fill, pressurize, and feed water to a boiler in a controlled manner sufficient for the power plant to reach a stable, part-load condition, but not necessarily a full load condition.
[0008] An example where a geared boiler feed pump drive of the arrangement described herein would be advantageous is one where the speed of the “full-size” pump at full load is in the 5500 to 6500 rpm range and the full load power is on the order of 20,000 horsepower to 35,000 horsepower, while for start up and part-load operation, the speed of the same “full-size” pump would be limited to approximately 3500 rpm and the power would be correspondingly lower, generally related to the cube of the speed ratio ((3500/6500) 3 ) which corresponds to the range of 5000 to 7000 horsepower. With the choice of motor speeds (generally 3600 rpm or 1800 rpm for 60 hz systems, or 3000 rpm or 1500 rpm for 50 hz systems) and the ratios of two sets of gears in series, the designer has ample opportunity to establish the rotational speed of the boiler feed pump so that the pump will provide limited but adequate feed water flow and pressure to start-up and to achieve stable part load operation of the boiler feed pump and of the main turbine-generator sufficient to provide adequate main steam from the boiler or adequate extraction steam from the main turbine to drive a mechanical drive steam turbine up to full speed and full power so as to complete the transfer of the source of power driving the boiler feed pump from the motor to the mechanical drive steam turbine, thereby permitting the motor to be shut down.
[0009] In an embodiment, after start-up using the motor and variable speed fluid drive to provide power to the “full-size” boiler feed pump, and the boiler has been fired and is operating stably, for example, with the steam from the boiler driving a main turbine-generator, then steam from the boiler or from an extraction point of the main turbine is admitted to a mechanical drive steam turbine for the purpose of driving the boiler feed pump up to the full load operating range, in which case the speed of this mechanical drive steam turbine, the output shaft of which is connected in series to an over-running clutch, is controllably brought up to match the speed of the boiler feed pump as provided by the motor, variable speed fluid drive, and any gear train, at which point the over-running clutch ceases to be over-running. As more steam is admitted to the turbine, the steam turbine picks up more load and when it has taken full load, the boiler feed pump speed will increase and a slidable gear disengages so that the boiler feed pump is driven entirely by the mechanical drive steam turbine.
[0010] Advantages associated with the use of a single “full-size” boiler feed pump that can be used for both limited start-up operation as well as for normal “full-size” operation are (a) reduced capital and maintenance expenses for the boiler feed pump, the associated high energy piping, and the control system comprising valves and instrumentation, all parts of which have great economies of scale and are expensive to purchase and to maintain, (b) substantially reduced space requirements for the equipment, and (c) the ability to warm up the main pump slowly during start-up and a very smooth transition to full-load operation.
[0011] The equipment of the system of this invention may require an oil conditioning system comprising oil pumps, oil coolers, filters and valving which can be used for lubricating all of the equipment, for supplying all of the circuit oil used by the fluid drive, for supplying high pressure oil to oil jets, or nozzles, that discharge oil at sufficient flow and velocity to be able to turn gears that are associated with the variable speed fluid drive output shaft during the engaging process of a slidable gear, and for supplying high pressure oil to assure that the slidable gear actually fully engages prior to starting the motor and/or to assure that the slidable gear fully disengages once disengagement of the slidable gear is initiated or is desirable.
[0012] The fluid drive may be a conventional variable speed fluid drive. The boiler feed pump, motor, over-running clutch, mechanical drive turbine, and oil conditioning system are all conventional pieces of equipment. Conventional over-riding clutches suitable for this application are designed and manufactured by SSS Clutch Company. While the gears of this arrangement use conventional teeth profiles and conventional manufacturing techniques, the gear arrangements are specially adapted for use in this invention.
[0013] In accordance with an embodiment of this invention, generally stated, a geared fluid drive arrangement is provided in which a constant speed motor is used to start a “full-size” boiler feed pump, and is able to operate the pump at a limited speed and correspondingly limited power adequate to fill, to pressurize and to feed water to a boiler such as would be used for an electrical generating plant to start-up and to operate stably at part load, but not necessarily full load. After the boiler is operating stably, usually with the steam from the boiler driving a main turbine-generator, then steam from the boiler or from an extraction point of the main turbine is admitted to a mechanical drive steam turbine in order to drive the same “full-size” pump to the normal operating range. In the transfer process from motor drive to turbine drive, the speed of the mechanical drive steam turbine is increased to match the speed of the boiler feed pump at which point an over-running clutch ceases to be over-running, and as more steam is admitted to the mechanical drive steam turbine, this turbine picks up more load, and when it has taken full load, the boiler feed pump speed will increase and the slidable gear would disengage so that the boiler feed pump is now driven entirely by the mechanical drive steam turbine. The motor used for start-up can now be shut down.
[0014] The foregoing and other objects, features, and advantages of the invention as well as presently preferred embodiments thereof will become more apparent from the reading of the following description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] In the accompanying drawings which form part of the specification:
[0016] FIG. 1 is a somewhat schematic top plan view of a geared fluid drive of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The following detailed description illustrates the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the invention, describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
[0018] Referring to FIG. 1 , reference number 1 indicates a boiler feed pump operatively connected to a boiler not here shown. The boiler feed pump has a shaft 2 coupled via a flexible coupling 4 to a driven shaft 3 passing through a housing shaft sealing gland 11 in a wall of a housing 10 , and connected to an over-riding clutch 6 , hence, to an input drive shaft section 8 within housing 10 .
[0019] Secured to the output shaft 3 is a driven gear 12 , located between thrust bearings 41 . A slidable gear rotor assembly 14 comprises two separate gears 14 . a and 14 . b each secured to a shaft 15 , wherein the slidable gear rotor assembly 14 is axially slidable to selectively engage a gear 14 . b with driven gear 12 and to disengage a gear 14 . b from driven gear 12 , while a gear 14 . a remains always engaged with the elongated driving gear 18 . As shown in FIG. 1 , the slidable gear rotor assembly 14 is shown in the disengaged position, that is, as shown, gear 14 . b is not engaged with driven gear 12 . The slidable gear rotor assembly 14 is moved in and out of engagement by a hydraulic shifter 16 , with the axial range of sliding motion limited by thrust bearings 42 .
[0020] The hydraulic shifter 16 comprises an extension of shaft 15 with an enlarged section 15 . 1 that acts as a dual-acting hydraulic piston within a fixed housing 17 that has three (3) floating ring seals 17 . 1 to control the leakage of hydraulic oil and to maintain the desired pressure at each end of the piston. To engage slidable gear 14 . b into driven gear 12 , high pressure oil is fed into port 101 , and to disengage slidable gear 14 . b from driven gear 12 , high pressure oil is fed through port 102 . The extension of shaft 15 through the hydraulic shifter is hollow for two reasons: (a) to reduce the weight so as to control the overhang weight of shaft 15 , thereby improving rotor dynamics, and (b) to permit vent holes to be easily located through the circumferential wall of the shaft extension, wherein vent hole 17 . 6 is used to vent off the hydraulic oil at the end of the engagement stroke, and vent hole 17 . 7 is used to vent off the hydraulic oil at the end of the disengagement stroke. The purposes of the vent holes are (a) to reduce the pressure of the oil in the selected chamber while the selected shift direction is activated and the shift in the selected direction is complete, and (b) to reestablish the pressure in the selected chamber preventing the shift direction to be reversed should forces on the gear teeth be reversed.
[0021] A fluid drive assembly 25 comprises a driving gear 18 that is secured to an output shaft 20 with runner 21 fixedly attached thereto and axially restrained by thrust bearings 43 , an impeller 22 , and impeller casing 23 which are fixedly attached to an impeller input shaft 24 extending through a suitable shaft housing sealing gland 11 in a wall of housing 10 , where it is coupled, through a flexible coupling 26 to an output shaft 28 of a constant speed motor 30 .
[0022] The input drive shaft section 8 extends through a suitable shaft housing sealing gland 11 of a wall of housing 10 where it is connected to a flex coupling 36 , connected in turn to an output shaft 38 of a mechanical drive steam turbine 40 .
[0023] The fluid drive 25 can illustratively be of a type generally described in U.S. Pat. Nos. 5,331,811, 5,886,505, 5,315,825, or 7,171,870. It requires an oil conditioning system, not here shown, that may have separate oil pumps for lube oil and circuit oil, or may have one oil pump for both lube oil and circuit oil with suitable valving. Depending upon the operating pressures of the lube oil and/or circuit oil pumps, a separate oil pump may be necessary to supply oil to hydraulic jets 19 , which serve to rotate the fluid drive driving gear 18 very slowly, for example, on the order of 1 to 5 revolutions per minute, to ensure proper engagement of the slidable gear 14 . b and the driven gear 12 . The motor for the separate oil pump can be fractional horsepower, and the pump can also be small, for example, a gear pump sized to provide oil flow and discharge velocity from the nozzle to rotate gear 18 and slidable gear rotor assembly 14 .
[0024] In the sequence to put the boiler feed pump into service, assume that the slidable gear rotor assembly 14 is disengaged. Activate the oil conditioning system by starting a pump that supplies lube oil to all of the bearings. A next step is to activate the hydraulic jets 19 to turn the driving gear 18 and, hence, the slidable gear rotor assembly 14 by admitting oil to the jets, or nozzles, 19 either from the lube oil/circuit oil system if the pressure from this pump/these pumps is sufficiently high or from a separate high pressure oil pump, if necessary. After the slidable gear rotor assembly 14 starts to rotate, as detected by instrumentation, not here shown, that detects teeth of gear 18 passing by a suitable sensor, the hydraulic shifter 16 is activated by starting an appropriate high pressure hydraulic pump and admitting high pressure hydraulic oil to the engagement chamber via port 101 so as to shift the slidable gear 14 . b into engagement with the driven gear 12 . Upon full engagement, the hydraulic oil escapes through a vent hole 17 . 6 in the shaft wall so that there is no hydraulically induced axial force acting on the thrust bearing 42 . When instrumentation, not here shown, detects that the slidable gear 14 . b is fully engaged, a permissive switch is activated so that the motor 30 may now be started.
[0025] Another step in the starting sequence is to assure that the scoop tube of the fluid drive, not here shown, is moved to its minimum power transmission position. The scoop tube is used to control the speed of the output shaft and the power transmitted to it, as described amply in the referenced patents on variable speed fluid drives.
[0026] After motor 30 is started, it runs at a constant speed, and it turns the input shaft 24 of the fluid drive 25 at the same rotational speed as the motor rotor 28 . With the scoop tube in the minimum power position, the fluid drive output shaft 20 rotates slowly, on the order of 500 to 700 rpm, and this causes the slidable gear rotor assembly 14 to rotate along with the output shaft 3 , the flexible coupling 4 , and the boiler feed pump rotor 2 at rotational speeds determined by the various gear teeth ratios.
[0027] The scoop tube of the fluid drive 25 is then operated to increase the rotation of the shaft 20 , until the boiler feed pump is running in the speed range desired for start-up, perhaps 1,000 psi. The boiler is then ignited and begins to generate steam, which may be used to drive the main turbine-generator or which may be diverted to the mechanical drive steam turbine 40 to start that turbine. As long as the speed of the turbine shaft 38 is below the boiler feed pump speed as provided by the motor, fluid drive and gear train, generally on the order of 3500 rpm, the over-ridding clutch 6 operates to maintain shaft 8 disengaged from the output shaft 3 . When the speed of the steam turbine shaft 38 begins to exceed the speed of the boiler feed pump, generally on the order of 3500 rpm in this example, the over-riding clutch 6 no longer overrides, and the over-riding clutch engages input shaft 8 with output shaft 3 , and the steam turbine 40 begins to take over the rotation of the boiler feed pump. At that point, the hydraulic shifter 16 is energized to cause the slidable gear rotor assembly 14 to move to a disengaged condition wherein slidable gear 14 . b disengages from the driven gear 12 .
[0028] Various portions of the control logic of the present invention can be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. Control logic for the present invention can also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or an other computer readable storage medium, wherein, when the computer program code is loaded into, and executed by, an electronic device such as a computer, micro-processor or logic circuit, the device becomes an apparatus for practicing the invention.
[0029] Control logic for the present invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented in a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
[0030] Numerous variations in the construction and operation of the device of this invention will occur to those skilled in the art in light of the foregoing disclosure. For example, the geared drive device of this invention can be applied to complex operating systems such as driving a compressor string of a refinery wherein partial operation of a substantial portion of the refinery must be achieved before either steam generation equipment or high-pressure hot gas generation equipment can be started and become available to provide the power to a steam turbine or hot gas expander, respectively, that can pick-up the load from the motor, variable speed fluid drive, and slidable gear train of this device, and then drive the compressor string up to full load operating conditions.
[0031] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results are obtained. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0032] All patents mentioned herein are hereby incorporated by reference.
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A geared fluid drive arrangement in which a constant speed motor is used to start a “full-size” boiler feed pump, and is able to operate the pump at a limited speed and correspondingly limited power adequate to fill, pressurize and feed water to a boiler such as would be used for an electrical generating plant to start-up and to operate stably at part load, but not necessarily full load. After the boiler is operating stably, steam from the boiler or from an extraction point of the main turbine is admitted to a mechanical drive steam turbine in order to drive the same “full-size” pump to the normal operating range.
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FIELD OF THE INVENTION
The invention relates to a filter apparatus for separating impurities from a fluid stream by using a filter element accommodated in a filter housing.
BACKGROUND OF THE INVENTION
Similar hydraulic filters and filter apparatus are readily available on the market in a plurality of embodiments (e.g., DE 197 11 589 A1). In addition to suction filter apparatus, filter apparatus as return line filters, in-line filters, or ventilation filters are known. In generic terms they are often referred to as hydraulic filters. Generally, these hydraulic filters are devices for separation of solids, with fibrous, grainy, or lattice-shaped filter media being used to separate solids from liquids or for separating dusts from gases.
Furthermore, other separation devices in the prior art (e.g., DE 42 14 324 A1) are cyclones which are devices with which the action of a centrifugal force separates particles of solids from gases or liquids which are subsumed in the jargon under the generic term fluid. In the aforementioned solution, the cyclone is located in a ventilation path leading from a driving mechanism space (crank space) to the intake line of an internal combustion engine so that aerosols entrained by the air are separated in the cyclone and can be delivered by an outlet to an oil sump of the internal combustion engine. To be able to prevent unwanted feed of oil from the oil sump into the cyclone even under extreme operating conditions, a stop safeguard in the form of a float valve is on the outlet side.
This cyclone separation technology has also already been used in combination with filter devices. Thus, DE-OS 37 35 106 discloses a process for separating liquid particles from gases, in particular in the form of aerosols from exhaust gases, in which the gases are centrifuged first and then filtered. Some of the filtrate gases are then relayed to a cyclone. The liquid particles entrained in the gas flow are combined into droplets by frequent deflection of the direction of their motion (swirling flow). The droplets emerge by their own weight from of the separation device.
Furthermore, U.S. Pat. No. 6,129,775 A discloses a cyclone separator with a predominantly conically running separation housing in which, following the wall of the separation housing and with the formation of a swirl space spaced analogously, a usually self-contained guide body enables improved swirl guidance for separating the particles in the swirl space for a tangentially supplied fluid flow with particle fouling. Filtration by a filter element is not possible with the known solution.
The prior art (e.g., EP 06 59 462 A1) also discloses solutions in which, for further particle separation, in the bypass flow of a cyclone separator a filter element is held in a separate filter housing following in the direction of the fluid stream. The filtration line of these known solutions still leaves much to be desired.
SUMMARY OF THE INVENTION
An object of the invention is to provide a filter apparatus with improved filtration properties.
This object is basically achieved by a filter apparatus where the filter housing has a swirl space such that the fluid stream to be filtered is routed at least partially around the filter element in a swirling flow. For actual filtration operation, the properties of the cyclone are used in so far as the swirl space of the filter housing causes repeated deflection of the direction of motion of the fluid to be filtered. The associated swirling flow is able to be established along the entire filter surface of the filter element, with the result that the fluid stream to be filtered passes through the filter element to an increased degree and with high energy input, with simultaneous retention or separation of impurities. The swirling flow achieved in the filter housing caused by the action of the swirl space yields a laminar, helix-like fluid flow. In contrast to the otherwise conventional radial throughflow of a filter element transversely to its longitudinal axis, the filter apparatus of the invention leads to improved filtration performance and results. In this way, an increased throughput rate of the fluid to be filtered through the filter element can be achieved.
In one preferred embodiment of the filter apparatus according to the invention, the swirl space is formed by a conical widening of the filter housing in the direction of its one housing end. The feed inlet for the unfiltered medium extends through the filter housing off-center to the longitudinal axis of the filter element. This off-center feed causes improved generation of a cyclone-like flow under the action of the swirl space in the filter housing.
The conical widening of the filter housing in the region of the swirl space preferably undergoes transition into a cylindrical housing part or into one with a small conical tilt, with the result that partial damping of the swirl-like fluid flow occurs with reduced wall distances between the outside of the filter element and the inside of the filter housing. A kind of forced guidance for the purpose of a compressed fluid flow then results to increase the feed amount of fouled fluid for the filter element in this way.
In another preferred embodiment of the filter apparatus according to the invention, with a definable axial distance above on the free end of the filter element, a collecting space adjoins likewise contributing to making the fluid flow uniform in the upper region, and helping prevent supercritical turbulences within the fluid flow. This supercritical turbulence otherwise could adversely affect the filtration performance of the filter apparatus.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
It has proven especially advantageous with respect to the described structure of the filter housing to use as filter elements those whose filter element extends conically. It has also proven especially advantageous to use slit screen tube filter elements as filter elements.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure and which are schematic and not to scale:
FIG. 1 is a perspective view in section of a filter apparatus according to an exemplary embodiment of the invention;
FIG. 2 is a perspective view of the filter apparatus of in FIG. 1 in the state closed on the housing side and in another viewing direction.
DETAILED DESCRIPTION OF THE INVENTION
The filter apparatus according to the invention is used to separate impurities from a fluid stream, for example formed by a hydraulic medium. Fundamentally, the filter apparatus can also be used for gaseous media, aerosols, etc., which likewise form fluids. FIGS. 1 and 2 correspond to the conventional installation direction. To the extent the terms “top” and “bottom” are used below in this respect, they relate to the representations of the operating situation of the filter apparatus as shown in FIGS. 1 and 2 .
The filter element 10 shown in FIG. 1 is accommodated by a filter housing 12 of the filter apparatus. The filter housing 12 on its top end has a swirl space 14 used to route the fluid to be filtered at least partially in a swirling flow or cyclone flow around the filter element 10 . In the illustrated solution, the swirl space 14 is formed by a conical widening of the filter housing 12 in the direction of its top end 16 . Instead of this conical widening produced by the housing wall, in addition or as an alternative, on the inside of the filter housing 12 flow baffles—also in the manner of turbulators—(not shown) could be used. To produce the swirling flow, the feed inlet 18 for the unfiltered media is located off-center to the longitudinal axis 20 of the filter element 10 and in this respect extends through the housing wall on the top end of the swirl space 14 . To the outside the feed inlet 18 is provided with a flange-like widening 22 for connecting other fluid-carrying pipe elements or other line elements (not shown).
After the fluid to be filtered flows from the outside to the inside through the filter element 10 , the filtrate stream, that is, the filtered fluid, is withdrawn from the filter housing 12 via the drain 24 in the housing top. The free end of the drain 24 is in turn provided with a flange 26 used like the flange 22 to connect fluid-carrying lines to the filter apparatus. The drain 24 is placed on the top end of the filter housing 12 and, viewed in cross section, has a slightly larger cross section at the top fluid exit site 28 out of the filter housing 12 . The feed inlet 18 and drain 24 can optionally be produced in one piece together with the filter housing 12 . The corresponding connection to the remaining filter housing 12 is possible by weld connections.
As furthermore follows especially from FIG. 1 , the conical widening forming the swirl space 14 undergoes transition in the direction of the bottom of the filter apparatus into a cylindrical housing part 30 also having a smaller conical tilt (not shown) opposite the swirl space 14 . The swirling flow produced in the swirl space 14 is made uniform over the further housing part 30 in terms of the progression of the cyclone. This uniformly promotes fluid passage through the filter element 10 . The cross sectional reduction from the swirl space 14 to the housing part 30 also contributes to this fluid passage. The free end 32 of the filter element 10 is oriented in the direction of the closed end 34 of the filter housing 12 . At a definable axial distance to the filter element 10 the closed end forms a collecting space 36 which, in spite of the partially turbulent flow dictated by the swirl space 14 , leads to more uniformity of the fluid stream penetrating the filter element 10 and otherwise produces good filling in the interior 38 of the filter housing 12 . This arrangement promotes energy-efficient operation of the filter apparatus.
In particular, in this way fluid-free cavities do not form within the filter apparatus. This forming otherwise could lead to damaging cavities for the hydraulic circuit connected to the filter apparatus in operation. The closed end 34 can also be produced by a switch fitting 40 (cf. FIG. 2 ) which, for example, made as a ball valve enables opening of the bottom end of the filter housing 12 . In this way, for example, it would be possible, with the switch fitting 40 closed, to carry out the already described filtration operation, and when the bottom end of the filter housing 12 is opened, for example, the impurities arising in a backflushing process to be carried out and discharged from the filter apparatus. In the pertinent backflushing operation, cleaned fluid is routed from the inside to the outside through the filter element, preferably from the clean side of the filter apparatus, that is, coming from the drain 24 . This operation leads to cleaning of the passages in the filter element 10 . The dirt backflushed in this way could then be discharged from the filter apparatus by way of the interior 38 of the filter housing 12 and by way of the lower bottom opening of the filter housing 12 .
Fundamentally, for backflushing a housing situation as shown in FIG. 1 , the cleaned fluid is backflushed from the clean side (drain 24 ) in the direction of the unfiltered material side (feed inlet 18 ). The delivery of unfiltered material would have to be stopped. With a somewhat smaller tilt than applies to the housing wall of the swirl space 14 , the collecting space 36 tapers likewise conically in the direction of the free or closed end 34 of the filter housing 12 . This conical tapering allows a partial pressure rise in the collecting space 36 for operation of the apparatus, promoting complete filling for the filter apparatus.
The filter element 10 , as already addressed, is made as a slit screen tube filter element. DE 197 11 589 shows the more detailed structure of such a slit screen tube filter element. This element 10 includes individual supports bars around which a wire profile is wound in individual turns, leaving exposed gaps through which fluid can pass. A weld is in the region of each contact site of the wire profile with the assignable support bar. For improved filtration operation, the filter element 10 is made conical. The turns of the wire profile decrease in diameter in the direction of the tilted ends of the support bars. The length of the slit screen tube filter element measured in the direction of the longitudinal axis 20 is roughly 11 times greater than the largest exit cross section in the region of the outlet or drain 24 . Since slit screen tube filter elements are fundamentally prior art, the pertinent element 10 in FIG. 1 is shown only in terms of its conical structure.
The conical structure of the slit screen tube filter element 10 results in less resistance being offered to the fluid stream entering the housing 30 from the swirl space 14 , relative to a solution with an exclusively cylindrically made element, with the result that the pressure difference for the entire filter apparatus is reduced in an energy-efficient manner. A constant liquid stream is also achieved by the conical structure when the element 10 is backflushed. Conversely for a cylindrical element (not shown) which could likewise be used in this embodiment, the speed in its longitudinal direction continuously increases. This increasing speed opposes uniform entry into the interior of the filter element.
The installation conditions are implemented such that viewed in the longitudinal direction (longitudinal axis 20 ) of the filter element 10 , the overall length of the swirl space 14 with its conical housing wall 16 and of the collecting space 36 corresponds to a least one third, but less than half, of the installation length of the filter element 10 . The overall length of the swirl space 14 corresponds essentially to the overall length of the collecting space 36 extending from the end 32 of the filter element 10 to the end 34 of the filter housing 12 .
The filter apparatus according to the invention, in particular when it is built essentially in one piece except for the filter element 10 , can be extremely economically produced and therefore operated as a disposable article. Depending on the pressures which arise, the filter apparatus can also be made as a plastic injection molding or can be made of metallic materials including sheet metal and casting materials. The housing wall 16 of the swirl space 14 can be made as a dished bottom.
In a further configuration of the filter apparatus according to the invention which is not shown, it can be additionally provided that potential light floating materials may be removed from the filter housing via another outlet site in the region of the top housing end 16 of the filter housing 12 with formation of a kind of overflow line. Preferably the respective sealing opening relative to the longitudinal axis 20 is diametrically opposite the feed inlet 18 . The overflow line, comparably to the other connection sites, can have a corresponding flange body, as shown.
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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A filter apparatus deposits impurities from a fluid stream by use of a filter element ( 10 ) accommodated in a filter casing ( 12 ). The filter casing ( 12 ) has a swirl space ( 14 ) such that the fluid stream to be filtered is conducted at least partly in a swirling flow around the filter element ( 10 ). The properties of a cyclone are utilized for the actual filtration operation to the extent that the swirl space of the filter casing brings about multiple deflection of the direction of motion of the fluid to be filtered.
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This is a continuation of application Ser. No. 08/735,954 filed Oct. 23, 1996 now U.S. Pat. No. 5,947,489.
FIELD OF THE INVENTION
This invention relates to creepers for permitting mechanics to work on the undercarriage of automotive vehicles, and more particularly it relates to folding creepers which fold into a compact storage configuration.
BACKGROUND OF THE INVENTION
Creepers are well known in the art. For example, U.S. Pat. No. 5,330,209 to J. L. Pool, issued Jul. 19, 1994, discloses a Low Profile Mechanics Creeper. This patent is directed to the feature of mis-shaping the frame of the creeper upon which the creeper platform is mounted to position caster wheel pivot mounts above the planar platform surface upon which the mechanic lies. However, there is no provision for folding the creeper into a compact storage configuration when not in use, which is an objective of the present invention.
Representative of several problems encountered in prior art foldable creepers is U.S. Pat. No. 1,226,585 of W. E. Parker, et al., May 15, 1917. To enable folding, in this case, inward folding of side flaps is required before folding end to end. The creeper is undesirably complex and interferes with any provision of mid-length weight bearing caster wheels. Accordingly, the mid-position hinging structure must include a weight bearing mechanism of sufficient ruggedness to support a substantial portion of a mechanic's weight and probable added forces should the mechanic push against the vehicle undercarriage. The ability to carry the mechanic's weight at the midsection and the reliability of the hinging mechanism is further compromised by the placement of a pair of weight supporting caster wheels at either end of the creeper, thus tending to sag the creeper and distort the folding mechanisms. Furthermore, with the caster wheels mounted directly onto the platform underside for support, further disadvantages occur. Thus, it is difficult to position the platform close to the floor working surface. This is a problem since space to reach the undercarriage is usually limited. Also the platform structure must be shaped to allow the caster wheels to protrude through the platform in the folded position.
A further problem with the prior art foldable creepers is seen in U.S. Pat. No. 5,451,068 to T. Shockley, Sep. 19, 1995 for Transformable Mechanic's Creeper, wherein the cushions of the creeper must be removed before folding and stored separately.
It is therefore an object of this invention to provide a novel and improved foldable creeper that resolves the aforesaid prior art problems.
A further object is to provide a foldable creeper which is strong, rugged and simple to construct without complex or expensive assembly and which is easily and safely folded into a compact and easily handled assembly.
Further objects, features and advantages of the invention will be apparent from the following description and the accompanying drawings.
SUMMARY OF THE INVENTION
The creeper of this invention has two articulated rectangular shaped wheeled cushioned assembly units that are placed end to end and joined into a comfortable weight bearing creeper platform for moving a mechanic under a vehicle for undercarriage repairs. The cushioned units have an articulation mechanism for folding the creeper platform from its bistable position for creeping under vehicles into a second bistable position in which the two units are folded back to back into a compact storage configuration with caster wheels positioned between the two juxtapositioned cushion assemblies lying in substantially parallel planes.
The cushioned assembly units have cushions permanently affixed to a weight bearing platform base member. The units have side rails along two sides, spaced from the cushions so that they may be grasped for carrying. Supporting transverse straps attach the rails to the platform base. Three caster wheels are attached to the metal bars for each unit, so that when two cushion arrays are placed end to end one wheel is on each side of the resulting creeper in a weight bearing support intermediate the length of the resulting six wheeled creeper.
The two end to end cushioned units are articulated at joints between rail ends on opposite sides of the creeper body, thereby permitting the two cushioned units to be folded back to back with wheels therebetween to form a compact storage configuration with the two outermost cushions lying substantially in parallel planes. The metal rails constitute handles and in their parallel folded configuration permit the creeper to be stood on edge, or to be hung from a hook if desired.
The articulation joints on opposite sides of the creeper are formed by a length of U-shaped metal channel link that nests the ends of the metal rails on the respective end to end cushion units. The opposite ends of the metal channel link have the U bottom portion removed, thereby to form parallel walls serving to journal a pivot joint with each of the rails. The rails are thus pivotable in the articulation joints for folding the two cushion units together with the caster wheels therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, wherein like reference characters are employed in the respective views for similar features to facilitate comparison:
FIG. 1 is a perspective view, partly broken away, of the folding creeper configuration afforded by this invention ready for use of a mechanic in a stable unfolded configuration for servicing the undercarriage of a vehicle;
FIG. 2 is a broken away, exploded view in perspective of the foldover articulation joint assembly on one side of the creeper, looking into the creeper;
FIG. 3 is a side view in elevation of the creeper shown in FIG. 1;
FIG. 4 is a bottom view of the creeper;
FIG. 5 is a standing-on-end, side view of the folded up creeper; and
FIG. 6 is an end view in elevation looking into lines 6--6 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen from FIG. 1, the creeper 10 is formed from two wheeled framework-cushion assemblies 11, 12 supporting upper padded platform surfaces comprising cushions 13, 14, one having the headrest 15, upon which a mechanic lies to move under a vehicle to work on the undercarriage. As seen from the broken away left end, the cushions 13, 14 comprise plastic covered foam 16, or the like, resting upon and permanently attached to a weight bearing support platform or baseboard 17 shown as metal, but which could be of wood, or the like.
The framework disposes the generally square profile side rails 20 on each side of the cushions 13, 14, and spaced therefrom so that they may be grasped as handles when folding or carrying the creeper assembly. Near respective ends of each cushioned unit 11, 12, the transverse bracing straps 21, 22 extend from side rail to side rail and are attached by bolts or the like 25 to the bottom support platform 17, as better seen in the bottom view of FIG. 4.
In FIG. 4, the arrangement of the six caster wheels 26, etc. is shown, three caster wheels being attached to each framework-cushion unit 11, 12. In this creeper, each unit is movably supported on three caster wheels for a total of six creeper casters aligned with three wheels on each side of the creeper. The caster wheels 27, 28 thus provide intermediate weight bearing support in the mid-region of the creeper, which moves along a work surface 29 as shown in FIG. 3. The front and rear end casters 26 and the intermediate casters 27, 28 are pivoted from respective side rails 20 of the respective framework assemblies 11, 12 on opposite sides of the creeper. By pivoting these caster wheels 26, etc. in the side rails 20 at positions between the back panel 17 and upper surface of the cushions 13, 14, the advantage is obtained of lowering the creeper surface closer to the floor and giving the mechanic more room for underchassis work space. Also the outer rail mount of the caster wheels makes the creeper more stable by eliminating any tipping forces that might be encountered by forces applied near the edges. These side rail braces 20 extend along and are substantially the same length as the length of the rectangular cushions 13, 14 and corresponding integral supporting platforms 17. The upper surface of the rail braces 20 are substantially coplanar with the upper cushion surfaces of the creeper.
Thus the folding creeper of this invention has two units 11, 12 are connected together end to end by the articulation member 30, including separate pivot joints for the respective rail braces 20 on the leading and trailing units 11, 12 on opposite sides of the creeper. The articulation structure is shown in detail in FIG. 2.
The articulation joint is formed by nesting the juxtaposed meeting ends of two square profile side rail bracing members 20 on the respective two units 11, 12, into the U-shaped length channel iron articulation member 31, as shown in phantom view. As also seen from the bottom view of FIG. 4, the opposing ends 33, 34 of the articulation member 31 have the U bottom portion removed. Thus, the articulation member 31 serves together with the extended transverse ends of strap 22 as a detent locking stop holding the creeper stable in a weight bearing joint in the unfolded position. The joint thus permits the two units 11, 12 to fold towards the caster wheels 26 into the back to back compact assembly of FIG. 5. Therein the two cushioned units 11, 12 pivot on the articulation member 31 about the pivot bolts 33a, 34a to terminate back to back in parallel planes with the caster wheels 26 extending therebetween to provide a compact folded array. As seen in FIG. 5, the unit may be compactly stored by standing on any one edge. Conversely it may be stored with the cushion 13 downward on a flat surface such as a shelf.
Pivot pins 33a, 34a, seen in FIG. 2, respectively extend through the apertures in end portions 33, 34 of the articulation member 31 and the respective mating aperture arrays 35, 36 in the juxtaposed ends of rails 20 of the respective cushioned units 11, 12. Thus respective units 11, 12 fold towards the folded-up position of FIG. 5, as permitted by the open ends 33, 34 where the bottom of the U channel is removed. Note that in the creeper position, the rail braces 20 are supported on both the extensions of the transverse straps 22 and the bottom of the U-shaped channel to hold the extended creeper assembly stable and supported across the seam between the juxtapositioned end to end rectangular cushioned units 11, 12. Note that the two units 11, 12 are of the same cross section and only differ in the arrangement of the headrest 15 and the position of the intermediate caster wheels 27, 28 thus contributing to compactness in the storage state.
Thus, having advanced the state of the art, those features of novelty setting forth the spirit and nature of the invention are defined with particularity in the following claims.
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A folding creeper articulates two rectangular platform sections with padded cushions and three caster wheels to fold the sections back to back into a compact storage configuration with wheels in between. The articulation joint simply pivots the two sections away from a stable creeper state with the joint locked in place to withstand loading at the abutment joint between the two juxtapositioned platform sections.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage entry of PCT/ES2011/000038 filed Feb. 15, 2011, under the International Convention claiming priority over Spain Application No. P201000283 filed Mar. 2, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates to a wind rotor with a vertical shaft, permanently oriented against the wind, intended to form part of a wind turbine.
[0003] The object of the invention is to provide a wind rotor with a vertical shaft which, by means of the combination of two types of blades conferring to it a low starting torque and auto-regulated turns, does not need conventional brakes, is adapted for gusty, swirling, directional, and upward winds, etc., and always exploiting the wind to the maximum regardless of its direction and strength.
[0004] The invention is thus in the scope of renewable energies, and more specifically in the scope of machinery for exploiting wind energy.
BACKGROUND OF THE INVENTION
[0005] Different types of wind turbines, the operation of which is due to the exploitation of either drag forces or lift forces, such as for example the Darrieus model and the large wind generators with a horizontal shaft which mainly use the lift force of their aerodynamic profile in their operation, when the leading edge of the profile faces the direction of the wind, in a way similar to that of planes are known, while on the other hand there is the Savonius model, which mainly uses drag forces, concave surfaces facing the direction of the wind.
[0006] There are known wind rotors with a horizontal shaft which present a number of problems and drawbacks, such as the need of a mechanical brake for regulating and stopping the rotor, as well as the need of having to stop them when the winds are turbulent, hurricane-like, because if they are not stopped, breakage thereof can occur, since they offer great resistance due to their horizontal position.
[0007] Furthermore, the vibration of rotors with a horizontal is very noticeable as well as the generation of a loud noise during their operation, being polluting elements, on the other hand, for birds, as they do not easily detect them due to the horizontal arrangement.
[0008] Different rotor systems are known for the configuration of wind turbines as the main component for capturing wind energy, particularly wind turbines with a vertical shaft, all of them having poor energy output; one part directly faces the wind, independently of its nature, and not needing orientation; the other part is hidden from the wind, whereby producing no energy.
[0009] The mentioned wind rotors can be observed in documents: ES1002396; ES1049887; ES1070534; ES2028718; ES2237268; ES2267837; GB189915505; U.S. Pat. No. 4,115,032; U.S. Pat. No. 4,650,403; RU2096259; RU2135824; EP0679805; U.S. Pat. No. 4,970,404; among others.
[0010] These rotors present a problem which is fundamentally centered on the following aspects:
[0011] They require a high starting torque,
[0012] They require a braking system in the presence of strong winds.
[0013] They require the orientation or disorientation with respect to dominant winds.
[0014] They require only the use of laminar winds.
[0015] They require being arranged at great heights.
[0016] For them to be profitable in practice, they must be very large machines.
DESCRIPTION OF THE INVENTION
[0017] The wind rotor proposed by the invention satisfactorily solves the previously mentioned problems for each and every one of the different aspects discussed.
[0018] Said rotor is configured based on a vertical rotation shaft, to which two supports included in respective and imaginary parallel planes are orthogonally coupled, perpendicular to said shaft and located at the ends thereof, these supports being carriers of respective aerodynamic profiles, hereinafter referred to as blades.
[0019] According to the invention, the rotor starts from a theoretical aerodynamic profile, such as a “main profile”, an asymmetric profile of concave convex configuration and with a section optimized so that when it is under the action of the wind, pressure differences originate between the surfaces of the blade, creating a great lift force and a great liftability, as well as considerable stall.
[0020] With this main profile and according to the essential nature of the invention, by means of two different types of vertical projection, two different blades are obtained, hereinafter referred to as alpha and beta.
[0021] Both blades work simultaneously under lift and drag, regardless of the position that they occupy in the rotor and of the angle of attack of the predominant fluid.
[0022] These profiles are inclined, i.e., their ends are rotationally offset between the lower and upper support bases, and vertically towards the rotational direction of the rotor, whereby obtaining a greater favorable contact time of the blade with the fluid, eliminating the skipping when the action of the fluid passes from a blade to the space between them and to another blade; the so-called “leaping” are eliminated, thus performing a much more regular, continuous operation and a smoother start, needing less energy for initiating the movement.
[0023] The chord of both wing-like profiles decreases as their vertical projection advances by approximately, but not limited to, 5%; this confers to the circulating fluid in the concave part a spoon effect which leads to a Venturi effect, and accelerates the fluid therein, the fluid tending to leave more rapidly.
[0024] As its vertical projection goes upwards, together with all the aforementioned, as has been said the chord of the profile decreases, and furthermore the section becomes twisted, maintaining the basic characteristics of the main profile, whereby the angle which the section advances, in the direction of the rotation of the rotor, is not that which the angle of attack advances, but it is minimized in a counter-rotation performed by the chord itself in its twisting in an opposite direction, whereby leaving it exposed for a greater space and time period to better fluid optimizing conditions.
[0025] The final configuration and shape of each blade or wing-like profile is the result, in each case, of the foregoing integrated with the fact that the torsional moment generated in each infinitesimal section must be constant; and therefore internal stresses and strains are not generated in the mentioned wing-like profiles, and thus the entire profile works in identical conditions.
[0026] To that end, in the vertical projection thereof, the leading edge has a progressive displacement of the profile, inwards and outwards from the rotor, following a smooth curve, such that the upper edge of the blade is at a shorter distance from the center of the shaft of the rotor than the lower edge thereof, for compensating moments.
[0027] These are the general conditions which characterize both blades, and in the same manner.
[0028] In addition, each type of blade has another feature making them different from each other:
[0029] the alpha blade is prepared for obtaining the maximum performance from the drag forces.
[0030] and the other blade, the beta blade, is prepared for obtaining the maximum performance from the fluid lift forces.
[0031] There is an equal number of alpha and beta blades in the rotor and they are alternately arranged.
[0032] The alpha blades work as drag profiles and the beta blades as lift profiles, stalling when the speed of the wind exceeds a pre-established value, acting as a brake for the rotor.
DESCRIPTION OF THE DRAWINGS
[0033] To complement the description being made and for the purpose of aiding to better understand the features of the invention according to a preferred practical embodiment thereof, a set of drawings is attached as an integral part of said description, in which the following has been depicted with an illustrative and non-limiting character
[0034] FIG. 1 shows a schematic perspective view of a wind rotor with a vertical shaft made according to the object of the present invention, on its corresponding support post.
[0035] FIG. 2 shows a side elevational view of the rotor of the previous figure.
[0036] FIG. 3 shows a cross-section view of a detail of the rotor through the plane of section A-A of FIG. 2
[0037] FIG. 4 shows a schematic depiction of the alpha blade.
[0038] FIG. 5 shows a depiction similar to that of FIG. 4 but this drawing corresponding to the beta blade.
[0039] FIG. 6 shows a section of the main profile.
PREFERRED EMBODIMENT OF THE INVENTION
[0040] It can be observed from the figures described that the proposed rotor is formed from a shaft ( 1 ) located at the upper end of a support post ( 2 ), which post does not require having considerable height, as can be seen from observing FIG. 1 .
[0041] Respective supports ( 3 , 3 ′) are integral to the ends of the shaft, each of which supports is formed by a plurality of arms emerging from a common core, being co-planar, describing an arched trajectory in their distal portion, and being parallel to one other and perpendicular to the shaft ( 1 ), said arms ( 3 ) having equiangular spacing on respective supports, the arms of the upper support ( 3 ′) being shorter and having a curvature suitable to that of the blades ( 4 ) which must be arranged between the lower support ( 3 ) and the upper support ( 3 ′), which blades, as mentioned previously, are from a main aerodynamic profile ( 5 ), shown in FIG. 6 , in which figure reference number ( 6 ) corresponds to the leading edge, reference number ( 7 ) corresponds to the trailing edge, reference number ( 8 ) corresponds to the mid-line of the aerodynamic profile, reference numbers ( 9 and 10 ) correspond to the intrados and extrados, reference number ( 11 ) corresponds to the chord; reference number ( 12 ) corresponds to the sag and reference number ( 13 ) corresponds to the maximum thickness.
[0042] More specifically and as mentioned above, the number of blades ( 4 ) participating in the rotor must be even, and there are two types of blades based on the main aerodynamic profile ( 5 ), referred to as alpha and beta, that are especially shown in FIGS. 4 and 5 , reference number ( 4 ) being maintained for the alpha profile, whereas the profile beta has reference number ( 4 ′), the blades ( 4 , 4 ′) of both types being alternately arranged about the shaft ( 1 ), as shown in FIGS. 1 to 3 .
[0043] The main profile ( 5 ) has a thickness ( 13 ) in the order of 11% of the value of the chord ( 11 ), the radius of curvature is in the order of 13% also with respect to the length of the chord, the angle of the leading edge ( 6 ) is in the order of 8 degrees, its lower flatness 25%, the radius of the leading edge is in the order of 4.5%, the maximum lift coefficient is in the order of 2.5, the maximum angle of said coefficient is in the order of 12.5 degrees, the maximum drag coefficient is in the order of 11.2 and the maximum angle of said coefficient is 104 degrees.
[0044] As has also been mentioned above, the alpha blade ( 4 ) and beta blade ( 4 ′) are inclined, i.e., rotationally offset at their ends, their chord also decreases in both cases in an upward direction and its section progressively becomes twisted, having at its leading edge ( 6 ) a progressive displacement inwards and outwards from the rotor, which follows a smooth curve.
[0045] The alpha profile ( 4 ) is configured so that it works under the greatest possible drag for the purpose of maintaining the movement, making the rotor turn easily, such that the profile completely maximizes the surface oriented against the wind and contributes to the formation of an air pocket, as a result of the “spoon” effect in its drag position.
[0046] Since it is under the action of a flow, it behaves due to its own configuration as a lift element, but mainly as a thrust or drag element which tends to make the rotor or the assembly of blades rotate easily.
[0047] To that end, as the chord thereof decreases in its vertical projection, the section progressively becomes offset in favor of the rotation, there being a gradual opening between both supports ( 3 , 3 ′) between the base and the upper edge of the blade until reaching a rotational offset of 28° in favor of the rotation, which is what the blade is inclined, and at the same time the chord twists the profile 9° in the opposite direction, finally resulting in a variation of the chord of 19° in favor of the rotation, or in other words, in the 28° that the rotor rotates, it gains 9°.
[0048] This involves partially reorienting the blade to the orientation of the fluid as its profile rotates, whereby the blade is under drag for a longer space-time, whereby facilitating the start, and therefore reducing the minimum wind requirements for operation.
[0049] In turn, the beta profile ( 4 ′) is prepared to work under the greatest possible lift for the purpose of increasing the rotation revolutions of the rotor and maintaining the rotational inertia.
[0050] Since said profile is under the action of a flow, it behaves due to its configuration as a thrust element, but mainly as a lift element, transmitting speed to the system and stalling if the maximum speeds allowed are exceeded, taking into account the lift coefficient, in which case it will lose said lift and brake the system
[0051] To that end, as its chord ( 11 ) decreases in its vertical projection, the section progressively becomes offset in favor of the rotation, there being a gradual opening between both supports ( 3 , 3 ′) between the base and the edge upper of the blade until reaching a rotational offset of 37° in favor of the rotation, which is what the blade is inclined, while at the same time the chord twists the profile 3° in the opposite direction, finally resulting in a variation of the chord of 34° in favor of the rotation, or in other words, in the 37° that the rotor rotates, it gains 3°.
[0052] This involves partially reorienting the profile to the orientation of the fluid as its profile rotates, whereby said blade is under lift for a longer space-time, and whereby the speed increases, maintaining the inertia of the system, but braking it if the maximum speed is exceeded, stalling and therefore automatically limiting the maximum wind requirements for operation.
[0053] It thus constitutes the speed stabilizer of the rotor because the system slows down as its revolutions increase, until finally closing down.
[0054] The mentioned lift blade ( 4 ′) behave as an element which stalls if the maximum speeds allowed are exceeded, taking into account the lift coefficient, establishing braking means and speed stabilizing means for the rotor itself.
[0055] The blades ( 4 , 4 ′) are susceptible to variation if, due to the low prevailing winds in the area, it is necessary to increase the angles or the twists of the alpha blades to improve the start, sacrificing the revolutions of the beta blades by reducing the angles and twists thereof, if necessary.
[0056] The mentioned blades are uniformly distributed at the lower base of the rotor ( 2 ) with their angle of attack outwards, and the chord which is delayed in rotation with respect to the radius of the center to the leading edge in a portion equal to the maximum angle of the lift coefficient of the main profile, whereby being positioned at their maximum lift, in relation to the center of the rotor the angle of attack being in the same direction as the mentioned radius.
[0057] One alpha blade and one beta blade are provided alternately, and so on and so forth, and radially and equidistantly at the lower base.
[0058] These blades also exploit on their surfaces the turbulent winds produced at the tips of the other blades once the fluid has entered the center of the rotor and wishes to leave or escape, again producing work, and they maintain the aerodynamic lift of the assembly in the same manner.
[0059] A number of blades with a diameter and height which will be determined by the specific value of the surface facing the wind, such as the torque, r.p.m. and the corresponding scaling, necessary for obtaining the desired power will be involved in the rotor.
[0060] Depending on the speed of the dominant wind, the stalling moment is determined, resulting in an auto-regulation of the rotational speed of the rotor itself, not having to brake it in extreme wind conditions because it chokes and stalls.
[0061] Constructively, it is integrated in a preferred but non-limiting manner in a body formed by a series of helical-shaped blades which configure a conical frustum with a curvilinear generatrix, which limits and characterizes it.
[0062] These helical features of the blades allow the leading edges to face the wind continuously acting on it as the system rotates.
[0063] The trailing edge ( 7 ) of the profile of the blade, according to its position in reference to the direction of the fluid, drives the flow into the empty space of the rotor contrary to the rotation thereof so that it can be picked up by the trailing edge of the profile of the opposite blade, and this again generating movement in favor of the rotation thereof.
[0064] The conical shape limits the fluid compression capabilities, generating a blockage for the exit thereof (air), producing a loss in wind energy capturing and braking the system. It provokes a decompensation in the lift of the blades.
[0065] With winds that are considered excessive or dangerous, it enters a gain state versus stalling, known as “leaping” or choke, atmospheric vacuum which occurs when the air does not leave freely, this situation will occur at a determined speed, which is when the lift is exceeded, and it brakes itself rather than using the conventional mechanical brake.
[0066] The position of the leading edge of both blades on the lower part is fixed and adjustable in the trailing edge. At the upper end of the blade, both parts are moveable for their regulation according to the different wind intensities, thus capable of regulating the speed and the performance of the system.
[0067] The result is that this rotor is always oriented against the wind and there is no need to brake it even in extreme circumstances.
[0068] The system provides better wind performance advantages than current systems in light, gusty and turbulent winds as well as in storm or hurricane winds (it being understood that in these circumstances, the elements that can be found in the environment may not cause damage to the rotor).
[0069] All this is performed in its maximum simplicity in a simple, compact, economical and maintenance-free manner.
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This present invention relates to a wind rotor with a vertical shaft, formed by means of a vertical shaft ( 1 ), two horizontal end supports ( 3, 3′ ) and a plurality of blades ( 4, 4′ ) arranged between said supports. The features of the invention are centered on the fact that the blades ( 4, 4′ ) are of two types, in an alternating arrangement, blades ( 4 ) prepared and configured for forming drag elements and blades ( 4′ ) prepared for forming lift elements, with the additional particularity that the latter stall when they exceed a pre-established wind speed, causing a braking effect in the rotor. This structure eliminates many of the drawbacks of the known wind rotors with a vertical shaft, such that it does not require an important starting torque, a braking system with strong winds, or the orientation and reorientation with respect to the dominant winds. Nor is it limited to being used with laminar winds, and it does not require being arranged at great heights, being able to be installed on a short support post ( 2 ) in optimal operating conditions.
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This application is a division of application Ser. No. 07/922,176, filed Jul. 30, 1992 now U.S. Pat. No. 5,327,892.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention comprises, in general, devices which control vibration of buildings caused by seismic disturbances. In particular, the field of invention relates to air spring devices adapted to dampen vertical vibrations in buildings.
2. Description of the Prior Art
In order to protect a building from horizontal vibration, it is known to isolate the building superstructure from its base slab or foundation by interposing rolling members therebetween to permit the building superstructure to shift horizontally relative to its slab or foundation, thereby dissipating the energy of seismic vibration.
Since the average earthquake is mainly characterized by horizontal vibrations, the above-described isolation device can substantially cope with horizontal seismic shock. However, in the case of a large-scale structure located at the epicenter of an earthquake, it is quite possible that the structure will experience vertical, as well as horizontal vibrations, which, if not controlled, could cause structural damage.
Vertical vibration control devices are generally known in the prior art, comprising vertically-expanding air springs. However, prior art vertically expanding and contracting air springs possess little inherent capability to resist horizontal deflection. As a consequence, when a structure is subjected to both horizontal and vertical vibrations, a rocking, or similar, very unstable motion results that renders the air springs ineffective to control vertical vibration. Air springs are comprised of telescoping canisters. The greater the overlap of canister side walls, the greater is the resistance to lateral deflection. However, as the resistance to lateral deflection is increased, the capacity of the air spring to dampen vertical vibrations is decreased.
SUMMARY OF THE INVENTION
The present invention has been proposed in view of the above-discussed limitations of prior art vertical vibration control devices. The primary purpose of the present invention is to provide a vertical vibration control device which is reinforced against horizontal deflection so that the device will function efficiently in response to seismic vertical vibration. To attain this objective, the subject inventive control device comprises an air spring placed between a foundation and a superstructure. An upper support is fixed to the superstructure so as to support an upper end of the air spring, and a lower support is fixed to the foundation so as to support a lower end of the air spring. Guide means are positioned on opposite sides of the air spring to guide the vertical motion of the air spring.
In one preferred embodiment of the invention, the guide means include vertically extending guide rails on opposite sides of the air spring and integrally secured to the lower support. A guide block, slidably engaged with the guide rail, is fixed to a movable part of the air spring through an elastic coupling.
In another preferred embodiment of the invention, the guide portion includes a peripheral collar secured about the external telescoping cylinder of the air spring. Supporting guide means are secured to and project downwardly from the upper air spring support for slidable guiding engagement with the peripheral collar.
In this manner, according to the present invention, the air spring is designed to smoothly respond only to the vertical motion of the superstructure, that is, only for the vertical vibrations, wherein the horizontal motion of the air spring can be acceptably restricted by means of the constraints of the guide portions.
OBJECT OF THE INVENTION
It is the primary object of the present invention to provide a vertical vibration control device which is reinforced against horizontal deflection.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the invention will become apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings, in which:
FIG. 1 is an elevational view, partially in section, showing a vertical vibration control device as a first preferred embodiment of the present invention;
FIG. 2 is a cross-sectional plan view taken along the line 2--2 of FIG. 1;
FIG. 3 is an elevational view, partially in section, showing a vertical vibration control device as a second preferred embodiment of the present invention; and
FIG. 4 is an elevational view, partially in section, showing a vertical vibration control device as a third preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, showing a first preferred embodiment of the subject invention, a vibration control device 1 is positioned between a foundation 2 and a superstructure 3. The vibration control device 1 comprises an air spring 4 provided between the foundation 2 and the superstructure 3 and is made of telescoping cylinders comprising an external cylinder 4a and an internal cylinder 4b, an upper support spacer 5 fixed to the superstructure 3 to support an upper end of the air spring 4, a lower support 6 fixed to the foundation 2 to support a lower end of the air spring 4, and guide means 7L and 7R for guiding the vertical motion of the air spring 4 and restricting horizontal deflection of the air spring 4.
The vibration control device 1 of FIG. 1 has the guide rails 7L and 7R disposed on opposite sides of the air spring 4, secured to and extending vertically from the lower support 6. Guide rails 7L and 7R include vertically extending guide bars 8L and 8R secured thereto. Guide blocks 10L and 10R are slidably engaged with guide bars 8L and 8R, respectively, and are also fixed to a movable part of the air spring 4 through elastic couplings 9L and 9R.
The guide rails 7L and 7R in this embodiment are made of H-section structural steel members, or the like. The elastic couplings 9L and 9R inserted between the guide blocks 10L and 10R and the movable part of the air spring 4 absorb deflection by deforming when a horizontal force is applied to the air spring 4, so that the guide bars 8 and the guide blocks 10 are maintained in slidable alignment. Thus, the air spring 4 of the vibration control device 1 is restrained from horizontal deflection but is unrestrained for vertical movement.
FIG. 3 discloses a second preferred embodiment of the invention, wherein like numerals identify like parts. Reference numeral 2 in FIG. 3 identifies a foundation such as the concrete frame of a building vibrated by an earthquake or the like, and numeral 3 identifies a superstructure such as a base-isolation slab completely separated from the foundation 2 so as to isolate the superstructure 3 from vibration. The air spring 4 is provided between the foundation 2 and the superstructure 3 and is made of telescoping cylindrical casings comprising an external cylinder 4a and an internal cylinder 4b slidably interconnected.
The lower end of the internal cylinder 4b is fixed to the foundation 2 by means of bolts or the like. A height adjusting upper support spacer 5 is secured between the upper end of the external cylinder 4a and the superstructure 3. In this manner, the superstructure 3 is supported on the foundation 2 through the air spring 4 and the upper support 5.
A segmented collar 12 having a radially projecting horizontal flange portion 11 is attached to the periphery of the external cylinder 4a of the air spring 4. The collar 12 is comprised of a pair of semi-circular segments fitted to the periphery of the external cylinder 4a by bolts 13. The horizontal flange portion 11 is provided with bearings 14L and 14R as vertical through holes to receive therethrough shafts 15L and 15R, respectively, for sliding engagement.
The shafts 15 and the internal cylinder 4b are secured normal to the foundation 2 by means of a connecting lower support plate 6. The shafts 15 are erected in parallel with, and on opposite sides of, the air spring 4. In this manner, when the foundation 2 is vibrated vertically by an earthquake or the like, the vertical vibration is absorbed by the variations in relative positions between the external cylinder 4a and the internal cylinder 4b, so that the vertical vibration transmitted to the superstructure 3 is minimal.
The external cylinder 4a is restrained to move only in a vertical direction, i.e., in the direction of the shafts 15, since the segmented collar 12, fixedly attached to the external cylinder 4a, is guided by the shafts 15. The upper support spacer 5 provides adequate clearance between superstructure 3 and the upper end portions 15A of the shafts 15L and 15R so that no impact will occur therebetween.
The third preferred embodiment of the subject invention is shown in FIG. 4, wherein, it will be noted, shafts 15 are secured normal to the superstructure 3, which is the reverse of the embodiment of FIG. 3. Thus, the lower end of the external cylinder 4a of the air spring 4 is fixed to the foundation 2 through the lower support and spacer height adjusting pedestal 6, so that the superstructure 3 is supported at the upper end of the internal cylinder 4b of the air spring 4. The segmented collar 12 is fitted with bearings 14 in its horizontal flange portion 11, so as to provide sliding engagement with shafts 15. The third embodiment of the subject invention is, in every respect, an inversion of the embodiment of FIG. 3, and functions in a similar manner.
It will be noted that in FIG. 3 pipe stubs 18L and 18R are secured to plates 20L and 20R, which are secured to lower support plate 6A. The lower portions of shafts 15L and 15R are vertically aligned and secured in pipe stubs 18L and 18R, respectively, by upper pipe caps 22L and 22R and disc plates 16L and 16R secured to the interiors of pipe stubs 18L and 18R, respectively. Ends 15B of shafts 15 may be secured to disc plates 16 by any fastening means well understood by those skilled in the art, such as by threaded fastening means 24L and 24R. The upper portions of shafts 15L and 15R are vertically aligned and stabilized by bearings 14L and 14R which reciprocate on shafts 15L and 15R responsive to vertical movement of segmented collar 12.
The essential difference between the embodiment of FIG. 3 and the embodiment of FIG. 4 is that plates 20L and 20R of FIG. 4 are secured to upper support plate 5A rather than to lower support plate 6A. Otherwise, the segmented collar 12, bearings 14, rods 15, disc plates 16, and pipe stubs 18 provide the same stability function as the like components of FIG. 3, although inversely positioned as heretofore described.
As described above, the vibration control device of the present invention can allow the air spring in the vibration control device to act smoothly only for the vertical motion of the superstructure separated from the foundation, that is, only the for vertical vibrations, by restricting the horizontal motion of the air spring by the guide portion. Accordingly, the arrangement for allowing the air spring to smoothly move only in a vertical direction by restricting horizontal deflection thereof prevents rocking or like unstable motion due to compound vertical and horizontal movement of the air spring.
The foregoing disclosure and discussion relate to preferred exemplary embodiments of the invention, but it should be understood that other variants and embodiments thereof will become apparent to those skilled in the art upon a reading of the specification taken in conjunction with a study of the attached drawings. Furthermore, it should be understood that such variants and embodiments are possible within the spirit and scope of the invention, as defined by the appended claims.
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A device to control vertical vibration of a building caused by seismic disturbance. Air springs are positioned and secured between the building foundation and the building superstructure to attenuate vertical vibration of the building. Vertical support rails are secured to the foundation and/or to the building superstructure on opposite sides of, and adjacent to, the air springs. Horizontal connecting brackets are rigidly secured to the air springs and slidably secured to the adjacent rails. The brackets restrain horizontal deflection of the air springs without interfering with vertical reciprocation of the air springs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for the liquid treatment of cloth in which cloth can be impregnated advantageously with a treating liquid in an untensioned state.
In subjecting a cloth to the liquid treatment such as dyeing, scouring, bleaching and washing continuously, it is necessary to impregnate the cloth with a prescribed amount of a treating liquid in an efficient manner. There have been many proposals for the liquid treatment apparatus of a cloth to perform the impregnation treatment uniformly with high efficiency. For instance, as for the liquid treatment of an easily expandable cloth such as a knitted one, a liquid treatment apparatus has been proposed to perform the treatment with no tension.
2. Description of Prior Art
However, in a conventional liquid treatment apparatus, particularly in a liquid treatment apparatus with no tension, it is the present status that a sufficient impregnation with a liquid cannot be done due to the reason that a cloth can hardly be held in a liquid tank for a sufficient period. To prolong the dwell period in the liquid medium, it has been considered to enlarge the liquid treating tank, but there are problems in the space required for and cost of the apparatus. An apparatus has also been proposed to use a deep liquid tank having a U-shaped cloth passage, but such an apparatus has not as yet any distinguished merit in prolonging the dwell period of the cloth in the liquid medium.
SUMMARY OF THE INVENTION
The present invention affords an adequate dwell time. The principal object of the present invention is, in a liquid tank having a U-shaped cloth passage, to U-turn the cloth by folding it zigzag at the lower portion of the passage to increase the amount of the cloth held in the tank and thus to prolong its dwell period in liquid medium.
Another object of the invention is to offer an apparatus in which a cloth can be transferred through a U-shaped passage smoothly with no tension by U-turning the cloth at the lower portion of the U-shaped passage without destroying the zigzag arrangement of the cloth passing through the U-shaped passage in a folded state. While such an arrangement of a cloth, as in the first object, is apt to be destroyed frequently to tangle the cloth owing to the buoyancy of the cloth and others, the second object is to avoid such a problem.
BRIEF EXPLANATION OF THE DRAWINGS
The figures show sectional side views of different embodiments of the present inventive apparatus for the liquid treatment of a cloth.
FIG. 1 displaying Example 1,
FIG. 2 displaying Example 2 and,
FIG. 3 displaying Example 3.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained in detail according to the accompanied figures in the following.
In FIG. 1, (1) is a nearly U-shaped liquid tank. In about an upper half portion of the tank (1), there are provided a freely rotatable central endless net conveyor (2) extending vertically and a pair of outer endless net conveyors (3) and (3') which are equipped rotatably along the central net conveyor (2) in parallel on both sides thereof to form narrow cloth inlet- and outlet-passages (a) and (a') therebetween. In about a lower half portion of the liquid tank (1), there are provided a freely rotatable rotary drum (4) at the center and a freely rotatable endless net conveyor (5) along the wall to form a cloth passage in liquid medium (b) broader than the cloth inlet- and outlet-passages. (6) is a liquid receiving tank to receive a treating liquid flowing over the liquid tank (1), and the liquid receiving tank (6) is connected through a pump (7) to a plurality of liquid jet nozzles (9) so as to jet the liquid received in the liquid receiving tank (6) against a cloth to be treated passing through the cloth passages (a) and (a') and to return the jetted liquid to the liquid tank (1).
Four comb-like cloth holding frames (10) are attached to the rotary drum (4) and extend radially outwardly from it at equal intervals so as to be rotatable with the rotation of the rotary drum (4), thereby avoiding contact with comb-like guide frames (11) provided vertically along the broader cloth passages between the central conveyor (2) and the rotary drum (4). Namely, the teeth of the cloth holding frames (10) are arranged so as to pass the gaps of the guide frames (11). (12) are a plurality of steam jet pipes provided at the bottom of the liquid tank (1).
While the construction of the apparatus in Example 1 is as above mentioned, the operation process by using said apparatus will be described in the following. At first, the endless net conveyors (2), (3) and (3') are rotated respectively in the direction of the arrow with a prescribed speed, and the drum (4) and the endless net conveyor (5) are rotated at the lower portion of the liquid tank also respectively in the direction of the arrow but with a speed slower than the conveyors (2), (3) and (3'). The treating liquid is sprayed through the liquid jet nozzles (9) by driving the pump (7).
Two sheets of cloth (8), (8') piled one on the other en bloc are then transferred into the cloth inlet passage (a), sent down therethrough by rotating the conveyors (2) and (3), and the liquid is sprayed from the liquid jet nozzles (9). The cloths collide alternately with the conveyors (2) and (3) on both sides of the cloth passage (a) due to the jetting liquid pressure from the nozzles (9), releasing the weight of the cloths of their own, so that the cloths descend zigzag through the cloth passage (a) in a relaxed state with no tension. The cloths thus sent down are immersed in a treating liquid in the liquid tank (1) and are transferred in a folded state zigzag through the broader cloth passage in liquid medium (b) because the revolution speeds of the drum (4) and the conveyor (5) are slow and the buoyancy of the cloth is superposed. Furthermore, since the drum is equipped with the cloth holding frames (10) rotating together with the drum (4), the folded cloths are transferred orderly without missing their arrangement and with no tension, and can be U-turned smoothly in the liquid medium.
In consequence of the effect that the cloths are folded zigzag in the liquid medium, there is such merit in that the cloths are immersed in the treating liquid for a long time prolonging the reaction time and affording an efficient liquid treatment.
Example 2 in FIG. 2 differs from Example 1 in its construction for transferring the cloth in the liquid tank. The cloth transferring construction in this example comprises a central endless net conveyer (13) extending vertically down to the lower portion of the liquid tank and an endless net conveyer (15) passing around the central conveyer (13) in a way as shown in the figure with the aid of a plurality of guide rolls (14) provided on both sides of said central conveyer (13). The means to flow the treating liquid and other operation processes are the same as in Example 1. In this example, a pair of endless net conveyers (13) and (15) forms the cloth inlet- and outlet-passages (a) and (a') as well as a cloth passage in liquid medium (b) to transfer the cloth in a folded state simultaneously. Therefore, Example 2 has the merit in that the conveyers are spared as compared with Example 1 and the construction of the apparatus is simplified.
FIG. 3 shows the construction of the apparatus in Example 3. (1) is a nearly U-shaped liquid tank. In the central portion of this liquid tank, a central endless net conveyer (2) is provided vertically down to the lower portion of the liquid tank so as to rotate freely guided by a pair of guide rolls (4) and (4') situated at a certain distance. (3) is an inlet endless net conveyer provided vertically along one side of the central endless net conveyer (2) extending over the whole length thereof forming a narrow space therebetween, and (5') is an outlet endless net conveyer provided vertically along the other side of the central endless net conveyer (2) within the upper portion thereof forming a narrow space therebetween. Thus, narrow cloth inlet- and outlet-passages (a) and (a') are formed respectively between the central endless net conveyer (2) and the inlet endless net conveyer (3) and between the central endless net conveyer (2) and the outlet endless net conveyer (5'). In this example, the cloth inlet- and outlet-passages (a) and (a') are filled with the treating liquid.
At the lower side of both of the cloth inlet- and outlet-passages (a) and (a') a vertically extending, nearly J-shaped cloth passage (b) broader than the cloth inlet- and outlet-passages is formed between the central endless net conveyer (2) and the inner wall of the liquid tank (1) as shown in the figure. (6) is a liquid receiving tank for receiving the treating liquid flowing over the liquid tank (1), and the liquid receiving tank (6) is connected to a plurality of liquid jet nozzles (9) so as to jet the liquid received in the liquid receiving tank (6) by means of the driving force of a pump (7) against the cloth passing through the cloth passages (a) and (a') and to return the jetted liquid to the liquid tank (1). (12) are a plurality of steam jet pipes at the bottom of the liquid tank (1).
In the process using the apparatus in this example, the endless net conveyers (2), (3) and (3') are rotated respectively in the direction of the arrow, and the treating liquid is sprayed through the liquid jet nozzles (9) by driving the pump (7). Then, two sheets of a cloth (8) and (8') piled en bloc are transferred into the cloth passage (a) in the treating liquid in the liquid tank (1). The cloths adopt a wave-like configuration by receiving the liquid pressure due to the jetting of liquid from the liquid jet nozzles (9), they are pressed alternately to collide with both of the endless net conveyers (2) and (3), so that the cloths are sent down in a zigzag manner by rotating the conveyers (2) and (3) through the liquid medium in a relaxed state with no tension. The cloths thus transferred successively to the bottom portion of the liquid tank are folded zigzag with no tension in the broader cloth passage (b), are transferred smoothly toward the outlet due to their own buoyancy, and are supplied to the cloth outlet passage (a') situated between the two endless net conveyers (2) and (5'). The cloths in this cloth passage (a') are pressed alternately to collide with the both endless net conveyers (2) and (5') due to the jetting liquid pressure of the liquid jetted from the liquid jet nozzles (9), so that the cloths are transferred upward with no tension by the driving force of the endless net conveyers (2) and (5').
As above explained, the present inventive apparatus enables a cloth to be transferred with a single sheet or two more sheets piled en bloc, in a liquid tank in a relaxed state with no tension, so that the apparatus is quite effective to treat an easily expandable cloth such as a knitted one in a liquid medium. Since the cloth is immersed in the liquid medium in a folded zigzag state the impregnation duration of the cloth is prolonged, and therefore, the impregnation can be done uniformly and sufficiently. Moreover, since the present inventive apparatus is arranged so that the cloth existing at the bottom of the liquid tank can float up in a folded state by its own buoyancy, the cloth can be transferred orderly with no entanglement in the liquid tank.
The present invention is particularly effective in the liquid treatment of two or more sheets of an easily expandable cloth en bloc at the same time.
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An apparatus for the liquid treatment of cloth consists of a U-shaped liquid tank for a treating liquid, a cloth inlet passage and a cloth outlet passage located in the tank and each having a relatively narrow spacing between vertical endless net conveyers which define the opposed sides of the passages. A plurality of liquid jet nozzles are provided along the cloth passages to spray a treating liquid against a cloth so that the cloth collides alternately with the conveyers on the opposite sides of each passage. Another cloth passage is located in the treating liquid below and forms a connecting passage between the cloth inlet-and outlet-passages. The cloth passes in a folded zigzag state through the another cloth passage. This apparatus is particularly suitable for the liquid treatment of an easily expandable cloth such as a knitted cloth by piling a plurality of the sheets thereof en bloc.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the treatment of a slag generated in a blast furnace, converter or electric furnace of an ironworks. Particularly, it relates to a dry process for the treatment of a slag generated in an ironworks.
2. Description of the Prior Art
Up to this time, a slag generated in an ironworks has been used in reclamation after the selective recovery of a big ingot by hands or has been discarded as such. However, such a slag still contains metals as shown in Table 1, even after the above selective recovery. Therefore, the recovery of such remaining metals has been carried out.
In this specification, the term "metal" refers to one having a particle size of 0.5 mm or above contained in a slag.
TABLE 1______________________________________(weight %) metal content rate______________________________________stainless steel slag 1.5˜2.5common steel slag 2˜3special steel slag 0.5˜1.5______________________________________
For example, a slag generated in an ironworks, particularly, a stainless steel slag generated in a stainless steel-manufacturing step, has been treated by a process which comprises crushing a solidified slag into a proper particle size and passing the crushed slag through a gravity separater to thereby recover metals having high specific gravities.
The above process has been generally carried out by using a wet jig wherein the crushed stainless steel slag is thrown into flowing water to be divided into heavy metals and a light slag based on the difference in specific gravity. Therefore, the process has a disadvantage in that such a jig cannot be used in winter, because water freezes in that season.
Further, when a stainless steel slag is passed through a wet separator to thereby recover metals, the residual slag forms sludge and therefore must be suitably dried to be used as a resource such as filler material. That is to say, the process has another disadvantage in that the residual slag requires additional treatments.
On the other hand, although a process which comprises recovering metals from a crushed stainless steel slag having a proper particle size with a dry magnetic separator has been sometimes carried out, it has a disadvantage in that an austenitic stainless steel can not effectively be recovered from a slag containing it, because an austenitic stainless steel is not adherent to a magnet.
Although these disadvantages have been described with respect to a stainless steel slag, similar disadvantages occur when a common steel slag or a special steel slag is treated by a wet process.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above circumstances. The first object of the present invention is to provide a process for the recovery of metals from a slag generated in an ironworks (for example, stainless steel slag or common steel slag) which can be carried out even in a cold district.
The second object of the present invention is to recover a residual slag remaining after the recovery of metals from a slag generated in an ironworks in a state of a dry power of granules and utilize it.
The process for the treatment of a slag generated in an ironworks according to the present invention having the above objects comprises the steps of rough crushing to crush the slag into pieces having a particle size of 50 mm or less by use of a dry-type crusher, further crushing for separation in a ventilated mill to classify said roughly crushed slag into a light slag dust and a residual heavy slag having a particle size of 20 mm or less, separation by specific gravity to extract metal components having a high specific gravity from said crushed and separated residual slag by use of a dry-type classifier, and magnetic separation to recover magnet-adherent metals from the remaining slag from which said metal components are extracted. The separation by specific gravity is performed with a dry vibrating air classifier of the upward-draft type which is provided with a vibrating screen sloped at an angle to the horizontal, which screen is vibrating at a frequency between 5 and 20 Hz while air is blown vertically upward from below the screen. In operation, the components of larger specific gravity are moved forward or upward on the screen, while the particles with a lower specific gravity are moved in the opposite direction as a result of being lifted by the air.
The term "a slag generated in an ironworks" involves stainless steel slags generated in the step of manufacturing stainless steel, common steel slags generated in the step of manufacturing common steel and special steel slags generated in the step of manufacturing special steel.
Further, a process is set forth wherein a jaw crusher and a circumferential discharge mill are used as a crusher and the solidified slag is primarily crushed with said jaw crusher and further crushed with said circumferential discharge mill into a particle size of 50 mm or below is preferred.
Furthermore, a process is set forth wherein a granular slag is recovered from a light slag dust separated with a gravity settling room which is a dust precollector of a bag filter or a dust collector such as a cyclone. Metals having high specific gravities are recovered from the granular slag with an air classifier and the remaining granular slag is subjected to magnetic separation to recover a magnet-adherent metal is also possible.
The slag dust remaining after the recovery of a granular slag with a dust precollector or the granular slag remaining after the recovery of a magnet-adherent metal by magnetic separation may be used as a filler material for use in, for example, civil engineering works.
As described above, according to the present invention, it is possible to treat a slag generated in an ironworks by a dry process using no water and the treatment can be smoothly carried out even in a cold district where water freezes in winter.
Further, the slag component of a dry state can be obtained from a slag generated in an ironworks, so that the slag component is easily handled and stocked and can be used as a filler for plastics or engineering works as such or after suitable pulverizing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing an example of the process for the treatment of a slag generated in an ironworks according to the present invention.
FIGS. 2 and 3 are partially cutaway side elevations illustrating the action of a dry vibrating air classifier used in the above example.
FIG. 4 is a side elevation illustrating a ventilated mill used in another example according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIG. 1, a stainless steel slag 10 which is an example of the slag generated in an ironworks (hereinafter "slag") is crushed into a suitable size with a breaker 11 fitted with a hydraulic unit and further crushed with a jaw crusher 12 into a size of about 100 to 150 mm.
The slag 10 crushed with the jaw crusher 12 is further crushed with a circumferential discharge mill 13 to a size of 50 mm or below. This circumferential discharge mill 13 comprises a rotary drum 14 and a rod 15 (crushing medium) provided therein as shown in the figure. The slag 10 is thrown into the drum 14 from a material inlet 16, crushed with the rods 15, discharged from a plurality of discharge orifices 17 formed on the circumference of the drum 14 and having a specified size to fall on a belt conveyor 20, which is an example of conveying means, through chutes 18 and 19.
The slag 10 fallen on the belt conveyor 20 is transferred by the belt conveyor 20 and discharged into a hopper 23 provided at material inlet 22 of a ventilated mill 21.
As shown in the figure, the ventilated mill 21 comprises a drum 25 fitted with a plurality of rods 24 (crushing medium) therein and four rollers 28 accepting rail rings 26 and 27 provided on the outer circumference of the drum 25. Further in the mill 21, an air current flows from the material inlet 22 to a material outlet 29 by the action of a suction fan, which is not shown in the figure, connected to the material outlet 29.
Further, the ventilated mill 21 is provided with a lattice screen 30 therein to discharge only a residual slag having a particle size of 20 mm or below downward (that is, in the direction of the material outlet 29). In the mill 21, uncrushed slag 10 having a size of more than 20 mm is impact-crushed with the rods 24 into a particle size of 20 mm or below.
A conical guide drum 31 is provided at the center of the screen 30. The slag 10 moves upward with the rotation of the drum 25 and falls to go toward the material outlet 29.
A transport pipe 32 is provided at the outlet 29 of the mill 21 in a state apart therefrom to transport the material discharged from the outlet 29. Further, a falling chute 33 is provided near the end of the pipe 32 to collect a residual coarse slag 34 and make it fall into a container 35.
On the other hand, a light slag dust 36 blown off in the transport pipe 32 by an air current having a velocity of 15 to 25 m/sec is transferred into a gravitational settling room 37 which is an example of the dust collector to be connected to the pipe 32 and a cyclone 38 which is an example of the dust collector to recover granular slags 39 and 40 from the dust 36, respectively.
The granular slags 39 and 40 are collected in containers 41 and 42, respectively, and divided by an air classifier 43 into metals 44 having high specific gravities and a light granular slag 45.
In this air classifier 43, an air current flows from an inlet 46 to an outlet 46a by the action of a fan which is not shown in the figure and divides the falling granular slags 39 and 40 based on the difference in settling velocity. The flow velocity of the air current is 5 to 10 m/sec which is lower than that of the air current flowing in the transport pipe 32, so that a metal 44 is effectively recovered. In the figure, numerals 43a, 43b and 43c are rotary valves.
Although a metal having a large particle size is recovered with the air classifier 43, a metal having a small particle size is still contained in the light granular slag 45. The slag 45 is divided into a magnet-adherent metal 48 and a tailing 49 with a magnetic separator 47 and placed in containers 50 and 51.
The above magnetic separator 47 has a well-known construction, that is, comprises a vibrating feeder 53 provided in the lower part of a chute 52 which is a material inlet, a rotary drum 54 provided in the lower part of the feeder 53, a magnet 55 provided in the rotary drum 54 and a separating plate 56 provided in the lower part of the drum 54. The slag 45 thrown from the top is divided into a metal 48 and a tailing 49 by magnetic force.
A powdery dust 57 which has not been collected with the cyclone 38 which is an example of the dust collectors is collected by a known bag filter 58 and placed in a container 59.
On the other hand, the residual slag 34 which has been discharged from the ventilated mill 21 and collected by the falling chute contains a metal having a relatively large particle size and a slag having a large particle size. The slag 34 is divided into a metal 61 and a slag 62 with a dry vibrating air classifier 60.
The fundamental principle of the above dry vibrating air classifier 60 will be described in more detail by referring to FIGS. 2 and 3. The residual slag 34 thrown from a hopper 63 falls on a screen 64. The screen 64 is vibrated in an ascending direction that is in the direction of A-B shown in FIG. 3 with a frequency of vibration of about 5 to 20 c/sec by a vibrating machine driven by a motor which is not shown in the figure. The screen 64 is tilted by about 1 to 2 degrees against the horizontal plane and a fan which is not shown in the figure is provided under the screen 64 to give an air current of a velocity of 1 to 5 m/sec blowing from under the screen 64 to over the screen 64. The aircurrent blows through the residual slag 34 on the screen 64 to float a slag 62 having a small specific gravity. The slag 62 floated by the air current is transferred downward because of the slope of the screen 64.
On the other hand, although a metal 61 having a high specific gravity contained in the residual slag 34 is not floated by the upward air current to remain on the screen 64, the metal 61 is pushed in the direction of B shown in FIG. 3 by the vibration of the screen 64 to result in upward transfer, thus separating the metal 61 from the slag 62.
The metal 61 is thus recovered from the residual slag 34, but the slag 62 still contains a metal having a relatively small particle size. Magnet-adherent metals such as Fe or Ni are recovered by a magnetic separator 65 from the slag 62. The magnetic separator 65 has the same construction as the one of the above magnetic separator 47, so that the same numerals as those used in the separator 47 are used in the separator 65 to omit any detailed description.
A magnet-adherent metal 66 is recovered from the slag 62 with this separator 65 and reused as a material for steel as well as the metals 44 and 61 and the magnet-adherent metal 48. The residual tailing 67, can be used as a filler for civil engineering works, plastics or the like as well as the tailing 49 and and the dust 57.
In the above example, the same dry vibrating air classifier at the above-described one may be used instead of the air classifier 43.
Although a stainless steel slag is used as a slag generated in an iron works in the above example, the present invention can be also applied to a common steel slag or a special steel slag.
For reference, the composition of the tailing obtained in the above example is shown in Table 2.
TABLE 2______________________________________(weight %)SiO.sub.2 Al.sub.2 O.sub.3 T.Fe CaO MgO Cr Ni______________________________________A 19.0 5.9 5.0 50.2 7.3 1.4 --B 10.3 1.2 15.4 43.9 5.4 -- --C 50.3 2.7 3.4 17.0 24.8 1.9 0.03______________________________________ wherein A is a tailing of a stainless steel slag, B is the one of a commo steel slag and C is the one of a special steel slag.
The particle size distribution of the powdery dust 57 collected by the bag filter 58 in each case using various steel slags is shown in Table 3.
TABLE 3______________________________________(weight %)μm +149 149˜105 -105 TOTAL______________________________________D 1 6 93 100E 2 8 90 100F 3 8 89 100______________________________________ wherein D is the case of using stainless steel slag as raw material, E is the case of using common steel slag and F is the case of using special steel slag.
The particle size distribution of the tailing 49 obtained in each case using various steel slags is shown in Table 4.
TABLE 4______________________________________(weight %)μm +149 149˜105 -105 TOTAL______________________________________G 10 19 71 100H 12 23 65 100I 13 21 66 100______________________________________ wherein G is the case of using stainless steel slag as raw material, H is the case of using common steel slag and I is the case of using special steel slag.
The particle size distribution of the tailing 67 remaining after the treatment with the magnetic separator 65 is shown in Table 5.
TABLE 5______________________________________(weight %)mm +15 15˜10 10˜7 7˜5 5˜3 -3 TOTAL______________________________________J 2 11 15 32 30 10 100K 3 13 21 30 25 8 100L 4 12 20 28 30 6 100______________________________________ wherein J is the case of using stainless steel slag as raw material, K is the case of using common steel slag and L is the case of using special steel slag.
Although a parallel-flow ventilated mill wherein the direction of proceeding of a material is the same as the one of an air current flowing in the drum 25 was used as a ventilated mill 21 is the above example, a countercurrent one 69 wherein the direction of flowing of an air current is opposite to the direction of proceeding of a slag (i.e. material) may be used as shown in FIG. 4 to enable the more effective crushing of the slag 10.
As shown in the figure, this countercurrent ventilated mill 69 comprises a drum 72 fitted with rail rings 70 and 71, four drive tyres 73 supporting the drum 72 rotatably via the rail rings 70 and 71, steel ball 74, which is an example of crushing media, provided in the drum 72, a material outlet 75 provided at the center of one side of the drum 72 and a material inlet 76 provided outside the outlet 75. The slag 10 thrown from the material inlet 76 is transferred into the drum 72 by a screw conveyor 77 and crushed by the impact of the steel ball 74 caused by the rotation of the drum 72.
The slag 10 thus crushed is divided into metals which can not be easily crushed and a light slag. The slag is blown off by the air current to be transferred to the material outlet 75, while the metals are discharged from an outlet 78 having a specified size and formed on the other side of the drum 72.
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The present invention relates to a process for the treatment of a slag generated in an ironworks and comprises rough crushing a solidified slag generated in an ironworks with a crusher into a specified particle size, a step of further crushing for separation, and dividing the crushed slag by specific gravity separation with a dry vibrating air classifier and a step of magnetic separation into a metal component and a slag component. This process can be carried out even in a cold district where water freezes in winter.
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BACKGROUND AND SUMMARY
The invention relates to a method for operating a working machine and a working machine.
The invention is applicable on working machines within the field of industrial construction machines, in particular wheel loaders. Thus, the invention will be described with respect to a wheel loader. However, the invention is by no means limited to a particular working machine. On the contrary, the invention may be used in a plurality of heavy working machines, e.g. articulated haulers, trucks, bulldozers and excavators.
Wheel loaders are generally provided with an internal combustion engine, a transmission line, a gearbox, driving wheels and a working hydraulic system.
The combustion engine provides power to the different functions of the wheel loader. In particular, the combustion engine provides power to the transmission line and to the working hydraulic system of the wheel loader.
The transmission line transfers torque from the combustion engine to the gearbox, which in turn provides torque to the driving wheels of the loader. In particular, the gearbox provides different gear ratios for varying the speed of the driving wheels and for changing between forward and backward driving direction of the wheels.
The working hydraulic system is used for lifting operations and/or for steering the wheel loader. For this purpose there are at least one hydraulic working cylinder arranged in the wheel loader for lifting and lowering a lifting arm unit, on which a bucket or other type of attachment or working tool is mounted for example forks. By use of another hydraulic working cylinder, the bucket can also be tilted or pivoted. Further hydraulic cylinders known as steering cylinders are arranged to turn the wheel loader by means of relative movement of a front and rear body part of the wheel loader.
To protect the combustion engine of a wheel loader from rapid changes in the working conditions of the gearbox and the driving wheels it is common to provide the transmission line with a hydrodynamic torque converter or similar arranged between the combustion engine and the gearbox. The hydrodynamic torque converter provides an elasticity that enables a very quick adaptation of the output torque to the changes in the working conditions of the gearbox and the driving wheels of the loader. In addition, the torque converter provides an increased torque during particularly heavy working operations, e.g. during acceleration of the loader. However, these advantages are paid by high losses, since the elasticity and the increased torque provided by the torque converter are obtained by slipping between the impeller, turbine-wheel and the stator of the torque converter.
To utilize the advantages of a torque converter with respect to elasticity and torque increase for handling rapid changes in the working conditions, at the same time as the advantages of a purely mechanical transmission is utilized with respect to efficiency (in principle 100%), it has been increasingly common in working machines of today to introduce torque converters with a lock-up function. A lock-up function can provide a mechanical locking of the torque converter at a certain low degree of slipping, i.e. the gear ratio of the torque converter becomes fixed (1:1) at a certain low degree of slipping, e.g. at a low degree of slipping obtained during transportation speed. This may certainly be an alternative for wheel loaders in some specific applications.
However, the most typical application for wheel loaders is the so-called short-cycle load, in which the wheel loader moves materials between two places near to each other, e.g. moves gravel from a heap to the loading platform of a nearby truck. The transportation distances in such cycles are too short to let the torque converter reach the lock-up state. Moreover, a lock-up may not always be preferred since there is a strong interaction between the hydraulic system and the transmission line, which implies that the combustion engine benefits from the elasticity of the torque converter to reduce the interaction of the transmission line with the vehicle wheels. This is emphasized in modern wheel loaders wherein the combustion engine is utilized at lower rotational speeds due to fuel economy reasons, giving the engine even greater difficulties to recover from sudden increases in working load.
One may summarize by saying that designers would actually prefer a torque converter with a lock-up function adapted for transportation purposes. However, a lock-up function cannot be utilized in typical short-cycle loads or similar. Therefore a comparably rigid torque converter is chosen as the second best alternative. With a comparably rigid torque converter it is possible to obtain a good fuel economy both by utilizing a lower rotational speed for the combustion engine and by reducing any power consuming slipping in the torque converter. In the same way as in a rigid spring a rigid torque converter reacts less on an outer load than a soft converter. Hence, a rigid torque converter gives a reduced degree of slipping compared to a soft torque converter and the other way around; a rigid converter provides certain torque increase at a lower degree of slipping compared to a soft converter.
However, in some phases of a typical short-cycle load a much softer torque converter is preferred or even needed instead of the comparably rigid torque converter that is normally used. One such critical phase is produced when the bucket of a wheel loader is emptied on a nearby truck. Here, the bucket is usually nearly completely raised as the wheel loader approaches the truck. At the same time the hydraulic lift and tilt functions are exercised to raise the bucket even further and to finally emptying the bucket on the truck platform. In this situation it is desirable to roll slowly forward towards the truck in a controlled manner. However, a rigid torque converter will typically provide traction power for the driving wheels of such magnitude that the wheel loader rolls faster than desired even if the combustion engine is running on idle. This forces the operator of the loader to exercise the lifting, tilting and throttle controls to balance the lifting and tilting operations with the engine power (lifting and tilting may require more throttle to create the necessary power), at the same time as he has to exercise the brake to control the rolling speed. This is a rather complicated operation which lowers the productivity even for more experienced operators. In addition, this has the potential to increase the fuel consumption since the operator may choose to run the combustion engine at a higher rotation speed to meet the load from the hydraulic system while the forward rolling of the loader is controlled by the brake pedal.
Another critical phase is produced when the bucket of a wheel loader is to be filled. Naturally, it is preferred that the bucket is filled in a quick and efficient manner. This is accomplished by the operator trying to find the right balance between the bucket movement (controlled by the lifting and tilting functions) and the penetration the forward rolling controlled by the throttle pedal). Here, the traction forces from the wheels of the loader are in many situations counteracting the forces from the moving bucket i.e. the tilt and lift movements). To accomplish a quick and efficient filling of the bucket and simultaneously handling the forces from the wheels and the bucket is a more or less complicated task depending on the characteristics of the wheel loader. Here, the rigidness of the torque converter is an essential component.
Hence, both in the bucket emptying phase and in the bucket filling phase it is preferred to utilize a soft torque converter. In the bucket emptying phase this enables an improved coordination of the bucket and wheel loader movements. In the bucket filling phase this enables an improved balancing of the forces created by the bucket and wheel loader movements.
However, a soft torque converter is only preferred in such critical phases of a short-cycle load as those described above and similar. In the other phases of a short-cycle load a rigid torque converter is preferred for the reasons of performance and fuel economy.
Considering the above there is clearly a need for a working machine with a transmission line comprising a transmission unit {e.g. a torque converter) where the working machine is provided with an ability to overcome the shortcomings of known transmission units being less suitable for at least some working conditions of the working machine.
It is desirable to provide a method of the kind referred to in the introduction, which creates conditions for a more effective operation of the working machine.
According to an aspect of the present invention, a method is provided for operating a working machine provided with: a power source and a plurality of driving wheels; a working hydraulic system comprising at least one hydraulic pump powered by the power source for moving an implement on the working machine and/or for steering the working machine; a transmission line arranged between the power source and the driving wheels for transmitting torque from the power source to the driving wheels; and a transmission unit arranged in the transmission line for reducing the mechanical interaction between the power source and the driving wheels.
The method is characterized by the steps of:
detecting at least one operational parameter indicative of a working condition of the working machine, determining if the characteristic of the transmission unit should be altered on the basis of a magnitude of the detected operational parameter, altering the characteristic of the transmission unit if it is determined to be required.
Altering the characteristic of the transmission unit by means of the above method provides a working machine with an improved ability to overcome the shortcomings of known transmission units being less suitable for at least some working conditions of the working machine.
This is particularly so if the working condition determines a predetermined working operation with the implement, since this constitutes a typical situation in which the need for altering the characteristic of the transmission unit can arise. Here, it may e.g. be advantageous to altering the characteristic of the transmission unit so as to reduce the mechanical interaction between the power source and the driving wheels even more leaving the driving wheels with less power and the hydraulic system with an increased power.
It is preferred that the characteristic is altered by means of at least one electric machine, since this enables a flexible and compact design. An electric machine can also be powered by means of a plurality of power sources (e.g. batteries, generators, fuel cells etc), which provides an increased freedom in the design. Moreover, electric machines react fast on commands providing an improved control over the alteration of the characteristic of the transmission unit.
It is particularly preferred that at least first electric machine is arranged downstream the transmission unit for subtracting torque from the downstream side of the transmission unit and converting this torque to electric energy. This provides energy that can be used for altering the characteristic of the transmission unit. Hence, it is not necessary to have an auxiliary power source and the requirements on a possible auxiliary power source can be relaxed. Typically, the energy should otherwise have been supplied to the driving wheels. However, the working conditions at which the characteristic of the transmission unit is advantageously altered are typically admitting that energy can be withdrawn from the driving wheels.
In addition it is preferred that at least a second electric machine is arranged upstream the transmission unit for receiving electric energy from the first electric machine and converting at least a part of this energy to torque that is added to the upstream side of the transmission unit. The use of a first and a second electric machine in this manner provides an excellent control over the alteration of the characteristic of the transmission unit.
It is also desirable to provide a working machine of the kind referred to in the introduction, which working machine enables a more effective operation of the working machine.
According to another aspect of the present invention, a working machine is provided with: a power source and a plurality of driving wheels; a working hydraulic system comprising at least one hydraulic pump powered by the power source for moving an implement on the working machine and/or for steering the working machine; a transmission line arranged between the power source ( 120 ) and the driving wheels for transmitting torque from the power source to the driving wheels; and a transmission unit arranged in the transmission line for reducing the mechanical interaction between the power source and the driving wheels.
In addition the working machine comprises:
at least one detecting unit for detecting at least one operational parameter indicative of a working condition of the working machine, at least one control unit for determining if the characteristic of the transmission unit should be altered on the basis of a magnitude of the detected operational parameter, at least one torque-modifying unit controlled by said control unit for altering the characteristic of the transmission unit if it is determined to be required.
The working machine displays the same or similar advantages as the method described above.
Further advantages and advantageous features of the invention are disclosed in the following description.
DEFINITIONS
The term “electric machine” should be understood as a term for an electric motor and/or generator. The electric machine can be driven by electricity to supply an output torque to a shaft or be mechanically driven by receiving torque on a shaft for producing electricity.
The term “transmission unit” comprises hydraulic clutches, both hydrodynamic clutches such as torque converters and hydrostatic clutches, as well as mechanical clutches. Thus, “transmission unit” comprises both torque converters which can increase the torque and ordinary skid clutches without ability to increase the torque.
The term “case load” refers to the working condition for a specific transmission unit at a given point in time. The “case load” at a given point in time can e.g. be described by means of the input torque Tjn and the input rotational speed njn applied to the transmission unit in conjunction with the output torque Tout and the output rotational speed nout received from the transmission unit at that point in time.
The term “driving wheels” is meant to comprise vehicle wheels for direct engagement with the ground as well as vehicle wheels for driving a ground engaging member, such as tracks, crawlers or similar.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed description of the present invention is given below with reference to a plurality of exemplifying embodiments as illustrated in the appended figures, in which:
FIG. 1 is a lateral view illustrating a wheel loader having a bucket for loading operations, and a working hydraulic system for operating the bucket and steering the wheel loader,
FIG. 2 is a schematic illustration of a working hydraulic system for a wheel loader,
FIG. 3 is a schematic illustration of i.a. transmission line of a wheel loader according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is an illustration of an exemplifying wheel loader 1 having an implement 2 in the form of a bucket 3 . The bucket 3 is arranged on an arm unit 4 for lifting and lowering the bucket 3 . The bucket 3 can also be tilted or pivoted relative to the arm unit 4 . For this purpose the wheel loader 1 is provided with a working hydraulic system comprising at least one hydraulic pump (not shown in FIG. 1 ) and working cylinders 5 a , 5 b , 6 for lifting and lowering of the arm unit 4 , and for tilting or pivoting the bucket 3 . In addition, the working hydraulic system comprises working cylinders 7 a , 7 b for turning the wheel loader 1 by means of relative movement of a front body 8 and a rear body 9 . These features of the wheel loader 1 and variations thereof are well known to those skilled in the art and they need no further explanation.
FIG. 2 is a schematic illustration of an exemplifying working hydraulic system 140 . The embodiment illustrated in FIG. 2 comprises two working cylinders known as lifting cylinders 5 a , 5 b . The lifting cylinders 5 a , 5 b are arranged for lifting and lowering the arm unit 4 . A further working cylinder known as tilting cylinder 6 is arranged for tilting-in or tilting-out the bucket 3 relative to the arm unit 4 . In addition, two working cylinders known as the steering cylinders 7 a , 7 b are arranged for steering the wheel loader 1 . Three hydraulic pumps 142 , 144 , 146 supply the hydraulic cylinders with hydraulic oil. An operator of the wheel loader 1 can control the working cylinders by means of instruments connected to a control unit (not shown). Preferably the cylinders 5 a , 5 b , 6 , 7 a and 7 b schematically illustrated in FIG. 2 correspond the cylinders 5 a , 5 b , 6 , 7 a and 7 b shown in FIG. 1 .
FIG. 3 is a schematic illustration of i.a. a transmission line 110 of a wheel loader 1 according to an embodiment of the present invention. The internal combustion engine 120 of the wheel loader 1 is arranged at one end of the transmission line 110 , whereas the driving wheels 130 of the wheel loader 1 are arranged at the other end of the transmission line 110 . It follows that the internal combustion engine 120 is arranged to supply torque to the driving wheels 130 of the wheel loader 1 via the transmission line 110 . It is preferred that the transmission line 110 comprises a gearbox 118 for varying the speed of the driving wheels 130 of the wheel loader 1 and for changing between forward and backward driving direction of the wheels 130 . The gearbox 118 may e.g. be an automatic gearbox implying that there must not necessarily be a clutch (not shown) between the gearbox 118 and the driving wheels 130 , which is common in the case of a manual gearbox.
As discussed above in the background to the present invention the transmission line 110 of a wheel loader is usually provided with a transmission unit 114 for reducing the mechanical interaction between the internal combustion engine 120 and the driving wheels 130 , i.e. for providing slipping or skidding or even for temporally disengaging the internal combustion engine 120 from the driving wheels 130 . The main purpose is to protect the combustion engine 120 from rapid changes in the working conditions of the gearbox 118 and the driving wheels 130 .
The transmission unit 114 is preferably a hydraulic clutch of the type called hydrodynamic torque converter. As is well known, a torque converter is adapted to increase the input torque applied to the converter and the output torque can be in the interval of e.g. 1-3 times the input torque. The torque converter may also have a free wheel function and/or a lock-up function providing a direct operation without any increased torque. In case of a lock-up function it is preferred that the lock-up state provides a fixed transmission ratio of substantially 1:1. It should be added that alternative embodiments of the present invention may comprise a transmission unit 114 in the form of a skid clutch or similar without any torque-increasing ability. The skid clutch could be a hydraulic clutch as well as a mechanic clutch.
The exact position of the transmission unit 114 within the transmission line 110 is not decisive. However, it is preferred that the transmission unit 114 is positioned after or down streams the combustion engine 120 and before or up streams the gearbox 118 .
In addition, the transmission line 110 of the wheel loader 1 is provided with a power transferring unit 116 for driving the hydraulic pumps 142 , 144 , 146 of the working hydraulic system 140 so as to enable the lifting and steering operations as mentioned before. The power transferring unit 116 may e.g. be gear wheels or some other suitable means arranged to interact with the transmission line 110 for transferring power from the combustion engine 120 to the hydraulic pumps 142 , 144 , 146 . The power transferring unit 116 is preferably arranged to interact with the transmission line 110 in a position upstream the gear box 118 and more preferably in a position between the internal combustion engine 120 and the transmission unit 114 .
It should be added that the combustion engine 120 can be replaced by other power sources, e.g. a power sources in the form of a gas turbine or even a fuel cell arrangement. In addition, the power transferring unit 116 may be fully or at least partly replaced by other power transferring means based on hydraulic or electric principles. For example, the hydraulic pumps 142 , 144 , 146 may be powered by means of electric motors receiving power from the combustion engine 120 via a generator arrangement or similar.
As can be seen in FIG. 3 the transmission line 110 is provided with at least two electric machines 112 a , 112 b or similar torque-modifying unit or units for adding and/or subtracting torque to and/or from the transmission line 110 . The electric machines 112 a , 112 b are arranged to operatively adapt the characteristic of the transmission unit 114 and particularly to adapt the rigidness of the transmission unit 114 depending on the working condition of the wheel loader 1 . Preferably, a first electric machine 112 a is arranged in a suitable position downstream the transmission unit 114 (i.e. at the gear box side of the transmission unit 114 ), whereas a second electric machine 112 b is arranged in a suitable position upstream the transmission unit 114 (Ae. at the combustion engine side of the transmission unit 114 ). More precisely, the first electric machine 112 a is preferably arranged in a position between the transmission unit 114 and the gearbox 118 , and the second electric machine 112 b is preferably arranged in a position between the internal combustion engine 120 and the transmission unit 114 . Naturally, other alternative positions are conceivable. The electric machines 112 a , 112 b and the torque converter 114 are coupled so that torque can be exchanged between the first electric machine 112 a and the input shaft of the transmission unit 114 , and between the second electric machine 112 b and the output shaft of the transmission unit 114 . The first electric machine 112 a should preferably be able to operate in at least two quadrants, i.e. as generator in both clockwise and counter-clockwise direction of rotation. The second electric machine 112 b should preferably be able to operate in at least one quadrant, i.e. as motor in at least one direction of rotation.
The electric machines 112 a , 112 b in FIG. 3 are electrically connected to each other via a transmission-control unit 200 or a similar control unit being arranged to control the machines 112 a , 112 b for adapting the characteristic of the transmission unit 114 . This is preferably accomplished by controlling the motor and generator abilities of the electric machines 112 a , 112 b . The transmission-control unit 200 is preferably implemented as a hardware unit provided with the appropriate circuitry and software needed to accomplish the required functions, e.g. circuitry for processing and storing; and software for executing and controlling any required processing and storing. It should be emphasised that some embodiments of the present invention may have a very simple transmission-control unit 200 comprising a simple on/off switching function for connecting and disconnecting the electric machines 112 a , 112 b , e.g. on a command from the operator of the wheel loader exercising a push button or similar. However, other embodiments may have a more sophisticated transmission-control unit 200 provided with substantial processing capabilities and advanced switching functions for controlling the motor and generator abilities of the electric machines 112 a , 112 b depending on algorithms working on data received from sensors 113 a , 1136 arranged within the wheel loader 1 and preferably connected to the transmission-control unit 200 . For this purpose the transmission-control unit 200 may e.g. use data in the form of sensed, measured or even calculated input torque Tin and input rotational speed nin applied to the torque converter 114 , and output torque Tout and output rotational speed nout received from the torque converter 114 . It should be emphasised that it is well known by those skilled in the art that input torque Tin and output torque Tout can be calculated by knowing the characteristic of the transmission-control unit 200 and the input rotational speed njn and the output rotational speed nout. Sensors for measuring torque and rotational speed are well known to those skilled in the art. Likewise, a wide range of commercially available control units with substantial processing capabilities and advanced switching functions for controlling electric machines are well known by those skilled in the art and they need no further description.
The transmission-control unit 200 is arranged to operatively connect the electric machines 112 a , 112 b to each other so that the first electric machine 112 a operates as a generator and so that the second electric machine 112 b operates as a motor. In particular, the transmission-control unit 200 is arranged to operatively connect the electric machines 112 a , 112 b so that the electric energy generated by the first electric machine 112 a is used in the second electric machine 112 b . This enables the first electric machine 112 a downstream the transmission unit 114 to subtract torque from the downstream side of the transmission unit 114 and to convert this torque to electric energy, whereas it enables the second electric machine 112 b upstream the transmission unit 114 to receive the electric energy produced by the first electric machine 112 a and to convert this energy to torque that is added to the upstream side of the transmission unit 114 . In this way the internal combustion engine 120 will experience a transmission unit with a softer characteristic compared to the actual and unaffected characteristic of the used transmission unit 114 .
There are several strategies for adapting the characteristic of the transmission unit 114 as can be illustrated by the exemplifying embodiments describe below.
In an embodiment of the present invention it is preferred that substantially all electric energy produced by the first electric machine 112 a is transferred by the transmission-control unit 200 to the second electric machine 112 b . In other words, substantially all the torque subtracted by the first electric machine 112 a from the downstream side of the transmission unit 114 is added by the second electric machine 112 a to the upstream side of the transmission unit 114 .
In another embodiment of the present invention it is preferred that a determined portion of the electric energy produced by the first electric machine 112 a is transferred by the transmission-control unit 200 to the second electric machine 112 b . In other words, a determined portion of the torque being subtracted the by first electric machine 112 a from the downstream side of the transmission unit 114 is added to the upstream side of the transmission unit 114 .
In still another embodiment of the present invention it is preferred that a variable amount of the electric energy produced by the first electric machine 112 a is transferred by the transmission-control unit 200 to the second electric machine 112 b . In other words, a variable amount of the torque being subtracted from the downstream side of the transmission unit 114 is added to the upstream side of the transmission unit 114 .
The feedback of a variable amount of torque makes it possible to e.g. adopt a strategy wherein the torque subtracted from the downstream side of the transmission unit 114 is added to the upstream side of the transmission unit 114 in an amount that maintains the input torque from the combustion engine 120 to the transmission unit 114 at a substantially constant level. Naturally, this may only be accomplished to the extent and within the limits the subtracted torque is sufficient to maintain a substantially constant input torque. However, the support from an additional power source may extend the limits within which the input torque from the combustion engine 120 can be maintained substantially constant. This may e.g. be accomplished by means of an electric storage means 210 providing additional electric energy to the second electric machine 112 b . An electric storage means 210 is illustrated in FIG. 3 and it will be more thoroughly discussed below.
In addition, the feedback of a variable amount of torque makes it possible to e.g. adopt a strategy wherein the output torque from the transmission unit 114 is maintained at a substantially constant level by subtracting a variable amount of torque from the downstream side of the transmission unit 114 and add this torque to the upstream side of the transmission unit 114 . Naturally, this may be most feasible when the torque on the output side of the transmission unit 114 is provided with an increasing torque, e.g. due to an increased input torque to the transmission unit 114 from the combustion engine 120 . The other way around, this may not be feasible when the torque on the output side of the transmission unit 114 is provided with a declining torque, e.g. due to a declining input torque to the transmission unit 114 from the combustion engine 120 . However, an external power source, e.g. a battery, may certainly change this.
Moreover, the feedback of a variable amount of torque makes it possible to use a first transmission unit 114 having a first rigid characteristic for emulating a second transmission unit having a second softer characteristic.
To accomplish this it is necessary to know the characteristics of the soft transmission unit to be emulated. This characteristic can e.g. be represented by means of a suitable lookup table that is built on empirical measurements in laboratory conditions and/or by sampling data during real life use.
An exemplifying table representing the characteristics of a transmission unit to be emulated may e.g. comprise the following variables:
Tin=input torque to the transmission unit
nin=input rotational speed to the transmission unit
Tout=output torque from the transmission unit
nout=output rotational speed from the transmission unit
This illustrates that a certain torque Tjn and a certain rotational speed njn being inputted to the transmission unit correspond to a certain torque Tout and a certain rotational speed njn being outputted from the soft transmission unit. Such a table can comprise all relevant cases of load for a certain transmission unit, e.g. measured in laboratory conditions and/or sampled in real life use.
Alternatively or additionally, the characteristic of a transmission unit may be described by means of one or several mathematical expressions or similar. For example, the simplified converter model given by the two exemplifying mathematical relations 1 and 2 below is commonly used to describe the characteristic of a transmission unit in the form of a hydrodynamic torque converter. Naturally, depending on the nature of the transmission unit there are clearly other mathematical expressions or similar that can be used to describe the characteristic of a particular transmission unit.
The simplified converter model mentioned above is based on two simple empirical relations.
T
in
=
k
(
v
)
n
in
2
,
where
k
(
v
)
=
T
in
·
ref
v
n
in
·
ref
2
(
1
)
T
out
=
μ
(
v
)
T
in
(
2
)
wherein
Tin represents the present input torque
Tin.ref represents the input torque at a determined reference input rotational speed
Tout represents the present output torque
nin represents the present input rotational speed
nin.ref represents a determined reference input rotational speed
k(v) represents the absorption factor for the converter in question at different input and output rotational speeds
μ(v) represents the amplifying factor for the converter in question at different input and output rotational speeds
v represents the input rotational speed njn divided by the output rotational speed nout.
Values for the factors k(v) and μ(v) for a certain torque converter can be obtained by running the converter at a reference input rotational speed njn,ref (e.g. at 1000 rpm) while the output rotational speed is varied. The simplified converter model described by the relations 1 , 2 above and the manner of obtaining the factors k(v) and μ(v) are well known facts to those skilled in the art and they need no further explanation.
Considering the present invention and the above discussion of the characteristic of a transmission unit it should be clear that a first rigid transmission unit can be used to emulate a second soft transmission unit by subtracting a first amount of torque from the downstream side of the rigid transmission unit and by adding a second amount of torque to the upstream side of the rigid transmission unit. The amount of torque subtracted from the downstream side of the rigid transmission unit and the amount of torque added to the upstream side of the rigid transmission unit should then be determined so that the current case load is adapted to a case load that is determined by the characteristic of a softer transmission unit.
As an example we can use the two relations Tin=k(v)nin 2 and Tout=μ(v)Tin described above and the known factors krigid(v) and μrigid(v) for a rigid torque converter to calculate the input and output torques Tjn rigid and Tout rigid for the rigid torque converter at a specific input and output rotational speed nin, nout. Likewise, given the known factors ksoft(v) and μsoft(v) for a softer torque converter we can also calculate the corresponding input and output torques Tin_soft and Tout_soft for the soft converter at the same input and output rotational speeds njn, nout. Hence, by maintaining the same input and output rotational speed njn, nout and by subtracting a first amount of torque from the downstream side and adding a second amount of torque to the upstream side of the rigid torque converter so that the new input and output torques equals the input and output torques Tin_soft and Tout_soft it is possible to adapt the current case load for the rigid torque converter to a corresponding case load for the soft torque converter. A combustion engine connected to the input shaft of the rigid torque converter will then experience the characteristic of the soft converter instead of the characteristic of the unaffected rigid converter.
The same can be accomplished by using a look-up table, e.g. the exemplifying look-up table described above or similar defining the characteristic of a softer torque converter. Knowing the current input and output rotational speeds njn, nout for a rigid torque converter it is be possible to find the same or at least similar pair of input and output rotational speeds in the look-up table for the soft converter together with the input and output torques Tin_soft and Tout soft for that converter at that input and out put speed. By maintaining the same input and output rotational speed nin, nout and by subtracting a first amount of torque from the downstream side and adding a second amount of torque to the upstream side of the rigid torque converter so that the new input and output torques equals the input and output torques Tin_soft and Tout_soft it is possible to adapt the current case load for the rigid torque converter to a corresponding case load for the soft torque converter.
Naturally, it is preferred that the characteristic of the transmission unit 114 is adapted only for those phases in the working condition of a wheel loader that requires a softer transmission unit. As previously described, the bucket filling phase and the bucket emptying phase in a short-cycle load are examples of such phases.
Both the bucket filling phase and the bucket emptying phase in a short-cycle load are performed while the wheel loader is running on the lowest gear or at least on a low gear. Hence, in an embodiment of the present invention it is preferred to adapt the characteristic of the transmission unit 114 when the wheel loader is running on the lowest gear or at least on a low gear.
Similarly, at least the bucket emptying phase in a short-cycle load is typically performed while the operator exercises the brakes to accomplish a slow forward movement for the wheel loader. Hence, in an embodiment of the present invention it is preferred to adapt the characteristic of the transmission unit 114 when the operator exercises the brakes.
In addition, a push button or some other control can be used for manually activating and/or selecting the desired strategy for adapting the characteristic of the transmission unit 114 .
It should be added that an embodiment of the present invention comprises an additional power source in the form of an electric energy storage means 210 for receiving electric energy from the first electric machine 112 a and providing electric energy to the second electric machine 112 b . The electric storage means 210 makes it possible to at least temporary provide the second electric machine 112 b with an amount of electric power that exceeds the amount currently produced by the first electric machine 112 a when subtracting torque from the downstream side of the transmission unit 114 . In addition, the electric storage means 210 may be provided with charging electric energy from the first electric machine 112 a , e.g. when the amount of electric power currently produced by the first electric machine 112 a exceeds the amount currently required for the second electric machine 112 b . This provides an improved flexibility in reducing the rigidness of the transmission unit ( 114 ) by means of the first and second electric machines 112 a , 112 b as described above. The electric storage means 210 may e.g. be a battery or a super capacitor or some other suitable electric storage means.
Although the exemplifying working hydraulic system 140 illustrated in FIG. 2-3 has three hydraulic pumps 142 , 144 , 146 other embodiments may have one, two, four or more hydraulic pumps. In a preferred embodiment of the invention the working machine has at least two implement and/or steering functions, and at least one said hydraulic pump is arranged for each implement and/or steering function.
As described in connection to the FIG. 1 , the working machine 1 can have an implement 2 in the form of a bucket 3 which is operated by means of the working hydraulic system 140 . However, it should be emphasised that other implements are usable. When applying the invention on a working machine such as an articulated hauler or a truck, the implement can instead be for example a dump body. Usually a hydraulic pump and working cylinders are used for the operation of the dump body during the dumping movement.
It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims.
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A working machine and a method for operating the same are provided. The working machine is provided with: a power source and a plurality of driving wheels; a working hydraulic system including at least one hydraulic pump powered by the power source for moving an implement on the working machine and/or for steering the working machine; a transmission line arranged between the power source and the driving wheels for transmitting torque from the power source to the driving wheels; and a transmission unit arranged in the transmission line for reducing the mechanical interaction between the power source and the driving wheels. The method includes: detecting at least one operational parameter indicative of a working condition of the working machine; determining if the characteristic of the transmission unit should be altered on the basis of a magnitude of the detected operational parameter; altering the characteristic of the transmission unit if it is determined to be required.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an intrauterine device (IUD) and to an inserter for placing the same. More specifically the invention relates to a combination of a one-hand-held inserter for positioning a T-shaped intrauterine device and to a T-shaped intrauterine device that are designed to make insertion easier while minimizing patient's discomfort and pain.
[0003] 2. Discussion of the Related Art
[0004] Intrauterine devices and inserters for the same are well known. An intrauterine device (IUD) is a reversible, long acting, contraceptive device that is placed inside the uterus and can remain there for a few years. At any time that the woman plans to have a child, it can be easily removed by a clinician. Many women find the IUD to be very convenient because unlike oral contraceptives which require daily attention, an intrauterine device requires little action once it is in place.
[0005] Over the years various types of intrauterine devices have been proposed and applied. At present there are two types of IUDs in use: a copper-based IUD and a hormonal IUD. Copper-based IUDs are available in the T-framed shape or as frameless IUDs. The T-shaped IUDs comprise a T-shaped plastic frame having an elongated body partly wrapped by a copper coil and a pair of flexible transverse arms that hold the IUD in place near the top of the uterus. The IUD is inserted into the uterus with the transverse arms folded to facilitate the insertion through the cervical canal. Once the device is positioned inside the uterus, the arms are released and assume their transverse orientation. Depending on the particular device, the arms are either folded backward against the stem, as for example in TC-380A. (e.g., ParaGard®), or are folded in the forward direction against each other as in Nova-T type IUDs. The frameless copper IUD (e.g., GyneFix®) does not contain a T-shape frame but is a loop that holds several copper tubes and is anchored into the uterus fundus by a suture.
[0006] Of particular interest of the present invention are hormonal IUDs (also known as intrauterine system—IUS) which contain reservoir of hormone that is gradually released into the uterine cavity. At present there is only one hormonal IUD available for use, the T-frame LNG-20 distributed by Schering Og under the name Mirena®. It consists of a flexible plastic T-shaped frame surrounded by a hormone (levonorgestrel) cylinder. Hormonal IUDs have other benefits besides being contraceptive and may also be given for treatment of hormonal disorders and for hormone replacement therapy. Compared to copper-based IUDs such as for example the Nova-T, the LNG-20 is bulkier, having a body of larger diameter. Its insertion procedure requires more expertise and may be associated with more discomfort and pain to the patient.
[0007] The insertion and removal of an IUD is a medical procedure performed by a physician. The IUD is inserted through the cervix and into the uterine cavity by means of an inserter that typically includes an insertion tube that accommodates the IUD and a plunger. For T-shaped IU) the lateral arms are folded prior to insertion. An IUD typically also includes a string extending from its bottom end, which serves for monitoring the IUD and for facilitating its removal.
[0008] IUD is one of the most effective reversible contraceptive methods and has certain advantages over other birth control means with respect to cost-effectiveness and convenience, and because it is a long-term, reversible method, it can meet the needs of many women. However, despite these advantages, IUDs are widely used only in a few large countries, such as China, Egypt, and Vietnam, and are little used in most countries. In the United States, for example, only about 2% of women who use birth control means, use IUDs.
[0009] One of the reasons for IUDs not being more popular is the fear of the discomfort and pain associated with the insertion procedure. In addition, the general practice to perform insertion during the menstrual period may add to the discomfort felt by potential users. Further, although there is no minimum age for using IUD, it is often believed that IUDs should not be given to young women or to women who have never been pregnant.
[0010] There is therefore a continuous need to improve intrauterine devices and insertion procedure that may lead to greater acceptability and use of IUDs.
[0011] Accordingly, it is the general object of the invention to simplify IUD insertion procedure and to minimize the patient's discomfort and risk of complications during and after insertion.
[0012] In particular, it is an object of the present invention to provide an inserter for an intrauterine device that is easier to manipulate, that will make insertion procedure easier to the physician and less painful to the patient and that is simple to manufacture and to use.
[0013] It is another object of the present invention to provide an intrauterine device that is easier to insert and remove, that has a simple structure and is easy and inexpensive to manufacture.
SUMMARY OF THE PRESENT INVENTION
[0014] One aspect of the present invention is an inserter for placing a T-shaped intrauterine device inside a patient's uterus. The inserter comprises a sleeve part and a plunger part. The sleeve part comprises an open tube dimensioned to receive the contraceptive body of the intrauterine device and a first engaging member. The plunger part comprises a rod, a handle attached to one end of the rod and a second engaging member. The first and second engaging members are configured for reversibly and slidably engaging the sleeve part and the plunger part when the rod is inserted into the tube, and when the sleeve part and the plunger part are engaged, to temporarily lock the relative position between the tube and the rod. In accordance with an embodiment of the invention, the first engaging member comprises a disk attached to one open end of the tube, the disk having a central opening aligned with the open end and two opposite recesses and the second engaging member comprises two resilient arms dimensioned to be received in the two opposite recesses of the disk. The sleeve part and the plunger part can be separated into two separate parts.
[0015] Another aspect of the invention is a T-shaped intrauterine device comprising a transverse member and an elongated contraceptive body suspended from said transverse member. The transverse member comprises a pair of wings having a relaxed configuration in which the wings extended laterally and a contracted folded configuration in which the wings are folded against each other. Preferably the wings are convex. Optionally, the elongated contraceptive body is suspended from the transverse by means of a string connected to the junction zone between the two wings. Optionally, the string is threaded through an eyelet in the junction zone. The string may be connected to an eyelet at provided at one end of the elongated contraceptive body or may run along the central longitudinal axis of the elongated contraceptive body. Optionally the intrauterine device further comprises at least one removal string suspended from the bottom end thereof. The elongated contraceptive body may comprise a reservoir of at least one contraceptive agent and a sustained release means adapted for providing a sustained release of the contraceptive agent. The contraceptive agent may be a progesterone analog, e.g., levonorgestrel. Alternatively the elongated contraceptive body may comprise copper.
[0016] Yet, further aspects of the invention are a combination of the inserter and intrauterine device of the invention and a kit for the positioning of an intrauterine device inside a patient's uterus that includes the combination under sterile packaging.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
[0018] FIG. 1 is a schematic side view of the plunger part of an inserter for positioning an intrauterine device, in accordance with an embodiment of the invention;
[0019] FIGS. 2A and 2B are side and bottom views, respectively, of the sleeve part of an inserter for positioning an intrauterine device, in accordance with an embodiment of the invention;
[0020] FIG. 3 is a schematic illustration of an intrauterine device in accordance with an embodiment of the invention;
[0021] FIG. 4 is a schematic illustration of an intrauterine device in accordance with another embodiment of the invention;
[0022] FIG. 5A is a broken view demonstrating the assembled inserter and the intrauterine device in a storage position;
[0023] FIG. 5B is a broken view illustration the intrauterine device and the inserter in a pre-inserting position; and
[0024] FIG. 5C is a broken view illustrating the intrauterine device and the inserter after the intrauterine device is released from the inserter and before the inserter is withdrawn.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the drawings, FIGS. 1 and 2 depict the disassembled parts of an inserter for an intrauterine device in accordance with an embodiment of the invention. The assembled inserter, generally designated 10 , is depicted in FIGS. 5A to 5C . Inserter 10 comprises a sleeve part 3 and a plunger part 2 . Parts 2 and 3 can be easily assembled manually with no need for any tools and similarly can be easily disassembled into two separate parts to facilitate the removal of the inserter after the intrauterine device is positioned correctly inside the uterus.
[0026] Plunger part 2 comprises a thin rod 22 and a handle 24 fixedly attached to one end of the rod. Handle 24 comprises an elongated portion 26 to facilitate gripping by hand and two opposite resilient arms 28 , a second engaging member 29 , extending upwardly in the direction of and on opposite sides of rod 22 , Arms 28 are configured as tweezers arms that can bend inwardly toward each other. Rod 22 and handle 24 are preferably made from a rigid sterilizable polymeric material such as polyethylene or the like. Rod 22 , due to its small diameter/length ratio can easily flex to assume any curvature. Preferably part 2 is formed as a one integral piece, for example by mould injection. Alternatively, rod 22 can be attached to handle 24 by any other method including heat fusing, adhering and the like, or can be inserted into a bore drilled or otherwise formed in handle 24 .
[0027] Sleeve part 3 comprises a tube 32 provided with a disk a first engaging member 33 , at its proximal end. Tube 32 is a hollow tube made of medical grade sterilizable semi-rigid polymeric material such as polyethylene, polypropylene and the like. The inner diameter of the tube is dimensioned to receive the contraceptive body of a T-shaped intrauterine device, such as the devices depicted in FIGS. 3 and 4 . The distal (upper) part of tube 32 is slightly curved to better adapt to the curvature of the uterus. The tube may be further bent before insertion and after examining the curvature of the uterus. Tube 32 may be further provided with a movable marking ring 35 which can slide along the tube. Ring 35 serves to mark the correct depth of insertion, i.e., the length of the uterine lumen, measured prior to insertion, as is well known in the art. Tube 32 may also include imprinted scaling marks (not shown) to facilitate positioning of ring 35 . As shown in FIG. 2B , disk 34 comprises a central opening 36 , substantially of the same diameter as the inner diameter of tube 32 and two opposite recesses 38 . Recesses 38 are dimensioned to receive arms 28 of plunger 2 .
[0028] Inserter 10 is assembled by inserting rod 22 of plunger 2 into tube 32 through opening 36 of disk 34 and forcing arms 28 of the plunger into recesses 34 of the disk, such that the tube can slide along the arms. As mentioned above, arms 28 are resilient and act like tweezers. When no pressure is applied on the arms, sleeve 3 can slide up and down arms 28 to assume any desired relative position between plunger and sleeve. When arms 28 are pressed against disk 36 , the sleeve is locked to the plunger to maintain their relative position. Thus, disk 34 and arms 28 serve as engaging members that allow not only to easily assemble/disassemble the plunger and sleeve but also to easily lock/release their relative position. The inward surface of arms 28 may be smooth or may be toothed, as depicted in FIG. 1 , to enhance the grip of disk 34 by arms 28 . Alternatively, recesses 38 may be each provided with a small protrusion and arms 28 may be each provided with a complementary longitudinal slot running along the inward surface thereof for serving as a rail for sliding the disk along the arms (not shown).
[0029] In use, the inserter is held by one hand with portion 26 of handle 24 resting against the palm and arms 28 held between finger and thumb near the location of disk 34 . When adjustment of the relative position of the tube and the rod is required in order to withdraw the IUD into the tube or to expose it, this can be easily done by gripping disk 36 between finger and thumb and sliding it axially along arms 28 in the required direction. When the relative position between tube and rod should be kept fixed, i.e., when the IUD is inserted through the cervix, the arms are pressed by finger and thumb against recesses 38 to lock sleeve 3 onto plunger 2 , thus preventing possible relative movement between tube 32 and rod 21 and maintaining the IUD in its contracted configuration at the top of tube 32 as depicted in FIG. 5B . Arms 28 include markings 25 which mark the correct position of disk 34 when the inserter and IUD are ready for insertion.
[0030] It will be appreciated that the inserter of the present invention has the advantage of allowing the physician to manipulate both plunger and tube by one hand during the whole insertion procedure while leaving his other hand free to use other instruments or perform other operations as necessary. It will further appreciated that inserter 10 further allows for easily disengaging the plunger part from the sleeve part, thus allows withdrawal of the inserter, after the IUD is correctly placed, not as a whole unit, but by parts, namely first the plunger then the sleeve, to ensure that the monitoring string of the IUD is not entangled within the inserter and to reduce the risk of withdrawing the IUD along with the inserter.
[0031] Inserter 10 is designed for the insertion of a T-shaped IUD that comprises a cylindrical contraceptive body, i.e., copper-bearing or hormone releasing body, and a pair of foldable arms. Inserter 10 can be used for the insertion of any IUD of this type, including Nova-T and LNG-20 (Mirena®). However, in accordance with the general objective of the invention to make insertion easier while minimizing discomfort and pain, there is also provided a new IUD directed at this objective. The IUD of the invention, unlike known T-shaped frame IUDs, does not comprise a vertical stem that runs through the contraceptive body, but rather the contraceptive body is suspended from the middle node between the two transversal arms. The elimination of a central shaft allows for reducing the diameter of the contraceptive body, making insertion easier. The absence of a central relatively rigid shaft further allows for greater flexibility of the body, resulting with reduced bleeding and pain.
[0032] FIGS. 3 and 4 depict two embodiments designated 4 and 5 , respectively, of an intrauterine device of the invention. Both embodiments comprise a pair of foldable resilient wings 44 , 54 and a contraceptive body 42 , 52 suspended from the junction zone between the two wings. Wings 44 , 54 are of substantially similar shape as of those of the Nova-T and Mirena® devices. The wings are made of one resilient piece having a junction zone from which the two convex wings divert. In their expanded relaxed configuration, the wings are generally directed at opposite lateral directions substantially perpendicularly to the elongated body and having their tips 46 directed downward. The wings can easily flex toward each other around the junction where they meet and can reach a full contracted configuration to abut each other, as in FIG. 5B . Tips 46 are of substantially hemispherical shape forming a rounded leading end when the wings are pressed against each other in the contracted configuration. Preferably tips 46 are dimensioned to be slightly wider than opening 31 of tube 32 such that when the IUD is withdrawn into tube 32 they stop the RID at the correct position and prevent it from being withdrawn deeper into the tube. The structure and flexibility of the wings insures that the device can easily adapt to the lateral dimensions of the uterus and can easily respond to uterus contractions while minimizing the pressure applied on the uterus walls. In accordance with the embodiments shown in FIGS. 3 and 4 , the wings comprise an eyelet 45 , 55 , respectively, in the junction zone between the wings.
[0033] In the embodiment depicted. FIG. 3 , body 42 is provided with two extensions 42 a and 42 b at the upper and bottom ends, respectively, which comprise eyelets 43 and 41 . In accordance with this embodiment, wings 44 and body 42 are connected by a flexible string 47 which is threaded first through one of eyelets 45 and 43 and is tied to form a first knot, then is threaded and tied around the second eyelet to form a second knot and loop. The ends of the string can be cut close to the knots. A second string 48 is tied to bottom eyelet 41 . String 48 is used for monitoring the IUD and to facilitate its removal Body 42 , which carries the contraceptive agent, may be a reservoir of contraceptive compound such as levonorgestrel or any other suitable progesterone analog. Body 42 may comprise a core of suitable polymeric matrix impregnated with the contraceptive agent and enveloped by a permeable membrane for controlling sustained release of the contraceptive agent into the uterus cavity over a prolonged time. Alternatively, body 42 may comprise a core enveloped with copper. Extensions 42 a and 42 b of body 42 may be formed as part of the envelope. It will be appreciated that body 42 may contain other or additional active therapeutic agents for treating various conditions of the uterus.
[0034] In the embodiment depicted in FIG. 4 , only one string 56 is used for both connecting wings 54 to body 52 and as the monitoring and removal string. In accordance with this embodiment string 56 is inserted through the body substantially along its central longitudinal axis and is tied around eyelet 55 . String 56 is inserted through body 52 either through a pre-fabricated channel that runs from top to bottom or by forcing the string through the resilient body by means of a needle-like instrument. The two ends of the string extending from the bottom end of body 52 are tied close to the body and serve for monitoring and removing the IUD. In accordance with the embodiment shown here, both ends of the string are inserted through the body, however it will be easily realized that alternatively only one end of the string may be inserted through the body such that the two ends of the string are extending from the opposites ends of the body, one end is tied to the wings while the other end is tied on itself to form a knot close to the body and is left to serve as the removal string. Body 52 may be of the type described above in association with FIG. 3 , or alternatively may comprise copper rings or copper wire surrounding the string.
[0035] FIGS. 5A to 5C demonstrate the relative position of the tube, plunger and the IUD during storage ( 5 A); immediately before insertion ( 5 B); and immediately after the IUD is positioned in the uterus and before the inserter in withdrawn ( 5 C).
[0036] During storage, the intrauterine device and the inserter are kept as a kit under sterilized sealed packaging. The package is opened a short time before the insertion and only after examination to determine the size, position, and curvature of the uterus.
[0037] As depicted in FIG. 5A , the packaged kit preferably contains inserter 10 in the assembled configuration and with the contraceptive elongated body 42 of IUD 4 inside the forward end of tube 32 , protected thereby. During storage, wings 44 must be stored in the expanded configuration in order to prevent fatigue which might cause the wings to lose their flexibility. If the IUD is retained in the tube with its wings folded for a prolonged period, permanent deformation might occur and the arms might not return to their expanded configuration when released from the tube. At this position, i.e., with the IUD body protected inside tube 32 and wings 44 outside tube 32 , tube 32 is mounted near the free ends of arms 28 and the tip 21 of plunger rod 22 does not contact the IUD but is located at certain distance below it.
[0038] FIG. 2B demonstrates the inserter and the IUD ready for insertion. At this configuration, wings 44 are withdrawn into tube 32 to assume their contracted configuration and the tip of plunger rod 22 contacts the bottom end of the IUD. To achieve this configuration, disk 34 , held between finger and thumb, is retracted on arms 28 toward the handle and/or the handle is pushed forward until disk 34 is positioned on marks 25 . At this configuration the IUD is entirely housed within tube 32 but for tips 46 which are exposed, and is ready for insertion. As mentioned above, tips 46 stop the IUD from being withdrawn further into the tube.
[0039] To place the IUD, the inserter as configured in FIG. 5B is inserted through the cervical canal into the uterus while pressing arms 28 inwardly against disk 34 to maintain the IUD in its contracted configuration within tube 22 . When the IUD is in the correct position it is released from tube 22 by retracting disk 34 backward along arms 28 until it reaches handle 24 and cannot be further moved. FIG. 5C illustrates the configuration of the IUD and the inserter after release. The distance between marks 25 and the bottom end 27 of arms 28 substantially equals the length of the IUD in its contracted configuration.
[0040] After the IUD is correctly placed inside the uterus, inserter 10 may be withdrawn. In accordance with the invention withdrawal of the device may be performed by first withdrawing the plunger part, then withdrawing the sleeve part. Such a procedure reduces the risk, that removal string 48 will get entangled between the sleeve and the plunger which might result in the IUD being displaced or accidentally removed along with the inserter. In order to remove the plunger, disk 34 may be held steady while handle 24 is pulled backward until arms 28 are released from the disk and the plunger can be removed. Thereafter the sleeve part may be withdrawn.
[0041] It will be realized that the inserter of the invention may be used for the insertion of any type of T-shaped IUD while the IUD of the invention may be positioned by means of any other suitable inserter. However, the combination of the novel inserter and IUD of the invention provides certain advantages with respect to ease and simplicity of insertion, such as smaller diameter and more frontal flexibility, as well as with respect to simplicity and cost of manufacturing.
[0042] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined only by the claims which follow.
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An inserter for placing a T-shaped intrauterine device inside a patient's uterus and a T-shaped intrauterine device are disclosed. The inserter includes a sleeve part and a plunger part, the sleeve part includes a tube and a first engaging member and the plunger part includes a rod, a handle attached to the rod and a second engaging member. The first and the second engaging members are configured for reversibly engaging the sleeve part and the plunger part to temporarily lock the relative position between the tube and the rod. The T-shaped intrauterine device includes a pair of wings having a relaxed extended configuration and a contracted folded configuration and an elongated contraceptive body suspended from a junction between the wings.
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BACKGROUND OF THE INVENTION
[0001] Field of the Invention: The present invention relates generally to systems and methods for tracking the location of motor vehicles, and more particularly to an improved system and method for tracking the location of a plurality of motor vehicles at a particular location or lot to ascertain the exact position at which any motor vehicle is parked, as well as when a motor vehicle enters or leaves the location or lot.
[0002] Locations at which a relatively large number of motor vehicles are stored present the problem of determining exactly where each motor vehicle is located, and even whether or not a particular motor vehicles located at a particular location or lot when the business has several different lots. This problem is particularly common to large motor vehicle dealerships, and is equally applicable to automobiles, trucks, recreational vehicles, or other similar motor vehicles. In addition, such businesses must also deal with the theft of motor vehicles, wherein one or more motor vehicle is illegally removed from the location or lot.
[0003] A number of different methods have been used in the past to deal with the problem of tracking the location of a large number of motor vehicles at a location or lot. The oldest of these methods is by keeping an inventory register of each motor vehicle and its location, either in a paper journal of some kind or more recently, in a computerized database. Inventory registers depend on each individual who may move a motor vehicle for any reason recording that move, as well as the motor vehicle's new location. Ultimately, this system will not accurately reflect the location of all motor vehicles simply because not all employees at the location will enter each move of a motor vehicle. Similarly, another common system which relies on the placement of the keys of each motor vehicle on a large board in a position reflecting the location of the motor vehicle also requires the full time cooperation of each person at the location or lot, and hence also will not work all of the time due to human nature.
[0004] As might be expected, a variety of different approaches have been taken to attempt to solve the problem of monitoring large numbers of motor vehicles at a location or a lot. This approaches vary widely, encompassing both increased security measures and electronic vehicle monitoring. With regard first to increased security measures of particular application to motor vehicles at a location or lot, the measures taken commonly include security fences or compounds, the use of video monitoring of areas in which motor vehicles are stored, the use of motion sensors in such areas, and the use of security guards to patrol such areas. While such approaches may reduce the incidence of theft somewhat, they are not useful in addressing the primary problem contemplated by the present invention, namely how to keep track of the location of a number of motor vehicles located at a particular location or lot.
[0005] The electronic security measures mentioned above also vary widely, from the use of electronic cards, to highly complex electronic motor vehicle communication system, to the use of simple electronic motor vehicle tags which may be read as a motor vehicle passes a location having an electronic tag reader.
[0006] An example of the use of electronic cards associated with each motor vehicle is illustrated in U.S. Pat. No. 5,459,304 to Eisenmann, which discloses a smart card for containing a variety of information pertaining to a particular motor vehicle. The electronic card approach is not helpful to the situation contemplated herein, since it does not contain information pertaining to the location of a motor vehicle, but rather information about a particular motor vehicle and its owner and operator.
[0007] An example of the use of electronic motor vehicle communication system is illustrated in U.S. Pat. No. 5,552,789 to Schuermann, which teaches a highly complex system for performing a variety of functions in the vehicle. The Schuermann system is simply too complex and too expensive to find application in the present situation.
[0008] Example of electronic motor vehicle tags which may be read by an electronic tag reader are found in Schuermann, as well as in U.S. Pat. No. 5,311,186 to Utsu et al., U.S. Pat. No.5,635,693 to Benson et al., and U.S. Pat. No. 5,661,473 to Paschal. Schuermann describes the use of a transponder on each motor vehicle, which may be used for premises or toll access. Utsu et al. teaches a communication system between a motor vehicle transponder and a devise for interrogating the transponder. Paschal teaches such a system which may be used to automatically identify stolen motor vehicles. Benson et al. is perhaps the most detailed of such electronic motor vehicle tag/electronic tag reader system, and a brief description of the Benson et al. system is illustrative of both the benefits and the limitation of such systems, as they are currently known. The Benson et al. system attempts to resolve the situation addressed by the present invention by electronic and automatically tracking motor vehicles as they enter and leave a dealership lot. An electronic tag located in each motor vehicle is read whenever that motor vehicle passes an electronic checkpoint at an entrance to or exit from the location or lot. The present invention central monitoring station tracks all the motor vehicles at location as they enter lot leave without the use of electronic entrance checkpoint readers.
[0009] While the Benson et al. system is highly useful and represents a significant improvement in the art, it does not address the problem addressed by the present invention, namely maintaining the location of motor vehicles at a location or lot. The Benson et al. system is not capable of determining where on a location or lot each motor vehicle is, but rather only information relating to each motor vehicle entering or leaving a location or lot.
[0010] Another example of mobile object tracking system is illustrated in The U.S. Pat. No. 5,631,642 to Brockelsby et al. Which describes an array of signpost stations distributed in a area and a vehicle based become transmitter arranged to transmit a vehicle identification signal and a vehicle location signal driven from the signpost identification signal. The Brockelsby et al. system does not address the problem addressed by the present invention namely maintaining the location on particular motor vehicle at a particular parking space. The Brockelsby et al. System is not capable of determining where on a location or lot each motor vehicle is parked. But rather only information relating to each motor vehicle passing a street comer or a wide area in a town.
[0011] Example of a Method for retrieving vehicle collateral U.S. Pat. No. 6,025,774 to Forbes Illustrates Vehicle equipped with GPS antenna receiver and a cellular phone capable transmitting location data regarding the vehicle and monitoring default loan status and establishing a data link from a base terminal to the transmitter of the vehicle upon an occurrence of the default. The transmitter is capable of sensing any physical tampering therewith and transmitting a temper signal in response to any sensed tampering.
[0012] The present invention uses a tamper proof GPS receiver and a cellular phone modem or two-way pager, for location identification. In the present invention each one of said vehicle Transceiver unit. GPS antenna/receiver and the GPS base cellular phone unit is equipped with, a pressure sensing tamper switch mounted on the mounting surface side against said vehicle body (windshield) to monitor security violation and location of a particular vehicle at a site. Said vehicle ignition or fuel pump electronic circuitry communicating with an RF or Digital data with said vehicle mount GPS base Phone and Transceiver unit. If an unauthorized attempt is made to tamper or remove any of said units, said vehicle mount GPS based phone and the RF transceiver unit will transmit a signal to interrupt the ignition or fuel pump of said particular vehicle by use of RF communication or digital data link, and Send a security violation tamper signal to a monitoring station.
[0013] Forbes system fails to describe the presence of a GPS base phone and Vehicle transceiver unit with a tamper-sensing circuitry which will immobilizes a vehicle starter. Ignition or fuel pump and signals a monitoring station after a tamper-sensing circuitry detects unauthorized removal of a GPS base phone or transceiver unit. There shall for, Forbes “physical tampering detection signal” may be received by a monitoring station. But Forbes system can not locate the vehicle, due to the fact in Forbes teaching, after a vehicle GPS equipment is tamper with, the vehicle is not immobilized. There shall for vehicle could be in motion, and the GPS/phone unit pending on damage severity caused during tamper, the units could be inoperative, and the monitoring station cannot know where a moving vehicle location is. Contrary to the present invention, if and when vehicle RF or GPS/phone units are tampered with. The monitoring station upon receipt of tamper signal from said vehicle unit, it can locate the particular vehicle base on last known vehicle location, due to fact the tampered vehicle is immobilized and last location is known to a monitoring station.
[0014] Example of Asset Location System U.S. Pat. No. 6,069,570 to Herring illustrates an Asset Location System, wherein an asset is equipped with a pager receiver. A GPS receiver and a cellular phone, communicating with a monitoring station. When a movable asset is to be located, a call is sent out to an asset equipped with a pager when the pager receives said signal it power-up the GPS antenna and the cellular phone to sent location information to a central station relating to a particular asset.
[0015] The present invention teaches, a GPS based phone or two way pager installed in a vehicle and operating in a stand by mode (not being powered-up by a pager signal as Herring) and is equipped with a tamper sensing switch on its mounting side against the vehicle, utilized to immediately notify a monitoring station (contrary to Herring. A pager call is sent) and immobilize vehicle ignition upon said switch detecting unauthorized removal of said GPS antenna. Mobile phone. Two-way pager and vehicle transceiver unit.
[0016] Example of Programmable Vehicle Monitoring U.S. Pat. No. 5,986,543 to Johnson, describes a Vehicle security system with intrusion detecting devise connected to a GPS base phone unit. When intrusion takes place said vehicle GPS base phone transmits an intrusion signal to a central monitoring station which will identify and locate said vehicle in addition the monitoring station is capable sending a signal to shut said vehicle ignition or fuel pump and Lock/unlock doors via the mobile phone installed in said vehicle. The intrusion detecting RF transceiver and GPS based phone units used in the present invention is tamper sensing and using pressure sensing switch and it is mounted in a vehicle against the vehicle body or as described in the invention mounted within rear view mirror (camouflaged), a substantial improvement over prior art Johnson system. If the GPS or RF Transceiver or cellular modem units being tampered (disconnected or removed) said vehicle intrusion detecting RF transceiver unit will transmit a RF tamper signal, and GPS based phone unit will transmit a tamper signal to a central monitoring station and in addition will shut down said vehicle ignition or fuel pump, contrary to Johnson, without the need of receiving command from a central monitoring station, and the low power base station RF transceiver sends signals to control particular vehicle door lock and unlock circuitry, and to flash lights or immobilize a particular vehicle engine in a lot without the acquiring cost. In Contrary to Johnson, which teaches a monitoring station sending signals, to immobilize vehicle engine and lock/unlock doors via costly phone service
[0017] Example of Car Rental System U.S. Pat. No. 5,289,369 to Hirshberg, describes vehicle and a central control equipped with a computer keyboard and a Monitor, in a car rental system, the user using a card access to operate vehicle mount control system. The system comprises for detecting in a real time the exact location of a rental car while travels through streets of town by means of street intersection post mount transceivers communicating with rental car system to indicate to driver vehicle location and said street transceiver being connected by use of phone line or other mean, communicating to central control unit, indicating to said central control said street transceiver and vehicle location.
[0018] The present invention plurality of vehicle transceiver units does not require driver access card, in order to operate vehicle installed transceiver unit. Hirshberg system is not capable of determining where on a parking lot each motor vehicle is parked, but rather only information relating to each motor vehicle passing a street in a town. As such it is an objective of the present invention that it be capable of identifying the particular location of each vehicle at a location in a parking space is performed by use of unidirectional infrared and or electromagnetic communication signals between vehicle transceiver unit and parking space units (with a 6-8 feet range), without interfering the communication between other parking space unit(s) and vehicle transceiver unit(s) located within next to its proximity (approx. 6 feet apart). Since Hirschberg system uses (Omni directional) RF signal to communicate between vehicle and street transceiver unit. If one were to relocate Hirschberg's pole mount transceivers from that of street comer locations, into a plurality of parking space slots (6 feet apart) from each other to communicate with vehicle mount transceiver unit in a lot, using similar method of Hirsch bergs vehicle transceiver unit, for the purpose of plurality of vehicles and plurality of parking space unit to communicate next to each other's proximity, in such a close parking slot. With use of Hirsch berg post mount transceivers and vehicle mount transceivers unit, the communication will definitely interfere each other. The vehicle mount transceiver will not be able to determine one post unit location from the other. There for Hirschberg system cannot operate in a parking lot, and be able to identify a particular vehicle location at a particular parking space, due to signal collision between the vehicles and parking space units. The location identification will definitely be misread. In addition Hirschberg central control system fails to retrieve from a particular vehicle transceiver unit the location of said vehicle, in a particular parking space on a lot.
[0019] Example of Vehicle Waiting Time indicator U.S. Pat. No.5,163,000 to Rogers, describes a Vehicle Service station having multiple lanes; each lane has one or more sensors for sensing the presence of vehicles in lane. Each station computer is responsive to the lane sensors for computing the waiting time for vehicle.
[0020] The present invention is not used for monitoring vehicles waiting inline to be serviced. The prior art “Roger” invention does not teach having a station computer capable of communicating with a vehicle mount RF transceiver unit and identifying each one of said particular vehicle information parked at a particular parking space.
[0021] Example of Hired Vehicle Transportation System U.S. Pat. No. 5,726,885 to Klein et al. Teaches a Hired Vehicle Transportation system wherein plurality of usable vehicles are available for hire with one or more collection and return point. A control center is equipped with automatic collection and return mechanism which issues authorized persons driving authorization for the vehicles parked at the respective collection and returns point in the form of associated vehicle keys and take back again the keys of the vehicle at the end of a journey. The disposition center ascertains the individual availability of vehicles and makes reservation.
[0022] The present invention is relatively defers and it is an improvement over “Klein's Automatic Key Collection and return Machine. Herein each one of said Vehicle Key Track Unit (Key Dispenser) is equipped with a computer. A keyboard. A monitor to indicate vehicle information and location on a lot and a user Finger Print Reader and RFID (transponder) Key reader. when a Authorized person put their finger on “key track” finger read scanner, the “Key Track” unit upon reading persons valid (pre-programmed) fingerprint pattern, The Key Track unit signals to the user to enter (through said Keyboard) a selected vehicle ID code (VIN Number) Upon receipt of the selected vehicle ID code The Key Track unit will dispense a particular vehicle key containing RFID Tag to an authorized user, said vehicle Key RFID Tag information will be read by said Key Track Unit, and said Key Track unit will indicate a particular vehicle Key is being check out from its inventory, and memorize in its memory the person ID information which whom took a particular vehicle key at a particular site at a particular Time. When the user dispenses back said vehicle Key in to the “Key Track” unit. The key Track unit Reads The RFID Key Information and logs back in its inventory the presence of a particular vehicle Key, and time stamps in its memory.
[0023] In the present invention plurality of said Key Track Units could be installed in different sites. Each one of site Vehicle Key Track Units are interfaced to Each other via a network of computers or by a Web server.
[0024] Additionally said Key Track Unit is equipped with a microphone. A voice recognition processor and a speaker used to give verbal instruction to the user. For user identification it utilizes user voice recognition system to dispose a particular vehicle key. In the preferred embodiment of the present invention, user gives verbal commends in order to select a particular vehicle and receive the particular vehicle Keys from said Key Track Unit without the use of a Keyboard.
[0025] The present invention teaches a Key Track System in which only authorized personal who's fingerprints and or voice is preprogrammed into said Key Track unit can get access to particular vehicle keys found in a “Key Track” System. Contrary to Klein system is designed to achieve for public hire vehicle transportation system, any one having in their possession a valid access card could get access to particular vehicle key.
[0026] It is according the primary objective of the present invention that it provides an electronic vehicle tracking information system which will track the present location of each of a plurality of motor vehicles at a location in a lot, such as for example a motor vehicle dealership. As such it is an objective of the Electronic Vehicle Monitoring System of the present invention that it be capable of identifying the particular location of each motor vehicle at a location in a parking space is performed by use of directional infrared (Ultrasonic) or electromagnetic communication signal between vehicle transceiver unit and parking space units, without interfering the communication between parking space units and vehicle transceiver units located within next to each other proximity. In addition eliminating any possibility of a vehicle transceiver to misread a parking space unit next to of its proximity.
[0027] It is a further objective of the Electronic Vehicle Monitoring System of the present invention that it be capable of automatically determine when each motor vehicle at a location or lot entered in to a base station computer interface unit upon vehicle ignition being turned off and the base station computer is capable determining vehicle presence in the lot or at a particular parking space location by signaling a particular vehicle transceiver with a unique code, and the vehicle transmitting a unique coded signal back to base station computer interface unit identifying its presence and location on the lot at a particular parking space.
[0028] It is still another objective of the present invention that it be capable of optionally providing additional features in the nature of motor vehicle security system to each vehicle. It is still further objective of the present invention to provide a mechanism whereby information located at a base station can be transmitted to a particular motor vehicle which might include command to start or stop vehicle engine. To arm or disarm the alarm unit or lock and unlock the doors. To exchange information identifying a particular vehicle. Ascertain the location of a particular vehicle location by use of tamper proof GPS receiver unit and able to inventory control plurality of motor vehicle located on a lot. Time stamp vehicle presence and absence and control car Key track (Automated Key dispenser) and additionally to report any security violation to a central monitoring station, by use of a digital or voice “Auto dialer”
[0029] Finally, the Electronic Vehicle Monitoring System of the present invention, wherein the vehicle transceiver, and the GPS unit are tamper proof design, if unauthorized attempt is made to tamper with, remove or cut the harness the vehicle ignition or fuel line will be immobilized, the vehicle horn will honk, and the presence of tamper with vehicle mount GPS unit will be reported to a monitoring station via a cellular, UHF, or Satellite modem.
[0030] Nevertheless, the Hirschberg system U.S. Pat. No. 5,289,369 as well as the other electronic vehicle tracking systems mentioned above are important and useful background to the present invention. Accordingly, U.S. Pat. No. 5,311,186, to Utsu et al., U.S. Pat. No. 5,552,789, to Schuermann, U.S. Pat. No. 5,635,693, to Benson et al., U.S. Pat. No. 5,661,473, to Paschal, U.S. Pat. No. 5,631,642 to Brockelsby, U.S. Pat. No. 6,025,774 to forbes. U.S. Pat. No. 6,069,570 to Herring. U.S. Pat. No. 5,986,543 to Johnson. U.S. Pat. No. 5,163,000 to Rogers U.S. Pat. No. 5,726,885 to Klein et al. each hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
[0031] The disadvantages and limitations of the background art discussed above are overcome by the present invention. With s invention, interacting electronic components are located in each motor vehicle to be monitored, in each parking slot at a location or lot such as, for example an motor vehicle dealership in which the motor vehicles may be stored, and at a base station from which the Electronic Vehicle Monitoring System of the present invention is to be operated.
[0032] A motor vehicle at the motor vehicle dealership contains a vehicle unit which is mounted in the motor vehicle and which includes a low power infrared or electromagnetic transmitter. The signal from the vehicle unit are short range directional so that they can only be received by a parking space unit when the motor vehicle in which the vehicle unit is mounted is parked in the park slot in which the parking space unit is mounted and a transceiver to receive and transmit RF signal which identifies the particular vehicle unit.
[0033] Each parking space unit which is located at each parking space in the motor vehicle dealership contains a Infrared or electro magnetic Receiver to receive infrared or electro magnetic signal from a motor vehicle unit parked in at that particular parking slot. A transmitter to transmit a radio frequency (RF) signal which identifies the particular parking space in which the parking space unit is located.
[0034] Thus when a motor vehicle is parked in a particular parking slot. Upon vehicle ignition is system is turned off the vehicle unit transmits a infrared or electro magnetic signal, the parking space unit receives the infrared or electro magnetic signal from the vehicle unit. The parking space unit upon receiving the infrared or electro magnetic signal transmits a RF signal identifying the particular parking slot in which the parking space unit is located. Additionally the vehicle unit upon vehicles ignition system being turned off transmits a secondary RF signal identify the particular vehicle unit.
[0035] In the present invention, the parking space unit also capable transmitting a RF signal identifying both the particular motor vehicle unit and particular parking space unit. In addition in the present invention plurality of parking slot space units could signal vehicle transceiver units, by means of a motion detector or pressure sensor switch installed in plurality of parking space. When a vehicle enters a particular parking space area, the sensor detects the vehicle movement and signals the parking space unit upon receipt the signal, transmits a RF signal identifying both the particular motor vehicle unit and particular parking space unit.
[0036] In a preferred embodiment of the present invention, the base station computer interface unit signals plurality of vehicles unit and the vehicle units signals a particular parking space unit. The parking space unit upon receiving the signal transmits an infrared or electromagnetic signal to a vehicle unit and the vehicle unit signals with an RF signal to a base station unit information containing both the particular vehicle unit and particular parking space unit.
[0037] The RF signal from each of the vehicle units and parking space units are provided to a base station transceiver unit which is connected to a computer to store and maintain information relating to the vehicle and its location.
[0038] The base station computer is capable of monitoring the presence and location of the vehicles located on the lot periodically at a set time by transmitting a RF signal to the vehicle and parking space units to send a RF signal back to base station unit containing information relating to the presence of particular vehicles and their locations.
[0039] In a second additional aspect of the present invention, the base station is capable of monitoring a motor vehicle on a lot without the use of parking space unit. In this aspect the base station computer can give a user information relating particular vehicles presence and absence on a lot for a particular time.
[0040] Optionally, additional features may be included in the vehicle unit, for example, a motor vehicle security system may be integrated into the vehicle unit, thus, for example, the vehicle unit may monitor access to the motor vehicle through the use of an ignition switch sensor, a motion sensor, or a door, hood trunk sensors etc. Motor vehicles lights and horn or an alarm siren may also be provided. The vehicle unit in the present invention is capable of signaling the base station unit. The presence of a security violation at least one of security violation taking place. The signal from the vehicle to base station is transmitted by a RF signal. In the present invention, the security violation signal should be transmitted to a base station by means of an auto dialer phone or a pager installed within the vehicle. The base station computer capable of transmitting RF signals containing special data to pre-selective motor vehicles containing a vehicle unit. Such data including commands to immobilize the vehicle engine lock or unlock doors, start the vehicle engine, arm & disarm the vehicle alarm system, and transmit vehicle ID information or control a car key track unit, giving access to vehicle key to authorized individual.
[0041] In the present invention plurality or vehicle could be equipped with a GPS antenna and the monitoring station could locate a particular vehicle location and in the event of security violation (such as a stolen vehicle) the base station could monitor the speed of stolen vehicle and shut down the particular vehicles ignition or fuel pump at a safe speed.
[0042] Additionally, a remote control may be provided for use purchaser of the vehicle to control the vehicle security system integrated into vehicle unit. In this case the vehicle unit will be of use in determining when the vehicle visits the motor vehicle dealership, for example, for service.
[0043] In an alternate embodiment, the parking space units may be hard-wired to the base station instead of using RF for these components to communicate with each other, if desired. It may therefore be seen that the present invention teaches an electronic vehicle monitoring system which will track the present location of each of a plurality, of motor vehicles at a location or lot such as, for example, a motor vehicle dealership. As such, the Electronic Vehicle Monitoring System of the present invention is capable of identifying the particular location of each motor vehicle at the location or lot. The monitoring of motor vehicle location at the location or lot be performed completely automatically by the Electronic Vehicle Monitoring System of the present invention, without requiring any information regarding location or movement of motor vehicles to be manually provided to the system when it is operating.
[0044] The Electronic Vehicle Monitoring System of the present invention is capable of automatically determining when each motor vehicle at the location or lot enters or leaves the location or lot without the use of gate units. Optionally the electronic vehicle tracking information system of the present invention is capable of providing additional features in the nature of a motor vehicle security system to each vehicle if desired.
[0045] Electronic Vehicle Monitoring system of the present invention is capable of determining when a vehicle transceiver or GPS unit has been tampered with. By the use of tamper proof switch on the mounting side of the vehicle and GPS unit, by sensing removal or tampering of the units from the vehicle. When such violation takes place, both the vehicle transceiver and GPS unit will transmit a signal to the vehicle ignition circuitry to immobilize the vehicle engine, honk the car horn, flash the lights and transmit said security violation signal to a monitor station.
[0046] The Electronic Vehicle Monitoring System of the present invention is both durable and of long lasting nature, and it will require little or no maintenance to be provided by the user through out its operation lifetime. The Electronic Vehicle Monitoring System of the present invention is also of relative inexpensive construction to enhance its market appeal and to thereby afford it the broadest possible market. Finally all of the aforesaid advantages and objectives of the Electronic Vehicle Monitoring System of the present invention are achieved without incurring any substantial relative disadvantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] [0047]FIG. 1—Is General Block Diagram of Electronic Vehicle Monitoring System.
[0048] [0048]FIG. 2—Is a Electronic Vehicle Monitoring System, wherein a vehicle transceiver unit initiating a signal to a parking space transceiver unit, and parking space and vehicle transceiver unit communicating with the base computer.
[0049] [0049]FIG. 3—Is an Electronic Vehicle Monitoring System, wherein Parking space transceiver unit, initiating a signal to a vehicle transceiver unit. The vehicle and the parking space transceiver unit communicating with the base station computer connected to a electronic Key Track system.
[0050] [0050]FIG. 4—Is an Electronic Vehicle Monitoring System, wherein a vehicle transceiver unit communicating with a parking space transceiver unit. And the vehicle transceiver unit is communicating with the base station computer.
[0051] [0051]FIG. 5A—Illustrates tamper proof adhesive mount vehicle RF transceiver unit.
[0052] FIG. B—Illustrates tamper proof magnet or bracket mount vehicle RF transceiver and GPS based cellular or satellite transceiver unit.
[0053] FIG. C—Illustrates side view of FIGS. A and B
[0054] FIG. D—Illustrates, tamper proof rear view mirror, in it vehicle RF transceiver and GPS antenna with mobile phone transceiver system.
[0055] [0055]FIG. 6A—Illustrates, tamper proof vehicle transceiver unit mounted into a vehicle windshield or mirror.
[0056] FIG. B—Illustrates, a tamper proof vehicle transceiver with GPS unit mounted on a vehicle with bracket or magnet.
[0057] [0057]FIG. 7—is the base station computer database.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0058] The preferred embodiment of the electronic vehicle monitoring system is illustrated in the FIG. 1—Block diagram. Indicating a base station computer 21 , which is the main control center, contains all necessary data to communicate with base station transceiver unit 20 . Which, is used to receive data. Log in parking space and vehicle location information, and initiate commands. And to communicate with electronic Car Key Track system 24 , to keep all Key Track and user records and provide vehicle location info to said Key track machine 24 , which displays the information on the Key Track monitor 29 . The base station transceiver 20 communicates with vehicle transceiver unit 23 , which sends and receive vehicle and parking space unit data through RF signal. The invention uses a Base station transceiver unit 20 , to communicate with parking space transceiver unit 22 , by sending a signal to parking space unit 22 and receiving back parking space 22 and vehicle transceiver unit 23 data with an RF or hard wire signal. The communication between the vehicle transceiver unit 23 , and the parking space unit 22 , is performed through a directional infrared and or RF electromagnetic Transceiver unit 30 . In the present invention, the parking space unit 22 , could be connected to a motion sensor 40 , or a switch sensor 41 , to determine the presence of a motor vehicle at a particular parking space, and the sensors 40 and 41 communicating with the parking space transceiver unit 22 , to generate a communication link with the vehicle transceiver unit 23 , parked in at that particular parking space. The present invention in addition to RF communication, for additional distance coverage and security, utilizes the mobile phone or radio pager unit 28 , to receive and transmit data between the base station computer unit 21 , and the vehicle transceiver unit 23 . In addition a GPS antenna receiver unit 50 , is connected to the mobile phone/radio pager unit 28 , which transmits vehicle location information to the monitoring station. The GPS antenna unit 50 , could be connected directly to vehicle RF transceiver unit 23 , in which vehicle location data will be transmitted via a mobile phone/radio pager unit 28 to a base station 21 , or vehicle location information could be sent to a monitoring station.
[0059] The Electronic Vehicle Monitoring system's vehicle transceiver unit 23 used in the invention, by receiving commands from base station computer 21 , is capable of controlling the vehicles lights 12 , horn 13 , engine immobilization 18 , central door locking/unlocking 14 , and report an intrusion alarm to a base station computer by use of. Door switch sensor 15 , voltage drop sensing circuitry 16 , and shock or motion sensor 17 circuitry.
[0060] Operation: As shown in FIG. 2 Shows plurality of parking spaces on a lot, having plurality of parking space transceiver units 22 , 42 , 62 . Equipped with infrared or RF electromagnetic receivers, and a low power RF or hardwire transceivers. A vehicle 56 , equipped with a unidirectional infrared or electromagnetic transmitter and an RF low power transceiver unit 23 , a Base station transceiver 20 , interfaced to a computer 21 communicating with said parking space transceiver units and said vehicle transceiver units.
[0061] A vehicle 56 , equipped with a vehicle transceiver unit 23 signaling with unidirectional short range (6-8 feet) infrared or electromagnetic coded signal 30 , to a parking space transceiver unit 22 , located on parking space 22 , to indicate its presence. And the parking space transceiver unit 22 , upon receiving said signal, transmitting through RF or hardwire a coded signal 52 , containing information for both particular motor vehicle unit 23 and particular parking space unit 22 , to a base station transceiver unit 20 , which is interfaced to the base station computer 21 , in which logs in its database said particular vehicle 56 presence, time entered, and vehicle info. Along with the particular parking space information that said vehicle 56 is parked in.
[0062] The vehicle transceiver unit 23 periodically or at time interval transmitting a signal to said parking space unit 22 . And said parking space unit 22 upon receiving said signal, transmitting said particular vehicle unit 23 and parking space transceiver unit 22 information to said base station transceiver unit 20 , to update said computer database automatically, with the information relating to the presence of the particular motor vehicle 56 at the particular parking space 22 . In the present invention, the base station computer can retrieve a particular vehicle location at a particular parking space in a lot, at any given time, by sending manual or automatic (scan) vehicle location commend signal, through an RF or Hardwire signal 51 . If the vehicle 56 departs from the particular parking space 22 , the base station computer 21 , manual or automatic scan command can not communicate with a vehicle mount transceiver unit 23 , the computer database deletes said vehicle 56 from it's database, as vehicle no longer being in the inventory system. If the Base station computer 21 cannot communicate with the vehicle transceiver unit 23 , more then 2 intervals, due to vehicle were removed without prior vehicle removal entry into the base station computer database. The base station computer will initiate an alarm signal, and send said security violation signal to a central monitoring station or to a public pager network.
[0063] The present electronic vehicle monitoring system is also capable of, as such, if and when a vehicle is parked in a lot wherein there are no parking space transceiver units. Said vehicle upon its ignition being turned off or emergency brake being pulled off, transmits an RF coded signal 10 indicating its presence on a lot. Said lot base station transceiver unit 20 receiving said vehicle transceiver unit signal, and the base station computer 21 interface logs said particular vehicle 56 info into it's database. The base station computer 21 initiates random or at time interval RF coded signal 11 through said base station transceiver unit 20 , to communicate with a particular motor vehicle 56 transceiver unit 23 to verify the presence of the particular vehicle on the lot. If more then 2 intervals of communication attempt by the base station computer 21 does not generate a successful link between the base station computer 21 and the vehicle transceiver unit 23 , the computer indicates the departure of the particular vehicle 56 from its inventory system. If and when the base station computers 2 interval communication attempts cannot communicate with the particular vehicle transceiver unit 23 , due to vehicle was removed from the lot without prior removal authorization data entry into the computer. The computer 21 will initiate an alarm signal.
[0064] In the present invention, the vehicle RF transceiver unit 23 optionally is equipped with an intrusion alarm. The base station is capable receiving any security violation RF signal 10 from a vehicle transceiver unit 23 parked on the lot, such as a intrusion alarm, unauthorized vehicle door been open, a shock sensor being triggered, unauthorized vehicle ignition is being turned on or vehicle voltage drop sensed due to a vehicle door being open, or ignition being turned on. In the present invention the base station computer 21 is capable of sending RF signal 11 , to a particular vehicle unit 23 , on a lot to Lock/unlock the doors, to flash the lights, to honk the horn and immobilize vehicle engine.
[0065] [0065]FIG. 3 Describes an Electronic Vehicle Monitoring system wherein a plurality of parking space transceivers units are installed at a particular parking space 22 , 42 , and 62 . Parking space transceiver 22 is equipped with unidirectional Infrared or electromagnetic transmitter, and an RF low power transceiver. Parking space transceiver 42 additionally is equipped with a motion sensor 40 . Parking space transceiver unit 62 is equipped with a pressure-sensing switch. A vehicle 56 is equipped with a vehicle transceiver unit 23 , having a RF infrared or electromagnetic receiver and a low power RF transceiver. In addition the vehicle transceiver unit 23 is connected to a mobile phone/radio pager 28 with GPS antenna receiver unit 50 . A base station transceiver 20 interfaced to a computer 21 , which is connected to an electronic Key Track unit 24 . The base station computer 21 communicates with said parking space units, vehicle transceiver units and Electronic Key Track unit 34 .
[0066] A parking space unit 22 transmitting a unidirectional infrared or electromagnetic coded constant or time interval signal. And a vehicle 56 equipped with an infrared or electromagnetic receiver unit 23 , receiving said signal 31 , and transmitting said data with a low power RF signal 10 , containing information to both to the parking space transceiver unit 22 , and vehicle transceiver unit 23 , to a base station computer transceiver interface. Which upon receipt of said signal logs in, the particular vehicle 56 and parking space 22 info into its memory and displays said information on its monitor. The base station computer 21 can update itself the presence or absence of a particular vehicle 56 at a particular parking space 22 by means of, sending coded signal to the particular vehicle transceiver unit 23 via base station transceiver 20 . By signaling with an RF or hardwire random or time interval (scan) signal 51 to the parking space unit, and said parking space unit 22 retrieving data from said vehicle mount transceiver unit 23 . The base station computer 21 also can retrieve data directly from the vehicle transceiver unit 23 , by means of, the base station computer 21 sending random or time interval RF signal 11 to a particular vehicle transceiver unit 23 and said vehicle transceiver unit 23 upon receipt of said signal, sends an RF signal 10 , containing information for both vehicle and parking space transceiver unit.
[0067] The invention utilizes an additional method for signaling a vehicle transceiver unit. Such as, the parking space transceiver 42 is connected to a motion sensor, when a vehicle 56 enters the particular parking space 42 , the motion detector 40 senses the presence of the motor vehicle 56 and the parking space transceiver unit 42 transmits a directional infrared or electromagnetic signal to the vehicle transceiver unit 23 . The invention also teaches another method of signaling a vehicle unit, which is illustrated in FIG. 3 where the parking space unit 62 , is connected to a pressure-sensing switch 41 , when a motor vehicle 56 enters the particular parking space 62 , upon vehicle rolling over the pressure-sensing switch 41 . the parking space transceiver unit 62 , transmits a direction infrared or electromagnetic signal, to the vehicle transceiver unit 23 .
[0068] The Electronic Vehicle monitoring system of the present invention Additional to the use of RF transceiver unit 23 , uses a GPS based 50 cellular phone or pager modem unit 28 , for base station be able to communicate and locate the motor vehicle location. Especially when the motor vehicle(s) 56 to be monitored is out of particular parking space on the road. Where low power RF transceiver communication range becomes un Useful. The RF transceiver 23 , GPS 50 , mobile phone/pager modem unit 28 , used in the invention are of tamper proof and each one of said units are equipped with a pressure sensing tamper switch 70 FIG. 5-A. And the tamper switch sensing side of the units are mounted against the vehicle windshield 22 FIG. 6-A, or mounted within rear view mirror 81 FIG. 6-A and or mounted against the vehicle body 24 FIG. 6-B. Said vehicle RF transceiver or GPS/phone units are communicating with an RF or hardwire signal with vehicle mount Immobilizer circuitry. If and when an attempt is been made to tamper or remove the vehicle mount RF transceiver 23 or GPS 50 , mobile phone/pager modem 28 , the vehicle will be immobilized, Such as Gradual fuel pump cut off, starter interrupt, Ignition Immobilization Etc.
[0069] The Electronic vehicle monitoring system in addition is capable of controlling an Electronic Key Track unit 24 . Which is equipped with a Keybord 17 for user to select desired vehicle, a monitor 27 to indicate vehicle information and location on the lot, and a user Finger print Bio-optic reader 25 , and RFID (transponder) key reader 19 . When an authorized person put their finger on Key Track finger read bio-optic scanner 25 The bio-optic scanner upon reading persons valid (pre-programmed) fingerprint pattern. The Key Track unit displays on its monitor 27 for user to enter a selected vehicle ID number by use of keyboard 17 . The Key Track unit 24 upon receipt of selected vehicle ID code dispenses the chosen vehicle key containing RFID tag. Said vehicle Key RFID Tag information is read by said Key Track RFID Key Tag reader 19 , and said Key Track unit indicates a particular vehicle key being checked out from its inventory. And logs inn in the computer memory the person ID information, which who took a particular vehicle key at a particular site at a particular time. When the user dispenses back the vehicles key in the dispenser 82 . The Key Track unit reads the key RFID information and logs back in it's inventory the presence of a particular vehicle key, and time stamps the key return event in it's memory.
[0070] Additionally the Key Track unit 34 is equipped with a microphone 33 , a voice recognition processor and a speaker 34 , used to give verbal instruction to the user. For user identification it utilizes user voice recognition technology. User gives its given password (pre-Recorded) through said microphone 33 . Upon user voice recognition, The Key Track unit 24 allows the user to gets access into selecting to receive a vehicle key. In the preferred embodiment of the present invention, user gives verbal commends in said microphone 33 , to select a particular vehicle and receive the particular vehicle key without the use of the keyboard.
[0071] The invention also teaches another practical method of determining the presence of motor vehicle at a particular parking space on a lot. As illustrated in FIG. 4 there are plurality of parking space unit 22 , 42 , and 62 . A vehicle 56 equipped with Directional Infrared or electromagnetic transceiver unit and an RF low power transceiver unit 23 , and a base station transceiver unit 20 with an antenna 98 , interfaced with a computer 21 . A vehicle 56 entering a particular parking space 22 , the particular vehicle transceiver unit 23 is transmitting a directional Infrared or electromagnetic signal. The parking space transceiver unit 22 receiving said signal and upon receipt is transmitting a unidirectional infrared or electromagnetic coded signal towards the vehicle transceiver unit. The vehicle transceiver unit 23 , upon receipt of said signal, said vehicle transceiver unit 23 is transmitting a RF low power signal containing information to said parking space unit 22 and to said vehicle transceiver unit 23 , to a base station transceiver unit which is receiving said signal using an antenna 98 . Said base station transceiver 20 computer interface 21 unit upon receipt of said signal, logs in the presence of said vehicle 56 and the parking space 22 information in its database memory.
[0072] AS shown in FIG. 5-A the vehicle transceiver 23 of the present invention is tamper proof Having a pressure sensing tamper switch 70 . Protected by a protection metal “O” ring 74 And is mounted against the vehicle windshield or on to the vehicle body, by use of Velcro or double sided tape 72 . And has an infrared Diode 71 , opening to communicate with parking space units. And has an antenna 73 , to communicate with base station computer interface unit. As shown in FIG. 5-B the vehicle transceiver in addition has a built-in GPS receiver antenna 78 , and instead of Velcro mounting tape the system utilizes a magnet 77 , for mounting the unit against vehicle body. And the unit can be mounted by use of mounting bracket 76 . In the as shown in FIG. 5-B the vehicle transceiver unit utilizing the electromagnetic transceiver 75 . The transceiver, the GPS antenna and the mobile phone/pager unit utilized in the present invention could be implemented in a vehicle with highly undetectable by thieves. By incorporating into a rearview mirror as shown in FIG. 5-D
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An Electronic Vehicle Monitoring System and Related method for tracking the location of the location of motor vehicles, is disclosed which tracks the location of plurality of motor vehicles at a particular location, to ascertain the exact position at which any motor vehicle is parked. The system of the present invention also automatically determines, when each motor vehicle at a location enters or leaves the location or a particular area. The system of the present invention also automatically determines which of plurality of motor vehicles having a security violation. In addition the system immobilizes the vehicle if tamper to the vehicle mount Transceiver CPU or GPS system is detected, and report said violation to a monitoring station. The system also utilizes an Electronic Key Track
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns a device for forming a shed in weaving machines, in particular of the type which consists of harnesses and drive means to move the harnesses to and fro.
2. Description of Related Art
In the case where a method and a device are applied as described in Belgian patent No. 903.190, whereby a part of the weaving machine is replaced in order to change an article, the present invention offers the advantage that such a change of an article can be carried out even faster.
SUMMARY OF THE INVENTION
An objective of the invention is to provide a device which allows height adjustment of the harnesses in relation to their drive means to be carried out in a simple manner.
Another objective of the invention is to provide a device which allows that the harnesses can be coupled and uncoupled in relation to their drive means in a simple and fast manner, such that the harnesses can be easily dismounted.
Another objective of the invention is to provide a device whereby the drive means for the harnesses can be mounted in such a way that they do not obstruct the insertion of the cloth roll deeper into the weaving machine, which provides considerable space saving.
Another objective of the invention is to provide a device which allows the harnesses to be mounted very close to one another, so that not only the above-mentioned drive means but also the harnesses can be built into a limited space.
To this end the invention provides a device for forming a shed, consisting of a harness and accompanying coupling elements to couple the harness to the drive means and, characterized in that it is provided with setting means at the side beams of the harness which allow for an individual setting of the harness in relation to its coupling elements.
By permitting the height adjustment to be done on the harness itself, offers the advantage that the height adjustment can be done when the harness is inside as well as outside the weaving machine.
Preferably, these setting means consist of setting screws which have been integrated into the side beams of the harnesses and which are accessible at their tops to do a setting.
As these setting means are mounted at the height of the side beams, they do not occupy any additional space and they are easily accessible.
Preferably, the device is also provided with coupling means which allow to coupling and uncoupling of the harnesses to the drive means in a simple way.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better explain the characteristics of the invention, by way of example only and without being limitative in any way, the following preferred embodiment is described below with reference to the accompanying drawings, where:
FIG. 1 shows a schematic representation of a weaving machine;
FIG. 2 shows a schematic representation of a device according to the invention;
FIG. 3 shows a view of the part indicated in FIG. 2 by F3, to a larger scale and partly in cross-section;
FIG. 4 shows a view of the part indicated in FIG. 2 by F4, in perspective;
FIG. 5 shows a view according to arrow F5 in FIG. 3;
FIG. 6 shows an embodiment of the drive means of the device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to illustrate the invention, FIG. 1 shows a schematic representation of a weaving machine in which a number of parts have been indicated, such as the frame 1, the warp beam 2, the warp threads 3, the device 4 for forming the shed 5, the sley 6 with the reed 7 in order to strike the weft threads inserted in the shed 5 against the cloth line 8, the weave 9 and the cloth beam 10 to wind the weave 9.
As is known and as shown in FIGS. 1 and 2, the above-mentioned device 4 mainly consists of at least two harnesses 11, guide pieces 12 and 13 along which the harnesses 11 can be moved, and drive means 14 to move the harnesses 11 to and fro, usually up and down.
The harnesses 11 consist of side beams 15 and 16 which are connected by a top beam 17 and a bottom beam 18. In each harness 11 a number of heddles 19 are mounted which are each provided with a thread eye 20 through which a warp thread 3 is guided.
In certain applications it is desirable to move the path A over which the harnesses are moved to and fro by adjusting the height of the harnesses relative to the drive.
This is the case for example when the weaving surface 21, which is horizontal in FIG. 1, is slanted by moving the back rest 22 up or down. This is also the case for special weaving techniques whereby the middle of the path A may not coincide with the weaving surface 21. In order to realize this, a height adjustment of the harnesses 11 is necessary.
According to the invention, use is made to this end of a device 4 for forming the shed 5 which has the characteristic that at the height of the side beams 15 and 16 of the harnesses 11, setting means 23 are provided which allow for an individual, preferably continuous, height adjustment of the harnesses 11 in relation to their drive means 14, in particular in relation to the coupling elements described below by which the harnesses 11 are coupled to the drive means 14.
As shown in FIGS. 2 and 3, these setting means 23 preferably consist of setting screws 24, such that by turning these setting screws 24 the harnesses 11 can be set higher or lower.
Setting screws 24 are preferably integrated in the side beams 15 and 16. In the example shown the setting screws 24 consist of rods which go through the side beams 15 and 16, which are coupled to the drive means 14 at their lower ends 25 in a freely turnable manner, and which are provided with a screw thread 26 which cooperates with the screw thread 27 in a bore hole 28 in the underside of the side beam 15 or 16 concerned.
Each setting screw 24 is accessible at the top of the harnesses 11 and is provided with an element 29 which allows an operator to turn the setting screw 24, such as a rotary button or a knob into which a key or device similar fits. The height adjustment can be read from a scale 30 which is mounted next to each element 29.
As a result, height adjustment of the harness is possible when the harness is inside as well as outside the weaving machine.
In order to lock the harnesses in relation to the setting screws 24, each setting screw 24 is also provided with a lock nut 31 which cooperates with a screw thread part 32 and which can be tightened against the top of the side beam 15 or 16 concerned. Between the side beam 15 or 16 and the lock nut 31 a joint in the shape of a washer can be provided.
According to the invention, coupling means 33 which allow the harnesses 11 to be detached from the drive means 14 are provided preferably on either side underneath the side beams 15 and 16. The coupling means 33 are designed such that the harnesses 11, when being mounted, can first be put down and then coupled to the drive means 14 by a shift sideways.
To this end the coupling means 33 mainly consist, as shown in FIGS. 2 to 4, of a first coupling element 34 which is fixed to the drive means 14 and a second coupling element 35 which is connected to the harness 11 concerned and which can act upon the first coupling element 34.
As shown in FIG. 4, each first coupling element 34 has a supporting plane 36 and a hook 37. The hook 37 is formed by an upright part 38 and a fork-shaped part 39 running parallel to the supporting plane 36. As shown in FIG. 3, the supporting plane 36 is longer than the above-mentioned part 39, namely over the indicated distance D.
The second coupling element 35 mainly consists of a first part 40 formed by the end 25 of the setting screw 24 concerned, which fits into the fork-shaped part 39 and a second part 41 which is connected to the first part 40 and which has the shape of a broadened head which fits into the opening 42 of the above-mentioned hook 37 and acts upon the back of the teeth of the fork-shaped part 39.
According to a variant, the parts 40 and 41 may be formed of an element which is fixed to the ends 25 of the setting screws 24.
As shown in FIG. 2, the hook-shaped parts 39 on either the right and left side of the harnesses 11 are pointed towards the same side, such that the harnesses 11 with the second coupling element 35 can be lowered onto the supporting planes 36 and coupled to the first coupling elements 34 by a sideways shift.
FIG. 2 shows the situation whereby the harnesses 11 have just been lowered, but not yet coupled. FIG. 3 shows the situation whereby the harnesses 11 are coupled to the drive means 14.
It is clear that the device according to the invention is hereby also provided with means 43 which allow the harnesses 11 to be moved sideways. To this end the above-mentioned guide pieces 12 and 13 have guide elements 44 for the harnesses 11 which are in turn mounted into guide pieces 45 which form a portion of part 46 of the frame 1. The guide elements 44 have ribs 47 which fit into grooves in the edges of the side beams 15 and 16. The guide elements 44 can be moved sideways and positioned in relation to the part 46 of the frame 1, for example by means of adjusting means 48 mounted on either side of the harnesses 11.
The above-mentioned construction is very advantageous in weaving machines which, as described in Belgian patent No. 903.190, have a frame 1 which, as is also indicated in the present FIGS. 1 and 2, consists of a fixed part 49 and a detachable part 46, whereby in the detachable part 46 at least the harnesses and the warp beam 2 are mounted. When the above-mentioned part 46 is removed, according to the present invention, the harnesses can be uncoupled from the drive means 14 in a very simple manner by moving them sideways. In order to prevent the harnesses 11 from falling out of the guide elements 44 when the part 46 of the frame 1 is lifted, locking elements 50 can be mounted between the guide elements 44 and the harnesses 11, such as cables which hold the harnesses 11.
As shown in FIGS. 2 and 4, the drive means 14 have elements 51 which are moved up and down by means of lever arms 52 driven to and fro. The elements 51 are at their top end connected to a part 53 which can be moved in guide pieces 54. By the turning of the lever arms 52 the elements 51 make an arched shift at their bottom ends, changing the angle between the elements 51 and the parts 53. In order to compensate for this change of angle an elastically bendable leaf 55, for example a leaf spring, is provided between the elements 51 and the parts 53. The use of such leaves 55 has the advantage that, contrary to the use of hinge clutches, the elements 51 remain very narrow and the harnesses 11 can be mounted very close to one another.
FIG. 4 shows only one element 51 and one lever arm 52. However, several elements 51 can be coupled to the lever arm 52 in order to move different harnesses 11 at the same time. In addition, as shown in FIG. 6, a second lever arm 56 is provided on either side of the harnesses 11 which makes an opposite movement in relation to lever arm 52, so as to drive those harnesses 11 which move in an opposite direction relative to the harnesses 11 which are coupled to the lever arms 52.
The drive of the lever arms 52 and 56 can be done arbitrarily. For the sake of completeness an example is shown in FIG. 6.
The lever arms 52 and 56 are driven in opposite directions via connecting rods 57 and 58 by means of cranks 59 and 60 which are fixed to a turnable shaft 61. The shaft 61 is moved to and fro by means of a crank 62 and a rod 63 which is connected to a crank mechanism 64.
The rods 57 and 58 can be coupled in various places, 65-66 ana 67-68 respectively, to the lever arms 52 and 56. In addition, the cranks 59 and 60 can be fastened to the shaft 61 at various angles. By switching the rods 57 and 58 or replacing them by others and by turning the cranks 59 and 60 in relation to the shaft 61, another type of motion can be obtained for the harnesses 11 which can provide for a symmetrical as well as an asymmetrical movement. In other words, the crossing line of the warp threads 3 can be made to either coincide or not coincide with the above-mentioned weaving surface 21.
The course of the cranks 59, 60 and 62 can be changed by means of setting means 69.
As shown in FIG. 6, use can hereby be made of a weaving machine with three drive shafts 70, 71 and 72, which in the example shown are coupled such that the middle shaft 71 turns half as fast as the two other shafts 70 and 72.
The middle shaft 71 drives the crank mechanism 64. The shaft 70 provides for the drive of the sley 6.
In the example shown, the shaft 70 is driven via a main clutch 73 by a main drive motor 74. The shaft 72 can also be driven via a slow motion clutch 75 by means of an auxiliary drive motor 76, whereby the clutch 73 is declutched.
According to a variant, the auxiliary drive motor 76 and the slow motion clutch 75 are not present.
According to yet another variant, the main drive motor 74 is coupled directly to the shaft 72, without making use of a main clutch 73, an auxiliary drive motor 76 and a slow motion clutch 75.
It is clear that for driving the harnesses 11 it is not necessary to make use of the mechanism shown in FIG. 6, as other means can be used to the same effect. These means may for example consist of a classic dobby, an outside cam motion or a jacquard mechanisms and can for example be coupled to the shaft 72 via a pick find clutch and a transmission. The pick find clutch may be situated at the height of the slow motion clutch 75, as shown in FIG. 6, such that the auxiliary drive motor 76 can either drive only the means for the drive of the harnesses 11 via the slow motion clutch 75, or the entire weaving machine via the above-mentioned pick find clutch.
According to a variant, the main drive motor 74 can also be coupled directly to the above-mentioned means for the drive of the harnesses 11 and provide for the drive of the entire weaving machine via the above-mentioned pick find clutch.
It is clear that the present invention also concerns a device whereby the above-mentioned coupling elements, with which the harnesses are coupled to their drive means, are of another type than those shown in the figures, for example of the type whereby the coupling elements are fixed to the drive means 14.
The present invention is in no way limited to the embodiment described by way of example and shown in the accompanying drawings; on the contrary, such a device for forming a shed in weaving machines can be realized in various forms and dimensions while still remaining within the scope of the invention.
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A device for forming a shed in weaving machines includes a harness and coupling elements for coupling the harness to a drive mechanism. The height of the harnesses is made adjustable by mounting respective coupling elements on setting screws integrated into the side beams of the harness elements and movable relative to the side beams for enabling individual height adjustment of each harness element relative to its coupling element. Because the height adjustment is done on the harness itself, the height adjustment can be done when the harness is inside as well as outside the weaving machine. The setting screws extend through the side beams to the coupling elements, which are situated below the harness, adjustment being effected by turning the screws from the top of the side beams to move of the harness up and down relative to the ends of the setting screws and coupling elements coupled thereto at the bottom of the side beams.
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BACKGROUND OF THE INVENTION
The present invention relates to a ribbon-weaving loom construction, and more particularly to a ribbon-weaving loom construction wherein two or more ribbons are being woven simultaneously and must be withdrawn in substantial parallelism.
In circumstances where a single ribbon is being woven on a loom, the withdrawal of the woven ribbon presents no difficulty because the ribbon is withdrawn over a breast beam or a roller or a shaft replacing the breast beam in downward direction, and is then engaged by a withdrawing roller cooperating with a counterpressure roller. Each ribbon is associated with a separate withdrawing arrangement, or else two or more ribbons (located laterally adjacent one another) can be withdrawn by a single withdrawing arrangement.
However, there are ribbon weaving looms where two or more ribbons are being woven simultaneously and are so located relative to one another that they must be withdrawn in parallelism. If under these circumstances the ribbons are supplied in overlying relationship to the breast beam or the roller replacing it, various disadvantages are experienced. The outermost ribbon of the overlying ones particularly if the ribbons are relatively thick, will be withdrawn more rapidly than the innermost ribbon because the thickness of the ribbon becomes added to the diameter of the withdrawing roller and thus the radius of the withdrawing roller is in effect increased by the thickness of the innermost ribbon, which explains why the outermost ribbon will be withdrawn faster.
An additional drawback is the fact that the outermost ribbon is not in contact with the withdrawing roller, which is usually provided with a friction-promoting coating or surface, since the innermost ribbon is interposed between the withdrawing roller and the outermost ribbon. This means that slippage of the outermost ribbon with reference to innermost ribbon can occur, especially if the ribbons are of relatively smooth or slippery material. This, in turn, can result in qualitative problems.
The prior art has recognized these difficulties and has proposed to supply ribbons which issue from the loom in parallelism and substantially overlying relationship, to the breast beam or the withdrawing arrangement in a slightly converging manner so that they will contact the breast beam or the withdrawing roller not in overlying relationship but in side-by-side relationship. This does avoid the disadvantages which have been outlined above, but it brings with it a new problem, namely the ribbons will become laterally stretched so that they are no longer straight in that the material of the ribbons is stretched more along one lateral side than the other.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a ribbon-weaving loom construction of the type wherein at least two ribbons are being woven simultaneously and must be withdrawn in substantial parallelism, which avoids these disadvantages.
Still more particularly, the invention aims to provide such a ribbon-weaving loom construction which assures a completely uniform and even withdrawal of the ribbons.
In keeping with these objects and with others which will become apparent hereafter, one feature of the invention resides in a ribbon-weaving loom, in which at least two ribbons are being woven simultaneously and must be withdrawn in substantial parallelism. In this construction, the invention provides a combination which comprises at least one withdrawing roller for each of the ribbons and about which the respective ribbon is trained so that the roller is located beneath the ribbon, and means for rotating the respective rollers. It is advantageous that the rollers all are of identical diameter, that they be jointly driven so that the rate of withdrawal for all of the overlying ribbons is exactly uniform. Of course, if several ribbons are located laterally adjacent one another and in effect form one layer of ribbons, and another layer or additional layers overlie the first layer, then the rollers for each layer can of course be mounted on a common shaft or they can be of one piece with one another. Each roller can be associated with a breast beam or with a ribbon reversing roller and with a pressure roller.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic side view illustrating one embodiment of the present invention, for two overlying ribbons and without the use of breast beams;
FIG. 2 is a view similar to FIG. 1 but illustrating an arrangement for three overlying ribbons;
FIG. 3 is a view similar to FIG. 1 but illustrating a different embodiment using breast beams and a distance roller or spacing roller for the upper ribbon;
FIG. 4 is a vertical section on line A--A of FIG. 1 but illustrating a somewhat modified embodiment; and
FIG. 5 is a view similar to FIG. 4 but illustrating still another modified embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
I wish it to be understood that the drawings show the various embodiments in diagrammatic illustrations. It is believed that this is entirely sufficient for persons of ordinary skill in the art to understand and be able to practice the invention, inasmuch as the construction and operations of ribbon-weaving looms per se is conventional and well-known to those having skill in this art.
With the above comments in mind and referring firstly to FIG. 1, it will be seen that reference numeral 1 identifies a sley which pivots about the axis 2 as indicated by the double-headed arrow X. Two overlying warps 3, 3' are provided into which needles or shuttles insert the weft thread in a manner not illustrated because it is entirely conventional. The thread is beaten up by the reed 4. This results in the production of two ribbons 5, 5' of which the ribbon 5 is located above the ribbon 5'.
The lower one of these ribbons, namely the ribbon 5, is directly trained about a withdrawing roller 6 against which it is pressed by the counterpressure roller 7, to subsequently descend under the influence of gravity into a non-illustrated bin or the like. The upper ribbon 5' is trained about a withdrawing roller 6' against which it is pressed by a counterpressure roller 7' to also descend downwardly. The rollers, 7, 7' are rotatable about axes 10, 10', respectively, and the rollers 6, 6' are rotatable about axes 9, 9', respectively.
The embodiment in FIG. 2 is substantially the same as in FIG. 1, except that here three warps 13, 13', and 13" are provided. The operation of the sley and the reed is the same as before, and in this embodiment three ribbons 15, 15' and 15" are being produced. The lower ribbon 15' is trained about and withdrawn via the withdrawing roller 16 which cooperates with a counterpressure roller 17, the intermediate ribbon 15' is trained about and withdrawn by the roller 16' which cooperates with a counterpressure roller 17', and the upper ribbon 15" is trained about and withdrawn by withdrawing roller 15" which cooperates with counterpressure roller 17".
FIG. 3 shows an embodiment in which, as in the case of FIG. 1, two warps 23, 23' are provided from which two ribbons 25, 25' are produced in the same manner as in FIG. 1. In FIG. 3, however, the ribbons 25, 25' are each deflected around a breast beam 28, 28', which in the illustrated embodiment is configurated as a deflecting or reversing roller. Subsequently, the ribbons 25, 25' pass onto the withdrawing rollers 26, 26' which cooperate with the counterpressure rollers 27, 27'.
In addition, the embodiment of FIG. 3 provides for the upper ribbon 25' a distancing or spacing roller 30 which is spaced from the beating-up location by the same distance as is the breast beam 28. The roller 30 cooperates with two counterrollers 31, and is driven in rotation by the roller 26' or the shaft 29' of the latter, via a drive belt 32 or the like. This particular measure has been found to be of advantage if the ribbons 25, 25' are of such nature as to exhibit a certain elasticity, because this can mean that the degree to which the ribbons 25, 25' can stretch would be of differential magnitude. This, in turn, would mean that the density of the weave would differ in the two ribbons. The problem is avoided by the use of the spacing roller 30, which incidentally an also be used in the embodiment of FIG. 1; in the latter case the spacing roller would have to be spaced from the beating-up location by the same distance as is the roller 6.
FIG. 4 shows that two or more ribbons can be located laterally adjacent one another. Thus, in the embodiment of FIG. 4 it is shown that several of the ribbons 5 are located laterally adjacent one another, and of course another layer (only diagrammatically illustrated) is represented by the overlying ribbons 5'. In such an arrangement the withdrawing rollers associated with the respective layer of ribbons can be mounted on a common shaft being laterally adjacent one another. In FIG. 4 this has been shown by illustrating two withdrawing rollers 6, and their associated counterpressure rollers 7, with the withdrawing rollers 6 being mounted on a common shaft 9, and the rollers 7 on a common shaft 10. The same would be true of the rollers 6' and 7' which have not been illustrated in FIG. 4.
FIG. 5, finally, shows still another embodiment analogous to that of FIG. 4, but indicating that instead of providing separate rollers 6, and 7 for the individual ribbons of a layer, the rollers 6 for the various ribbons of the layer and the associated rollers 7, can be made of one-piece with one another. Only the rollers 6 and 7 are shown for ribbons 5, although it should be understood that similar rollers 6' and 7' will be provided for the diagrammatically illustrated layer of ribbons 5'.
With the present invention it is possible to withdraw two or more ribbons entirely uniformly and to avoid, in particular, an irregular density of the weave. Moreover, with the arrangement of the present invention access to the loom from the front and viewing of the loom is in no way subject to interference. Since, there is no lateral shifting of the ribbons as they are being withdrawn, but instead, all ribbons are being withdrawn in a perfectly straight line from the loom to the respective withdrawing roller, there is no possibility that the ribbons might become twisted or unevenly pulled and thus damaged or at least reduced in quality.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a ribbon-weaving loom withdrawing arrangement, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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In a ribbon-weaving loom, in which at least two ribbons are being woven simultaneously and must be withdrawn in substantial parallelism, at least one withdrawing roller is provided for each of these ribbons and so located that the respective ribbon is trained about it with the roller being located beneath the ribbon. A drive arrangement is provided for driving the respective rollers.
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FIELD OF THE INVENTION
[0001] The invention is in the field of methods and systems of delivering messages between computer programs via a message server. This invention more specifically pertains to the field of Message Oriented Middleware (MOM).
BACKGROUND OF THE INVENTION
[0002] MOM enables multiple computer programs to exchange discrete messages with each other over a communications network. MOM is characterized by ‘loose coupling’ of message producers and message consumers, in that the producer of a message need not know details about the identity, location or number of consumers of a message. Furthermore, when an intermediary message server is employed, message delivery can be assured even when the ultimate consumers of the message are unavailable at the time at which it is produced. This can be contrasted with Connection Oriented Middleware, which requires a computer program to have details of the identity and network location of another computer, in order that it can establish a connection to that computer before exchanging data with it. To establish a connection, both computers must be available and responsive during the entire time that the connection is active.
[0003] This invention pertains specifically to the case where an intermediary message server in employed to store and distribute messages to consumers. Although the producers and consumers (collectively referred to as clients) are loosely coupled with each other when communicating via MOM, the intermediary message servers are normally required to communicate with these clients in a connection-oriented fashion. Thus permitting senders and receivers to communicate without both being available at the same time requires the server to be available at all times. Furthermore all clients that may wish to exchange messages must be connected to the same server, or different servers which are capable or working together to achieve the equivalent functionality of a single server, i.e. to serve as a single logical server. MOM is often used in systems in which a large number of servers have to serve as one logical server, as one of the reasons for employing MOM is to alleviate the requirement of defining which programs may exchange data with each other a priori. This means that large organizations that use MOM for computer applications distributed throughout the organization, or organizations that use MOM to provide service to the general public over the Internet, must be ready to accommodate many thousands of programs communicating through a single logical server.
[0004] This invention pertains specifically to the case in which a MOM server is realized as a cluster of multiple computers. In the context of this document, we will define a cluster as a group of computers that work together to provide a single service with higher capacity and higher reliability than can be achieved using a single computer. In order to insure high reliability in the case of the failure of one or more machines in the cluster, the messages held by the server, and their associated state information, must be stored redundantly on multiple computers. This insures that the data is still available to the cluster if one computer fails.
[0005] The invention pertains to the reliable cluster that uses a primary/backup style of redundant storage. In this case, for some subset of the messages process by the message server cluster, one computer acts as the primary node. The primary node is responsible for storing the messages and actively delivering them to message consumers. One or more other computers act as backup nodes for that primary. The backup nodes are responsible for storing an identical copy of the data stored on the primary node, but they will not actively undertake to deliver stored messages to consumers. If the primary node fails, the backup node(s) must detect this failure and insure that exactly one backup is promoted to the role of primary and begins actively delivering messages to consumers. The backup(s) identify the failure of the primary through the fact that they are no longer able to communicate with it. In order to guarantee the proper behavior of the messaging system, it is important that exactly one node in the cluster act as the primary node at one time for a given subset of messages. The exact meaning of “proper behavior” will be described below.
[0006] In addition to the failure of individual computers, another type of failure that can occur in such a cluster is a network partition. The term “network partition” refers to the situation in which the data network that connects the computers in the cluster is split into two or more separate sub-networks. Each of these separate sub-networks is referred to as a partition. Each partition functions correctly except for the fact that the computers in the partition cannot communicate with the computers in the other partition. The symptom of a network partition is the same as that of node failures, namely that one or more computers become unavailable for communication. For this reason, it is, in the general case, not possible for a backup node to distinguish between an event in which it's corresponding primary node fails, and the event in which the network becomes partitioned and the corresponding primary node continues to function but is in a different partition.
[0007] This gives rise to a fundamental dilemma in the field of primary/backup style server reliability. If a primary node becomes separated from a backup node by a network partition, but the corresponding backup node assumes that it has failed, then the backup becomes a primary node. This results in the cluster having two primary nodes for the same set of messages at the same time. If both of these primaries are in contact with message consumers, then it will no longer be possible to guarantee proper behavior of the message server. If on the other hand, the primary node fails, but the corresponding backup node assumes that it is in different network partition, then the backup node will not become primary and the reliability of the message server cluster is not achieved, as no messages will then be delivered.
[0008] Message server cluster implementations according to the state of the art assume that failure to communicate with one or more computers indicates that these computers have failed. This is reasonable if one considers that computer failures occur more often than network partitions. In the case of a primary/backup reliability scheme, this leads to incorrect system behavior during network partitions, due to the fact that two computers can become primary node for the same set of messages at the same time. This invention is unique in that it provides a means to guarantee proper behavior of a clustered messaging system that uses primary/backup reliability, even during network partitions. It can do this without needing to discover if a communication failure is due to computer failure or network partitioning. As such, the invention does not provide a novel means for discovering the nature of the failure, but rather provides a means of providing primary/backup style high availability that is robust in that it guarantees the proper behavior without the need to handle both types of failure in different ways.
[0009] It is important to define the behavior that the message server cluster must exhibit in order to be considered correct. This invention guarantees correct behavior of a messaging system as defined in version 1.0.2 of the specification of the Java Message Service (JMS) application programming interface (API) published by Sun Microsystems Inc. The definition of this interface is available at http://java.sun.com/products/jms/docs.html. The key aspects of this behavior are:
[0010] Guaranteed Message Delivery: JMS defines two message delivery modes: persistent and non-persistent. It is permissible to loose non-persistent messages in the event of system failures. A JMS compliant messaging system must, however, guarantee that persistent messages can always be recovered after a system failure and that these will eventually be delivered to the intended recipient(s). Computer programs that use a messaging system to send messages with a persistent delivery mode should not need to take any additional measures to insure that the message is successfully delivered to appropriate recipient(s). It is one object of the invention to provide guaranteed persistent message delivery even in the case of network partitions separating the computers that comprise the message server cluster. (The invention also prevents the loss of non-persistent messages in the event of network partitioning, even though such loss would actually be permissible.)
[0011] Guaranteed One Time Only Delivery: JMS defines two messaging domains: point-to-point and publish/subscribe. Point-to-point messages must be delivered exactly one time to exactly one eligible recipient. These generally correspond to actions, such as depositing money in a bank account, which are not permitted to be executed more than once. Publish/subscribe messages must be delivered exactly once to each eligible subscriber. Such messages generally contain information, which may be disseminated to any number of recipients, but must be delivered exactly one time to each recipient. (In both delivery modes, the client has the option to specify that duplicate deliveries to one consumer are permissible). If a message consumer processes a message and then terminates unexpectedly before acknowledging the receipt of the message, then the message is considered undelivered according to JMS. It is a further object of the invention to guarantee both correct point-to-point and correct publish/subscribe message delivery in spite of network partitions that separate the computers comprising a message server cluster.
[0012] In Order Message Delivery: One client of a JMS messaging system may have multiple producers and consumers. These producers and consumers are grouped together into one or more sessions, where each session contains zero or more producers and zero or more consumers. All messages produced within one session must be delivered to consumers in the same order in which they were produced. The JMS specification explicitly identifies failure conditions in which it is not possible to assure both guaranteed delivery and in order delivery: when a message is delivered to a consumer, and that consumers fails before acknowledging receipt of the message, but after subsequent messages produced in the same session have been delivered to other consumers. In this case, it is permissible to deliver the message in question to another consumer, although it is out of order.
[0013] Transactions: As mentioned in the previous point, any number of the producers and consumers of one client may be grouped together into one session. Each session may optionally be specified as “transacted”. The client must instruct a transacted session to commit all message produced and consumed since the last commit before the delivery of these messages becomes effective. All production and consumption of messages that occur between successive commits must succeed or fail as a single unit. This means that despite any system failure that might occur, there are only two permissible outcomes for the set of messages produced and consumed within one transacted session between two successive commits: 1) the consumption of all received messages is verified to the messaging system at the time of commit, and the produced messages become available to deliver to consumers at the time of commit, or 2) all produced messages are aborted, and all consumed messages are refused, effectively rolling back the session to the state that it was in immediately after the previous commit. Thus, if two messages are issued within the same transaction, one instructing the withdrawal of a sum of money from a bank account, and the other instructing the deposit of the same amount into another bank account, then it is never possible for the withdrawal to occur without the corresponding deposit to occur. It is thus another object of the invention to provide correct transaction semantics in spite of network partitions that may occur before a transaction is successfully committed.
[0014] In addition to the above, we intend for this invention to provide one additional aspect of behavior, which is not specified by JMS, but is critical to fulfilling the basic purpose of a messaging system:
[0015] The messaging system is at all time available to accept messages from message producers: JMS does not explicitly state any requirements regarding availability of the messaging system. A server based messaging system is, however, intended to alleviate computer programs for the need to implement store and forward messaging functionality themselves. A messaging system cannot fulfill this intention without providing some guarantee of availability. Moreover, being available to accept messages at from producers at all times is more critical in this respect that being available to distribute message s to consumers. The JMS specification, and messaging systems in general, do not guarantee a minimum delivery time from producer to consume. This is outside the control of the messaging system since it cannot assume that there are consumers available to receive messages at all times. For this reason, message consumers must be designed in a way that they are robust with respect to delays in message delivery. On the other hand, consider a simple message producer that interactively collects order information from a human user, packages that as a message, sends it to the message system, confirms to the user that the order has been placed, and only then is ready to process another order. If the message system is not ready to take responsibility for the message during this cycle, then either: 1) the user must wait an indefinite amount of time until the message system is available before he receives confirmation that the order was placed, or 2) the message producer must provide reliable, recoverable storage of the message until the message system is available. Both of these options defeat the purpose of using a message system in such a scenario. Therefore we consider the ability to accept produced messages at any time to be the paramount availability criterion for message server availability. It is thus yet another object of the invention to insure that a clustered message server is always available to accept messages from message producers, and to guarantee proper delivery of those messages, even when the cluster is subject to network partition.
[0016] This invention provides robustness to network partitioning specifically for the clustered message server described in patent application Ser. No. 09/750,009, “Scaleable Message System”. For details about this messaging system, it is referred to the publication of this application, the application being incorporated herein by reference. Only a brief description will be presented here. The scaleable message system is depicted in Drawing 1 . The scalable message system consists of two or more logical nodes. Each node may run on a separate computer, or multiple nodes may run on the same computer. There are two types of node: Client Managers (CM) and Message Managers (MM). Message Manager nodes are responsible for storage and distribution of messages. They are not directly accessible by Clients. Clients must connect to Client Manager nodes, and the Client Manger nodes relay Client requests to the Message Manager nodes via a reliable, atomic multicast message bus. The message bus allows data to be sent from one node to several other nodes at one time, without consuming more network resources than are required to send the same data to only one machine. Individual Client Manager nodes do not contain state information that is critical to continued function of the system, so the failure of one or more Client Manager nodes can be tolerated without the need for a backup node. If a Client Manager node fails, the Clients that were connected to it automatically reconnect to another Client Manager node and continue normal operation. Drawing 1 shows a cluster of interconnected Client Managers and Message Managers.
[0017] Message Manager nodes contain state information that is critical to the continued function of the system. For this reason their state information must be stored redundantly on multiple nodes. There are two types of Message Manager nodes: primary and backup. At any one time, each of the primary Message Manager nodes is responsible for storing and distributing a subset of the messages being transferred by the messaging system. Together, all of the primary Message Manager nodes are responsible for the complete set of messages being transferred by the messaging system at any one time. For each primary Message Manager, there is any number of backup Message Manager nodes. Each backup Message Manager node is responsible for maintaining an exact copy of the state of it's corresponding primary Message Manager node, and must be ready to assume the role of primary Message Manager if the original primary Message Manager fails. Each primary Message Manager node interacts closely with its corresponding backup Message Manager nodes, but has little interaction with other Message Manager nodes. For this reason, each groups of one primary Message Manager node and its corresponding backup Message Manager nodes is referred to as a sub-cluster.
[0018] The message server cluster described above is composed of two different types of nodes, and there are some advantages to locating these nodes on different physical computers. It is important to note that this type of message server cluster could be realized with a single type of node by combining the functionality of the Client manager and the Message Manager into a single node type. Our ability to describe the invention is, however, facilitated by using the model in which these node types are physically separate, and this model will be used throughout this document.
[0019] The invention relies heavily on the concept of a synchronous network view. The view is the list of machines with which a given node can communicate over the data network at a certain point in time. The invention assumes that all nodes that are in the view of a given node posses themselves, the same view; that is: if A is in the view of B, and C is not in the view of B, then C is not in the view of A. Thus when there is no network partition, then all nodes possess all other nodes in their view, and when the network is partitioned, then all of the nodes in a partition posses the same view, and the view does not contain any node that are in other partitions. In the preferred embodiment, the responsibility of detecting the view and reporting changes in the view is delegated to message bus that provides multicast communications within the cluster. The preferred embodiment uses the product iBus//MessageBus from Softwired AG (www.softwired-inc.com) for this purposes, as it provides both reliable, atomic, in order multicast communication and view management.
SUMMARY OF THE INVENTION
[0020] This invention provides a means for a clustered message server to accept messages from message producing clients, and distribute these messages to message consuming clients in a way that e.g. conforms to the conditions of current JMS specification versions such as JMS specification version 1.0.2 and following versions and insures that the cluster is highly available for accepting messages, even when computers in the cluster fail or the data network that connects the computers in the cluster is split into several network partitions.
[0021] This invention is e.g. applicable to the type of message server cluster specified in U.S. patent application Ser. No. 09/750,009, “Scaleable Message System” and described previously in the background section. U.S. patent application Ser. No. 09/750,009 describes a new type of message server cluster in more detail and is incorporated herein be reference. This type of message server cluster is considered highly available, because all messages and associated state information that the server must store in order to assure proper operation can be redundantly stored on multiple different computers. This allows the message server cluster to continue normal operations without interruption and without loosing messages, in the event that one or more of the computers in the cluster fail unexpectedly.
[0022] However, the invention is also usable to message cluster systems of an architecture different from the above mentioned U.S. patent application Ser. No. 09/750,009 node architecture. An only prerequisite of a cluster to be employed with the is that a plurality of message managers is present. The message managers can in principle also function as client managers at the same time.
[0023] For point-to-point messaging, the conditions of the specification require that each persistent message be delivered to exactly one of the eligible message receivers. For publish/subscribe messaging, the conditions of the specification require that each message be delivered exactly once to each eligible subscriber. These requirements imply actions that are time consuming to coordinate among nodes on multiple physical machines. These actions include deciding which eligible receiver shall receive a message in the point-to-point domain, and when messages have been delivered to all subscribers and may safely be deleted in the publish/subscribe domain. In order to perform these actions in an efficient manner, at any given time, only one Message Manager node in the cluster should be responsible for the delivery of a given message. This is designated as a primary Message Manager node. All other Message Manager nodes that store that same message are backup Message Managers and play a passive role. Correct system behavior is assured when only one primary Message Manager exists for a given set of messages at any one time. Thus a backup Message Manager should only become a primary Message Manager after it has determined that no primary Message Manager currently exists.
[0024] This primary/backup scheme cannot insure that there is only one single primary Message Manager when the network connecting the computers is partitioned. The result of this fact is that the computers in the partitions cannot know if the computers with which they have lost contact are have ceased to operate, or if they continue to operate in another network partition. This inventions provides a scheme in which each network partition may contain a primary Message Manager for the same set of messages, without violating the conditions of the JMS specification, and without preventing Clients from sending new messages to the message server cluster.
[0025] In order to permit each network partition to have a primary Message Manager responsible for the same set of point-to-point messages as primary Message Managers in other partitions, we define two types of primary Message Manager for the point-to-point domain: normal and restricted. A normal primary is permitted to perform the full range of functions associated with a primary Message Manager for point-to-point messages. A restricted primary is not permitted to dispatch point-to-point messages sent prior to the onset of the current network failure. It is sufficient to insure that there is not more than one normal (unrestricted) primary Message Manager in a cluster in order to guarantee proper JMS semantics in the point-to-point domain.
[0026] In the publish/subscribe domain, there is no need to restrict any primaries from delivering messages. It is necessary, however, to insure that publish/subscribe messages are not deleted (except due to message expiration) from the Message Managers until the network partition or computer failure is rectified, in order to insure that possible consuming Clients in other partitions may ultimately receive all messages intended for them. In this mode of operation the primary Message Manager must retain all publish/subscribe messages and their associated delivery state, and the primary Message Manager is referred to as a retaining primary Message Manager. Note, that at any time when a partition separates Message Managers from the same sub-cluster, all primary Message Managers from that sub-cluster begin retaining publish/subscribe messages, while at most one can be a normal primary Message Manager for point-to-point messages.
[0027] After a network partition is corrected, the multiple primaries Message Manager that were previously separated in different partitions must synchronize their states so that all are updated to reflect the activity that occurred in the other partitions. Then all but one of the primaries Message Managers must revert to being backups and the single remaining primary Message Manager assumes full responsibility for the messages of that sub-cluster.
[0028] In order to reliably determine when a failure has occurred, and to determine what level of functionality the primary Message manager in a particular partition may have (normal, retaining or retaining/restricted), the following information must be available to all nodes:
[0029] Cluster Configuration: This is the configuration of cluster, as defined by the system administrator. It contains the complete description of what nodes should exist, what type they are (Client Manager or Message Manager), how they are grouped into sub-clusters and on which computers they should be running. This will normally be the same for all nodes at all times.
[0030] Network View (View): This is the list of computers that are reachable via the multicast message bus. When there is no failure, all computers share the same view, and this should be consistent with the Cluster Configuration. When a failure has occurred, then the View will not be consistent with the Cluster Configuration. If the failure is due to a network partition, then the computers within each partition will share the same view, but the view will naturally be different in each partition.
[0031] The invention uses a discrete state model to determine if the primary Message manager in a particular sub-cluster should be retaining and/or restricted. This partition state has four possible values, which are denoted by the letters A, B, C and D. Each time a view change occurs, the state of a node is re-evaluated based on the number and previous partition state of the Client Managers and Message Managers in the new Network View, as well as the intended Cluster Configuration. State A represents normal operation with no failures or failures of Client Managers only. In states B and C, the primary Message Manager is retaining but not restricted. In state D, the primary Message Manager is restricted and retaining. The state model allows both a high degree of continued operation and guaranteed JMS conformance even when multiple successive complex network partitions occur.
[0032] For publish/subscribe messaging, a retaining primary will function almost the same as a normal primary. The single difference is that a retaining primary cannot know if there are subscribers in other partitions that have not yet received a given message, so it should not delete messages until the failure is corrected and all primaries for that sub-cluster can reconcile their state, except in the case that messages expire before the failure is corrected.
[0033] For point-to-point messaging, a restricted primary is more limited in the actions that it is allowed to perform, compared to an unrestricted primary. A restricted primary may accept incoming messages at any time. It may only distribute messages that have been received after the most recent View change, as these messages are guaranteed not to be present in any other partition. Since all messages produced by a single session must be delivered in order, it is possible that messages received by a destination in the current view are queued behind messages from the same Client session received during a previous view, and are thus not available for distribution until partitioning is corrected.
[0034] The invention does not assume that View change events are issued immediately after a failure occurs. There is usually some time delay before the view manager (the multicast message bus in the case of the preferred implementation) can determine conclusively that a failure has occurred without risking excessive false alarms. It is possible that after a network partition occurs, each partition detects the failure at different times. This can result in dangerous scenarios in which one partition promotes a backup Message Manager to be an unrestricted primary before the primary Message Manager in the other partition detects that it must commence restricted operation.
[0035] In order to prevent duplicate message delivery during the interval between the occurrence of a failure and a view change, there is an extra check performed by the Client Manager during message dispatch. Each time a message is sent from a Message Manager to the Client Managers for dispatch, each Client Manager that receives the message sends an acknowledgement to all other Client Managers that confirms that it has seen the message. The one Client Manager that is actually responsible for forwarding the message to a Client consumer will hold the message until it receives acknowledgements from a majority of the other Client Managers in the same network view. If a failure has occurred that could potentially lead to duplicate message delivery before the corresponding view change is reported, the majority of acknowledgements cannot be received and the message will be rejected by the Client Manager.
[0036] In general, an important idea of the invention is that in an event of a network partition, each node evaluates a partition state information. A first, important distinction is between the two operational states restricted and an unrestricted. It has to be made sure that two message managers can not dispatch the same point-to-point message. Thus, a criterion is established ensuring that of two message managers not “seeing” each other, i.e. not being able to communicate due to lacking (hardware or software) network connection, and being responsible for dispatching the same point-to-point messages only one can be in the unrestricted state. Only message managers in the unrestricted state can dispatch messages created prior to the time the network partition occurred.
[0037] There are different possibilities to establish a criterion for determining whether a message manager is to be put in a restricted or unrestricted category, i.e. in the restricted or unrestricted operational state. According to the four state model mentioned above and outlined in more detail further below, the criterion is that the message manager has to have partition state A, B or C to be in the unrestricted state. Whether a server is attributed partition state A, B or C depends on the number and kind of nodes available for communication as well as on the history, i.e. on which was the partition state before the last view state change.
[0038] This four state model or a simplified or even a more sophisticated version of it can apply to architectures with two distinct kinds of nodes—message managers and client managers—of the kind disclosed in the above mentioned U.S. patent application as well as e.g. to architectures of the conventional kind where every server acts as both, client manager and message manager. A further possible criterion is e.g. to designate one server node to be a particular (alpha, or “tie-breaker”) server. All servers contained in the partition of the alpha server are unrestricted, all other servers are restricted. Further criteria may use information about particular client connections etc. It, however, is crucial that always only one partition may be unrestricted.
[0039] A second, important distinction is between the two operational states retaining and an non-retaining. According to the four state model a message manager is in the non-retaining operational state if it is in partition state A, otherwise it is in the retaining operational state. According to this model, partition state A is attained if all message managers are available within the sub-cluster and if at least one client manager is available.
[0040] According to a special embodiment there may optionally be further partition states relating to the quantity of message server nodes available. Also this embodiment is explained with reference to the mentioned four partition state model.
[0041] The invention is motivated by the wish to obtain a method which guarantees JMS semantics during the event of a network partition or a node failure, which two events can not be distinguished by a server of the cluster. However, the invention is equally well suited for guaranteeing proper operation in the event of a network employs a different middleware, especially a message oriented middleware. The expert will immediately realize that the concept of the invention is not based on a specific computer software or computer language but rather relates to network architectures as such.
BRIEF DESCRIPTION OF DRAWINGS
[0042] [0042]FIG. 1 shows a clustered message passing system.
[0043] [0043]FIG. 2 illustrates a Partition State Transition Graph consisting of nodes and unidirectional vertices interconnecting the nodes.
[0044] [0044]FIG. 3 shows a clustered message passing system after a network partitioning has occurred.
[0045] [0045]FIG. 4 illustrates the processing of a simple transaction in a clustered message passing system.
[0046] [0046]FIG. 5 illustrates the execution of a transaction over time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] In the following, preferred embodiments of the invention are described with reference to drawings.
[0048] The cluster illustrated in FIG. 1 contains two sub-clusters 1 and 2 , each containing three Message Managers MM, and five Client Managers CM. Each of the five Client Managers has a number of Clients connected. In each of the sub-clusters there is one primary Message Manager and two backup Message Managers. The drawing shows how the nodes (Client Managers and Message Managers) are connected on a cluster-wide message bus.
[0049] According to the model represented in FIG. 2, four different states represented by nodes A, B, C, D are assumed. Each node represents a Partition State, and this Partition State is determined independently for each sub-cluster in each network partition. The unidirectional arrows represent an event resulting in a transition from one Partition State to another. Transitions occur as the result of view change events. Below, each of the events leading to a transition from one Partition State to another (or the same) is described:
[0050] Vertex aa—All Message Managers within the same sub-cluster remain available, and one or more of the Client Managers are available to those Message Mangers
[0051] Vertex ab—All but one of Message Manager within the sub-cluster have become unavailable, and a majority Client Managers are available to the remaining Message Manager.
[0052] Vertex ba—All other Message Managers within the same sub-cluster have become available, and one or more of the Client Managers are available to those Message Managers.
[0053] Vertex bd—One or more, but not all, Message Managers from the same sub-cluster having current Partition State D have become available in this partition, along with the single Message Manager from this sub-cluster (which previously had Partition State B) that was already in this partition, and one or more of the Client Managers are available to those Message Mangers.
[0054] Vertex bb—The single Message Manager from this sub-cluster (which previously had Partition State B) that was already in this partition remains the only Messages Manger from this sub-cluster that is available in this partition, and one or more of the Client Managers are available to that Message Manager.
[0055] Vertex ac—Two or more, but not all, Message Managers from this suc-cluster remain available, and a majority of the Client Managers are available to those Message Managers.
[0056] Vertex ca—All other Message Managers within the same sub-cluster have become available, and one or more of the Client Managers are available to those Message Managers.
[0057] Vertex cb—All but one of Message Manager within the sub-cluster have become unavailable, and a majority Client Managers are available to the remaining Message Manager.
[0058] Vertex cc—Two or more Message Managers from this sub-cluster remain available, a majority of the Client Managers remain available to those Message Managers, and at least one Message Manger from this sub-cluster remains unavailable.
[0059] Vertex cd—A majority of the Client Managers have become unavailable and at least one Message Manager from this sub-cluster remains unavailable, or other, but not all, Message Managers from the same sub-cluster having current Partition State D have become available. Vertex ad—A majority of the Client Managers have become unavailable, and at least one Message Manager from this sub-cluster has become unavailable
[0060] Vertex da—All Message Managers are available within the sub-cluster, and one or more Client Managers are available to those Message Managers.
[0061] Vertex dd—At least one Message Manager from this sub-cluster remains unavailable.
[0062] As can be seen from the drawing, a partition containing Message Managers and Client Managers being in Partition State A, B or C can have a primary Message Manager operating in unrestricted mode with regards to point-to-point messages, and it may dispatch point-to-point messages normally. On the other hand, in Partition State D a primary Message Manager is operating in restricted mode with regards to point-to-point messages. With regards to publish/subscribe messages, the primary Message Manager operates in non-retaining mode and can run normally in Partition State A. In Partition States B, C and D, the primary Message Manager operates in retaining mode and may not delete messages prior to their expiry.
[0063] For each network partition, one partition will move to Partition State B or C and all others will move to Partition State D. To move out of Partition State D, all Message Managers must be available within the same partition. Thus, only one partition can have Partition State B or C at any time.
[0064] According to a further, simplified embodiment of the invention, a three state model may be applied combining states A, C, and D. In analogy to the above model, a message manager is attributed an unrestricted operational state if it is in partition state A or C and a restricted state operational state if it is in partition state D. Also, it is attributed a non-retaining operational state if it is partition state A and a retaining operational state otherwise. According to this simplified model, only the number and kind of nodes available for communication decides which partition state is attributed to a server and not its ‘history’:
[0065] state A: all message managers within the sub-cluster are available
[0066] state C: not all message managers within the sub-cluster are available and a majority of the client managers is available
[0067] state D: not all message managers within the sub-cluster are available and not a majority of the client managers is available.
[0068] Also this simplified model ensures JMS semantics. The four state model, however, in comparison includes more situations (c.f. vertex bb) where the server is attributed an unrestricted operational state.
[0069] The ultimate purpose of the four state model or more sophisticated or simpler variations of it is to properly handle the case of multiple successive network partitions. This might be case when an inexperienced technician incorrectly tries to repair the original partition, or when the firmware in a network switch goes berserk and start randomly segregating computers. The state model provides a very high degree of robustness and prevents the system from becoming vulnerable to total failure after the first partition occurs.
[0070] In complete analogy to the cluster represented if FIG. 1, the cluster of FIG. 3 contains two sub-clusters 1 and 2, each containing three Message Managers, and five Client Managers. Each of the five Client Managers has a number of Clients connected.
[0071] The drawing shows how a network partitioning has partitioned the sub-clusters in such a way that sub-cluster 1 is not affected by the partitioning other than the fact that two Client Managers are unavailable. As such, the nodes in sub-cluster 1 are still in Partition State A. Sub-cluster 2, on the other hand, has been partitioned in such a way that the primary Message Manager was partitioned away from its backup Message Managers. The original primary Message Manager resides within the partition having a majority of the Client Managers whereas the other two Message Managers have a minority of the Client Managers. In the absence of a primary Message Manager, the partition of sub-cluster 2 originally having two backup Message Managers has promoted one of the backup Message Managers to primary.
[0072] However, this new primary Message Manager will have Partition State D and thus be restricted and retaining. The original primary Message Manager is in Partition State B, and is retaining.
[0073] [0073]FIG. 4 illustrates the processing of a simple transaction in a clustered message passing system. As can be seen, the transaction spans two sub-clusters, illustrated with gray shading, and consists of a message being sent and a message being received.
[0074] In FIG. 4, a Client connected to the Client Manager has created a transacted session. The Client Manager acts as a Transaction Manager. The Client then sends a message, which destination is in sub-cluster 1, and receives a message located on a destination in sub-cluster 2. The Client then requests the transaction to be committed, which the Transaction Manager multicasts on the multicast bus, and returns the result of that operation.
[0075] [0075]FIG. 5 illustrates the execution of a transaction over time. The messages of a transaction includes the messages sent and received in a transacted session since the last abort/commit. As can be seen from the figure, the transaction contains three message operations—the sending of a message, and two message receptions—and a commit.
[0076] The invention neither prevents the occurrence of, nor rectifies node failures and network partitions. Instead, the invention recognizes that these events are possible, and presents a solution enabling the cluster to still be able to guarantee the JMS semantics even during these period after such events occur and before they are rectified. This is done by enabling all the Client Managers and Message Managers, and thus the whole partition(s), to detect and identify when a cluster (or a partition of it) is in a state where performing certain operations could lead to a break in JMS semantics. Specifically, having detected and identified such a state, each node is able to conclude whether a given operation—on message granularity—could lead to the JMS semantics being broken, and thus refrain from performing the operation until it is semantically safe again to do so.
[0077] The invention supports proper operation when the cluster is concurrently split into any number of network partitions. However, the invention assumes that the cluster is configured in such a way that all Client Managers can never be partitioned from all Message Managers. The consequence of this would simply be that the cluster would stop functioning. This can easily be guaranteed by co-locating some Client Managers and Message Managers on the same machines.
[0078] The invention also supports the sub-cluster abstraction meaning that the cluster can have one or more sub-clusters each containing a primary Message Manager and zero or more backup Message Managers. Each sub-cluster is responsible for delivery of a disjoint subset of messages as determined by the load balancing logic. Since a primary Message Manager and all its backups are located in a single sub-cluster, node failures and network partitioning issues are handled in each sub-cluster separately. The case in which responsibility for messages is not spread over multiple sub-clusters, and all messages are handled by a single cluster of message managers is a special case of the sub-cluster abstraction in which the number of sub-clusters is equal to one.
[0079] Finally, the invention also supports transaction processing, that is, the atomic execution of multiple message operations (send/receive), and guarantees JMS semantics even during node failures and network partitions when executing transactions.
[0080] The invention relies on each Client Manager and Message Manager in a cluster to be able to detect and identify the state of the cluster (or a partition of it) by holding various state information. This state information is used to give each node knowledge about the expected and the actual state of the cluster, which is an important aspect in order to make the nodes aware of when potential semantical errors can occur, and thus enabling them to prevent the JMS semantics from being broken. The states held by the Client Manager and Message Manager that are relevant to the invention are:
[0081] Configured State—Defines how the cluster is configured, that is, how many Client Managers and Message Managers, and the grouping into sub-clusters, which the Administrator has configured the entire cluster to have. Every time the Administrator adds a node or removes a node from the cluster, this state changes. A state sequence number identifies the state—containing information about the Client Managers, Message Managers and their grouping into one or more sub-clusters—which is incremented each time the state is updated. For the nodes in the cluster to function properly they must have a consistent view of the Configured State.
[0082] To ensure the highest level of flexibility by allowing the Administrator to change this state during node failures and/or network partitions, but at the same time ensure consistency across nodes, a majority voting approach is used when changing the state. The majority voting approach allows the Administrator to change the Configured State as long as at least a majority of nodes are available. The nodes unavailable when the Administrative changes the Configured State will thus be inconsistent, and will be updated when they reconcile with the rest of the cluster.
[0083] View State—Defines the current view of the cluster as seen by the underlying multicast layer, that is, how the cluster currently appears in terms of Client Managers and Message Managers, and the grouping in sub-clusters. In contrast to the Configured State, each node's View State only contains those nodes that are currently reachable to the node via the multicast layer. The state is identified by a state sequence number, which represents a data structure containing information about the Client Managers, Message Managers, and the grouping in sub-clusters within the view. As two partitions may both have the same state sequence number, but the context of the two states are different, the state sequence number does not map one-to-one to a data structure.
[0084] The state changes every time one or more nodes become available or unavailable to the cluster. As such, the View State changes due to node failures and recovery or partitioning and healing of the network as well as the Administrator adding or removing a node to/from the cluster, that is, changing the Configured State.
[0085] Partition State—Defines what the partition—given how the cluster/sub-cluster currently appears according to the View State compared to the Configured State—or whole cluster, if no failures have occurred, in terms of message handling is allowed to do. All nodes within a sub-cluster have the same Partition State if no failures have occurred. There might at some point be inconsistency between the nodes with regards to the Partition State, but that will be resolved once a View State change—that will have to come—triggers and the nodes then synchronize.
[0086] Where as the Configured State and the View State have infinite state sequence numbers, the Partition State takes a finite value of A, B, C or D depending on the number of Client Managers and Message Managers in the current View State compared to the current Configured State. As such, a change to the Partition State is triggered by a change in the View State by the multicast layer.
[0087] Since the Client Managers are shared between multiple sub-clusters, and the Client Managers need to know the Partition State of a given sub-cluster, this means that the Client Managers should be able to hold multiple Partition States—one for each sub-cluster represented in the current View State. The reason that Client Managers need to know about the Partition State is that they must to be able to block messages from being sent by a given sub-cluster, if necessary, as will be described later.
[0088] Destination State—Defines the internal state of each destination per Message Manager, which includes the messages currently stored in the destination, with their global identification, priority, delivery mode, and publishers, along with delivery state, locks, subscription definitions, individual subscription states, etc. A Destination State does not have an identifying sequence number, but is defined by its data structure representing the above-mentioned information.
[0089] The nodes in a sub-cluster exchange state information during View State changes. Using this approach, state conflicts—the scenario where multiple nodes have different Configured States, View States, Partition States and Destination States—are detected as part of a View State change. If a state inconsistency is detected, it is resolved by synchronizing the state as described later.
[0090] During the lifetime of a cluster/sub-cluster its—and thus its nodes'—Partition State may change multiple times as part of View State changes, depending on the frequency of network partitions and node failures. The invention uses a state machine approach to define the possible state transitions for the Partition States. Drawing 2 shows the possible Partition States, represented as nodes, and the possible transition events between them, represented as vertices. The starting point for the transition graph is Partition State A where it is assumed that all Client Managers and Message Managers are available initially when the system starts. As can be seen from Drawing 2 , a partition containing Message Managers and Client Managers being in Partition State A can have a primary Message Manager that operates normally. On the other hand, in Partition State B, C and D a primary Message Manager cannot operate normally in that it is:
[0091] Restricted—in terms of point-to-point messages, the primary Message Manager is restricted in what point-to-point messages it can send. A primary Message Manager is restricted in Partition State D. and/or
[0092] Retaining—in terms of publish/subscribe messages, the primary Message Manager has to retain publish/subscribe messages that would otherwise have been disposed. A primary Message Manager is retaining in Partition State B, C and D.
[0093] The semantics of being restricted and retaining is described later. During all state transitions, any partition without a primary Message Manager will promote a backup Message Manager as new—and perhaps restricted/retaining—primary, and any partition that has an normal primary Message Manager will be demoted to restricted primary Message Manager when entering Partition State D, and demoted to retaining primary when entering Partition States B, C or D
[0094] Another important point to note from Drawing 2 is that the cluster/sub-cluster can only leave Partition State D by going to Partition State A. This can occur if and only if all Message Managers within the cluster/sub-cluster as defined in the Configured State are available, meaning that the cluster/sub-cluster in terms of available Message Managers should fully recover from the network partitioning or node failures. Expressed in terms of states, this means that when the current View State of the cluster/sub-cluster in terms of Message Managers grouped per sub-cluster equals the configuration as set up by the Administrator and as represented in the Configured State.
[0095] This categorization of Partition State means that if a partitioning of the network into two disjoint partitions occurs one partition must have Partition State D and the other must have Partition State B, C or D. The reason for having both the Partition State B and C is to prevent unecessary restrictions in the event of successive network partitions. Drawing 3 shows an example of a partitioned cluster/sub-cluster with Partition States annotated.
[0096] The implications of being a restricted/retaining primary Message Manager in Partition State D for queue and topic destinations is as follows:
[0097] For point-to-point destinations, it means that the restricted primary Message Manager is restricted from sending messages that have been received in any previous View State. Instead, point-to-point messages are blocked, as they are potential duplicate message candidates. The reason for this is that another normal, and thus unrestricted, primary Message Manager could run in another network partition, and might or might not send the candidate messages. In addition to blocking point-to-point messages received in any previous View State, the restricted primary Message Manager also blocks queue messages succeeding a blocked message on a destination, if they originate from the same session. This way the partial ordering of messages is ensured. The point-to-point messages being blocked cannot be sent until the sub-cluster recovers from the network partition or node failures in such a way that it would be in Partition State A.
[0098] If a primary Message Manager nevertheless tries to send a duplicate queue message candidate, due to a state inconsistency at the time of the partitioning of the network, the message will be sent back to the Message Manager by the Client Manager—responsible for dispatching the message to the Client—with a notification that the primary Message Manager should stop sending the messages from a previous View State. The reason that the messages will be sent back is that the receiving Client Manager requires—as part of the checking to prevent duplicate message candidates from being sent—but will not receive acknowledgements from a majority of the other Client Managers within the current View State permitting it to dispatch the message to the Client. The reason it will never receive acknowledgements from a majority of Client Managers is that at most one partition may contain Message Manager that are not in state D. If this one partition is subsequently split, then at most one of these subsequent partitions may contain a majority of Client Managers.
[0099] As such, if, destination at the point in time where the network partitioning occurs, a point-to-point destination does not contain messages to be processed, the “restricted” primary Message Manager has no restrictions in the new View State. Thus, under these conditions the restricted primary can continue normal operations without breaking the JMS semantics.
[0100] For publish/subscribe destinations the implications of being a retaining primary Message Manager are different, since the notion of avoiding duplicate messages in the publish/subscribe sphere does not make sense. As such, for publish/subscribe destinations the retaining primary Message Manager does not block any messages. The semantic requirement of publish/subscribe destinations is that messages published to a destination are all delivered to all of the subscribers of that destination. Once a publish/subscribe message (durable or non-durable) has been delivered to all interested subscribers, the message manager can then remove the message. This causes a problem during a network partitioning, as Clients (subscribers) connected on one partition cannot receive the messages published on another partition due to the partitioning. Therefore, it is impossible to know when a given publish/subscribe message has been delivered to all subscribers in the cluster. To deal with this, the invention proposes halting of disposal of publish/subscribe messages in all Partition States other than A—only publish/subscribe messages in Partition State A will be disposed. Instead, publish/subscribe messages will be kept on the destinations until the network partitioning has healed in such a way that the entire cluster is back in Partition State A. Since all primary Message Manager regardless of their Partition State cannot reach all subscribers due to the network partitioning, they are all retaining meaning that they have to retain the publish/subscribe messages instead of disposing them. An exception from this relates to message expiration. The invention lets message expiration take precedence over delivery to all subscribers during node failures and network partitioning, which is in compliance with the JMS semantics.
[0101] When a partitioning of a network is rectified, the partitions of the cluster/sub-cluster merge together, and thus a Partition State transition occurs as part of the View State change. The Partition State transition also occurs if another partitioning of the network immediately overtakes an existing partitioning of the network. In both scenarios the nodes may have different Configured States, Partition States and View States, though the states are consistent within the partitions; at minimum a majority of the nodes agrees on the Configured State. To merge the network partitions, all nodes within the new view—partitioned or not partitioned cluster/sub-cluster—must first agree upon and set a new View State sequence number to the highest View State sequence number found in the new view incremented by 1, and update the View State data structure correspondingly.
[0102] Having updated the View State, each of the nodes in the new view exchanges the Configured State and Partition State that they possessed prior to the view change, and whether or not they are primary Message Manager. This state information is exchanged by multicasting a message to be received by all other nodes. Having received this message from all nodes in the new view, each of the nodes updates their state information using the following rules:
[0103] The highest Configured State sequence number between all the nodes in a View State takes precedence over a lower Configured State sequence number. The nodes within the new view—partitioned or not partitioned cluster—adapts the highest Configured State number between all nodes, and the nodes updates their configuration corresponding to the new Configured State, if necessary.
[0104] Using it's own current Partition State and the new View State compared to the new Configured State, each of the nodes update the Partition State using the partition transition graph showed in Drawing 2 . This will lead all nodes within a view to have the same Partition State.
[0105] Having synchronized these states, the Message Managers have to agree on a primary Message Manager in each of the sub-clusters affected by the state change. From the information multicasted, each Message Manager can detect if other Message Managers are claiming to be primaries. If no Message Manager claims to be primary within a sub-cluster, the Message Manager in each sub-cluster having the highest rank then promotes itself to primary. If, on the other hand, more than one Message Managers claim to be primaries, all primary Message Managers except for the primary Message Manager with the highest rank—a rank indicated by the order in which the Message Manager was enrolled into the cluster—demote themselves as primaries. In this process, the primary Message Manager checks to see what Partition State it is in. If it is in Partition State B, C or D, it demotes itself to only retaining primary Message Manager, and if it is in Partition State D it also demotes itself to restricted primary Message Manager.
[0106] Having agreed on a primary Message Manager in each sub-cluster, the Message Managers then synchronize their Destination State in order to achieve consistency with regards to destinations, that is, exchange information about messages that might have been received from producers or sent to consumers in each partition during the network partitioning or node failure. This is done by using a approached based on anti-entropy, that is, a method for reconciliation of two entities—in this case partitions. Having synchronized the Destination State, the primary Message Manager in each sub-cluster evaluates if some unsent queue or topic messages should be sent. Also, the primary Message Manager in each sub-cluster evaluates if there are blocked messages, and whether or not they have been sent or not, and in the latter case whether they can now be sent. Finally, the primary Message Manager in each sub-cluster evaluates if there are topic messages that can now be disposed.
[0107] The node states and their deterministic behavior provide a solid foundation on which message delivery can be performed in a fasion that is semantically correct during node failures and network partitioning. However, for this to succeed the message delivery mechanism has to be adapted to and exploit it.
[0108] For general message passing, a Client sends a message to the Client Manager on which it is connected. Upon receiving the message, the Client Manager tags the message with the current View State sequence number. The purpose of the tag is to identify messages received during one View State and sent during a newer View State. These are exactly the messages that are potential duplicate message candidates. The reason is that when the View State changes, a network partitioning may have occurred after which the primary Message Manager in both network partitions will try to send the same message in the belief that they were the only one doing it. Thus, using the tag messages that are potential candidates for duplication can be identified and appropriate actions taken.
[0109] The Client Manager now sends the message to its destination, that is, queue or topic on the Message Managers. The Client Managers all know about all possible destinations, and thus stamps the message with the selected destination before multicasting the message on the sub-cluster multicast layer. Upon receiving the message, only the primary Message Manager acknowledges the reception of the message. The backup Message Managers does not acknowledge it, but instead they simply listen for the primary Message Manager to acknowledge the message. Having done so, the backup Message Managers registers this. This is useful in the scenario where the primary becomes unavailable after having received a message but before having acknowledged it; a new primary Message Manager would then know if the message should be acknowledged to the Client Manager or not. Once a Client Manager receives an acknowledgement for a message by the Message Manager, it acknowledges the reception to the Client and removes the message from memory.
[0110] The primary Message Manager now selects a single Client that should receive a given queue message, or multiple Clients for a given topic message. Having done so the primary Message Manager stamps the message with the identification of the session(s) to receive the message and multicasts it on the sub-cluster channel to be received by the Client Managers and Message Managers. Upon multicasting the message, all Message Managers (primary and backups) receive the message sent by the primary Message Manager and all register that the primary Message Manager sent it out. Before a Client Manager does the actual dispatching of a message to the client, it needs to receive acknowledgement to do so from a majority of the Client Managers in the current View State. Each Client Manager—including the Client Manager that is responsible for the actual dispatching—that receives a message to be sent will acknowledge the receipt by multicasting an acknowledgement on the sub-cluster multicast layer. The acknowledgement by the Client Manager responsible for the sending of the message is received and registered by all Message Managers. If the responsible Client Manager receives a majority of acknowledgements from the Client Managers—including its own vote—the message is then sent to the Client, and the Client Manager will then wait for an acknowledgement from the Client. The reason for using this acknowledgement scheme is to ensure that a message cannot be sent in a partition with a minority of Client Managers in the current view state, even before the view change occurs.
[0111] When the Client Manager receives acknowledgement from the Client, it multicasts this acknowledgement on the multicast layer to be received by all Message Managers in the sub-cluster. The Message Managers and the sending Client Manager all registers that the message has been successfully received by the Client, and mark the message to be cleaned up.
[0112] If the Client session is not available on the Client Manager anymore when the primary Message Manager sends a message, the Client Manager sends a message back stating this, which causes the Message Managers to unmark the message as being sent to a Client Manager, and then, in the case of a point-to-point message, it can be resent. In the case of a non-durable publish/subscribe message, the Client Managers simply sends back a message saying not to send to the specific Client anymore, no further action need be taken. For durable subscribers the Client Manager would send a message back saying that the Client did not receive the message, and thus the message must be retained at least until that time when the durable subscriber reconnects to the message server cluster.
[0113] Destinations may for various reasons at any point in time receive messages from a given Client session out of sequence. This can happen if a session for instance misses one or more messages from a Client session. Specifically, a destination may be requested to receive message having sequence number X+10 without having received all previous messages. This only happens if some failure in the cluster occurs at which a Client that was publishing on a destination on one sub-cluster is moved to publish on the same destination on another sub-cluster. This could potentially lead to out-of-order delivery to the Clients if the primary Message Manager would send message X+10 published to a destination on one sub-cluster to a Client before the primary Message Manager sent the message X+9 published to the same destination on another sub-cluster.
[0114] Specifically, this can happen if a Client looses its connection to a Client Manager on which it has produced messages to some destination after which it will reconnect to the cluster from another Client Manager. Normally, this does not pose a problem as the new Client Manager from the reconnect request can see which sub-cluster the Client has been publishing to per destination. However, assuming that the cluster/sub-cluster is network partitioned and the new Client Manager used as entry point to the cluster/sub-cluster is in another partition than the former Client Manager, there is a potential semantic problem. The problem lies in maintaining the partial ordering of message delivery on a given session. The problem origins from the fact that a given destination can be split across multiple sub-clusters—each having a subset of the entire set of messages—and that during failures Client sessions may have had to publish to the same destination on different sub-clusters.
[0115] The reconnect request by the Client can reveal that the Client previously published messages to another sub-cluster. As such, to prevent any semantic problems from arising, the Client Manager tries to reconnect the Client to the previous sub-cluster if this is possible. If this is not possible, the Client Manager will accept the reconnection request anyway and leave it to the primary Message Manager to solve any semantic problems.
[0116] To solve the potential semantic problem, each message published by a Client to a destination has an identification, assigned by the Client, of the session, destination and message sequence number within that combination of destination and session—whether this is a part of the unique identification or not. From this information, the primary Message Manager can then see if there are gaps in the messages sequence for the destination. Once the primary Message Manager detects that messages from a given session to a given destination are missing, the successive messages are blocked, that is, they will not be sent before synchronization of the destinations leading to a complete sequence of in-order messages on the destination, and the partial ordering thus is observed.
[0117] The invention also ensures semantically correct processing of transactions, that is, the atomic execution of multiple message deliveries, during network partitions and node failures. The invention supports processing of transactions spanning multiple sub-clusters as illustrated in Drawing 4 . For transaction processing the Client Manager acts as the Transaction Manager, which means that the Client Manager on which the Client is connected is then responsible for coordinating and executing the different stages of the transaction with the different sub-clusters. The invention uses a 2 Phase-Commit transaction scheme.
[0118] In order to use transactions, the Client must specify its session to be transacted. By specifying a session to be transacted, the Client is required at some point to either commit or abort a complete set of messages sent to or received from the cluster The 2 Phase Commit process is handled entirely by the transaction manager in the Client Manager and is transparent in the Client. The Transaction Manager therefore does this transparently. However, there is no requirement as to how often the Client should either commit or abort the transaction. Given that the Client can commit or abort multiple times during the lifetime of the transacted session, conceptually one can say that a transacted session contains multiple autonomous transactions separated by the commit/abort instructions issued by the Client. If one of the transactions is aborted or fails it has no influence on the previous or successive transactions. Drawing 5 illustrates a transaction containing three messages and a commit executed over time. Having specified its session as transacted, a Client can send a number of messages to the Transaction Manager and Client can receive messages sent by the primary Message Manager via the Transaction Manager.
[0119] At some point the Client sends a commit to the Transaction Manager. Upon receiving the commit request the Transaction Manager transforms this into an initial prepare operation, which is then multicasted to the sub-clusters participating in the transaction, followed by a subsequent commit or abort depending on the result of the prepare request. The prepare request contains identifications of all the messages sent and received categorized per sub-cluster included in the transaction. Upon receiving the prepare request the Message Managers in the participating sub-clusters check to see if they have received all messages that they were supposed to according to the message identifications included in the prepare request. If this is the case the Message Managers respond positively to the Transaction Manager, otherwise negatively.
[0120] If only one Message Manager, primary or backup, responds negatively to the prepare request, the Transaction Manager aborts the transaction by multicasting it to the sub-clusters and reports the abort to the Client. If all Message Managers respond positively the Transaction Manager multicasts a commit operation to the Message Managers in the sub-cluster participating in the transaction and subsequently reports the successful commit to the Client. Upon receiving a commit request, all Message Managers update the message store in such a way that the send operations are now public and that the messages received are now considered to be delivered.
[0121] State changes caused by node failures and network partitions pose a problem to the transaction processing. During a state change the execution environment of the transaction may change in such a way that the transaction could break the semantics of message handling if this situation is not handled correctly. This could for instance happen in the case where a Transaction Manager gets partitioned from the cluster/sub-cluster along with a primary Message Manager that gets demoted to restricted/retaining primary Message Manager. To avoid the semantics from being broken, a state change in a participating sub-cluster or the whole cluster therefore triggers an abort of a transaction by the Message Managers participating in the transaction if:
[0122] the consequence of the state change is that the Partition State of the partition containing the Transaction Manager changes to D (even if it already was D) or
[0123] the Transaction Manager is unavailable to the cluster/sub-cluster(s) participating in the transaction, that is, crashes or gets separated away into another partition.
[0124] In all other cases the transaction is not aborted, but will continue from where it left once the cluster has settled into it's new state.
[0125] At each Message Manager within a sub-cluster, the messages received and sent are marked with a tag stating that they are locked as a part of a transacted session and have not yet been committed. The transactions used are non-blocking in the sense that the locks held on the messages, obtained by the Transaction Manager, will be released as soon as a state change forces a transaction to abort. This means that the nodes in the transaction implicitly have a timeout value used by the underlying multicast layer to detect failures. However, there are no other timeout values that can affect the transactions.
[0126] If the Transaction Manager crashes or is partitioned away from the Message Managers during the executing of transaction, but before committing or aborting it, all the Message Managers participating in the transaction will simply abort the transaction after having realized the event via a View State change. If the Transaction Manager crashs, the Client initiating the transaction will receive an exception telling it that it lost the connection to the Transaction Manager and that the current transaction thus failed. The same happens if the Client initiating the transaction is partitioned away from the Transaction Manager. Included in the exception is the transaction sequence number. Using this transaction sequence number, the Client will at some point reconnect to another Client Manager and reinitialize its transaction, which is then restarted using a new Transaction Manager.
[0127] If the Transaction Manager becomes unavailable immediately after having received a request to commit from the Client, the Client will receive an exception that the connection to the Transaction Manager—Client Manager—has been lost. However, the Client does not know what happened to the transaction, that is, whether it actually committed or not. Having established a new connection by reconnecting to another Client Manager, the Client now tries to recover the transaction. The Client cannot just abort the transaction at this stage, because if the previous commit succeeded the messages may already be publicly accessible and for instance consumed by other Clients. Given that the Client does not know whether the previous commit was actually executed, it attempts to recommit the transaction from the new Transaction Manager—Client Manager. For this to be semantically valid, the commit operation is idempotent, so that no harm is done if the previous commit was in fact executed and a subsequent recommit of the same transaction occurs.
[0128] To reissue a commit, the transaction and the part of the transaction to be committed, that is, the messages sent and received since the last commit, should be identifiable to ensure that the right part of the right transaction is committed. The reason that each commit/abort part of the transaction must be uniquely identifiable is to ensure that a reissued commit does not commit a wrong part of the transaction.
[0129] Upon receiving the recommit operation, the new Transaction Manager transforms it into a prepare operation followed by a commit or abort. This is the default 2 -Phase-Commit transaction processing behavior. If the result of the prepare operation is positive, meaning that all the Message Managers—primaries and backups—participating in the transaction respond positively to the prepare operation, this means that the previous commit actually succeeded. If, on the other hand, the Message Managers participating in the transaction respond negatively to the prepare operation, this means that the previous commit did not succeed, and thus the transaction has been aborted following the state change triggered by the failure of the previous Transaction Manager. The above also applies to the scenario where the Transaction Manager fails after having received an abort operation from the Client.
[0130] In order for the scenarios above to work, each Message Manager—primaries as well as backups—participating in a transaction must for each transacted session keep track of the last performed transaction sequence number and the result of this transaction. This information is persisted by each Message Manager—primaries and backups.
[0131] In summary, the advantages featured by the invention comprise the following:
[0132] The method according to the invention guarantees JMS semantics during node failures and network partitioning of a clustered message passing system.
[0133] The invention specifically guarantees that no messages are delivered more than once to a client application during node failures and network partitioning of a clustered message passing system except for the exceptions as specified in the JMS specification.
[0134] The invention specifically guarantees that no messages are lost during node failures and network partitioning of a clustered message passing system, except for the permissible exceptions as specified in the JMS specification.
[0135] The invention specifically guarantees that all topic messages at some point are delivered to all client applications during node failures and network partitioning of a clustered message passing system, except if the topic messages expire before the recovery of the node failure or network failure.
[0136] The invention, as an extension to guaranteeing JMS semantics, insures that the clustered message passing system is always available to accept messages from message producers, and guarantees proper delivery of those messages, even when the cluster is subject to network partitioning. This of course assumes that not all nodes in the clustered message passing system have crashed.
[0137] Numerous other embodiments may be envisaged without departing from the spirit and scope of the invention.
Glossary of Terms Used
[0138] Cluster: A group of processes that run on more that one computer and work together to act like a single message passing server, but with increased performance and reliability. To a client, a cluster is functionally equivalent to a monolithic server, and it is thus transparent to the client.
[0139] Node: A single logical process within a cluster. Often a node will correspond to a single computer, but this not strictly the case. Multiple nodes sharing a computer will interact with other as though they are on different computers connected only by a network.
[0140] Monolithic Server: A complete message server running as a single node.
[0141] Server Instance: Generic term for a single logical message server. This can be a monolithic server or cluster as defined above.
[0142] Client: An application program connects to a node in a cluster to send (publish) messages to, or receive (consume) messages from, a server instance.
[0143] JMS: (Java Message Service) A standard application programming interface (API) for programs written in the Java language to use for accessing the services of a message system.
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A means for guaranteeing the proper behavior as specified by the JMS semantics of clustered message server when the individual computer that comprise the cluster are separated by a network partition. A clustered message server is responsible for the reliable transportation of messages between different distributed computer applications. It employs multiple computers to perform a function that otherwise appears to be performed by a monolithic server running on one computer, but with more capacity and reliability than can be provided by one computer. If a computer in the cluster fails, another computer should automatically assume the role of the failed computer. However, it is not possible for the other machines in the cluster to detect the difference between the failure of one or more computers in the cluster, and the failure of data network connecting those computers. In ordinary clusters, different actions would be required in these two cases, but since they are impossible to distinguish, computer failure is always assumed and network failure is ignored and the consequence non-deterministic. The invention described here provides a means of responding to failures that yields correct behavior as specified by the JMS semantics whether the failure is due to computer failure or network failure.
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