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This application is a continuation application based upon the applicants pending application Ser. No. 441,564, filed Nov. 15, 1982 and assigned to Completion Tool Company.
This application is related in subject matter to U.S. Pat. Nos. 4,420,159 and 4,402,517 which were copending with this prior application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to packer inflation systems and more particularly to the valves which control the inflation of packers.
2. Description of the Prior Art
The control of the inflation of well packers is important to obtain integrity between the packer and the well bore for purposes of working within the bore. It is known in the art to inflate packers by various mechanisms. See, for example, U.S. Pat. No. 3,503,445, issued Mar. 31, 1970, to K. L. Cochran et al, entitled "Well Control During Drilling Operations"; U.S. Pat. No. 3,351,349, issued Nov. 7, 1967, to D. V. Chenoweth, entitled "Hydraulically Expandable Well Packer"; U.S. Pat. No. 3,373,820, issued Mar. 19, 1968, to L. H. Robinson, Jr. et al, entitled "Apparatus for Drilling with a Gaseous Drilling Fluid".
In U.S. Pat. No. 3,437,142, issued Apr. 8, 1969, to George E. Conover, entitled "Inflatable Packer for External Use on Casing and Liners and Method of Use", there is disclosed an inflatable packer for external use on tubular members such as casings, liners, and the like. A valving arrangement is disclosed therein for containing fluid within the interior of the inflatable member after it has been inflated to prevent its return to the tubular member.
Arrangements of valving have been known in the prior art to prevent further communication between the interior of the tubular member and the interior of the inflatable element after the inflatable element has been inflated and set in a well bore. See, for example, U.S. Pat. No. 3,427,651, issued Feb. 11, 1969, to W. J. Bielstein et al, entitled "Well Control"; U.S. Pat. No. 3,542,127, issued Nov. 24, 1970, to Billy C. Malone, entitled "Reinforced Inflatable Packer with Expansible Back-up Skirts for End Portions"; U.S. Pat. No. 3,581,816, issued June 1, 1971, to Billy C. Malone, entitled "Permanent Set Inflatable Element"; U.S. Pat. No. 3,818,922, issued June 25, 1974, to Billy C. Malone, entitled "Safety Valve Arrangement for Controlling Communication Between the Interior and Exterior of a Tubular Member"; and U.S. Pat. No. 3,776,308, issued Dec. 4, 1973, to Billy C. Malone, entitled "Safety Valve Arrangement for Controlling Communication Between the Interior and Exterior of a Tubular Member".
Inflatable packers have also been used in other operations, such as sealing the annular space between a jacket and a piling. See for example U.S. Pat. No. 4,063,427, issued Dec. 20, 1977, to Erwin E. Hoffman, entitled "Seal Arrangement and Flow Control Means Therefor".
The seals that are used in valves, such as in Malone, are usually hardened rubber. Such rubber tends to extrude under extreme pressure differential across the rubber and cause friction between rubber and metal that adversely affects valve operation. None of the prior art, however, provides for mechanism for equalizing pressures across the seals of the valves used to inflate packers to prevent such extrusion.
SUMMARY OF THE INVENTION
The present invention utilizes a unique arrangement of sealing mechanisms in conjunction with a valve or valves to permit the inflation of an inflatable packer element while at the same time equalizing pressure around the rubber seals of the valve or valves to prevent distortion of the seals from undue high differential pressure, and the resulting friction.
The present invention, like the prior art, is constructed and arranged so that the valve or valves remain seated to prevent communication between the interior of a tubular member and the interior of an inflatable element carried on the exterior of the tubular member until at least a predetermined pressure has been reached. This reduces the possibility of premature inflation of the inflatable element by sudden pressure changes or pressure surges which may occur within the tubular member as the tubular member is being positioned within a well bore.
However, the valve arrangement of the inflation system of the present invention includes an appropriate arrangement of the valve structure to compensate for bore pressure to prevent extrusion from undue high differential pressures across the seals of certain rubber seals which must move in the valving operation.
BRIEF DESCRIPTION OF THE DRAWINGS
For further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 is a cross-section of a packer showing the three-valve collar for inflation of the packing;
FIG. 2 is an enlarged cross-section of the valve arrangement of FIG. 1 taken along section line 2--2 of FIG. 1;
FIGS. 3A-C are pictoral views of the cross-section of the valve arrangement of the present invention showing the valve and the sequence of steps for inflation of the packer shown inverted to the normal position of insertion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A tubular inflatable packer 10 is shown in FIGS. 1 and 2. This type of packer is specifically illustrated for a three valve embodiment and may be a casing packer as illustrated in copending application Ser. Nos. 407,898 and 408,123, filed Aug. 13, 1982 entitled "Packer Valve Arrangement" by Edward T. Wood and Edward T. Wood/Robert E. Snyder, respectively. Now U.S. Pat. Nos. 4,420,159 and 4,402,517 respectively. However, it should be understood that only one valve pocket is needed in the present invention although additional poppet or check valves could be included. The tubular inflatable packer 10 includes a short casing joint or casing sub 12 for connection to other tubular members and is secured by suitable means, such as threads as illustrated in FIG. 1, to a valve collar 14 secured to a tubular pipe member or mandrel 11. It should be noted that in one aspect of the present invention, the valve collar 14 could also be and is preferably secured to the sub 36 of other end of tubular pipe member 11. The valve collar 14 includes a valve mechanism 16 or system of valves and passageways (See FIG. 2) for placing fluid in the bore 21 of the pipe member 11 in fluid communication with a fluid channel or chamber 20 (See FIG. 2) under the inflatable packing element 30 carried externally on the tubular pipe member 11.
The inflatable packing element 30 includes spaced apart annular packer heads 24, 26. The head 26 is secured to the valve collar 14 while the upper head 24 is secured to a top or upper collar 35. The inflatable packing element 30 extends between the packer heads 24, 26 and is also secured to the pipe member 11 which extends along the inside surface of the packing element 30 between the valve collar 14 and the upper collar 35. The inflatable packing element 30 may be of any suitable length and is an elastomer cover and two sets of steel anti-extrusion ribs 32. The ribs 32 are connected to the elastomer cover, such as, for example, by vulcanizing the elastomer cover to the ribs 32 so that the ribs 32 extend into the ends of the elastomer cove. Each set of ribs 32 is connected to a steel back-up sleeve 34, and one set is connected to the valve collar 14 while the other set is connected to the valve collar 35. Sleeve 34 is also connected to the elastomer cover, such as vulcanized with the rubber, and to the valve collar 14. A tubular sub 36 is connected to the valve collar 35 for use with other tubular members in a string of pipe or casing (not shown).
As shown in FIG. 2, a first set of annular grooves 38 is formed in the valve collar 14. The set of grooves 38 includes internal, circumferential or annular grooves 40, 42 spaced longitudinally apart from one another and covered by juxtaposed screen sleeve 44. The screen sleeve 44 includes a hole 46 which receives a knock-off rod or plug 50, usually constructed of plastic, to isolate the valve system from fluid under pressure in the bore 21 of the pipe member during running of the inflatable packer 10 into a well bore containing fluid.
A port 52 extends partially through the wall of the valve collar 14 and connects a passageway 54 to the groove 42. The passageway 54 extends vertically in the wall of valve collar 14 between a valve in the valve mechanism 16 and the port 56 (See FIG. 2).
It should be noted that the valve collar is located at the upper end of the tubular member 10 instead of the lower end. In this manner, pressure cannot be trapped between, for example, the well bottom and the packer 30 which would have an effect on the differential pressure across the valve thereby preventing the valve from closing.
Referring to FIG. 3A, there is diagramatically shown an embodiment which utilizes a single inflation control valve in a single valve pocket 300. The valve pocket 300 is bored into a valve collar 14" (the double prime is used to denote a different collar than collar 14 with substantially the same pocket and passageway configuration, between the interior of the pipe member 21, the exterior of the valve body and the channel 20 to the interior of the packing element 30, except having one valve pocket and except as otherwise described in the description of this embodiment) or formed in a sleeve or other suitable location. Bore 301, first counterbore 302 and second counterbore 304 are the single valve pocket 300. Counterbores 302 and 304 are separated by stop wings 306, and the counterbores are formed by drilling or other suitable operation in pocket 300. Stop wings 306 form an upwardly facing shoulder 316 with counterbore 302 and a downwardly, outwardly facing shoulder 307 with enlarged counterbore 304. Passageways 54, 303, 137 and 236 are formed in the valve collar 14" to be in communication to bore 21 of the pipe member 11, the external surface of valve collar 14" on the outside of the packer 10, the fluid channel 20 and the interior of the packing element 30, respectively, and to the valve pocket 300. The valve element 318, which is inserted into the valve pocket 300, includes a first valve body member 320 having an upper surface 373 and a lower surface 346 located in a counterbore 304, a spring 322 located in a bore 302, and a second valve body member 324 having upper surface 372 located in bore 301 and a lower surface 374 located in a counterbore 302 in the initial assembled position. Passageway 303 has a lower surface 315 substantially coplaner with spring 322 in the initial assembled position.
First valve body member 320 includes an enlarged valve portion 330 having a groove 332 formed thereabout for reception of a seal 334 therein. Seal 334 is sized to sealingly engage the wall of the counterbore 304 and the bottom surface 336 of the groove 332. Valve stem 338 on the valve body member is of smaller diameter than the valve portion 330 and extends from the valve portion 330 longitudinally to the end of the counterbore 304 approximately coplaner with the shoulders 316. The diameter of valve stem 338 is substantially less than the diameter of the valve body portion 330 and forms a shoulder 340 at the interface between the valve stem 338 and the valve body portion 330. Stop wings 342 extend laterally from the valve stem 338 and are appropriately positioned along the length of stem 338 to perform as set out below approximately midway along the length of the valve stem 338. The longitudinal placement of the stop wings 342 is determined by the dimension of the shoulder 307. The stop wings 342 must be sufficiently displaced from the shoulder 340 along the surface of the valve stem 338 to permit the stop wings 342 to extend above the shoulder 316 when the shoulder 340 meets the lower downwardly outwardly extending surface 307. A first shear pin 344, or collet, or other suitable mechanism for prevention of reciprocation, extends through the surface of valve collar 14" and into the base 346 of the valve portion 330 and releasably holds the valve portion 330 in its initial position.
Spring 322 is of any suitable material having an inner diameter larger than the diameter of the valve stem 338 and having a collapsed length substantially equal to the distance from the shoulder 316 to the lower surface 315 of the passageway 314.
The upper valve element 324 includes a valve base portion 350 having a diameter greater than the diameter of the bore 301. The upper valve element 324 is reduced in size along the portion extending away from the valve base portion 350 to form a valve stem portion 352 having a smaller diameter than bore 301 with a shoulder 354 formed at the juncture of the valve stem portion 352 and the valve base portion 350. Two grooves 356, 358 are formed along the circumference of the valve stem portion 352 spaced such that circumferential seals 360, 362 may be fit therein and sealingly engaging the walls of bore 301 and the walls 364, 366 respectively of the valve stem portion 352. Grooves 356, 358 are spaced apart sufficiently so that the seals 362, 366 engage the walls on either side of the passage 137 when the shoulder 354 abuts the shoulder 368 formed between the counterbore 302 and the bore 301. A shear pin 369, or collet, or other suitable mechanism for prevention of reciprocation, extends through the surface of valve collar 14" and into a bore 370 formed in the valve stem portion 352 upon initial assembly and releasably holds the valve stem portion 352 in its initial position.
Referring to FIGS. 3A-3C, in operation the pressure from the bore 21 of the pipe member 11 is applied through the passageway 54 against the surface 372 of the upper valve body element 324. At the same time, pressure in the borehole external to the valve collar 14" is applied via passageway 303 to the areas defined by seals 362 and 334 in the pocket. Pressure in the borehole external to the valve collar 14" is applied via the packing element 30 and the passageway 236 to the other side of seal 334 and is applied via the packing element 30 and to the passageway 137 to the portion of the bore 301 located between the seals 360 and 362. When the pressure within tubular pipe member 11 is sufficient to overcome the shear strength of the shear pin 369, the shear pin 369 shears (FIG. 3B) permitting the pressure acting on the surface 372 to move the second valve body member 324 longitudinally towards second valve body member 320 and to compress the spring 322. Accordingly, the valve seal 360 no longer prevents flow of fluid from the passageway 54 to the passageway 137, and fluid then flows to passageway 137 from passageway 54. Fluid passageway 137 flows into channel 20 and thence to the interior of the packing element 30 and inflates the packing element 30. Fluid communication with the interior of the packing element 30 is accomplished through the passageway 236 equal to the pressure within the packing element 30. It will be noted that the pressure area across the seal 334 is larger than the pressure area across the seal 356 and thus when the fluid in the passageway 236 has reached a predetermined pressure, greater than or equal to the pressure in the passageway 303, as determined by the shear force of the shear pin 344, the shear pin 334 shears (FIG. 3C) forcing the second valve body member 320 to rise or move and the end surface 373 of the second valve body member 320 to abut the surface 374 of first valve body member 324. Because the surface area of the surface 346 is substantially greater than the surface area of the surface 372, the pressure in the passageway 236 acting on the surface 346 will eventually force both the second valve body member 320 and the first valve body member 324 to move through their respective bores until the shoulder 340 on the second valve body member 320 contacts the inclined surface 307. At this point, the seals 360, 362 on the second valve body member 320 would be again spaced around or to either side of the passageway 137 to prevent further flow of fluid into the passageway 137 from passageway 54 thereby retaining the inflation pressure in the packing element 30. Should there be a small loss in pressure in the passageway 236 against surface 346, the wings 342 (which can be optional) would prevent the valve body member 320 and the valve body member 324 from moving sufficiently to again permit flow between the passageways 54 and 137.
Although the system described in detail above is most satisfactory and preferred, many variations in structure and method are possible. For example, wings 342 may be eliminated. Also, the members may be made of any material suitable for the environment. Further, reciprocating member or valve body member 324 may be split horizontally so that the member has two pieces, each piece having one seal and the lower seal being of a poppet type.
The above are examples of the possible changes or variations.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught and because modifications may be made in accordance with the descriptive requirements of the law, it should be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A valve system for use in inflating packers mounted on mandrels is disclosed. The valve system uses one valve to permit, through the use of seals, the flow of fluid from the interior of a tubular mandrel to the interior of the inflatable packer when pressure applied in the mandrel exceeds at least a minimum pressure.
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BACKGROUND OF THE INVENTION
This invention relates to conductive coatings and specifically to a nonstick conductive coating for use with an electrosurgical cutting instrument.
Electrosurgical devices or surgical scalpels, which are adapted to use radio frequency electrical energy in the performance of hemostatic surgery, are disclosed in related commonly owned U.S. Pat. Nos. 4,232,676 to Herczog, and 4,248,231 to Herczog et al. Other such hemostatic surgical instruments are available in the prior art, for example, see U.S. Pat. No. Re. 29,088 for a heated surgical scalpel. There are other variations on the concept of hemostatic surgery including systems utilizing electric discharge to cut and cauterize, and related systems such as shown in U.S. Pat. Nos. 4,161,950, 4,033,351 and 3,913,583.
While the concept involved in the present invention might be adapted for use in many of the aforementioned electrosurgical devices, it is best exemplified for its usefulness in the cutting instruments of the type disclosed by Herczog et al. (hereinafter Herczog or RF blade). In one embodiment, currents are carried to separate electrodes which are desposited near the cutting edge of a glass or glass-ceramic material scalpel or blade. Moisture from incised tissue surfaces completes a circuit from one electrode to the other and the high frequency source generated currents pass through the tissue, generate heat and cause hemostasis in the vicinity of the electrodes.
In such a system it is possible for the blade to stick in the incision, thereby causing apparent dullness of the blade. The problem is alleviated when non-stick coatings are used, however, because of the nature of non-stick materials, many tend to be fragile and are abraded easily. Thus, the non-stick properties degrade in normal use, due in part to actual cutting, and partly due to the frequent wiping necessary in order to remove surgical debris adhered to the blade. When sticking is severe, the blade is unfit for further use and must be discarded. Further, when using the Herczog concept, the non-conductive nature of non-stick films tends to interfere with the conductivity of the electrodes.
There are a number of patents in the prior art disclosing non-stick coatings. These patents mainly relate to the use of fluorocarbon polymers on razor blades for increasing their lubricity and enhancing the comfort of such shaving instruments while in use. Such arrangements are described in U.S. Pat. Nos. 4,012,551 and 3,754,329. There is a copending patent application of R. E. Allen, Ser. No. 102,886, filed this same date and assigned to the assignee herein, disclosing conductive non-stick coatings applied to RF electrosurgical devices.
Allen's patent application teaches that the insulative nature of the non-stick materials normally interferes with the conductivity of the electrodes, but if the material is applied to textured electrodes and subsequently wiped away the surface of the electrode is free to conduct and the instrument exhibits non-stick characteristics. This occurs because the non-stick material permeates microscopic interstices in the electrode surface thereby providing a means for mechanical adherence of one to the other and the wiping step removes sufficient amounts of the insulative non-stick material from high profile points of the electrode surfaces to permit conduction. Allen discloses specific formulations of organic fluorocarbon materials such as those sold by E. I. DuPont de Nemours & Company under the registered trademark TEFLON®.
The present invention discloses additional useful non-stick materials. While the non-stick coatings hereinafter described, at least partially fill microscopic irregularities or interstices in the conductive material, as in Allen, the materials selected for non-stick properties are believed to exhibit a surface effect or chemical bond with the instrument. The application of the chemically bonded non-stick materials does not require subsequent wiping to effect the required conductivity of the electrodes.
SUMMARY OF THE INVENTION
The invention may be described briefly as an electrically conductive non-stick coating for making electrical contact with electrically conductive external materials comprising, an adherently interconnected mass of conductive material deposited on a substrate and a superposed molecular layer of non-stick material chemically bonded thereover. The conductive material is thus rendered nonstick but remains conductive.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Conductive non-stick electrodes are necessary for the proper operation of a RF-type hemostatic instrument. Non-stick may be defined generally as the condition wherein adhered surgical debris may be readily removed from the instrument by wiping with dry or damp surgical gauze.
The table below lists various materials which were investigated.
TABLE______________________________________Source Code Chemical Designation Type of Bond______________________________________Union A-1100 aminopropyl triethoxy- chemicalCarbide silaneDow Z-6040 glycidoxy propyl tri- chemicalCorning methoxysilane (a)Dow Z-6030 methacrylate propyl chemicalCorning trimethoxisaline (a)DowCorning DC-200 silicone fluid (b) mechanicalDowCorning DC-1107 silicone fluid (b) mechanicalDowCorning DC-803 resin (c) mechanicalDowCorning DC-804 resins (c) mechanicalDowCorning DC-805 resin (c) mechanicalDowCorning DC2-2300 lubricant (d) chemicalDowCorning FS-1265 fluorosilicone mechanical______________________________________ (a)-coupling agent (b)silicone fluid DC200 (Me.sub.2 SiO).sub.x DC1107 (Me.sub.2 SiOH).sub.x (c)resin DC800 series (RSiO) Where R may be a phenyl, methyl, dimethyl, phenylmethyl, and trimethyl (d)lubricant DC2-2300 (→ chemical Name) appeared to be superior in application and function.
EXAMPLE OF A PREFERRED EMBODIMENT
Prepare a scalpel having a conductive electrode. This may be accomplished by the procedures described in the above mentioned Allen application, but without a non-stick coating. The conductive electrode may be a screen printed silver paste such as Englehardt A3392 fired at about 500°-600° C. The paste is a mixture of silver, organic carriers and glass frit binder. Upon firing, the organics volatilize off while the silver and glass frit sinter and form an adherent conductive coating along the cutting edge of the scalpel. Thereafter prepare a 0.25% solution of 0.5 gms DC-2-2300 lubricant (50% solids in alcohol) by adding 100 gms of tap water. Dip the scalpel into the lubricant solution; rinse with distilled water, follow by a bake at 100°-110° C. for a period of 5-10 minutes.
DC-2-2300 is a water soluble cationic silicone material which, when applied as described above, renders the surface of the scalpel hydrophobic and protectively lubricated. The baked DC-2-2300 coating is permanently bonded to the blade and is non-migrating for durable protection and non-oily characteristics. While the mechanism for adherence is not fully understood, it appears that the DC-2-2300 is a cationic silicone, which has an affinity for anionic glass frit binder materials used for conductive electrodes. As a result, the silicone preferentially seeks out the glass frit and deposits on it through microscopic pinholes in the electrode. A thin film of silicone thus appears to "plate" onto the glass frit material and becomes part of it. This may be referred to as a chemical bond. This type of bond appears to be superior to a mechanical bond because, under normal operating conditions, it can only be removed chemically or by excessive heat. Mechanical type bonds are more readily removed, especially by abrasion.
Some of the chemically bondable materials tested above appear to be coupling agents. That is, the non-stick material molecularly bonds preferentially to the blade at one end of its organosilicone molecule while the other end thereof remains free. The chemically bonded materials appear to attach to the glass frit with a mono-molecular layer thereby allowing conduction therethrough while at the same time exhibiting the desired non-sticking characteristics.
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An electrically conductive non-stick coating for a substrate for making electrical contact with external materials comprising a layer of conductive material adherently deposited on the substrate and a superposed layer of organic non-stick material on said conductive layer being chemically bonded thereto.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/358,201, filed Feb. 19, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates generally to heat transfer compositions. More particularly, the present invention relates to heat transfer compositions with high electrical resistance for use in power-generating equipment or in engines. Such compositions are particularly useful in fuel cell assemblies.
BACKGROUND OF THE INVENTION
[0003] Heat transfer fluids (e.g., coolants) for internal combustion engines (“ICEs”) are known. Such fluids commonly contain about 50% water and 50% ethylene glycol (by weight) with trace amounts of additives, including corrosion inhibitors. However, the ICE may be obsolete within the coming decades. Fuel cells have emerged as a potential replacement. In general, a fuel cell is an electrochemical device that converts the chemical energy of a fuel into electrical energy. They provide several advantages over ICE. Fuel cells are more efficient in extracting energy from fuel (e.g., 60-70% efficiency as compared to 40% for turbodiesel engines and 30% for gasoline engines). Further, fuel cells are quiet and produce negligible emissions of pollutants. Also, the primary fuel source for the fuel cell is hydrogen, which is more readily available than ICE fuel sources (e.g., gasoline). However, replacement of the ICE with fuel cells may require the concomitant replacement of known heat transfer fluids.
[0004] Typically, a fuel cell consists of an anode (a positively charged electrode), a cathode (a negatively charged electrode) and an electrolyte in between the two electrodes. Each electrode is coated with a catalyst layer. At the anode, a fuel, such as hydrogen, is converted catalytically to form cations, which migrate through the electrolyte to the cathode. At the cathode, an oxidant, such as oxygen, reacts at the catalyst layer to form anions. The reaction between anions and cations generates a reaction product, electricity and heat.
[0005] The current produced in a fuel cell is proportional to the size (area) of the electrodes. A single fuel cell typically produces a relatively small voltage (approximately 1 volt). To produce a higher voltage, several fuel cells are connected, either in series or in parallel, through bipolar plates separating adjacent fuel cells (i.e., “stacked”). As used herein, a fuel cell assembly refers to an individual fuel cell.
[0006] The most common fuel and oxidant used in fuel cells are hydrogen and oxygen. In such fuel cells, the reactions taking place at the anode and cathode are represented by the equations:
Anode reaction: H 2 →2H + +2 e − (1)
Cathode reaction: ½ O 2 +2H + +2 e − →H 2 O (2)
[0007] The oxygen used in fuel cells comes from air. The hydrogen used can be in the form of hydrogen gas or a “reformed” hydrogen. Reformed hydrogen is produced by a reformer, an optional component in a fuel cell assembly, whereby hydrocarbon fuels (e.g., methanol, natural gas, gasoline or the like) are converted into hydrogen. The reformation reaction produces heat, as well as hydrogen.
[0008] Currently, there are five types of fuel cells, categorized by their electrolyte (solid or liquid), operating temperature, and fuel preferences. The categories of fuel cells include: proton exchange membrane fuel cell (“PEMFC”), phosphoric acid fuel cell (“PAFC”), molten carbonate fuel cell (“MCFC”), solid oxide fuel cell (“SOFC”) and alkaline fuel cell (“AFC”).
[0009] The PEMFC, also known as polymer electrolyte membrane fuel cell, uses an ion exchange membrane as an electrolyte. The membrane permits only protons to pass between the anode and the cathode. In a PEMFC, hydrogen fuel is introduced to the anode where it is catalytically oxidized to release electrons and form protons. The electrons travel in the form of an electric current through an external circuit to the cathode. At the same time, the protons diffuse through the membrane to the cathode, where they react with oxygen to produce water, thus completing the overall process. PEMFC's operate at relatively low temperatures (about 200° F.). A disadvantage to this type of fuel cell is its sensitivity to fuel impurities.
[0010] The PAFC uses phosphoric acid as an electrolyte. The operating temperature range of a PAFC is about 300-400° F. Unlike PEMFC's, PAFC's are not sensitive to fuel impurities. This broadens the choice of fuels that they can use. However, PAFC's have several disadvantages. One disadvantage is that PAFC's use an expensive catalyst (platinum). Another is that they generate low current and power in comparison to other types of fuel cells. Also, PAFC's generally have a large size and weight.
[0011] The MCFC uses an alkali metal carbonate (e.g., Li + , Na + or K + ) as the electrolyte. In order for the alkali metal carbonate to function as an electrolyte, it must be in liquid form. As a result, MCFC's operate at temperatures of about 1200° F. Such a high operating temperature is required to achieve sufficient conductivity of the electrolyte. It allows for greater flexibility in the choice of fuels (i.e., reformed hydrogen), but, at the same time, enhances corrosion and the breakdown of cell components.
[0012] The SOFC uses a solid, nonporous metal oxide as the electrolyte, rather than an electrolyte in liquid form. SOFC's, like MCFC's, operate at high temperatures, ranging from about 700 to about 1000° C. (1290 to 1830° F.). The high operating temperature of SOFC's has the same advantages and disadvantages as those of MCFC's. An additional advantage of the SOFC lies in the solid state character of its electrolyte, which does not restrict the configuration of the fuel cell assembly (i.e., an SOFC can be designed in planar or tubular configurations).
[0013] The final type of fuel cell, known as AFC, uses an aqueous solution of alkaline potassium hydroxide as the electrolyte. Their operating temperature is from about 150 to about 200° C. (about 300-400° F.). An advantage to AFC's is that the cathode reaction is faster in alkaline electrolytes than in acidic electrolytes. However, the AFC is very susceptible to contamination, so it requires pure reactants, i.e., pure hydrogen and oxygen.
[0014] In general, the reactions that take place within the fuel cell assembly (i.e., the electrochemical reaction and the reformation reaction) are exothermic. However, the catalyst employed in these reactions is sensitive to heat. To perform optimally, fuel cells should be maintained at a certain temperature that is nearly uniform across each cell in the stack. For example, at high temperatures, the catalyst may be destroyed, while at low temperatures, ice may form within the fuel cell assembly. Thus, to accommodate such temperature requirements, heat transfer compositions are needed.
[0015] Known heat transfer compositions are not amenable for use in fuel cell assemblies. Conventional heat transfer fluids contain corrosion inhibitors, which are generally metal or organic acid salts. Such salts exist as ions in solution. The presence of significant amounts of positive and negative ions in solution provides a path for a “stray electrical current.” Such stray current must be limited for several reasons. First, it may cause electrical shock hazards to the fuel cell operator. Second, such stray current may generate highly explosive hydrogen gas in the cooling system from hydrolysis. Lastly, a significant portion of the electricity generated by the fuel cell may be shorted through the fluid, rather than going to power production, thereby decreasing the efficiency of the fuel cell assembly. Thus, heat transfer fluids used in a fuel cell application must have lower electrical conductivities (i.e., higher electrical resistance) than those used in an ICE application.
[0016] In addition to electrical resistivity, there are additional considerations involved in the development of fuel cell heat transfer fluids. One consideration relates to their application. Fuel cell heat transfer fluids in an automotive application will likely be exposed to metals different from those in an ICE. For example, fuel cell assemblies are expected to contain stainless steel, some aluminum alloys, specially coated aluminum and insulating polymers, whereas ICE contain cast iron, steel, brass, solder and copper. Thus, the fuel cell heat transfer fluids must accommodate different types of metals. Another consideration relates to the physical properties of the heat transfer fluid. In fuel cells, the heat transfer fluid must be able to flow through the assembly in order to maintain uniform temperature across the catalyst layer. This depends on the heat transfer fluid's freezing point, vapor pressure, viscosity, pumpability and laminar flow. In addition to these properties, the ability of the heat transfer fluid to adsorb gases affects the conductivity of the heat transfer fluid. As a final consideration, fuel cell heat transfer fluids, like known heat transfer fluids, must be cost effective.
[0017] In general, water or deionized water have been used as the heat transfer fluid in fuel cell applications. See, U.S. Pat. Nos. 5,252,410; 4,344,850; 6,120,925; and 5,804,326. However, there are several disadvantages to using water as a fuel cell heat transfer fluid. First, a fuel cell may be exposed to extremes in environmental conditions, e.g., broad ranges in temperatures. For example, when the operating temperature of the fuel cell falls below the freezing point of water, the volumetric expansion of water may cause severe damage to the fuel cell. In addition, water may be corrosive to the different metals that are used in fuel cell applications. As a result, inorganic and/or organic inhibitors would be needed to provide long term corrosion protection. However, such inhibitors may change the electrical resistance of the heat transfer fluid. Lastly, the electrical conductivity of water may change over time as a result of accumulating degradation contaminates, by-products, and rust. Each of the above is detrimental to fuel cell performance.
[0018] Efforts at maintaining the temperature above the freezing point of the water heat transfer fluid have focused on the design of the fuel cell assembly. For example, U.S. Pat. No. 6,248,462 B1 (“the '462 patent”) discloses a fuel cell stack that contains a cooler plate interspersed throughout the fuel cell stack. The cooler plate circulates an antifreeze solution through its channels. Such cooler plate prohibits the diffusion of antifreeze into the rest of the fuel cell stack. While the cooler plate addresses the first problem associated with using water as a heat transfer fluid, it fails to obviate them all. Moreover, the addition of such a cooler plate to the fuel cell stack increases the overall weight and volume of the fuel cell stack.
[0019] Efforts to address these shortcomings have focused on the development of fuel cell assemblies that accommodate known antifreezes. For example, U.S. Pat. No. 6,316,135 B1 and International Publication No. WO 01/47052 A1 disclose a fuel cell assembly using only antifreeze as the heat transfer fluid. Such fuel cell assemblies contain certain “wetproofed,” i.e., substantially hydrophobic, components. The design of these assemblies prevents the antifreeze from contaminating the electrolyte and the catalyst, thereby eliminating the need to isolate the antifreeze from the components of the fuel cell assembly (e.g., in a cooler plate). As a result, fuel cell stacks can be made having lower weight and volume than those disclosed in the '462 patent. However, such fuel cell assemblies have several problems, including antifreeze contamination and reduced cooling effectiveness caused by the wetproofed materials.
[0020] New heat transfer fluids have also been developed. For example, each of U.S. Pat. Nos. 5,868,105; 6,101,988; 6,053,132; and 6,230,669 disclose a heat transfer fluid that is a substantially anhydrous, boilable liquid having a saturation temperature higher than that of water. The disclosed heat transfer fluids have a minimum content of water, for example, less than 5% by weight. An example of one such heat transfer fluid is propylene glycol with additives to inhibit corrosion. The use of propylene glycol as a heat transfer fluid suffers limitations. One important limitation lies in its viscosity. At low temperatures, propylene glycol is highly viscous. This reduces its flow through the fuel cell assembly, and consequently, its heat removal efficiency. The end result is a decrease in the efficiency of the fuel cell assembly.
[0021] Mixtures of water and alcohols have also been used as fuel cell heat transfer fluids. See, e.g., Japanese Patent Laying-Open Gazette No. 7-185303. Such mixtures suffer from deficiencies resulting from solvent vaporization. Alcohols, like methanol, may cause some of the heat transfer fluid to vaporize into the cooling layer. Such vaporization raises the pressure of the cooling layer, thereby preventing the heat transfer fluid from flowing at a constant rate through the fuel cell assembly. This effects the ability of the heat transfer fluid to maintain a uniform temperature across the catalyst layer.
[0022] Other fuel cell heat transfer fluids have also been used. For example, water-glycol mixtures, Thenninol D-12 (which is a hydrotreated heavy naphtha (petroleum)) and dielectric fluids (e.g., mineral oils and silicone oils) have been used in fuel cells. See, e.g., U.S. Pat. Nos. 5,565,279; 5,252,410; 5,804,326; and 6,218,038. The fuel cell heat transfer fluid disclosed in International PCT Publication WO 01/23495 comprises water, glycol and corrosion inhibitors. Each of the heat transfer fluids above has deficiencies, including flammability and increased conduction (i.e., reduced resistivity).
[0023] Thus, there remains a need for a heat transfer fluid composition that resists corrosion, freezing, vaporization and gas adsorption, while at the same time, provides long lasting performance and high electrical resistance.
SUMMARY OF THE INVENTION
[0024] One objective of this invention is to provide a heat transfer composition for use in fuel cell assemblies.
[0025] It is another objective of this invention to provide a heat transfer composition for use in fuel cell assemblies with high electrical resistance.
[0026] It is another objective of this invention to provide a heat transfer composition for fuel cell assembly with electrical resistance greater than about 5 KΩ·cm.
[0027] It is another objective of this invention to provide a heat transfer composition that confers corrosion protection.
[0028] It is another objective of this invention to provide a heat transfer composition that confers freezing protection.
DETAILED DESCRIPTION
[0029] In order that this invention may be more fully understood, the following detailed description is set forth. However, the detailed description is not intended to limit the inventions that are described by the claims.
[0030] The present invention provides heat transfer compositions for use in fuel cell assemblies. More particularly, the present invention provides heat transfer compositions for use in fuel cell assemblies comprising:
[0031] (a) from about 0% to about 90% by weight alcohol;
[0032] (b) from about 1% to about 90% by weight polyalkylene oxide;
[0033] (c) from about 0% to about 50% additive by weight;
[0034] (d) balance being water.
[0035] Such heat transfer compositions are particularly well suited for use in fuel cell assemblies to remove assuasive heat and maintain proper operating temperature while providing high electrical resistance.
[0036] The first component in the compositions of the present invention is alcohol. Suitable alcohols include monohydric or polyhydric alcohols and mixtures thereof. Preferred alcohols are methanol, ethanol, propanol, butanol, furfurol, tetrahydrofurfuryl alcohol (“THFA”), ethoxylated furfuryl, ethylene glycol, diethylene glycol, triethylene glycol, 1,2 propylene glycol, 1,3 propylene glycol, dipropylene glycol, butylene glycol, glycerol, monoethylether of glycerol, dimethyl ether of glycerol, sorbitol, 1,2,6-hexanetriol, trimethylolpropane, alkoxy alkanols (such as methoxyethanol) and mixtures thereof. More preferably, the alcohol is ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, glycerol, tetrahydrofurfuryl alcohol and mixtures thereof.
[0037] The alcohol is present in the composition in an amount of about 0% to about 90% (by weight), and preferably, about 20% to about 80%. More preferably, the alcohol is present in an amount of about 30% to about 70%, and even more preferably, about 40% to about 60%.
[0038] The second component in the compositions of the present invention is a polyalkylene oxide. Polyalkylene oxides useful in the compositions of the present invention have an average molecular weight from about 55 to about 380,000, and more preferably from about 135 to about 10,000.
[0039] Suitable polyalkylene oxides are polyoxyethylene (“EO”), oxypropylene (“PO”), oxybutylene (“BO”) polymers and mixtures thereof. Preferably, the polyalkylene oxide is a copolymer of EO and PO polymers having a weight ratio of EO to PO from about 1:100 to about 100:1, preferably from about 1:3 to about 3:1. More preferably, the polyalkylene oxide is UCON LB-135, UCON LB-165-Y24, UCON LB-165Y3, UCON LB-165, UCON 1281, UCON LB-65, UCON 50-HB-55, UCON 50-HB-260, UCON 50-HB-100, UCON 50-HB-5100, UCON 75-H-1400, UCON 75-H-90,000, UCON 50-HB-260-Y3, UCON HTF 500, LB165 Y24, LB165Y3; H1400, HB-100, HB-260, 50-HB-260-Y3, SYNALOX®, Polyglycol E200, Polyglycol E300, Polyglycol E400, Polyglycol E600, Polyglycol E900, Polyglycol E1000, Polyglycol E1450, Polyglycol E3350, Polyglycol E4500, Polyglycol E8000, Polyglycol E300NF, Polyglycol E400NF, Polyglycol E600NF, Polyglycol E900NF, Polyglycol E1000NF, Polyglycol E1450NF, Polyglycol E3350NF, Polyglycol E4500NF, Polyglycol E8000NF, MPEG 350, MPEG 550, MPEG 750, Polyglycol P-425, Polyglycol P-1200, Polyglycol P-200, Polyglycol P-4000, Polyglycol L-910, Polyglycol L-1150, Polyglycol 112-2, Polyglycol 15-200, Polyglycol EP530, Carbowax PEG 200, Carbowax PEG 300, Carbowax PEG 400, Carbowax PEG 540 Blend, Carbowax PEG 600, Carbowax PEG 900, Carbowax PEG 1000, Carbowax PEG 1450, Carbowax PEG 3500, Carbowax PEG 4600, Carbowax PEG 8000, Carbowax PEG 300 Sentry, Carbowax PEG 400 Sentry, Carbowax PEG 600 Sentry, Carbowax PEG 900 Sentry, Carbowax PEG 1000 Sentry, Carbowax PEG 1450 Sentry, Carbowax PEG 3350 Sentry, Carbowax PEG 4600 Sentry, Carbowax PEG 8000 Sentry, Carbowax MEG 350, Carbowax MEG 550, Carbowax MEG 750, Polypropylene Glycol 425, Polypropylene Glycol 1025 and Polypropylene Glycol 2025 from Union Carbide/Dow Chemical, PLURACOL E200, PLURACOL E300, PLURACOL E400, PLURACOL E600, PLURACOL E1000, PLURACOL E1450, PLURACOL E2000, PLURACOL E4000, PLURACOL E4500, PLURACOL E8000, PLURACOL P410, PLURACOL P1010, PLURACOL P2010, PLURACOL P4010 and Pluronic L-92 from BASF, POLY-G 200, POLY-G 300, POLY-G 400, POLY-G B1530, POLY-G 600, POLY-G 1000, POLY-G 1500, POLY-G 2000, POLY-G 300NF, POLY-G 400NF, POLY-G 600NF, POLY-G D400, POLY-G D1200, and POLY-G D2000 from Olin; Silwet L-7200, Silwet L-7230, Silwet L-7600, Silwet L-7604, Silwet L-7607, Silwet L-7657, Silwet L-7650, Silwet L-7664, Silwet L-8600, Silwet L-8620, Silwet L-77, Formasil 891, Formasil 593, Formasil 433, or Formasil 891 from Osi Specialties; or TBF-190 from Path Silicones, Inc.
[0040] Even more preferably, the polyalkylene oxide is UCON LB-135, UCON LB-165-Y24, UCON LB-165Y3, UCON LB-165, UCON 1281, UCON LB-65, UCON 50-HB-55, UCON 50-HB-260, UCON 50-HB-100, UCON 50-HB-5100, UCON 75-H-1400, UCON 75-H-90,000, UCON 50-HB-260-Y3, UCON HTF 500, LB165 Y24, LB165Y3; H1400, HB-100, HB-260, 50-HB-260-Y3, Pluronic L-92, Polyglycol P-425, Formasil 433, Formasil 891, Silwet L-7200, Silwet L-7230, Silwet L-7600, Silwet L-7604, Silwet L-7607, Silwet L-7657, Silwet L-7650, Silwet L-7664, Silwet L-8600, Silwet L-8620, Silwet L-77 or TBF-190.
[0041] The polyalkylene oxide is present in the composition in an amount of about 1% to about 90% (by weight), and preferably, about 2% to about 75%. More preferably, the polyalkylene oxide is present in an amount of about 3% to about 50%, and even more preferably, about 5% to about 25% (by weight).
[0042] Preferably, the weight ratio of alcohol to polyalkylene oxide is about 3:1, and more preferably about 5:1, and even more preferably about 15:1.
[0043] The third component in the compositions of the present invention is one or more additives. Such additives include, dielectric fluids [e.g., mineral, synthetic, and silicone fluids (e.g., Armul series from Witco Corporation) or oils and mixture thereof]; wetting agents (Rhodafac PL-6 from Rhodia); surfactants (e.g, Mazon RI or 14a series from BASF; Deriphat series from Henkel Chemical; Rhodameen T-15, Miranol CS Conc, Mirapol WT, Mirataine H2C-HA and Miramine TO-DT from Rhodia); antifoam and/or lubricants (e.g., polysiloxanes and polydimethylsiloxanes, Rhodafac PA-32, Lubrophos RD-570 and Lubrophos LB-400 from Rhodia; TBA4456 from Path Silicones, Inc.); solvents (e.g., Exxsol series from ExxonMobil); and corrosion inhibitors (TBF-77A and TBF-193 from Path Silicones, Inc.) and other additives known in the art that do not adversely affect the fuel cell assembly by reduction of electrical resistance.
[0044] The additive is present in the composition in an amount of about 0% to about 50% (by weight), and preferably about 1% to about 30%. Even more preferably, the additive is present in an amount about 2% to about 20%, and yet even more preferably, about 3% to about 10%.
[0045] Preferred compositions of this invention are described below.
[0046] One preferred composition comprises:
[0047] (a) from about 20% to about 80% by weight of an alcohol;
[0048] (b) from about 2% to about 75% by weight of a polyalkene oxide;
[0049] (c) from about 1% to about 30% by weight of an additive; and
[0050] (d) balance being water.
[0051] A more preferred compositions comprises:
[0052] (a) from about 30% to about 70% by weight of an alcohol;
[0053] (b) from about 3% to about 50% by weight of a polyalkene oxide; and
[0054] (c) from about 2% to about 20% by weight of an additive; and
[0055] (d) balance being water.
[0056] An even more preferred composition comprises:
[0057] (a) from about 40% to about 60% by weight of an alcohol;
[0058] (b) from about 5% to about 25% by weight of a polyalkene oxide;
[0059] (c) from about 3% to about 10% by weight of an additive; and
[0060] (d) balance being water.
[0061] According to one embodiment, the heat transfer compositions of the present invention provide high electrical resistance. Such heat transfer compositions have electrical resistivity values greater than about 5 KΩ·cm.
[0062] According to another embodiment, the heat transfer compositions of the present invention resist corrosion, freezing, vaporization and gas adsorption, while at the same time, provide long lasting performance without a change in electrical resistance.
[0063] The heat transfer compositions of the present invention can be prepared as concentrates. Such concentrates can be diluted with water.
[0064] The present invention also provides fuel cell systems comprising one or more fuel cell assemblies and a heat transfer composition of the present invention. Such fuel cell assemblies are selected from the group consisting of PEMFC, PAFC, MCFC, SOFC and AFC.
[0065] The present invention further provides methods for removing heat from a fuel cell assembly. Such methods comprise the step of contacting the fuel cell assembly, either directly or indirectly, with a heat transfer composition of the present invention. Such fuel cell assembly is selected from the group consisting of from PEMFC, PAFC, MCFC, SOFC and AFC.
[0066] In order that this invention may be better understood, the following examples are set forth.
EXAMPLES
[0067] 138 different heat transfer compositions were prepared (Examples 1-138). The components of these compositions are described in Tables 1-23 below. The abbreviations used in the tables below are as follows: Component A is alcohol, Component B is polyalkylene oxide, Component C is additive, Component D is water, EG is ethylene glycol, PG is propylene glycol, G is glycerol and THFA is tetrahydrofurfurol alcohol.
TABLE 1 Example No. Component (wt %) 1 2 3 4 5 6 Water 25 50 25 75 Inorganic Antifreeze 1 100 75 50 Organic Antifreeze 2 100 75 50 Electrical Resistance 1.7 0.7 0.4 13 0.5 0.3 (KΩ · cm)
[0068] [0068] TABLE 2 Example No. Component (wt %) 7 8 9 10 11 12 A EG 100 75 60 50 A PG 100 D Water 100 25 40 50 Electrical Resistance 0.9 5.9/2.2 1 2.4 2.0 1.2 50/7.3 1 (MΩ · cm)
[0069] [0069] TABLE 3 Example No. Component (wt %) 13 14 15 16 17 18 A PG 75 60 50 A 1,3 Propanediol 100 75 60 D Water 25 40 50 25 40 Electrical Resistance 3.6 2.2 1.1 33.3/11 1 11.3 6.0 (MΩ · cm)
[0070] [0070] TABLE 4 Example No. Component (wt %) 19 20 21 22 23 24 A 1,3 Propanediol 50 A G 100 75 60 50 50 A PG 50 D Water 50 25 40 50 Electrical Resistance 2.0 100 25/2.6 1 15 5.7 100 (MΩ · cm) after ASTM D1384 1.0
[0071] [0071] TABLE 5 Example No. Component (wt %) 25 26 27 28 29 30 A G 25 25 A PG 25 25 A EG 25 50 B UCON LB-135 100 B UCON LB-165-Y24 100 B UCON LB-165Y3 100 D Water 50 50 25 Electrical Resistance 2.3 3.0/1.0 1 4.9 >100 >100 >100 (MΩ · cm)
[0072] [0072] TABLE 6 Example No. Component (wt %) 31 32 33 34 35 36 B UCONLB-165 100 B UCON 1281 100 B UCON LB-65 100 B UCON 50-HB-55 100 75 60 D Water 25 40 Electrical Resistance >100 >100 >100 25 1.6 0.5 (MΩ · cm)
[0073] [0073] TABLE 7 Example No. Component (wt %) 37 38 39 40 41 42 B UCON 50-HB-55 50 B UCON 50-HB-260 100 75 60 50 B UCON 50-HB-100 100 D Water 50 25 40 50 Electrical Resistance 0.3 >100 3.7 0.7 0.3 100 (MΩ · cm)
[0074] [0074] TABLE 8 Example No. Component (wt %) 43 44 45 46 47 48 B UCON 50-HB-100 75 60 50 B UCON 50-HB-5100 100 75 60 D Water 25 40 50 25 40 Electrical Resistance 4.0 0.7 0.3 100 1.5 0.2 (MΩ · cm)
[0075] [0075] TABLE 9 Example No. Component (wt %) 49 50 51 52 53 54 B UCON 50-HB-5100 50 B UCON 75-H-1400 100 75 60 50 B UCON 75-H-90,000 100 D Water 50 25 40 50 Electrical Resistance 0.06 100 9.1 3.1 1.4 100 (MΩ · cm)
[0076] [0076] TABLE 10 Example No. Component (wt %) 55 56 57 58 59 60 C Polydimethysiloxane 100 C Octamethyltrsiloxane 36 C Decamethyltetrasiloxane 28 C Dodecamethyl- 17 pentasiloxane C Polydimethylsiloxane 17 C Vegetable Oil 100 C Soybean Oil 100 C Corn Oil 100 C Castrol Oil 100 Electrical Resistance >100 >100 >100 >100 >100 >100 (MΩ · cm)
[0077] [0077] TABLE 11 Example No. Component (wt %) 61 62 63 64 65 66 A G 50 25 A EG 25 50 B LB165 Y24 44 B LB165Y3 16 B H1400 5 5 C Petroleum Oil 100 C Cottonseed Oil 100 C Pine Oil 100 C Soybean oil 40 D Water 20 20 Electrical Resistance >100 >100 >100 >100 11.1 5.9 (MΩ · cm) after ASTM D1384 100 0.2 0.2
[0078] [0078] TABLE 12 Example No. Component (wt %) 67 68 69 70 71 72 A EG A G A PG 20 B H1400 B HB-100 40 B HB-260 20 B UCON 50-HB-260-Y3 100 75 60 B UCON HTF 500 100 75 D Water 20 25 40 25 Electrical Resistance 6.3 >100 9.1 3.4 8.3 (MΩ · cm) after ASTM 01384 1.0
[0079] [0079] TABLE 13 Example No. Component (wt %) 73 74 75 76 77 78 A THFA 100 B UCON HTF 500 60 B Pluronic L-92 100 50 C Mazon RI-4a 100 C Syltherm XLT 100 D Water 40 50 Electrical Resistance 1.9 2.0 0.008 >100 0.1 >100 (MΩ · cm)
[0080] [0080] TABLE 14 Example No. Component (wt %) 79 80 81 82 83 84 C Syltherm XLT 50 C Syltherm 800 100 50 C Rhodafac PL-6 100 50 C Rhodafac PA-32 100 D Water 50 50 50 Electrical Resistance 1.0 >100 11.1 0.2 0.04 0.5 (MΩ · cm)
[0081] [0081] TABLE 15 Example No. Component (wt %) 85 86 87 88 89 90 C Rhodameen T-15 100 C Deriphat 151C 100 C Lubrhophos RD-510 100 C Lubrhophos LB-400 100 C Exxsol D 130 100 50 D Water 50 Electrical Resistance 1.3 0.3 0.4 0.5 >100 0.6 (MΩ · cm)
[0082] [0082] TABLE 16 Example No. Component (wt %) 91 92 93 94 95 96 B Polyglycol P-425 100 50 B Formasil 433 100 50 B Formasil 891 100 50 D Water 50 50 50 Electrical Resistance 100 0.05 >100 1.2 1.3 0.03 (MΩ · cm)
[0083] [0083] TABLE 17 Example No. Component (wt %) 97 98 99 100 101 102 B Formasil 593 100 B Silwet L-7200 100 B Silwet L-7230 100 B Silwet L-7600 100 50 B Silwet L-7657 100 D Water 50 Electrical Resistance >100 >100 >100 100 0.2 1.4 (MΩ · cm)
[0084] [0084] TABLE 18 Example No. Component (wt %) 103 104 105 106 107 108 B Sliwet L-7657 50 B Silwet L-7650 100 50 B Siwet L-77 100 50 D Water 50 50 50 100 Electrical Resistance 0.03 100 0.4 1.2 0.1 0.4 (MΩ · cm)
[0085] [0085] TABLE 19 Example No. Component (wt %) 109 110 111 112 113 114 A EG 70 70 70 70 70 70 B Pluronic L-92 5 B Polyglycol P425 5 C Syltherm XLT 5 C Syltherm 800 5 C Rhodafac PL-6 5 5 C Exxsol D130 D Water 25 25 25 25 25 25 Electrical Resistance 1.5 1.5 2.1 0.03 1.6 0.8 (MΩ · cm)
[0086] [0086] TABLE 20 Example No. Component (wt %) 115 116 117 118 119 120 A EG 70 70 70 70 A THFA 10 10 B Formasil 433 5 B Silwet L-7600 5 B Silwet L-7650 5 B Silwet L-77 5 B 50-HB-260-Y3 45 50 D Water 25 25 25 25 45 40 Electrical Resistance 1.6 1.0 1.8 1.0 0.7 1.1 (MΩ · cm)
[0087] [0087] TABLE 21 Example No. Component (wt %) 121 122 123 124 125 126 A THFA 30 A 1,3 Propanediol 75 70 A EG 73.5 73.5 73.5 B 50-HB-260-Y3 30 5 B Formasil 433 4.4 B Silwet 7650 4.4 C Syltherm XLT 4.4 D Water 40 25 25 22.4 22.4 22.4 Electrical Resistance 8.5 11.6 7.9 2.4 2.4 1.2 (MΩ · cm) After ASTM D-1384 1.1 0.8 0.04 0.04 1.0
[0088] [0088] TABLE 22 Example No. Component (wt %) 127 128 129 130 131 132 A EG 67 70 70 70 70 A PG 67 B TBF-190 5 C TBF-193 5 C TBF-77A 5 C TBA-4456 5 D Water 33 33 25 25 25 25 Electrical Resistance nt nt 0.8 0.6 2.1 0.2 (MΩ · cm)
[0089] [0089] TABLE 23 Example No. Component (wt %) 133 134 135 136 137 138 A EG 74.99 70 70 70 70 70 B Silwet L-7604 5 B Silwet L-7664 5 B Sliwet L-7607 5 B Silwet L-8600 5 B Silwet L-8620 C TBA-4456 0.01 5 D Water 25 25 25 25 25 25 Electrical Resistance 2.2 1.4 0.8 1.6 0.7 1.0 (MΩ · cm)
[0090] Measurement of Solution Resistance
[0091] Electrical resistivity, R, is defined in ASTM standard D 1125, as the ac resistance in ohms measured between opposite faces of a centimeter cube of an aqueous solution at a specified temperature. Electrical resistivity is measured by applying an ac drive voltage between parallel platinum plates of known surface area and separation distance and measuring the resistance of the solution. The actual resistance of the cell, R x , is represented by the formula:
R
x
=R·L/A
[0092] where L is the separation distance of the plates in cm, A is the cross sectional area of the plates in cm 2 and R is the resistivity of the fluid in MΩ·cm. Resistivity values greater than about 5 KΩ·cm are considered acceptable for fuel cell applications.
[0093] Solution resistivity measurements were made using a Traceable© Bench Conductivity Meter 4163 with a glass platinum flow through probe. The instrument was calibrated to NIST (National Institute of Standards and Technology) standards. The probe was initially rinsed with deionized (“DI”) water, dried and rinsed in the test solution to avoid dilution and contamination of the test solution. The probe was immersed in approximately 50 ml of test solution. Measurements were taken as the probe was moved through the solution in a stirring motion. The stirring motion helps to prevent polarization. Electrical resistivity measurements were made following ASTM test method D 1125.
[0094] Tables 1-23 show that the heat transfer compositions of the present invention provide high electrical resistance (i.e., electrical resistance values greater than about 5 KΩ·cm). For example, Examples 35-37, 39-41, 43-45, 47-49, 51-53, 65-67, 69-70, 72-73, 77, 92, 94, 96, 101, 103, 105, 107, 109, 114-121, 123, 125-126, 129, and 134-137 have electrical resistances of about 11.1 to about 0.03 MΩ·cm. In contrast, the control compositions containing inorganic antifreeze (Examples 1-3) or organic antifreeze (Examples 4-6) exhibit low electrical resistances of 1.7 to 0.3 KΩ·cm.
[0095] Laboratory Modified ASTM D-1384-“Standard Test Method for Corrosion Test for Engine Coolants in Glassware”
[0096] Thirteen heat transfer compositions were prepared and evaluated under the conditions (modified as explained below) set forth by ASTM D1384. See Annual Book of ASTM Standards, section 15, Volume 15.05 (2000), incorporated herein by reference. ASTM D1384 is a standard test method for general corrosion of a variety of metals typically found in the cooling system and/or heating system of internal combustion engines. ASTM D1384 was modified in order to evaluate the metals that will be used in fuel cell assembly. Such metals include stainless steel, aluminum alloys and insulating polymers. ASTM D1384 was further modified so that the test formulations were not diluted with “corrosive water” (i.e., DI water containing 100 ppm each of SO 4 2 , HCO 3 and Cl − , all added as Na + salts) Such dilution accounts for variations in water added to traditional antifreeze concentrates, which may not occur with regard to fuel cell heat transfer fluids.
[0097] After preparing the compositions and subjecting them to the test procedures set forth in ASTM D1384 (the metal specimens were immersed for 336 hours in the heat transfer composition and maintained at a temperature of 88° C.), the weight change of the metal specimens were measured (average of duplicate measurements). A negative weight loss signifies a weight increase due to the formation of a protective coating on the metal surfaces. A weight loss of 10 mg for each of copper, brass, steel and cast iron, and 30 mg for each of aluminum and solder is the maximum allowed to pass ASTM D1384.
[0098] As shown in Table 24, the heat transfer compositions of the present invention provide general corrosion inhibition for both stainless steel and aluminum. For example, Examples 66-67, 123 and 125-126 exhibited stainless steel weight loss of <0.3 mg and Examples 65-67, 123 and 125 exhibited aluminum weight loss of <10 mg. Table 24 also shows that these formulations are effective general corrosion inhibitors for other metals compared to water (Example 7), water/propylene glycol mixture (Example 15 and 127), water/1,3 propanediol mixture (Example 122) and water/ethylene glycol mixture (Example 128) in ASTM D1384.
TABLE 24 Metal Weight Loss (mg) Modified ASTM D1384 Stainless Example No. Copper Brass Steel Steel Cast Iron Aluminum 7 2 5 219 nt 450 110 15 −1.4 −1.1 5.3 nt 8.7 −1.0 15 −2.3 −1.8 nt −1.3 nt 1.4 64 0.2 −0.6 −0.4 nt −1.1 −3.5 64 −1.9 −1.2 nt −0.7 nt −2.6 65 0.9 0.1 4.3 nt 24.8 −0.4 66 −1.4 −1.2 nt −0.1 nt 5.5 67 3.6 0.6 139 nt 206 −2.7 67 0.1 0.6 nt 0.1 nt −3.1 122 2.7 1.1 7.4 nt 145 0.6 122 1.4 1.0 nt −1.3 nt 32 123 2.9 1.2 50 nt 145 10 123 1.5 0.5 nt −1.6 nt 0.4 124 4.1 2.9 115 nt 254 0.3 124 4.1 2.2 nt 0.0 nt 1.8 125 1.5 2.7 82 nt 223 −1.6 125 2.6 0.3 nt −0.1 nt 1.8 126 −3.8 −1.3 10 nt 230 −2.4 126 −2.2 −1.2 nt 0.3 nt 1.8 127 4 5 214 nt 345 15 128 4 11 974 nt 1190 165
[0099] After completion of the modified ASTM D1384 test, electrical resistance was measured for 10 heat transfer compositions (Examples 21, 64-67, 122-126). As shown in Tables 11-12 and 21, the compositions of the present invention provide high electrical resistance even after exposure to different metal surfaces over extended test times. For example, Examples 65-67, 123 and 125-126 exhibit an electrical resistance of about 1 to 0.04 MΩ·cm after the ASTM D1384 test.
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The present invention relates generally to heat transfer compositions. More particularly, the present invention relates to heat transfer compositions with high electrical resistance for use in power-generating equipment or in engines. Such compositions are particularly useful in fuel cell assemblies.
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[0001] This is a 111A application of Provisional Application Ser. No. 06/570,787 filed May 13, 2004.
FIELD OF THE INVENTION
[0002] The invention relates generally to the field of dispensing of digital information from an automated transaction machine, and in particular to the dispensing of a CD or DVD.
BACKGROUND OF THE INVENTION
[0003] The use of CDs (compact discs) and DVDs (digital video discs) for recording and/or storing digital information is well known. Such digital information can include audio, sound, music, digital still images, video, data files, and the like.
[0004] Automated transaction machines are also well known. An example of an automated transaction machine is an automated teller machine (ATM) used for banking transactions. Such ATM are typically located in retail or service locations.
[0005] Automated transaction machines have been employed to dispense digital information disposed on CDs and/or DVDs. U.S. Pat. No. 5,949,688, incorporated herein by reference, is directed to a compact disc recorder/vending machine. U.S. Patent Application No. 2003/0040838, incorporated herein by reference, is directed to a digital media vending system for distributing digital media content. In such systems, a supply of recordable digital media (for example, CDs and DVDs) are provided and digital information is transferred to the digital media using a media writer (for example, a compact disc recording device or a digital versatile disc burner) which “burns” the digital media containing the digital information.
[0006] Accordingly, there exists a need for an apparatus and method to transport at least one recording media from the supply to the media writer so that transfer of the digital information to the digital media can occur. That is, there exists a need for an automated system for dispensing recordable digital media from a supply area.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide an automated system for dispensing digital information disposed on digital recording media, for example, a CD or DVD.
[0008] These objects are given only by way of illustrative example, and such objects may be exemplary of one or more embodiments of the invention. Other desirable objectives and advantages inherently achieved by the disclosed invention may occur or become apparent to those skilled in the art. The invention is defined by the appended claims.
[0009] According to one aspect of the invention, there is provided an automated system for dispensing digital information disposed on a CD or DVD.
[0010] According to another aspect of the present invention, there is provided an automated system for dispensing digital information disposed on a digital medium having a circular opening. The system comprises a supply area adapted to receive a plurality of digital medium, the supply area including a spindle having a non-circular cross-sectional shape adapted to receive the plurality of digital medium through the circular opening to form a stack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of the embodiments of the invention, as illustrated in the accompanying drawings. The elements of the drawings are not necessarily to scale relative to each other.
[0012] FIG. 1 shows a schematic of an automated transaction machine employed to dispense digital information disposed on recordable media.
[0013] FIG. 2 shows an exemplary recordable medium employable by the automatic transaction machine of the present invention.
[0014] FIG. 3 shows a plurality of recordable medium disposed in a stack.
[0015] FIG. 4 shows a prior art spindle.
[0016] FIG. 5 shows a spindle in accordance with the present invention.
[0017] FIG. 6 shows a perspective view of a spindle in accordance with the present invention.
[0018] FIG. 7 shows a front view of the spindle of FIG. 6
[0019] FIG. 8 shows a cross-sectional view of the spindle of FIG. 7 taken along line 8 - 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following is a detailed description of the preferred embodiments of the invention, reference being made to the drawings in which the same reference numerals identify the same elements of structure in each of the several figures.
[0021] Referring to FIG. 1 , there is shown a schematic of an automated transaction machine 10 employed to dispense digital information disposed on recordable media, such as CDs and/or DVDs. Machine 10 includes a supply area 12 of blank/recordable digital media (for example, CDs and DVDs), a source of digital information 14 , and a media writer 16 which burns the digital media containing the digital information. Known examples of a media writer include a compact disc recording device or a digital versatile disc burner. The source can be any source of digital information, for example, a computer, the internet, a CD, a DVD, a digital file, and the like.
[0022] Two known types of recordable media are CDs and DVDs. As shown in FIG. 2 , CDs and DVDs have a circular shape and include a circular opening 18 about which the recordable media rotates. With such a configuration, a plurality of CDs and DVDs can be formed as a stack 20 and a spindle 22 or other member can be disposed in their opening 18 to secure/hold the stack of CDs/DVDs, as shown in FIG. 3 .
[0023] With the recordable media disposed as a stack, supply area 12 can supply/dispense the stacked recordable media using gravity. That is, as shown in FIG. 3 , a stack/supply 20 of recordable media can be disposed in a vertical stack wherein gravity is employed to individually release/transport one recordable media from supply area 12 to media writer 16 .
[0024] Applicants have found that the cross-sectional shape of spindle 22 can affect the gravity-feed of the recordable media.
[0025] Referring to FIG. 4 , in current systems, a spindle 21 has a solid outer diameter less than the diameter of opening 18 . In such current spindles, the spindle may be solid or hollow.
[0026] Referring to FIGS. 5-8 , in the present invention, spindle 22 has an outer diameter less than the diameter of opening 18 . However, spindle 22 of the present invention does not have a solid outer diameter, that is, it does not have a circular cross-sectional shape. Rather, Applicants have determined that reducing the surface area of the spindle, without the need for reducing the outer diameter, promotes the gravity-feed of individual recording media from a supply area.
[0027] FIG. 5 shows a perspective view of a preferred configuration of spindle 22 disposed in a supply area. FIG. 6 shows another perspective view of spindle 22 of the present invention. FIG. 7 shows a front view while FIG. 8 shows a cross-sectional view of spindle 22 taken along lines 8 - 8 of FIG. 7 . As best shown in FIG. 8 , spindle 22 does not have a circular cross-sectional shape. Rather, spindle 22 has a cross-sectional shape representative of a fluted arrangement/configuration. Such an arrangement can be additionally be describe as slots, grooves or keyways within the spindle such that the spindle does not have a circular cross-sectional shape.
[0028] Spindle 22 can be comprised of any material, including a polymer or metal, or a combination thereof. Suitable metals include aluminum, steel, steel alloy, brass, iron, bronze, nickel. Further, the surface of spindle 22 can be polished and/or have a finish, such as an anodized finish.
[0029] The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.
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An automated system for dispensing digital information disposed on a digital medium having a circular opening. The system includes a supply area adapted to receive a plurality of digital medium, the supply area including a spindle having a non-circular cross-sectional shape adapted to receive the plurality of digital medium through the circular opening to form a stack.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/138,956 filed May 27, 2005 (now allowed), which claims the benefit of the filing date of GB Patent Application No. 0426177.2 filed Nov. 29, 2004 and EP Patent Application No. 05252010.3 filed Mar. 31, 2005, all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to digital medical image analysis, particularly by means of a computer-implemented algorithm.
[0004] 2. Background
[0005] Medical images are a valuable tool for detection, diagnosis and evaluation of response to treatment of disease, as well as surgical planning. A variety of physical techniques or modalities have been developed for producing these images, including projection X-rays, computed tomography (CT), ultrasound (US), positron emission tomography (PET) and magnetic resonance imaging (MRI). The images may be generated digitally (using, e.g., US, CT or MRI) or digitized from an analog image (e.g., film). Conventionally, trained radiologists or other clinicians review these images to facilitate detection of an abnormality, for example. A radiologist or clinician can review and annotate the digitized images and generate a report based on the review. All of the resultant data may be stored for later retrieval and analysis.
[0006] The task of a user (e.g., radiologist, clinician, etc.) can be made easier by reviewing the images with application software providing visualization and analysis tools to manipulate and evaluate these images in 2, 3 and 4 dimensions (for images that vary in time). However, the evaluation process can result in missed abnormalities because of normal limitations in human perception. This perception issue is worsened by the ever-increasing amount of information now available to the radiologist or clinician for review. Now, in the information-intense but resource- and time-constrained environments in which radiologists work, they are forced to make expedited decisions, potentially resulting in increased miss rate.
[0007] Computer Assisted Detection or Diagnosis (CAD) software has been designed to reduce errors of human perception, as well as to enhance the productivity of radiologists or other clinicians in an information-intense environment, by automatically performing for the user the more mundane tasks (e.g., automatic measurement) and focusing the radiologist's limited time on interpretation. CAD software can automatically or semi-automatically detect and measure abnormalities, characterize abnormalities, measure temporal progression or regression of disease and surgically plan based on CAD information. For example, the applicant's MedicHeart™, MedicLung™ and MedicColon™ diagnostic software perform semiautomatic and automatic analysis of CT scans of the heart, lung and colon, respectively.
[0008] CAD software uses algorithms to analyze a given medical image. No one algorithm is robust enough to analyze accurately all types of medical images. For example, abnormal structures in the lung have different image characteristics from those in the colon. Images acquired using different modalities or combinations of modalities (e.g., MRI, CT, US) have different resolutions and image characteristics, and hence require more specific algorithms to analyze them. Given a choice of CAD algorithms designed to more closely address the needs of a specific disease state or acquisition modality, the user of CAD software would likely opt for that algorithm designed more specifically (e.g., the clinical condition, modality or focused anatomy of the dataset) and select the appropriate algorithm for analysis of that type of image. Alternatively, the user may only be interested in analyzing one type of image and therefore only use one type of algorithm.
[0009] U.S. Pat. No. 5,235,510 to Yamada et al. describes a system for automating the selection of an appropriate algorithm for the analysis of a medical image by inspecting attribute data, identifying the image type and selecting an algorithm appropriate for that type.
[0010] Many CAD algorithms rely on a predefined set of parameter values for detection. For example, the Agatston method, as originally described in “Quantification of Coronary Artery Calcium Using Ultrafast Computed Tomography”, Agatston A S, Janowitz W R, Hildner F J et al., J Am Coll Cardiol 1990 15:827-832 (hereinafter “the Agatston article”), applies a threshold of 130 Hounsfield units (HU) to the CT image, and identifies all pixels above that threshold as containing calcium. A scoring system is then used to rate the severity of the calcification, based on the number of pixels above the threshold multiplied by a weight based on the highest intensity within the calcification. If the highest intensity is between 130 and 200 HU, then the weight is 1. If the highest intensity is between 200 and 300 KU, the weight is 2. If the highest intensity is greater than 300 KU, the weight is 3. The threshold of 130 HU works reasonably well with the types of CT scan images available at the time of publication of the Agatston article, but there is no general agreement as to how this threshold should be modified for new types of CT scan, such as data acquired with thinner collimation.
[0011] Alternatively, the CAD application software may allow the user to set the values of parameters used in the analysis. For example, CAR® software (available from Medicsight PLC, a company located in London, England), aspects of which are described in a prior patent application GB0420147.1 to Dehmeshki (published as GB2418094 A), provides a user interface allowing the user to interactively modify the parameters used by an algorithm. The results of any selected parameters are available to the user. While this user interaction provides great flexibility, the optimum parameter values may not be known. For example, the user may select a less optimal parameter value for analysis. In another example, the user may select the parameter value by trial and error, further impacting productivity.
[0012] Using predefined parameter values has the advantage of simplicity and consistency, but may not always provide better results, as compared to using parameter values that are not predefined. While user-defined parameter values provide greater flexibility, they may not provide better results unless the optimum parameter values are chosen. Allowing the user to set parameter values adds to the complexity of CAD software.
[0013] U.S. Pat. No. 6,058,322 describes an interactive user modification function in which the software displays detected microcalcifications, and the user may then add or delete microcalcifications. The software modifies its estimated likelihood of malignancy accordingly.
[0014] EP-A-1398722 describes a “dynamic CAD” system in which an image is processed to identify features of interest and to extract parameters from the features of interest. The image is post-processed using the extracted parameters to generate a second image. The post-processing parameters are derived from the image itself, rather than from metadata associated with the image.
[0015] U.S. Pat. No. 5,878,746 describes a computerized diagnostic system, which may process medical images to derive feature vectors. The system inputs the feature vectors together with other clinical parameters into a “fact database”, which is then processed to obtain a diagnosis.
BRIEF SUMMARY OF THE INVENTION
[0016] According to one aspect of the invention, there is provided a method of analyzing a digital medical image using a computer-implemented algorithm having one or more variable parameters, wherein the value of at least one of the parameters is selected automatically according to at least one indicated attribute associated with, but not derived from, the medical image.
[0017] At least one of the parameters may be selected according to at least one indicated attribute of the patient upon whom the image is based. At least one of the attributes may be a suspected or diagnosed clinical indication of the patient. At least one of the attributes may be all or a component of the clinical history of the patient. At least one of the attributes may be non-clinical patient data, such as age, sex, height, weight or other statistical data.
[0018] At least one of the parameters may be selected according to an indicated property or setting of an image acquisition device used to prepare the image. The property may be the type (e.g., make and/or model) of the acquisition device. The property value or setting may be a resolution, dose or other setting specific to the particular acquisition protocol used to create the image.
[0019] At least one attribute may be indicated by metadata associated with the image. For example, the indicated attribute may be in a header field of a file containing the medical image, a tag associated with the image, or data linked to the image. The metadata may be read automatically and used to set parameter values for the algorithm, without user intervention.
[0020] The at least one attribute may be indicated by the user, without requiring the user to specify parameter values used by the algorithm. For example, the user may input the clinical indication, clinical history data, or non-clinical statistical data for the patient. The method then selects the at least one parameter value according to the at least one attribute indicated by the user.
[0021] In one embodiment, the automated method selects an optimum parameter value set, which is then provided as input to the algorithm. The image is processed using the algorithm based on the selected one or more parameter values. A plurality of optimum parameter value sets may be stored, and the optimum parameter value set may be selected from the stored plurality of sets. Additionally or alternatively, the optimum parameter value set may be derived by a predetermined function of at least the one or more indicated attributes. The optimum parameter value sets and their relationship to the indicated attributes may be derived theoretically or empirically.
[0022] According to a further aspect of the invention, the relationship between attribute values and optimum parameter values is derived from a plurality of training digital medical images, each having associated metadata, for which analysis results are available.
[0023] In one embodiment, training images having known corresponding attributes are analyzed using the algorithm. Preferably, many training images are analyzed. The training images may be images of real patients or of phantoms (i.e., objects simulating structures in the body, and having known attributes). The analysis may be controlled by one or more users who are able to select the parameter values for the algorithm manually (for example, using the CAR® software described above). Preferably, the users are experienced radiologists and/or experienced users of the algorithm. The training images may also be inspected visually by experienced radiologists to facilitate determining abnormalities in the training images. The optimum parameter values for each training image may be determined as the parameter values for which the results of the algorithm most closely match the results of the visual inspection and/or as the optimum parameter values chosen by the experienced users. A plurality of different optimum parameter value sets may be derived for each training image, as a function of the desired sensitivity or specificity.
[0024] For example, the training images may be selected from images stored locally. In another example, the training images may be available over a local or wide-area network. A search may be performed to identify suitable training images. Selected training images may be weighted according to their relevance to the candidate image.
[0025] A relationship is then derived between the optimum parameter value sets for each of the training images and the associated attributes of the training images. The relationship may comprise a function, one or more rules, a neural net and/or fuzzy logic, to provide some examples.
[0026] An advantage of the method is that, for a given algorithm, the optimum parameters for that algorithm may be selected for any image. The optimum parameters may be selected automatically, without requiring user intervention, thus alleviating the time constraints on the radiologist. This may also enable accurate batch analysis of multiple images. In the case of the attributes being indicated by the user, this allows the user to enter known and/or meaningful data, rather than requiring the user to choose parameters that may have little meaning outside the context of the algorithm. However, the user may specify the criteria for which optimum parameters are selected, such as greater sensitivity or specificity.
[0027] The image metadata may have been entered by an operator of the image acquisition device or by a technician subsequent to the capture of the image. Alternatively, the image metadata may have been recorded automatically by the image acquisition device and/or its associated control devices. Hence, a user who enters the attributes and a user to whom the results of the algorithm are presented need not necessarily be the same. The entry of attributes and the review of the results may be performed using respective distinct data entry and output devices.
[0028] The derived optimum parameter values may be set as default parameter values, which the user may modify by means of user manipulated filters. The results of using the modified parameter values to analyze the image may be displayed prior to output of the final results. The results may be a modified version of the image, displayed so as to allow comparison with the original image. This allows the result of the user's visual inspection of the original image to be compared to the result of the analysis using the algorithm. According to an embodiment, the digital medical image and the modified version of the image are displayed simultaneously. In another embodiment, the digital medical image and the modified version of the image are displayed alternately.
[0029] The method of the present invention may be performed by software, hardware, firmware or any combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0030] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art(s) to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the leftmost digit(s) of a reference number identifies the drawing in which the reference number first appears.
[0031] FIG. 1 is a schematic diagram showing a medical image acquisition device and a remote computer to process image data received from the medical image acquisition device according to an embodiment of the present invention.
[0032] FIG. 2 is a block diagram of an example computer system, in which the present invention may be implemented as programmable code.
[0033] FIG. 3 is a flowchart of the main steps of a method according to an embodiment of the present invention.
[0034] FIG. 4 is a diagram of data relationships corresponding to the method according to an embodiment of the present invention.
[0035] FIG. 5 a shows an example input medical image.
[0036] FIG. 5 b shows an example result of processing the input medical image with a sphericity enhancement algorithm using optimum parameter values according to an embodiment of the present invention.
[0037] FIG. 6 is a graph illustrating a relationship between attribute values and optimum parameters according to an embodiment of the present invention.
[0038] FIG. 7 is a system in which multiple training images are accessed over a network.
[0039] FIG. 8 is a flow chart of the main steps of a method that allows a user to modify optimum parameter values according to an embodiment of the present invention.
[0040] FIG. 9 is a screenshot of a user interface for modifying the parameter values according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0000] I. Digital Medical Image
[0041] The present invention is applicable to digital medical images. One example of such an image is a CT scan image. A CT scan image is a digital image comprising one or a series of CT image slices obtained from a CT scan of an area of a human or animal patient. Each slice is a 2-dimensional digital grey-scale image of the x-ray absorption of the scanned area. The properties of the slice depend on the CT scanner used. For example, a high-resolution multi-slice CT scanner may produce images with a resolution of 0.5-0.6 mm/pixel in x and y directions (i.e., in the plane of the slice). Each pixel may have 32-bit grayscale resolution. The intensity value of each pixel is normally expressed in Hounsfield units (HU). Sequential slices may be separated by a constant distance along a z direction (i.e., the scan separation axis). For example, the sequential slices may be separated by a distance in a range of approximately 0.75-2.5 millimeters (mm). According to an embodiment, the scan image is a three-dimensional (3D) grey scale image, for example, with an overall size that depends on the area and/or number of slices scanned. In another embodiment, the scan image is a single two-dimensional (2D) grayscale image representing a single slice.
[0042] The CT scan may be obtained by any CT scanning technique, such as electron beam computed tomography (EBCT), multi-detector or spiral scan or any technique which produces as output a 2D, 3D or 4D image representing X-ray absorption.
[0043] The invention is not limited to CT scan images, and may be applied to other digital medical images, such as MRI, US, PET or projection X-ray images. Conventional X-ray images may be developed on an X-ray film prior to being digitized.
[0044] As shown in FIG. 1 , the scan image is created by a computer 104 . Computer 104 receives scan data from a scanner 102 and constructs the scan image based on the scan data. The scan image is often saved as an electronic file or a series of files which are stored on a storage medium 106 , such as a fixed or removable disc. The file or files include metadata associated with the scan image. The scan image may be processed by computer 104 , or the scan image may be transferred to another computer 108 which runs software for processing and displaying the image as described below. The image processing software may be stored on a computer recordable medium, such as a removable disc, or downloaded over a network.
[0000] II. Example Computer System
[0045] Computer 104 or 108 can be any type of computer system, including but not limited to an example computer system 200 described below with reference to FIG. 2 . Embodiments of the present invention may be implemented as programmable code for execution by computer system 200 . Various embodiments of the invention are described in terms of computer system 200 . After reading this description, it will become apparent to a person skilled in the art how to implement the invention using other computer systems and/or computer architectures.
[0046] Referring to FIG. 2 , computer system 200 includes one or more processors, such as processor 204 . Processor 204 may be any type of processor, including but not limited to a special purpose or a general-purpose digital signal processor. Processor 204 is connected to a communication infrastructure 206 (for example, a bus or network).
[0047] Computer system 200 also includes a main memory 208 , preferably random access memory (RAM), and may also include a secondary memory 210 . Secondary memory 210 may include, for example, a hard disk drive 212 and/or a removable storage drive 214 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. Removable storage drive 214 reads from and/or writes to a removable storage unit 218 in a well-known manner. Removable storage unit 218 represents a floppy disk, magnetic tape, optical disk, etc., which is read by and written to by removable storage drive 214 . As will be appreciated, removable storage unit 218 includes a computer usable storage medium having stored therein computer software and/or data.
[0048] In alternative implementations, secondary memory 210 may include other similar means for allowing computer programs or other instructions to be loaded into computer system 200 . Such means may include, for example, a removable storage unit 222 and an interface 220 . Examples of such means may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM or a PROM) and associated socket, and other removable storage units 222 and interfaces 220 which allow software and data to be transferred from removable storage unit 222 to computer system 200 .
[0049] Computer system 200 may also include a communication interface 224 . Communication interface 224 allows software and data to be transferred between computer system 200 and external devices. Examples of communication interface 224 may include a modem, a network interface (such as an Ethernet card), a communication port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, etc. Software and data transferred via communication interface 224 are in the form of signals 228 , which may be electronic, electromagnetic, optical, or other signals capable of being received by communication interface 224 . These signals 228 are provided to communication interface 224 via a communication path 226 . Communication path 226 carries signals 228 and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, a radio frequency link, or any other suitable communication channel. For instance, communication path 226 may be implemented using a combination of channels.
[0050] In this document, the terms “computer program medium” and “computer usable medium” are used generally to refer to media such as removable storage unit 218 , a hard disk installed in hard disk drive 212 , and signals 228 . These computer program products are means for providing software to computer system 200 .
[0051] Computer programs (also called computer control logic) are stored in main memory 208 and/or secondary memory 210 . Computer programs may also be received via communication interface 224 . Such computer programs, when executed, enable computer system 200 to implement the present invention as discussed herein. Accordingly, such computer programs represent controllers of computer system 200 . Where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 200 using removable storage drive 214 , hard disk drive 212 , or communication interface 224 , to provide some examples.
[0052] In alternative embodiments, the invention can be implemented as control logic in hardware, firmware, or software or any combination thereof.
[0000] III. General Method
[0053] According to an embodiment of the present invention, a method is provided to process a digital medical image using an algorithm to identify one or more medical abnormalities. In an embodiment, the method is performed using a computer program, though the scope of the invention is not limited in this respect.
[0054] FIG. 3 is a flowchart 300 of the main steps (steps 302 - 310 ) of the method according to an embodiment of the present invention. The invention, however, is not limited to the description provided by the flowchart 300 . 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 300 will be described with continued reference to the data relationships illustrated in FIG. 4 , though the method is not limited to that embodiment.
[0055] FIG. 4 is a diagram of data relationships corresponding to the method according to an embodiment of the present invention. In FIG. 4 , the metadata 402 is associated with the medical image 404 . The optimum parameter values 406 are based on the metadata 402 . As shown in FIG. 4 , the medical image 404 and the optimum parameter values 406 are provided as inputs to the algorithm 408 , which provides the analysis result 410 as an output.
[0056] Referring now to FIG. 3 , a medical image 404 is accessed at step 302 . Metadata 402 associated with the medical image 404 is accessed at step 304 . At step 306 , optimum parameter values 406 are derived from the metadata 402 . According to an embodiment, the optimum parameter values 406 are derived using a predetermined relationship between values of the metadata 402 and the optimum parameter values 406 . For example, the relationship between the optimum parameter values 406 and the metadata 402 can be determined, such that the optimum parameters 406 may be derived thereafter based on the metadata 402 and the relationship. At step 308 , the medical image 404 is processed using an algorithm 408 and the optimum parameter values 406 . For instance, the medical image 404 and the optimum parameter values 406 may be provided to the algorithm 408 , which produces an analysis result 410 at step 310 , based on the medical image 404 and the optimum parameter values 406 . Each of the steps 302 - 310 mentioned above is described in detail below with reference to FIG. 4 .
[0000] IV. Image Metadata
[0057] Referring to steps 302 and 304 , the metadata 402 may be generated at substantially the same time as the medical image 404 is created, for example by the computer 104 and/or the scanner 102 . The metadata 402 may be created automatically and/or entered by a user of the computer 104 .
[0058] As an example of automatically created data, a constant attribute of the scanner 102 , such as its modality, make and/or model may be recorded as the metadata 402 for each image 404 . As another alternative or additional example, a variable attribute specific to each image 404 , such as a setting for the scan used to create that image 404 , may be recorded as the metadata 402 . The setting may be an image resolution, a contrast setting, a radiation intensity setting or any other setting appropriate to the modality and/or type of the scanner 102 .
[0059] As an example of user-entered data, the user of the computer 104 may enter one or more attributes of the patient scanned by the scanner 102 to create the image 404 . The attributes may include one or more of: clinical information about the patient, such as a diagnosed clinical indication; a clinical estimation, such as a suspected clinical indication; and patient statistics, such as age, sex, height, weight or other statistical data which is not in itself a clinical indication.
[0060] The metadata 402 may be stored in a header field of a file containing the digital medical image 404 , in a tag associated with the image 404 , and/or in data linked to the image 404 . For example, the metadata 402 and digital medical image 404 may be recorded in the Digital Imaging and Communications in Medicine (DICOM) format, which stores metadata in a header of an image file, as defined by the specification available on 19 Nov. 2004 at:
[0000] ftp://medical.nema.org/medical/dicom/2004/03v04dif/.
[0061] Alternatively, the metadata 402 and digital medical image 404 may be recorded in the Analyze format, which stores metadata in a separate file from the image, as defined by the specification available on the same date at:
[0000] http://www.mayo.edu/bir/PDF/ANALYZE75.pdf.
[0062] In step 306 , optimum parameter values 406 are derived. Examples of such optimum parameter value derivation methods are described further below.
[0000] V. Algorithm
[0063] Referring to steps 308 and 310 , the algorithm 408 takes as its input the medical image 404 and one or more optimum parameter values 406 . Based on at least these inputs, the algorithm analyzes the image 404 to generate an analysis result 410 indicative of any abnormality in the object of the image 404 . For example, the analysis result 410 may indicate one or more of: whether an abnormality is present; the position of one or more abnormalities; a confidence level of the detection of an abnormality; a type of an abnormality; and a quantity relating to an abnormality, such as a mass or a volume.
[0064] One example of such an algorithm 408 is a sphericity enhancement algorithm, which has as input parameters a sphericity threshold, an intensity range and a size range. The sphericity enhancement filter analyzes each volume element (voxel) in a 3D scan image and compares each voxel with surrounding voxels of similar intensity to derive a 3-dimensional (3D) curvature of a surface of equal intensity. Surfaces having a sphericity exceeding the sphericity parameter are identified as belonging to spherical objects. Voxels contained within those surfaces are grouped together as parts of the same object. Once all such objects have been identified, those having a maximum intensity within the intensity range and a size within the size range are indicated in the analysis result 410 . The sphericity enhancement algorithm is used to identify nodules in images of the lung, such as lung CT images. FIG. 5 a shows an example single slice CT image of a lung phantom. FIG. 5 b shows the image of FIG. 5 a after processing by the sphericity enhancement algorithm using the optimum parameters.
[0065] Other examples of algorithms and their input parameters include an edge enhancement filter having edge enhancement parameters, for detecting abnormalities in the lung parenchyma, and a polyp filter having flatness parameters, for detecting objects having a spherical element and a flatness between maximum and minimum flatness values, for detecting polyps in the colon.
[0066] The algorithm 408 may be selected from a plurality of different available algorithms, based for example on some or all of the image metadata 402 . The optimum parameter values 406 may then be derived for the selected algorithm 408 .
[0000] VI. Optimum Parameter Derivation
[0067] Referring to step 306 , methods of deriving the relationship between metadata values and optimum parameter values will now be described. The relationship may be derived by theoretical knowledge of the effect of image attributes on the optimum parameters, or empirically. In an empirical method, a large number of training images, having known attributes which vary among the training images, are processed using the algorithm for which the relationship is to be determined. The training images may be images of real patients or of phantoms (i.e., objects simulating structures in the body and having known attributes). The processing may be controlled by one or more experienced users able to select the parameter values for the algorithm manually (for example, using the CAR® software described above). Preferably, the experienced users are experienced radiologists and/or experienced users of the algorithm. The training images may also be inspected visually by experienced radiologists to determine as accurately as possible any abnormalities in the training images. The optimum parameter values for each training image may be determined as the parameter values for which the results of the algorithm most closely match the results of the visual inspection and/or as the optimum parameter values chosen by the experienced users. Each training image may be associated with multiple sets of determined optimum parameter values, depending on the sensitivity/specificity requirements of the user.
[0068] Alternatively, the training images may include metadata indicating the results of analysis performed automatically and/or by visual inspection using the training images. The optimum parameter values for each training image may be determined as the parameter values for which the results of the algorithm most closely match the results of the analysis as indicated by the metadata.
[0069] The result of the processing is a set of one-to-one relationships between the attribute values of each of the training images and the determined optimum parameter values for the respective training images. The attribute values and optimum parameter values for each training image may be stored as training image data sets. However, the set of relationships should be generalized to one or more general relationships which can be applied to new images and their respective attribute values.
[0070] In a simplified example, a single image attribute value may be plotted against a single optimum parameter value, as shown in FIG. 6 . The result points from the training images are shown as stars, and a curve is then fitted to these points. The curve represents the generalized relationship in this example. To analyze a new image in an embodiment of the invention, a new attribute value x of the image is input, and the corresponding optimum parameter value y is derived from the curve. Hence, the curve represents the relationship between the attribute value and the optimum parameter value. The general relationship may involve more than one attribute, more than one parameter value, and/or a more complex relationship between them. The general relationship may comprise one or more functions, one or more rules, a neural net and/or fuzzy logic, to provide some examples.
[0071] As described above, the optimum parameter values may be derived from one or more training images. The training images are digital medical images which may be stored locally or accessed over a local or wide-area network. For example, as shown in FIG. 7 , the training images may be accessed using a picture archiving and communication system (PACS) network 702 to access multiple distributed sources of medical images 704 , 706 .
[0072] The training images may be selected from a large number of available digital medical images by searching for images using one or more search criteria and/or by selecting a desired set of images as the training images for optimum parameter derivation. The selected training images may be processed automatically to derive optimum parameters based on the selected training images.
[0073] To derive the generalized relationship, only the stored datasets, including the metadata and the optimum parameter values for the training images, need to be accessed. It is not necessary to access the training images themselves.
[0074] By selecting the training images used to derive the optimum parameters, the user may customize the optimum parameters for a particular image type represented by the training images. For example, the user may wish to optimize the parameters for a new CT scanner 102 . By selecting training images produced by other CT scanners of the same type, the user may configure the parameter values for the new CT scanner, without having to derive these by trial and error.
[0075] The user may weight the training images used to derive the optimum parameters, so as to give greater weight to those images which are more relevant to the application desired by the user. For example, the user may derive the optimum parameters for a specific patient using, as training images, previous scan images for that patient and scan images for other patients produced by the same scanner 102 . In this example, the user may select a higher weight for the previous scan images of the same patient than for scan images of other patients.
[0076] The parameters used by the algorithm may be optimized according to specific criteria, which can be selected by a user. For example, the user can specify that the parameters be optimized for greater sensitivity, or for greater specificity (e.g., so as to avoid false positives). Where the test images have multiple sets of optimum parameter values depending on sensitivity/specificity requirements, the general relationship may be derived from the set corresponding to the user's requirements.
[0077] Alternatively, the user may specify other criteria, such as the user's level of experience. Experienced radiologists may be able to tolerate a greater sensitivity setting, because they are more easily able to reject false positives. Less experienced radiologists may prefer a lower sensitivity. Thus, the user need not specify explicitly the required sensitivity. Instead, the user may specify the user's level of experience, from which a required sensitivity level may be derived.
[0078] The optimum parameters used by the algorithm may be adjusted adaptively according to the results of the algorithm based on past scans. In other words, scan images processed by the algorithm may be used automatically as training images to optimize the parameters for processing subsequent scans using the algorithm.
[0000] VII. Optimum Parameter Defaults
[0079] In the embodiments described above, the optimum parameter values 406 are used as input to the algorithm 408 . Advantageously, this reduces the need for the user to set parameter values manually. In an alternative embodiment, the derived optimum parameter values 406 are set as default values which may be adjusted by the user.
[0080] FIG. 8 is a flow chart of the main steps of a method that allows a user to modify optimum parameter values 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.
[0081] Referring now to FIG. 8 , steps 802 to 808 correspond to steps 302 to 308 of flowchart 300 in FIG. 3 . In FIG. 8 , the result provided by processing the image using the derived optimum parameter values is displayed at step 810 . A user interface includes means to allow the user to modify some or all of the parameter values. If the user does not change the parameter values, as determined at step 812 , then the final analysis result is output at step 814 . However, if the user modifies the parameter values, as determined at step 812 , the image is re-processed at step 808 using the modified parameter values, and the analysis results are re-displayed at step 810 , until the user confirms that the parameter values are not to be changed (i.e., the current parameter values are to be accepted) at step 812 . The final analysis result is output at step 814 using the accepted parameter values.
[0082] FIG. 9 shows a screenshot 900 of a user interface for modifying the parameter values as described above with respect to step 812 of flowchart 800 . The user interface is shown in a window comprising an original image pane 910 and an enhanced image pane 912 . The original image pane 910 displays a two-dimensional slice of a scan of a lung phantom (i.e., a model approximating the lung and containing objects with known properties, used for testing and calibration). The enhanced image pane 912 displays a version of the original image processed by the algorithm 408 so as to highlight features of the original image.
[0083] The current parameter values are displayed by a parameter window 916 , which allows the user to modify the parameter values. The user may click a button 930 in the parameter window 916 to apply the modified parameter values to update the enhanced image.
[0084] In an alternative user interface, a single scan image is displayed in the user interface window. The single scan image can be switched between the original image and an enhanced image by the user, for example by toggling a button in the filter window. Image display parameters are kept unchanged when switching between the original image and the enhanced image, so that the user can easily compare the enhancement and the original image.
[0000] VIII. Conclusion
[0085] Example embodiments of the methods, systems, and components of the present invention have been described herein. As noted elsewhere, these example embodiments have been described for illustrative purposes only, and are not limiting. Other embodiments are possible and are covered by the invention. Such other embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Thus, the breadth and scope of the present invention should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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A medical image is analyzed using an algorithm requiring input parameters. Values of the input parameters are derived from metadata, indicating properties of the medical image. For example, the metadata may indicate the type of image acquisition device or settings used to create the medical image. In another example, the metadata may relate to the patient upon whom the image is based. This allows optimum values to be selected for the parameters.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for preparing a polymer composition containing a physiologically active substance. More particularly, the present invention relates to a process for preparing a polymer composition containing a physiologically active substance and having a property of releasing the substance at a controlled rate.
2. Prior Art
The present inventors have previously invented a process for preparing a polymer composition having a property of releasing a physiologically active substance at a controlled rate which comprises contacting a polymerizable monomer and the physiologically active substance and irradiating them with light or an ionizing radiation to polymerize the monomer (Japanese Patent Application No. 27,109/78, U.S. Ser. No. 018,617) and, further, on the basis of this invention, have accomplished a series of inventions of a process for preparing a polymer composition having the same property which comprises dropping or injecting a mixture of one or more monomers vitrificable at low temperatures containing a high molecular weight substance and the physiologically active substance into a medium to make the mixture into a shape of spherical structure and irradiating it with light or an inoizing radiation (Japanese Patent Application No. 51,239/78, U.S. Ser. No. 018,617), a process for preparing a polymer composition in which the elution rate of the physiologically active substance is controlled by pH which comprises irradiating a uniform mixture of a polymer soluble in a pH within a certain range, a polymerizable monomer and the physiologically active substance with light or an ionizing radiation to polymerize the monomer (Japanese Patent Application No. 105,306/78, U.S. Ser. No. 18,617), a process for preparing a polymer composition having the same property which comprises mixing a polymerizable monomer and physiologically active substance in the presence or absence of crystallizable substance, adding an adsorbent thereto and irradiating it with light or an ionizing radiation (Japanese Patent Application No. 106,097/78, U.S. Ser. No. 18,617), and a process for preparing a polymer composition containing an antitumour agent and having a property of releasing it at a controlled rate which comprises mixing a polymerizable monomer with two or more antitumour agents, or one or more antitumour agents and a substance promoting antitumour effect and irradiating the mixture with light or an ionizing radiation (Japanese Patent Application No. 146,411/78, U.S. Ser. No. 095,496). However, a physiologically active substance is generally broken or decomposed by the action of radiation and thereby its activity lowers. In order to restrain the lowering of activity, in the processes of these inventions, the irradiation has been performed at ordinary temperatures or in a lower temperature domain as below 0° C. Therefore, the monomer to be used had to be a monomer polymerizable at low temperature.
SUMMARY OF THE INVENTION
As the result of research on the condition in the irradiation, the present inventors have found that the lowering of the activity of the physiologically active substance is promoted by the existence of oxygen in the reaction system and the activity is scarcely lowered when the radiation irradiation is performed under a vacuum of 10 -3 to 10 -4 mmHg without oxygen and also the polymerization of polymerizable monomer is promoted by the removal of oxygen, and that it is possible to avoid the lowering of the activity of physiologically active substance caused by the irradiation in an anhydrous system in which water is completely removed from the reaction system, even in a temperature domain above 0° C. The present inventors have, on the basis of these discoveries, accomplished the present invention which comprises a process for preparing a polymer composition containing a physiologically active substance which comprises contacting one or more polymerizable monomers and one or more physiologically active substances and irradiating them with light or an ionizing radiation while maintaining the system in an anhydrous state and in an airless state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymer composition containing a physiologically active substance according to the process of the present invention can be in any form, such as powder, film, sphere, rod or block. However, generally the physiologically active substance is not soluble but only dispersed in a polymerizable monomer and so, as an ideal controlled releasing agent, it is desired that the encapsulation is completed in a state that the physiologically active substance is uniformly dispersed through the polymer of polymerizable monomer. When the dispersion is not uniform the elution of physiologically active substance from the polymer composition cannot be satisfactorily controlled and the reproducibility is in danger of being difficult.
In order to disperse a physiologically active substance which is insoluble in a polymerizable monomer in a polymer uniformly, there is contemplated a process for preparing a polymer composition releasing the physiologically active substance contained at a controlled rate by coating the surface of the physiologically active substance with the minimum amount of polymerizable monomer and polymerizing the monomer. And in the case of a physiologically active substance which is relatively easily soluble in a polymerizable monomer, such as, for example ammonium chloride, creosote, ibuprofen, etc., the preparation of the controlled releasing agent is easy and any method or means of dispersion can be used since the encapsulation of physiologically active substance can be performed in an anhydrous system.
When combining one or more of any polymerizable monomers properly, a polymer soluble or insoluble in an acidic or basic aqueous solution can be obtained at will. For example, a polymer obtained by polymerizing dimethylaminoethyl methacrylate and methacrylic acid ester in an appropriate ratio is soluble in an acidic liquid (for example gastric juice) while a polymer obtained by polymerizing methacrylic acid and methacrylic acid ester in an appropriate ratio is soluble in a basic liquid (for example intestinal juice). But a polymer obtained by polymerizing one or more polymerizable monomers having an appropriate number of functional groups (for example vinyl group) alone or in combination, for example, the copolymer of 2-hydroxyethyl methacrylate and diethyleneglycol dimethacrylate is not soluble in either acidic or basic solutions.
In the method of obtaining polymers having various properties by various combinations as above described, the means of preparing the polymers is limited to a radiation polymerization method, although the kind, composition and components are optional. Further, one method of controlling the elution of a physiologically active substance from a polymer composition is to polymerize a polymerizable monomer in coexistence in an inert solvent such as polyethylene glycol, hydroxypropyl cellulose, etc. In such polymerization a void pore space is formed within the polymer by the elution of inert solvent. The void pore space is an important factor for controlling the elution of physiologically active substances since the void pore space can be controlled by selecting the kind and concentration of the inert solvent.
The present invention is not limited to a radiation of ordinary temperature or a lower temperature domain as 0° C., differing from the processes of the above described prior inventions, Therefore, there is no necessity for using a polymerizing catalyst and solvent normally necessary for polymerization in such low temperature domain, and so these are not mixed as impurities in the polymer composition. In addition, the present invention can be characterized in that the radiation sterilization of the polymer can be effected and that the polymerization and the encapsulation of the physiologically active substance are performed simultaneously so that the resulting composition is stable.
Polymerizable monomers suitable for use in the present invention include:
hydroxyethyl methacrylate, hydroxyethyl acrylate, hydroxypropyl methacrylate, hydroxyprophyl acrylate, diethylene glycol monoacrylate, diethylene glycol monomethacrylate, dipropylene glycol monoacrylate, dipropylene glycol monomethacrylate, triethylene glycol monoacrylate, triethylene glycol monomethacrylate, tripropylene glycol monoacrylate, tripropylene glycol monomethacrylate, tetraethylene glycol monoacrylate, tetraethylene glycol monomethacrylate, tetrapropylene glycol monoacrylate, tetrapropylene glycol monomethacrylate, polypropylene glycol monoacrylate, polypropylene glycol monomethacrylate, polyethylene glycol monoacrylate, polyethylene glycol monoethacrylate, methoxydiethylene glycol acrylate, methoxydiethylene glycol methacrylate, methoxydipropylene glycol acrylate, methoxypropylene glycol methacrylate, ethoxydiethylene glycol acrylate, ethoxydiethylene glycol methacrylate, ethoxydipropylene glycol acrylate, ethoxydipropylene glycol methacrylate, propoxydiethylene glycol acrylate, propoxydiethylene glycol methacrylate, propoxydipropylene glycol acrylate, propoxydipropylene glycol methacrylate, butoxydiethylene glycol acrylate, butoxydiethylene glycol methacrylate, butoxydipropylene glycol acrylate, butoxydipropylene glycol methacrylate, methoxytriethylene glycol acrylate, methoxytriethylene glycol methacrylate, methoxytripropylene glycol acrylate, methoxytripropylene glycol methacrylate, ethoxytriethylene glycol acrylate, ethoxytriethylene glycol methacrylate, ethoxytripropylene glycol acrylate, ethoxytripropylene glycol methacrylate, propoxytriethylene glycol acrylate, propoxytriethylene glycol methacrylate, propoxytripropylene glycol acrylate, propoxytripropylene glycol methacrylate, butoxytriethylene glycol acrylate, butoxytriethylene glycol methacrylate, butoxytripropylene glycol acrylate, butoxytripropylene glycol methacrylate, methoxytetraethylene glycol acrylate, methoxytetraethylene glycol methacrylate, methoxytetrapropylene glycol acrylate, methoxytetrapropylene glycol methacrylate, ethoxytetraethylene glycol acrylate, ethoxytetraethylene glycol methacrylate, ethoxytetrapropylene glycol acrylate, ethoxytetrapropylene glycol methacrylate, propoxytetraethylene glycol acrylate, propoxytetraethylene glycol methacrylate, propoxytetrapropylene glycol acrylate, propoxytetrapropylene glycol methacrylate, butoxytetraethylene glycol acrylate, butoxytetraethylene glycol methacrylate, butoxytetrapropylene glycol acrylate, butoxytetrapropylene glycol methacrylate, methoxypolyethylene glycol acylate, methoxypolyethylene glycol methacrylate, methoxypolypropylene glycol acrylate, methoxypolypropylene glycol methacrylate, ethoxypolyethylene glycol acrylate, ethoxypolyethylene glycol methacrylate, ethoxypolypropylene glycol acrylate, ethoxypolypropylene glycol methacrylate, propoxypolyethylene glycol acrylate, propoxypolyethylene glycol methacrylate, propoxypolypropylene glycol acrylate, propoxypolypropylene glycol methacrylate, butoxypolyethylene glycol acrylate, butoxypolyethylene glycol methacrylate butoxypolypropylene glycol acrylate, butoxypolypropylene glycol methacrylate; and, in addition, include:
methyl methacrylate, ethyl methacrylate, glycidyl methacrylate, propyl methacrylate, butyl methacrylate, isobutyl methacrylate, benzyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, hexyl methacrylate, lauryl methacrylate, methyl acrylate, ethyl acrylate, glycidyl acrylate, propyl acrylate, butyl acrylate, isobutyl acrylate, benzyl acrylate, cyclohexyl acrylate, 2-ethylhexyl acrylate, hexyl acrylate, lauryl acrylate, acrylic acid, acrylamide, acrylonitrile, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl toluene, styrene, vinyl benzene, vinyl pyrrolidone, vinyl carbazol, methacrylic acid, methacrylamide, methacrylonitrile, triallyl cyanurate, diallyl phthalate, diallyl maleate, diallyl itaconate, diallyl succinate, diallyl isophthalate, triacryl formal, dipropargyl maleate, trimethylolpropane trimethacrylate, trimethylolpropane triacrylate, neopentyl glycol dimethacrylate, neopentyl glycol diacrylate, diethylene glycol dimethacrylate, diethylene glycol diacrylate, triethylene glycol dimethacrylate, triethylene glycol diacrylate, tetraethylene glycol dimethacrylate, tetraethylene glycol diacrylate, polyethylene glycol dimethacrylate, polyethylene glycol diacrylate, hexanediol diacrylate, hexanediol dimethacrylate, pentanediaol diacrylate, pentanediol dimethacrylate, butanediol diacrylate, butanediol dimethacrylate, ethylene glycol diacrylate, ethylene glycol dimethacrylate.
Inert solvents used in the present invention include:
ethylene glycol, polyethylene glycol, cyclohexane, benzene, acetic acid, propionic acid, butyric acid, crotonic acid, maleic acid, succinic acid, sorbic acid, itaconic acid, liquid paraffin, ethanol, edible oils and fats, and the like, although any solvent inert in the interior of the living body may be used.
Physiologically active substances which can be used in the present invention include:
acetylchloline, noradrenalin, serotanin, callicrein, gastrin, secretin, adrenalin, insulin, glucagon, ACTH, growth hormone, genadotropic hormone, oxytocin, vasopressin, thyroxin, testicular hormone (testosterone), ovarian hormone (estradiol), corpus luteum hormone, luteal hormone (progesteroune), adrenocortical hormone, prostaglandin, various antihistaminic agents, antihypertensives, vasodilators, vasoprotectors, stomachics and digestives, anti-diarrheals and intestinal absorbers, contraceptives, antiseptics and disinfectants for derma, agents for dermatozoonosis, antiphlogistic, acetysalicyclic acid, ibuprofen, phenacetin, mefenamic acid, maproxen, tiaramide, indomethacin, vitamins, varous enzymes, antitumor agents (bleomycin, sarcomycin, actinomycin D, cyclophosphamide, nitrogen mustard, triethylene thiophosphoramide, mercaptopurine, methotrexate, 5-fluorouracil, mitomycin C, carzinophilin, chromomycin A 3 , 1-2(2-tetrahydro-furyl)-5-fluorouracil, etc.), radiopharmaceuticals, antibiotics (streptomycins, chloramphenicols, tetracyclines, ethythromycins, trichomycins, bacitracins, colistins, polymixins, gramicidins, penicillins, griseofulvins, etc.), sulfanilamide and its derivatives, antituberculosis drugs (TB preparations), antisyphilitics, antilep, varous biological preparations (vaccines, antiserums, toxins and antitoxins, etc.), amebicides, authelmintics, ataraxics, ophthalmological preparations (anticataract agents, antiglancoma agents, etc.), various fish drugs, agricultural drugs, interferon, auxin, gibberelline, cytokinin, absinthic acid, other phytohormones, sex pheromone, aggregation pheromone, alarm pheromone, trail pheromone, cast pheromone, other pheromones, various natural insecticidal substances (pyrethroid, rotinoid, nicotinoid, etc.), attractant, repellent, etc.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described in greater detail with reference to the following Examples:
In the process of the present invention, the irradiation is performed in an anhydrous condition. An extremely small quantity of water existing in the polymerizable monomer was removed by passing the monomer through a column filled with a drying agent such as Molecular Sieves 4A, silica gel, active carbon, active alumina, etc., and the physiologically active substance was dried by vacuum drying or lyophilization. The elution test of the physiologically active substance from the polymer composition obtained was carried out using 1,000 ml of liquid medium in a rotatable basket at 100 rpm and at a temperature of 37° C. according to USP XIX.
EXAMPLES 1 TO 5
1.2 g of aminophylline powder was added to 1 g of mixed polymerizable monomers of dimethylaminoethyl methacrylate and methyl methacrylate in an appropriate composition. Thereafter the reaction system was deaerated (10 -3 mmHg), and then was irradiated with γ ray from 60 Co at a dose rate of 5×10 5 R/hr at 28° C. for 3 hours in such a condition that aminophylline is covered uniformly with the polymerizable monomers to obtain a polymer composition containing aminophylline. The elution of aminophylline from the polymer composition crushed to 3.5 to 5.0 mm in size was held in a liquid medium at a pH of 3. The results are shown in Table 1.
TABLE 1______________________________________Elution of aminophylline from dimethylaminoethylmethacrylate-methyl methacrylate copolymerComposition of Amount of aminophylline elutedpolymerizable from liquid medium at a pH of 3, %monomer Time elapsed afterDAEMA MMA test started, hour% % 0.5 1 2 4 8 12______________________________________Example1 100 0 4.6 12.3 32.4 59.2 100 --2 70 30 3.1 5.2 14.6 48.3 92.4 1003 50 50 1.3 3.4 4.5 9.6 14.4 26.84 30 70 2.2 4.8 7.3 14.2 23.2 38.45 0 100 5.1 8.2 14.3 22.2 34.1 44.4Com-parativeExample1 70 30 2.1 3.6 6.2 11.2 17.6 24.62 30 70 1.8 4.0 6.7 13.4 20.6 36.2______________________________________ DAEMA: Dimethylaminoethyl methacrylate MMA: Methyl methacrylate Note 1. Comparative Examples 1 and 2 were carried out in a liquid medium at a pH of 6. Note 2. In case the amount of dimethylaminoethyl methacrylate is above 45%, the copolymer obtained is completely soluble in the liquid medium of a pH of and the solubility of the copolymer increases with the percentage of dimethylaminoethyl methacrylate.
EXAMPLES 6 TO 10
0.32 g of Tolbutamide was added to 0.3 g of mixed polymerizable monomers of methyl acrylate and methacrylic acid in an appropriate composition, and thereafter the reaction system was deaerated and then was irradiated with γ ray from 60 Co at a dose rate of 1×10 6 R/hr at 25° C. for 2 hours under the condition that tolbutamide is covered uniformly with the polymerizable monomers to obtain a tablet of polymer composition containing tolbutamide of 8 mm in diameter and 4 mm in height. The elution of tolbutamide from the polymer composition tablet was held in a liquid medium of a pH of 3.0. The results are shown in Table 2.
TABLE 2______________________________________Elution of tolbutamide from methyl acrylateand methacrylate acid copolymerComposition ofpolymerizableMonomerMethyl Meth- Amount of tolbutamide eluted fromacry- acry- a liquid medium of a pH of 7.0, %late lic acid Time elapsed after test started, hour% % 0.5 1 2 4 8 12______________________________________Example6 100 0 4.2 6.4 14.2 22.4 41.3 50.37 70 30 14.3 22.1 30.4 44.3 57.8 89.48 50 50 17.6 27.3 36.8 50.2 78.4 96.29 30 70 18.4 29.3 58.9 88.4 10010 0 100 32.1 54.1 84.2 100Com-parativeExample3 70 30 10.2 18.6 27.3 39.1 51.2 69.94 30 70 4.1 7.6 12.1 19.4 26.9 33.4______________________________________ Note 1. Comparative Examples 3 and 4 were carried out in a liquid medium of a pH of 3.0. Note 2. In case the amount of methacrylic acid is above 60%, the copolymer obtained is completely soluble in the liquid medium of a pH of 7.0 and th solubility of the copolymer increases with the percentage of methacrylic acid.
EXAMPLE 11
1.0 g of methyl salicylate, 0.4 g of 1-menthol, 0.1 g of peppermint oil, 0.4 g of dl-camphor and 0.2 g of thymol were added to 2 g of polymerizable monomer of 80% hydroxyethyl acrylate and 20% diethylene glycol dimethacrylate, and were cast using an inorganic glass plate to obtain a filmy polymer of 2 mm in thickness in which the chemicals are uniformly dispersed within the film, and which was then irradiated at γ ray from 60 Co with a dose rate of 4×10 5 R/hr at 31° C. for 3 hours.
The resulting filmy polymer composition was excellent in elasticity and flexibility and was not soluble regardless of the pH of the liquid medium. The results of the elution of chemicals from the filmy polymer composition are shown in Table 3.
TABLE 3______________________________________Elution of chemicals from filmy copolymer com-position of 80% hydroxyethyl acrylate and 20%diethylene glycol dimethacrylate Amount of chemicals eluted from filmy polymer composition after elution test started. Time elapsed after test started, hour 1 5 10 20 % % % %______________________________________Methyl salicylate 15 38 69 921-menthol 8 26 51 87Peppermint oil 21 47 81 100dl-camphor 19 41 74 98Thymol 7 21 46 79______________________________________
EXAMPLE 12
3 g of trimethylolpropane trimethacrylate, 1 g of polyethylene glycol #200 and 2 g of creosote were mixed uniformly and thereafter the resulting mixture solution was filled into a polyethylene tube of 3 mm in inner diameter and was irradiated at γ ray from 137 Cs with a dose rate of 3×10 5 R/hr at 26° C. for 4 hours.
The polymer composition so obtained was cut to a chip of 5 mm in length. This polymer composition has a porous structure by the elution of the polyethylene glycol #200. The elution of creosote from the polymer composition was carried out in pure water (pH 6.0), and creosote was eluted at a uniform rate for 10 days and approximately 87% in total was eluted. For comparison, in the case of preparing a similar chip-like polymer without making polyethylene glycol #200 coexistent in the system, the elution of creosote therefrom was only 41% for 10 days.
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A polymer composition containing a physiologically active substance and being capable of releasing it at a controlled rate can be prepared by contacting 10 parts, by weight, of one or more polymerizable monomers and 0.1 to 30 parts, by weight, of one or more physiologically active substances and irradiating them with light or an ionizing radiation while maintaining the system in an anhydrous condition and in airless state.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of prior application Ser. No. 12/079,876, filed Mar. 28, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
DESCRIPTION OF ATTACHED APPENDIX
[0003] Not Applicable.
BACKGROUND
[0004] This disclosure relates generally to the field of health care. Medicines are a crucial part of the modern health care system. The safe and effective use of medicines assure their usefulness. A medication does the most benefit to a patient if it is taken in the manner prescribed by the doctor and dispensed by the pharmacist. It frequently happens that people need help in taking medicines as prescribed. One very common problem is that people forget to take a medicine dose. Missed medicine doses contribute to both drug tolerance in the body and drug resistance of pathogens, neither of which is in the best interest of patients. Another very common problem is that people take medicine doses with improper time intervals between doses. People impaired by illness, medication, or simple forgetfulness may overdose. These very common problems have negative effects on patient health. In fact, people die every year from improperly administered medication. It is therefore highly desirable to improve how well a patient follows the dosing instructions for a prescribed medicine by giving them tools to help them take their medicines in the manner prescribed.
[0005] Additional problems affect people who take multiple medications. Keeping track of dosage amount and dosing times is made more complicated when a patient has multiple medications to manage. Each medication has its own proper dosing schedule so confusion between medications can lead to dangerous under- or over-dosing situations. Furthermore, the potential danger presented by drug interactions may make it necessary to have defined time separation between certain medicines. It is therefore highly desirable to decrease the potential for confusion when a patient has to take multiple medications.
[0006] Medication is typically dispensed in a container on which medical information pertaining to that medication is attached or affixed in some way. That medical information provides crucial data as to the identity of the medication and the dosing instructions for that medication. Continued access to that crucial data is important to the patient. Transferring medication from its original dispensary packaging is something that people tend to do, especially when they have multiple medications to manage. This is especially true for the blind, the elderly, and the physically challenged. In a typical scenario, an individual might count out the amount of pills of several different medications that they anticipate taking over the course of an entire week and then transfer those pills to a plastic container having a subcompartment for each day of the week. There are risks associated with separating medication from its dispensary packaging. Any action that leads to confusion or uncertainty in the patient has the potential to contribute to over- and under-dosing situations. Its is therefore highly desirable to reduce the potential for uncertainty and confusion in the patient by allowing medications to stay in their original dispensary packing.
[0007] Today's one-cap-fits-all Child/Adult approach to medicine dosage, with limited consideration to weight, age and gender, can be significantly improved to more accurately address these factors in addition to issues such as ethnicity and DNA. The ability to tailor dosing sequences with alerts from once a year to 24 times a day and anything in between and ensure a high degree of accuracy can improve and save lives. Also the trial and error approach used in the dosing administration of some drugs such as blood thinners, hypertension management and certain forms of cancer, can be replaced by the correct dosing sequences the first time and every time.
[0008] Nowhere in medical science is there a greater need for more flexibility and the coming of age of genome and the true application of pharmacogenomics is placing urgency on these needs. The FDA and Research Pharmacist are limited by safety concerns of accidental misuse of under/overdosing and may relax some rules if reasonably confident that, like childproof lids, there are significant inroads in addressing these factors. Critical new drugs abandoned because of dosing concerns, may be approved if simple, safe economical methods of ensuring adherence to dosing instructions, especially by the blind, the aged, and other physically and mentally challenged, are realized.
[0009] Devices in use are limited in application and do not generally or specifically address the needs of the blind; the aged and other physically challenged individuals. Some rely on color codes, which can be confusing to most and totally indistinguishable by others. Other devices rely on moving medicine from container to container, an obvious unsafe practice. Most focus only on the pill format and portability and do not address liquid, powders and gel medications and their containers and misuse. Still, even in a seemingly perfect environment, safety concerns of missed alerts due to laziness, forgetting to reload additional containers or simply leaving these devices at home and the adaptation of these devices to easily or automatically putting sequences back on track, are never addressed. Additionally, alarm creep due to response time, especially by challenged individuals, and progressive errors in accuracy and consistency are not recognized.
SUMMARY
[0010] The present invention is directed to methods and apparatus that satisfy the need for better patient compliance in the dosing of medicines. An apparatus for alerting a patient at medicine dosing times constructed according to the present disclosure will be small, flexible, inexpensive, and durable. An apparatus according to the present disclosure comprises an electronic timing mechanism that executes a medicine dosing schedule and alerts a person at times that correspond to the times at which doses of medicine should be administered. The electronic timing mechanism comprises a processor coupled to a memory, and a clock source for executing processor instructions at a uniform rate, and at least one timing channel for measuring elapsed time. The processor executes a control program which in turn executes a medicine dosing schedule. The dosing schedule, which resides in the memory, comprises information representing one or more dosing intervals, wherein a dosing interval comprises information corresponding to a finite amount of time, after which time a dose of medicine should be administered. The electronic timing mechanism produces at least one annunciator signal at the end of at least one dosing interval. The apparatus further comprises: at least one annunciator that is activated by one or more annunciator signals and one or more switches to enable human interaction with the apparatus. Furthermore, the apparatus is constructed using a flexible substrate upon which are mounted the electronic timing mechanism, one or more annunciators, and one or more switches. The flexible substrate is provided with a means of attaching the apparatus to other objects, and the flexibility of the apparatus is such that it can conform to curved surfaces of other objects.
[0011] The apparatus may further comprise a second timing channel for the purpose of measuring a second elapsed time. As a result of the second time elapsing, the control program may restart the execution of the dosing schedule from the beginning of the first dosing interval.
[0012] Additional features are presented in the present disclosure. The apparatus may be built with or without a power source, such as a battery or photovoltaic cell. In the case that the apparatus is built without a power source, it may be provided with a power source before it is used by an end user. A switch may be used to control power flow to the electronic timing mechanism. An on/off switch controlling power flow to the apparatus would enable manual restarts and extend the life of the apparatus.
[0013] The one or more annunciators may use audible, visual, or vibratory means to alert a person that a dose should be taken. The present invention specifically excludes a human readable time display, such as a liquid crystal clock display, thereby permitting the apparatus to be smaller and flexible.
[0014] The attachment means may be a pressure sensitive adhesive to facilitate a peel-and-stick method of applying the apparatus to a medicine container.
[0015] The apparatus may further comprise a flexible covering. The flexible covering may have human readable printing printed thereon. Human readable printing may be lettering, pictures, pictograms, or even braille for the visually challenged. The human readable printing in this example might read “once a day” or “24 Hrs”. The flexible covering may have holes in it that allow the annunciators to be seen or heard without obstruction from the flexible covering.
[0016] A switch or multiple switches may be used to interact with the electronic timing mechanism such that activating a switch when an annunciator is activated causes the dosing schedule to advance to the next dosing interval. Activation of a switch may also deactivate an already activated annunciator. Activation of a switch may be used to indicate to the apparatus that a dose has been taken. Activating a switch may have multiple effects such as advancing the dosing schedule to the next dosing interval, deactivating an already activated annunciator, and indicating that a dose has been taken.
[0017] The apparatus may further comprise a means for data communication, which would enable the downloading of a new dosing schedule or an update of the control program. Examples of wired data communication means would be RS-232 serial communications and Universal Serial Bus (USB) communications. Wireless means for data communication, including infrared and radio frequency links, would be better still as their non contact-means of data communication would improve the efficiency of operation and ease of use.
[0018] A method according to the present disclosure comprises the steps of dispensing medicine into a container, selecting an alert apparatus preprogrammed with a dosing schedule appropriate for said dispensed medicine, wherein said dosing schedule comprises at least one dosing interval, wherein each dosing interval corresponds to an amount of time, wherein the alert apparatus activates at least one human perceivable annunciator at the end of at least one dosing interval, and attaching the alert apparatus to a surface of the container. The method may further comprise the step of deciding on an initial start time and then synchronizing the start time of the electronic timing mechanism with a separate time piece such as a wrist watch or wall clock. The method may further comprise the step of starting the flow of power to the electronic timing mechanism of the alert apparatus. The method may further comprise the step of starting the flow of power to the electronic timing mechanism of the alert apparatus.
[0019] Another method according to the present disclosure comprises the steps of dispensing medicine into a container, attaching an alert apparatus that works according to the present disclosure to a surface of the container, programming the alert apparatus with a dosing schedule that is appropriate for the medicine, the dosing schedule comprising at least one dosing interval, wherein a dosing interval corresponds to an amount of time, wherein the alert apparatus activates at least one human perceivable annunciator at the end of at least one dosing interval. The method may further comprise the step of deciding on an initial start time and then synchronizing the start time of the electronic timing mechanism with a separate time piece such as a wrist watch or wall clock. The method may further comprise the step of starting the flow of power to the electronic timing mechanism of the alert apparatus. The method may further comprise the step of printing on the alert apparatus human readable printing corresponding to the dosing schedule. The method may further comprise the step of activating a switch means on the alert apparatus thereby deactivating an already activated annunciator. The method may further comprise the step of activating a switch means on said alert apparatus thereby advancing said dosing schedule to the next dosing interval. The method may further comprise the step of activating a switch means on the alert apparatus to indicate that a medicine dose has been taken.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0021] FIG. 1 shows a perspective view of an embodiment of the invention;
[0022] FIG. 2 shows a perspective view of another embodiment of the invention,
[0023] FIG. 3 shows a perspective view of an embodiment of the invention while attached to a medicine container,
[0024] FIG. 4 shows a system diagram indicating structural and functional relationships among and within elements of the apparatus according to an embodiment of the invention;
[0025] FIGS. 5A and 5B together are a program flowchart diagram illustrating a preferred method of implementing computer software control program according to an embodiment of the invention;
[0026] FIG. 6A shows an exemplary computer-readable data structure capable of storing dosing schedule information in accordance with an embodiment the invention;
[0027] FIG. 6B shows an exemplary computer-readable data structure capable of storing information associated with an individual dosing schedule entry in accordance with an embodiment of the invention;
[0028] FIG. 7A shows perspective view of an embodiment of the invention in an not-flexed state;
[0029] FIG. 7B shows a perspective view of the embodiment of FIG. 7A in a flexed state;
[0030] FIG. 8 shows a perspective view of an embodiment of the invention in which user readable printing is visible on the surface of the apparatus;
[0031] FIG. 9 shows a system diagram indicating structural and functional relationships among and within elements of the apparatus according to an an embodiment of the invention;
[0032] FIG. 10 shows a system diagram indicating structural and functional relationships among and within elements of the apparatus according to an an embodiment of the invention.
[0033] FIG. 11 is a program flowchart diagram illustrating a method for eliminating alarm creep according to an embodiment of the invention;
LIST OF REFERENCE NUMBERS APPEARING IN THE FIGURES
[0034] 1 , 1 a, 1 b —Apparatus for alerting a patient at medicine dosing times.
[0035] 2 —Container.
[0036] 4 —Flexible substrate.
[0037] 6 —Attachment means.
[0038] 7 —Flexible covering.
[0039] 8 a, 8 b, . . . —Openings in flexible covering.
[0040] 9 —Human readable printing.
[0041] 10 —Electronic timing mechanism.
[0042] 12 —Processor.
[0043] 14 —Clock source.
[0044] 16 —Memory.
[0045] 18 —Control program.
[0046] 19 a, 19 b —First and second timing channels.
[0047] 20 —Dosing schedule.
[0048] 21 —Dosing schedule entry.
[0049] 22 —Switch interface.
[0050] 24 —Annunciator signal generator.
[0051] 26 —Annunciator interface.
[0052] 28 —Power source.
[0053] 30 , 30 a, 30 b —Annunciators.
[0054] 32 —Switch.
[0055] 34 , 34 a, 34 b —Annunciator connections.
[0056] 36 , 36 a, 36 b —Switch connections.
[0057] 38 , 38 a, 38 b —Power source connections.
[0058] 40 —Power switch.
[0059] 42 —Data communication interface.
[0060] 44 —External communication system.
[0061] 46 —Communication channel.
DESCRIPTION
[0062] With reference now to FIG. 1 , an embodiment of a version of the invention is shown as an apparatus for alerting a patient at medicine dosing times 1 a comprising flexible substrate 4 , attachment means 6 , electronic timing mechanism 10 , power source 28 , switch 32 , and annunciator 30 . Attachment means 6 is adhered to the bottom surface of flexible substrate 4 for the purpose of attaching the apparatus to other objects. A preferred embodiment of attachment means 6 is a thin flexible film that presents a pressure sensitive adhesive on both of its surfaces, for example a double sided sticky tape. Attached to the top surface of flexible substrate 4 are electrical components: electronic timing mechanism 10 , power source 28 , switch 32 , and annunciator 30 . A preferred embodiment of flexible substrate 4 is a flexible printed circuit material, such as a polyimide film laminated with copper on one or both sides, which has the added advantage of being able to provide electrical connectivity between the electrical components of the apparatus. Use of flexible printed circuit material for flexible substrate 4 allows electrical components to be soldered in place while the electrical connections required to complete the circuit between electrical components are embodied as a printed circuit on flexible substrate 4 .
[0063] In an alternate embodiment, flexible substrate 4 may not use printed circuits on flexible substrate 4 to make electrical connection between electrical components. Instead, electrical connections between components may be made by means of discrete wires suspended above flexible substrate 4 . Such wires may be designed and assembled on to the apparatus with enough slack to allow flexible substrate 4 to conform to a curved object without breaking the wires or the electrical connection between electrical components. FIG. 7A depicts an embodiment of apparatus 1 a in which electrical connections are made by means of wires above flexible substrate 4 . Apparatus 1 a in FIG. 7A is shown in its not-flexed state. FIG. 7B illustrates the effect of flexing apparatus 1 a of FIG. 7A upon annunciator connections 34 , switch connections 36 , and power source connections 38 . FIG. 7B shows that the amount of slack in annunciator connections 34 , switch connections 36 , and power source connections 38 varies as apparatus 1 a is flexed.
[0064] FIG. 2 shows an embodiment of another version of the invention as an apparatus for alerting a patient at medicine dosing times 1 b. In this version flexible covering 7 is molded over the apparatus depicted in FIG. 1 . Flexible covering 7 is shown with openings 8 a , and 8 b which allow user access to switch 32 and annunciator 30 . A preferred embodiment of flexible substrate 7 is an elastic polymer compound of sufficiently low durometer to allow the apparatus to conform to curved surfaces of a size and shape routinely found on medicine containers. Durometers of less than 100 Shore A will be useful in various embodiments of the invention, with lower durometer numbers providing more flexibility. Flexible covering 7 is molded in such a way as to not interfere with the proper operation of attachment means 6 . In an alternate embodiment, attachment means 6 may be omitted from attachment to flexible substrate 4 , flexible covering 7 may be molded to encompass both top and bottom surfaces of flexible substrate 4 , and attachment means 6 may then be attached to flexible covering 7 . Flexible covering 7 may be fabricated with a material that presents a uniform color from the visible surface of the apparatus. A variety of colors may thereby be used to distinguish instances of the apparatus from one another.
[0065] FIG. 3 shows an embodiment of a version of the apparatus for alerting a patient at medicine dosing times 1 b attached to container 2 . Container 2 may be of any size and shape suitable for dispensing pharmaceutical pills, liquids, gels, and creams to patients. Since apparatus 1 b is designed and constructed to be flexible it is able to conform to the curvature presented by container 2 . The apparatus may be attached to nearly any surface, flat and curved surfaces included. The embodiment shown in FIG. 3 also depicts flexible covering 7 , openings in flexible covering 8 a and 8 b, and human readable printing 9 . In a medical application where container 2 contains medicine, it is typical that such a container is labeled with dosage and other important information. The flexibility of apparatus 1 b allows direct attachment to the original pharmacy container which may be an advantage in preserving the information labeled on that container. When multiple medications are used, a patient may derive further benefit by using a different apparatus 1 b on each container 2 .
[0066] The structures and functions of the various embodiments of the apparatuses depicted in FIGS. 1 , 2 , 3 , 7 , and 8 , may now be better understood with reference to FIG. 4 . In FIG. 4 electronic timing mechanism 10 is shown comprising processor 12 , clock source 14 , memory 16 , timing channel 19 a , switch interface 22 , annunciator signal generator 24 , and annunciator interface 26 . Located in memory 16 in computer-readable form are both control program 18 and dosing schedule 20 . Processor 12 executes control program 18 which in turn executes dosing schedule 20 . Clock source 14 allows processor 12 to execute instructions at a known rate. This known rate of execution enables processor 12 in conjunction with control program 18 to function as an timer capable of keeping track of at least one timing channel 19 a . Control program 18 may start, stop, and reset timing channel 19 a . Timing channel 19 a operates to keep track of elapsed time durations. Dosing schedule 20 contains information that includes the duration of one or more time intervals that pertain to when a medicine dose should be taken. Control program 18 fetches individual entries one at a time from dosing schedule 20 . Control program 18 causes timing channel 19 a to time the amount of time associated with an individual dosing schedule entry. When control program 18 has ensured that the entire time associated with a dosing schedule entry has elapsed, control program 18 causes annunciator signal generator 24 to generate and send a signal through annunciator interface 26 . The signal is propagated across annunciator connection 34 to annunciator 30 . Annunciator 30 thereby alerts a patient that a medicine dose is due to be taken by making any one of visual indication, audible indication, vibratory indication, or any combination thereof.
[0067] electronic timing mechanism 10 is capable of independently maintaining and timing more than one channel of timing. By way of example, a first timing channel 19 a may have a time period of 8 hours, while a second timing channel 19 b may have a time period of 24 hours. electronic timing mechanism 10 is capable of starting, stopping, and reseting first timing channel 19 a without interrupting the ongoing proper function of second timing channel 19 b . Likewise, electronic timing mechanism 10 is capable of starting, stopping, and reseting second timing channel 19 b without interrupting the ongoing proper function of first timing channel 19 a . FIG. 10 depicts a functional block diagram of a version of an embodiment according to this disclosure in which first timing channel 19 a and second timing timing channel are illustrated.
[0068] Processor 12 is operatively connected to switch interface 22 to receive indications of switch 32 activation by a user of the apparatus. Switch 32 communicates its state via switch connection 36 to switch interface 22 thereby making the state of switch 32 available to processor 12 for use during the execution of control program 18 .
[0069] electronic timing mechanism 10 receives electrical power from power source 28 via power source connection 38 . electronic timing mechanism 10 by virtue of its own power source connection 38 may then supply any power needed to operate annunciator 30 and switch 32 . In this way both switch connection 36 and annunciator connection 30 may be used to transmit both power and data to annunciator 30 and switch 32 respectively.
[0070] Processor 12 may be a conventional microprocessor in which case both clock source 14 and memory 16 may be contained within the microprocessor itself. Clock source 14 may also be a crystal or other oscillator external to a microprocessor. Memory 16 may consist of Read Only Memory (ROM), or Random Access Memory (RAM), or a combination of RAM and ROM. In the case that processor 12 is a conventional microprocessor, memory 16 of either RAM or ROM type, or both types, may be contained in the microprocessor itself.
[0071] Control program 18 and dosing schedule 20 are both stored in computer-readable form in memory. Owing to the characteristics of the types of memory available, namely random access memory (RAM) and read-only memory (ROM) types, various embodiments may have different desirable characteristics. For example, if both control program 18 and dosing schedule 20 are stored in ROM they would be expected to be unalterable once manufacture of the apparatus is complete. This would provide the advantage of tamper proof operation and ease of use. This would also facilitate the use of human readable printing 9 on flexible covering 7 to indicate which dosing schedule is embodied by an instance of the apparatus.
[0072] In another version of an embodiment of the apparatus, control program 18 may reside in ROM, while dosing schedule 20 resides in RAM. Thus dosing schedule 20 may be loaded after manufacture of the apparatus is complete. This would provide the advantage of being able to load dosing schedule 20 into memory 16 just prior to dispensing a medication. There is a potential cost advantage to manufacturing just one design of apparatus that can be configured after manufacture with the required dosing schedule prior to use by a patient. In addition, medicine dosage may be tailored specifically to a patient on the basis of age, gender, weight, sensitivity, DNA, or other relevant factors.
[0073] The structure and function of annunciator signal generator 24 , annunciator interface 26 , and annunciator connection 30 depend upon what is required to activate annunciator 30 . If, for example, annunciator 30 is a light emitting diode (LED), and blinking of that LED is the desired activation, then annunciator signal generator 24 may produce a signal that switches between ON and OFF states at the desired blink rate, annunciator interface 26 may be a transistor circuit controlled by said ON and OFF states to control a current that flows through annunciator connection 34 , which may be a simple conductor, thereby causing current to flow and the LED to illuminate during the ON state, and no current to flow causing the LED to be dark during the OFF state.
[0074] If, as another example, annunciator 30 is an audible beeper, and a sounding of that beeper is the desired activation, then annunciator signal generator 24 may produce a signal that switches between ON and OFF states at the desired beep rate, annunciator interface 26 may be a transistor circuit controlled by said ON and OFF states to control a current that flows through annunciator connection 34 , which may be a simple conductor, thereby causing current to flow and the beeper to emit sound during the ON state, and no current to flow and the beeper to be silent during the OFF state.
[0075] If, as another example, annunciator 30 is a small conventional speaker, and the desired activation is a human sounding voice that says “time to take your medicine” or any other desired phrase or set of phrases, then annunciator signal generator 24 may produce modulated waveforms that correspond to the desired sounds. Alternatively, annunciator signal generator 24 may retrieve computer-readable waveforms corresponding to the desired sounds from memory 16 . Annunciator interface 26 may then take the waveforms and amplify and filter as needed to drive the speaker through annunciator connection 34 , which may be one or more conductors.
[0076] If, as another example, annunciator 30 produces a sensible vibration when activated, such as produced by a tiny electrical motor with an unbalanced weight attached to its rotating shaft, then annunciator signal generator 24 may produce a signal that switches between ON and OFF states, annunciator interface 26 may be a transistor circuit controlled by said ON and OFF states to control a current that flows through annunciator connection 34 , which may be a simple conductor, thereby causing current to flow and annunciator 30 to vibrate during the ON state, and no current to flow and the annunciator 30 to be still during the OFF state.
[0077] The state of switch 32 is conveyed through switch connection 36 to switch interface 22 , which in turn makes the state of switch 32 available to processor 12 for use by control program 18 . This allows a user of the apparatus to interact with the apparatus. In a version of an embodiment of the apparatus switch 32 may be a momentary contact switch, switch connection 36 may be a conductor, and switch interface 22 may be a general purpose input pin on a conventional microprocessor.
[0078] In another version of an embodiment of the apparatus switch 32 may be a capacitive sensing non-contact switch, switch connection 36 may be a pair of conductors, and switch interface 22 may be a capacitance sensing circuit that produces and ON state indication when a touch near the capacitive sensor is detected and produces an OFF state indication otherwise.
[0079] FIG. 5A and FIG. 5B taken together illustrate a program flowchart for a preferred embodiment of control program 18 . Control program 18 has as its primary functions the execution of dosing schedule 20 , activation of annunciator signal generator 24 for the current dosing schedule entry, and responding to user input. User input is made available to control program 18 through the state of switch 32 . FIGS. 6A and 6B show exemplary data structures for dosing schedule 20 , and dosing schedule entry 21 which are used in conjunction with control program 18 . All control program sequence steps and all data structures are provided to processor 12 via computer readable media.
[0080] Control program 18 as shown in FIGS. 5A and 5B functions in the following way: dosing schedule 20 is executed one dosing schedule entry 21 at a time, annunciators are activated and deactivated when necessary, and user input is acted upon when necessary. As depicted in FIG. 6B , dosing schedule entry 21 comprises, but is not limited to, data representative of the time duration of a dosing interval, data indicating which of one or more annunciators to activate upon completion of the dosing interval, data indicating what actions to take upon sensing the activation of one or more switches, and data indicating which dosing schedule entry to execute upon the completion of the current dosing schedule entry. Including the ability to execute a prior dosing schedule entry gives the apparatus the ability to loop its execution of a portion or all of its dosing schedule. The apparatus may thereby be caused to repeat any number of dosing schedule entires indefinitely. At the end of a dosing interval, user input via one or more switches 32 may conditionally cause execution of additional control program sequences. If the current dosing schedule entry does not possess a next dosing schedule entry then control program 18 may not execute any more dosing schedule entries.
[0081] Control program 18 may start executing dosing schedule 20 immediately upon power being supplied to electronic timing mechanism 10 . An alternate embodiment of control program 18 may wait for an activation of one or more switches 32 before starting the execution of dosing schedule 20 .
[0082] FIGS. 3 and 8 both show another beneficial feature, human readable printing 9 , which may be printed on flexible covering 7 . The presence of human readable printing 9 makes it easy to determine the dosing schedule programmed into the apparatus. Human readable printing is not restricted to just text, it may be textual, numeric, pictographic, braille, or any combination thereof. Use of pictograms indicating dosing schedule is particularly helpful in populations with low literacy rates or persons with visual or auditory impairments.
[0083] Human readable printing on a visible portion of the apparatus may be used to identify instances of the apparatus having different dosing schedules. Braille imprinting or embossing may be used as an aid to the visually impaired. Varied audible tones may be produced for the benefit of the visually impaired. LED and vibration annunciators will enable use of apparatus 1 by those with auditory impairments.
[0084] FIG. 9 illustrates another embodiment of the invention in which multiple annunciators are operatively included in the apparatus. Any mixture of multiple annunciators are permitted, for example, annunciator 30 a may be a visible LED while annunciator 30 b may be an audible beeper. Also shown in FIG. 9 is power switch 40 which is included for connecting and disconnecting power to electronic timing mechanism 10 . Power switch 40 may be any switch, for example a miniature sliding single pole single throw switch, that is capable of interrupting and restoring power from power source 28 to a low power electronic device. Power switch connections 38 a and 38 b are electrically conductive elements connected so as to transmit electrical power from power source 28 to power switch 40 , and from power switch 40 to electronic timing mechanism 10 .
[0085] FIG. 10 illustrates another embodiment of the invention in which data communication interface 42 is operatively connected to processor 10 for the purpose of exchanging dosing schedules and other useful information between the apparatus and an external communication system 44 through a communication channel 46 . A simple embodiment of data communication interface 42 would be a serial RS-232 interface that may be found on suitable microprocessors, which may use a pair of wires for communication channel 46 , and a personal computer as external communication system 44 .
[0086] Of particular merit would be a data communication interface 42 that does not require a wired connection with external communication system 44 to exchange information with that system. A wireless scheme would only require that communication channel be air or a vacuum. Suitable wireless data communication interfaces would use infrared or radio frequency to carry information between the apparatus and external communication system.
[0087] Data communication interface 42 may receive data from external communication system 44 including but not limited to a new dosing schedule 20 and updated control program 18 . In addition, data communication interface 42 may transmit useful data to external communication system 44 including but not limited to current dosing schedule 20 and serial number information identifying that particular instance of apparatus for alerting a patient at medicine dosing times 1 .
[0088] The version of the invention illustrated in FIG. 10 includes multiple timing channels, denoted as first timing channel 19 a and second timing channel 19 b . The inclusion of multiple timing channels allows multiple time periods to be timed independently. While first timing channel 19 a is timing the time duration associated with current dosing schedule entry 21 , second timing channel 19 b may be independently timing a different time period. Control program 18 may cause various beneficial actions at the end of each time period timed by second timing channel 19 b.
[0089] As human beings are fallible, it may happen that a person either misses a dose, or takes a required dose late. In either case the person may find it advantageous to restart the apparatus at a particular time of day using a separate time piece such as a wrist watch or wall clock so as to synchronize the start of dosing schedule 20 with the time of day. Embodiments of the present disclosure enable a person to restart dosing schedule 20 from the first dosing schedule entry by means of a sequence of one or more switch activations. Alternatively, dosing schedule 20 may be restarted by first interrupting and then restoring power to electronic timing mechanism 10 .
[0090] Embodiments of an apparatus for alerting a patient at medicine dosing times 1 operating in accordance with the present disclosure will produce at least one alert when the time has come to take a dose of medicine. It may happen then that the patient for whom the alert is intended is not present and hence is not able to interact with the apparatus 1 to deactivate annunciator 30 which is giving the alert. Since power consumption while an annunciator is activated is expected to be higher than when not activated, it is desirable to limit power consumption when the patient is not present to react to an alert. One method of saving power consumption in this scenario is to use a reduced power alert mode. An alert may initially activate in a full power alert mode. After an amount of time has passed without patient interaction with the apparatus 1 while full power alert mode is active, apparatus 1 may switch to a reduced power alert mode. The reduced power alert mode may continue to produce an alert, however, it will do so in a manner that uses less power than the full power alert mode. By way of example, full power alert mode may comprise an audible tone that is produced at full volume, while reduced power alert mode may comprise an audible tone that is produced at less than full volume. Various full power and reduced power alert modes may be constructed for any or all of the annunciators used in the apparatus.
[0091] FIG. 11 embodies a method to combat the problem of alarm creep which arises in the timing of dosing times. Using a concrete example to illustrate the principle of alarm creep, consider a required dosing schedule of one dose per 12 hours. Suppose then that the first dosing interval starts and then expires in exactly 12 hours, and the apparatus alerts the patient by means of activating one or more annunciators. Five minutes later, when the patient has taken the required dose of medicine, the patient activates a switch on the apparatus to indicate that the dose has been taken. If the 12 hour dosing interval is started at this point then the second alert will occur 24 hours and 5 minutes after the the timing of dosing intervals began. In this example, 5 minutes of alarm creep have occurred after the first dosing interval. If continued in this manner, alarm creep will accumulate for every dose and alerts will be generated later and later because of the creep. It is therefor desirable to eliminate alarm creep.
[0092] One method of controlling alarm creep is the following: Second timing channel 19 b may be used to time recurring 24 hour periods. Each time that control program 18 determines that second timing channel 19 b has timed the entire 24 hour duration it may cause a restart of dosing schedule 20 , after which second timing channel 19 b may be restarted to time another 24 hour period. The effect of a restart of dosing schedule 20 every 24 hours is that alarm creep is reset to zero every time dosing schedule 20 is restarted.
[0093] Another method of eliminating alarm creep is to start timing the next dosing interval immediately upon the expiration of the current dosing interval. The patient alert would persist until cleared by the patient through the activation of a switch on the apparatus. Since the next dosing interval is already being timed when the alert is cleared there can be no alarm creep. Since alarm creep may be eliminated by this method, future patient alerts would occur exactly on schedule. In the concrete example of one alert per 12 hours, all subsequent alerts would occur at exact 12 hours intervals with no accumulated creep.
[0094] A method of reducing alarm creep is to issue an alert prior to the expiration of a dosing interval. This can be very useful in counteracting time loses that occur due to a patient's response time in responding to and alert. This method is illustrated by the program flowchart diagram of FIG. 11 . FIG. 11 is best understood in the context the software program flowchart of FIG. 5A , where flowchart connectors AA and CC in FIG. 11 indicate the same flowchart connections as depicted in FIG. 5A . Using the concrete example of one dose per 12 hours, a fixed amount of time, for example 15 minutes, is subtracted from the 12 hour dosing interval. 12 Hours minus 15 minutes becomes the creep adjusted dosing interval. At the expiration of the creep adjusted dosing interval a patient alert may be produced by the apparatus.
[0095] While the foregoing descriptions are intended to convey the structure and function of elements comprising preferred embodiments of the invention, the disclosure now turns to the manner and method of using various embodiments of the invention.
[0096] One particularly effective way of embodying the invention in an apparatus is for the dosing schedule to be preprogrammed at the factory and on that apparatus print a unique, clearly visible, human readable, representation of that dosing schedule. Human nature indicates that the easier a task is to perform the more likely a person is to comply with the performance of that task. Using a human readable representation of the dosing schedule in association with a preprogrammed dosing schedule reduces the number of steps that need to be performed to use the apparatus. A person would simply attach to the medicine container an apparatus that has been preprogrammed with a dosing schedule that matches the requirements of the medication. A person may decide on an initial start time, with reference to a separate time piece, and then take the first dose. When the first dose is taken execution of the dosing schedule may be caused to commence within the apparatus, thereby synchronizing the execution of the dosing schedule with the separate time piece. Depending on the embodiment of the invention, the apparatus may or may not have a user accessible power switch. If a power switch is user accessible then it may be switched on at the time of the first dose and thereafter the dosing schedule will execute according to the programming instantiated at the factory. If no power switch is user accessible then the user may press one or more switches to indicate that the first dose has been taken and thereafter the dosing schedule will execute according to the programming instantiated at the factory. The flexibility of the apparatus allows for it to be attached to and conform to surfaces, thereby allowing it to be directly affixed to the medicine container to which its dosing schedule pertains. Thus people with many medicines to take may use many such apparatuses, each one executing a dosing schedule appropriate to the medicine in the container to which it is attached. An apparatus attached to each medicine container helps to avert confusion by producing alerts that are specific to the medicine in each specific container.
[0097] After the apparatus has started executing its dosing schedule it will produce human perceivable alerts, by means of one or more of its annunciators, according to the individual dosing schedule entry that it is executing at the time. Upon noticing an alert, the person will take the required medicine dose and then indicate to the device, by means of one or more switches, that the required dose has been taken. The apparatus will continue operation by executing the next dosing schedule entry. If there is no next dosing schedule entry then the apparatus will become dormant and issue no more alerts. In a preferred embodiment, a single switch activation by the person may serve to simultaneously silence an alert, confirm that a dose has been taken, and advance the dosing schedule to the next dosing schedule entry.
[0098] In another embodiment of the invention it is envisioned that the apparatus may be dispensed at the same time that the medicine itself is dispensed by a pharmacist or other persons permitted to dispense medication. When dispensed by a pharmacist it may be beneficial to provide the pharmacist with an apparatus that is not preprogrammed with a dosing schedule. The pharmacist could program the appropriate dosing schedule into the apparatus, attach the now programmed apparatus to a medicine container and then dispense the medicine into the same container. The steps of programming, attaching, and dispensing could naturally be performed in any order and still accomplish the same objective. Programming the apparatus at the point of dispensing is made easier by using any of the various means of programming already disclosed, including infrared and radio frequency. After dispensing by the pharmacist, the apparatus may be used to alert a patient at the appropriate medicine dosing times.
[0099] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, there are many beneficial uses of a alert apparatus constructed as described in this disclosure. A 7 day alarm period may be useful for the scheduling of personal weekly activities such as taking out the trash or moving the car between alternate parking districts. A 1 hour alarm period may be useful for tracking parking meter expiration. A 3 month alarm period may be useful for prompting the replacement of filters in many situations. A 3 day alarm period may be useful in article rental situations. Larger apparatus may be constructed in keeping with the present disclosure, such apparatus additionally comprising permanent power supply, louder annunciators, and brighter annunciators. In addition, versions of the invention may be attached directly to or may be built in to other fixtures such as household medicine cabinets. Such apparatus may be used either independently or in conjunction with apparatuses placed on original medicine containers. Therefor, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
[0100] Other versions and embodiments of alert apparatus consistent with the present disclosure are possible. Alert apparatus may consider the fact that most medicine dosing schedules recognize sleep time at night and should function to keep those hours quiet. Also, because some homes are large and persons may keep their medicines in a cabinet that may be closed most of the time, the following additional disclosure will address ways of helping to ensure that alerts are detected. An amplification device, capable of detecting and amplifying sound and powered by batteries or regular home power supply can be placed in close proximity by attaching to or being built into medicine cabinets. Once activated such an amplification device may continue at full power until reset. Amplification devices may amplify audible signals, visual signals or both and thereby help in the perception of alerts by persons in larger homes.
[0101] Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. Section 112, Paragraph 6.
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Disclosed are apparatus for assisting a person in the correct administration of medicine and methods for beneficially using such a device. The apparatus comprises an electronic timing mechanism which executes a dosing schedule, the dosing schedule being comprised of at least one dosing time interval. One or more annunciators are activated at the end of at least one dosing interval thereby alerting a person that it is time to take a dose of medicine. Included are attachment means, such as a pressure sensitive adhesive, for attachment to a medicine container. Construction is with materials and structures that confer to the device the flexibility required to physically conform to curved objects such as typically encountered in prescribed medications. Alerts from the device may be visible, audible, vibratory, or any combination thereof. No human readable time is displayed. At least one switch is provided for human interaction with the device. Human readable information may be visible on the device for quick dosing schedule identification. The dosing schedule may be preprogrammed and unalterable. In other embodiments the dosing schedule may be reprogrammable.
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TECHNICAL FIELD
[0001] The present disclosure relates to self-adaptive cements. In particular, it relates to set cements that are “self-healing,” i.e., formulations that can adapt to compensate for changes or faults in the physical structure of the cement, or which adapt their structure after the setting phase of the cement in the cementing of oil, gas, water or geothermal wells, or the like.
BACKGROUND
[0002] During the construction of wells, cement is used to secure and support casing inside the well and prevent fluid communication between the various underground fluid-containing layers or the production of unwanted fluids into the well.
[0003] Various approaches have been developed to prevent failure of the cement sheath. One approach is to design the cement sheath to take into account physical stresses that might be encountered during its lifetime. Such an approach is described for example in U.S. Pat. No. 6,296,057. Another approach is to include, in the cement composition, materials that improve the physical properties of the set cement. U.S. Pat. No. 6,458,198 describes the addition of amorphous metal fibers to the cement slurry to improve its strength and resistance to impact damage. EP 1129047 and WO 00/37387 describe the addition of flexible materials (rubber or polymers) to the cement to confer a degree of flexibility on the cement sheath.
[0004] Nevertheless, the above-described approaches do not allow restoration of the zonal isolation once the cement sheath has actually failed due to the formation of cracks or microannuli.
[0005] A number of self-healing concretes are known for use in the construction industry. These are described for example in U.S. Pat. No. 5,575,841, U.S. Pat. No. 5,660,624, U.S. Pat. No. 5,989,334, U.S. Pat. No. 6,261,360 and U.S. Pat. No. 6,527,849, and in the document entitled “Three designs for the internal release of sealants, adhesives, and waterproofing chemicals into concrete to reduce permeability”, Dry, C. M., Cement and Concrete Research 30 (2000) 1969-1977.
[0006] Nevertheless, none of these self-healing concretes are immediately applicable to well cementing operations because of the need for the material to be pumpable during placement.
[0007] “Self-healing” cements were eventually developed for oil and gas industry applications such as described in U.S. 2007/0204765 A1, WO 2004/101951 and WO 2004/101952 A1. These formulations generally contain additives that react and/or swell upon contact with downhole fluids. When cement-sheath deterioration occurs, exposing the cement matrix or cement-sheath surfaces to downhole fluids, the additives respond and seal cracks or fissures, thereby restoring cement-matrix integrity and zonal isolation. Well cements are potentially exposed to several fluid types during service, including liquid and gaseous hydrocarbons, water, brines and/or carbon dioxide. Thus, depending on the anticipated wellbore environment, it would be desirable to incorporate additives that are able to respond to one or more types of downhole fluids.
[0008] Despite the many valuable contributions from the art, it would be desirable to have access to a self-healing set cement that responds to formation fluids that contain high concentrations of gaseous hydrocarbons.
SUMMARY
[0009] The present disclosure provides set cements that are self-healing when exposed to hydrocarbons, and methods by which they may be prepared and applied in subterranean wells.
[0010] In an aspect, embodiments relate to methods for maintaining zonal isolation in a subterranean well that penetrates one or more hydrocarbon-containing formations.
[0011] In a further aspect, embodiments relate to uses of thermoplastic block-polymer particles to impart self-healing properties to a cement formulation that is placed in a subterranean well penetrating one or more hydrocarbon-containing formations.
DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plot showing the swelling characteristics of styrene-isoprene-styrene (SIS) and styrene-butadiene-styrene (SBS) particles in the presence of methane at various temperatures and pressures.
[0013] FIG. 2 is a schematic diagram of an experimental apparatus for measuring the self-healing ability of fractured cement samples.
[0014] FIG. 3 presents normalized flow-rate reductions for set cements containing SIS and SBS particles exposed to methane.
[0015] FIG. 4 presents the effect of slurry density on normalized flow-rate reductions for set cements containing SIS and SBS particles exposed to methane.
[0016] FIG. 5 presents normalized flow-rate reductions for set cements containing SIS and SBS particles exposed to methane at various pressures.
DETAILED DESCRIPTION
[0017] At the outset, it should be noted that in the development of any such actual embodiment, numerous implementations—specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific points, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possessed knowledge of the entire range and all points within the range.
[0018] This disclosure concerns compositions for cementing subterranean wells, comprising a settable material, water and at least one additive that swells in the event of structural failure of or damage to the set material (i.e., the cement sheath). Such behavior restores and maintains a physical and hydraulic barrier in the failure zone. As a result, zonal isolation in the subterranean well is preserved. Such set cements are said to be “self-healing” or “self-repairing.” In this application, both terms are used indifferently, and are to be understood as the capacity of a cement sheath to restore hydraulic isolation after suffering a matrix-permeability increase, structural defects such as cracks or fissures, or debonding from casing or formation surfaces (i.e., microannuli).
[0019] Examples of settable materials include (but are not limited to) Portland cement, microcement, geopolymers, mixtures of cement and geopolymer, plaster, lime-silica mixtures, resins, phosphomagnesium cements or chemically bonded phosphate ceramics (CBPCs).
[0020] As stated earlier, there is a need for self-healing set cements that operate in an environment containing high concentrations of gaseous hydrocarbons, methane in particular. Surprisingly, the inventors have discovered that self-healing properties may be achieved in this environment by incorporating thermoplastic block-polymer particles in the cement formulation. Typical block polymers comprise alternating sections of one chemical compound separated by sections of a different chemical compound, or a coupling group of low molecular weight. For example, block polymers can have the structure (A-b-B-b-A), wherein A represents a block that is glassy or semi-crystalline and B is a block that is elastomeric. In principle, A can be any polymer that is normally regarded as thermoplastic (e.g., polystyrene, polymethylmethacrylate, isotactic polypropylene, polyurethane, etc.), and B can be any polymer that is normally regarded as elastomeric (e.g., polyisoprene, polybutadiene, polyethers, polyesters, etc.).
[0021] Further embodiments relate to methods for maintaining zonal isolation in a subterranean well having a borehole that penetrates one or more hydrocarbon-containing formations. The method comprises pumping a cement slurry comprising thermoplastic block-polymer particles into the well, and allowing the cement slurry to form a cement sheath. Those skilled in the art will recognize that a cement slurry is generally considered to be pumpable when its viscosity is less than or equal to 1000 mPa-s at a shear rate of 100 s −1 , throughout the temperature range the slurry will experience during placement in the well. The cement sheath may be located between the well casing and the borehole wall, or between the casing and another casing string. If microannuli, cracks or defects occur in the cement sheath, the casing-cement interface or the cement-borehole wall interface, the particles will be exposed to formation hydrocarbons, causing them to swell and enabling the cement sheath to have self-healing properties.
[0022] Yet further embodiments aim at uses of thermoplastic block-polymer particles to impart self-healing properties to a set cement sheath in a subterranean well that penetrates one or more hydrocarbon-containing formations. The particles swell when contacted by hydrocarbons from the formation, in particular gaseous hydrocarbons.
[0023] For all aspects, the tensile strength of the block polymer may be varied between (but is not limited to) about 1.5 MPa and 40 MPa, preferably between 3.4 to 34 MPa. Even more preferred tensile-strength may be between 2MPa and 3.45 MPa or between 28 MPa and 34 MPa.
[0024] Preferred thermoplastic block polymers include styrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS) and mixtures thereof. The block-polymer-additive may be in one or more shapes, including (but not limited to) spherical, ovoid, fibrous, ribbon-like and in the form of a mesh.
[0025] The concentration of the block-polymer particles is preferably between about 10% and 55% by volume of solids in the cement slurry, also known as percentage by volume of blend (BVOB). A more preferred particle concentration lies between about 20% and 50% BVOB. The particle-size range is preferably between about 100 μm and 900 μm, and more preferably between about 200 μm and 800 μm.
[0026] One of the current challenge that the industry is facing is the presence in some wells of high concentration of gaseous hydrocarbons such as methane, propane and/or ethane. Such gaseous hydrocarbons being much more volatile than hydrocarbons in liquid form have the tendency to penetrate the failures and/or microannuli that can be present and the cement sheath and thus modifying the pressure and safety conditions of the well as the integrity is diminished. The inventors have determined that the present compositions can solve this problem up to very high concentration of gaseous hydrocarbon. In a preferred embodiment, the gaseous concentration of hydrocarbon fluid is greater than about 91 mol %, and more preferably above about 95 mol %. In addition, the hydrocarbon pressure to which the cement sheath is exposed is preferably above about 3.5 MPa, more preferably above about 6.9 MPa and most preferably above about 13.7 MPa.
[0027] The block-polymer particles may be further encapsulated by a protective layer. The layer may rupture or degrade upon exposure to one or more triggers, including (but not limited to) contact with a hydrocarbon, propagation of a crack within the set-cement matrix, time and/or temperature.
[0028] In addition to the block-polymer particles, the cement slurries may also comprise customary additives such as retarders, accelerators, extenders, fluid-loss-control additives, lost-circulation additives, gas-migration additives and antifoam agents. Furthermore, the cement slurries may contain additives that enhance the flexibility and/or toughness of the set cement. Such additives include (but are not limited to) flexible particles having a Young's modulus below about 5000 MPa and a Poisson's ratio above about 0.3. Preferably, such particles would have a Young's modulus below about 2000 MPa. Examples include (but are not limited to) polypropylene, polyethylene, acrylonitrile butadiene, styrene butadiene and polyamide. Such additives may also include fibers selected from the list comprising polyamide, polyethylene and polyvinyl alcohol. Metallic microribbons may also be included.
[0029] The block-polymer particles may also be used in engineered-particle-size cement formulations involving trimodal or quadrimodal blends of small, medium and coarse particles. Such as formulations exemplified in U.S. Pat. No. 5,518,996 and/or CA 2,117,276.
[0030] The block-polymer particles may be further associated with one or more compounds from the list comprising an aqueous inverse emulsion of polymer comprising a betaine group, poly-2,2,1-bicyclo heptene (polynorbornene), alkylstyrene, crosslinked substituted vinyl acrylate copolymers, diatomaceous earth, natural rubber, vulcanized rubber, polyisoprene rubber, vinyl acetate rubber, polychloroprene rubber, acrylonitrile butadiene rubber, hydrogenated acrylonitrile butadiene rubber, ethylene propylene diene monomer, ethylene propylene monomer rubber, styrene-butadiene rubber, styrene/propylene/diene monomer, brominated poly(isobutylene-co-4-methylstyrene), butyl rubber, chlorosulphonated polyethylenes, polyacrylate rubber, polyurethane, silicone rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, epichlorohydrin ethylene oxide copolymer, ethylene acrylate rubber, ethylene propylene diene terpolymer rubber, sulphonated polyethylene, fluoro silicone rubbers, fluoroelastomer and substituted styrene acrylate copolymers.
[0031] Those skilled in the art will appreciate that the disclosed method and use may not necessarily be applied throughout the entire length of the subterranean interval being cemented. In such cases, more than one cement-slurry composition is placed sequentially. The first slurry is called the “lead,” and the last slurry is called the “tail.” Under these circumstances, it is preferred that the inventive slurry be placed such that it resides in regions where hydrocarbons exist. In most cases, this will be at or near the bottom of the well; therefore, the inventive method and use would preferably apply to the tail. Those skilled in the art will also appreciate that the disclosed method and use would not only be useful for primary cementing, but also for remedial cementing operations such as squeeze cementing and plug cementing.
[0032] Other and further objects, features and advantages will be readily apparent to those skilled in the art upon a reading of the description of the examples which follows, taken in conjunction with the accompanying drawings.
EXAMPLES
[0033] The following examples serve to further illustrate the disclosure.
[0034] Table 1 lists the styrene-isoprene-styrene (SIS) polymers and styrene-butadiene-styrene (SBS) polymers that were used in the examples.
[0000]
TABLE 1
Suppliers and Properties of SIS and SBS Polymers Employed in Examples.*
Property
SIS #1
SIS #2
SBS #1
SBS #2
SBS #3
SBS #4
Supplier
ICO
Kraton
ICO
ICO
ICO
Kraton
Polymers
Polymers
Polymers
Polymers
Product Name
ICO1
D1161
ICO 3
ICO 4
ICO 5
D1192 EM
PTM
Melt Index
13
13.5
<1
23-37
<1
<1
(200° C./5 kg)
(g/10 min)
Density (kg/m 3 )
963
920
940
940
981
940
Tensile strength
17
21
16
10
33
at break (MPa)
Hardness,
24
32
72
70
Shore A (30 s)
Elongation at
1400
1300
680
900
880
break (%)
*Test methods: ISO 1133 (Melt Index measurement) ISO 37 (Tensile Strength at Break and Elongation at Break measurements) ISO 2781 (Density measurement) ISO 868 (ICO Polymers) and ASTM 2240 (Kraton) (Hardness measurement)
Example 1
[0035] Several polymer particles were placed inside a pressure cell equipped with a window that allows one to observe the behavior of materials within the cell. The cell supplier was Temco Inc., Houston, Tex. (USA). The cell temperature was also adjustable. A camera captured images from inside the pressure cell, and image-analysis software was employed to interpret the behavior of materials inside the cell. For particle-size measurements, the software examined the cross-sectional area of the particles in the cell.
[0036] After the polymer particles were introduced into the cell, the cell was sealed. The cell was then heated to the desired temperature. The initial particle sizes were measured.
[0037] A methane-gas line was then connected to the cell, and the methane pressure was raised to 21 MPa over a 3-min period. The cell pressure was maintained for 2 hr, after which the particle sizes were measured again.
[0038] Tests were performed at 22° C. and 42° C. with an SIS polymer (SIS #1 from Table 1) and an SBS polymer (SBS #3). The results are presented in FIG. 1 . At both temperatures, both SIS and SBS polymer demonstrated good performance.
Example 2
[0039] The properties of cement slurries containing SIS or SBS particles were measured. The tests conformed to standard methods published by the International Organization for Standards (ISO): “Petroleum and natural gas industries—Cements and materials for well cementing—Part 2: Testing of well cements,” International Organization for Standards Publication No. ISO 10426-2. Two cement slurries were tested—one containing SIS particles (SIS #1), and the other containing SBS particles (SBS #3). The test conditions were as follows—bottomhole static temperature: 53° C.; bottomhole circulating temperature: 44° C.; bottomhole pressure: 21 MPa (3000 psi).
[0040] The composition of the slurry containing SBS is given in Table 2, and the test results are presented in Tables 3 and 4. The slurry density was 1606 kg/m 3 , and the solid volume fraction (SVF) of the slurry was 51.8%.
[0000]
TABLE 2
Composition of Test Cement Slurry Containing SBS as Self-Healing Particle.
Component
Type
Quantity (kg/m 3 )
Cement
Class G Portland cement
696
Self-healing particle
SBS #3
214.5
Silica
200 mesh (74 μm)
200.5
Water
Fresh
395
Lightweight particle
Acrylonitrile-butadiene copolymer
5
Antifoam
Polypropylene glycol
4
Dispersant
Polymelamine sulfonate
9
Antisettling
90% crystalline silica; 10%
1
polysaccharide biopolymer
Fluid-loss additive
RHODOFLAC ™, available from
72
Rhodia Nederland
Retarder
Calcium Lignosulfonate
2.5
[0000]
TABLE 3
Rheological Properties of Test Cement Slurry Containing
SBS as Self-Healing Particle.
Mixing
20-min Conditioning
PV: 233 cP
PV: 219 cP
Ty: 4.3 kPa (9 lbf/100 ft 2 )
Ty: 8.1 kPa (17 lbf/100 ft 2 )
[0000]
TABLE 4
Additional Properties of Test Cement Slurry Containing
SBS as Self-Healing Particle.
Measurement
Results
Free fluid
0.8%
Fluid loss
13 mL
Thickening time
8:53 (to 70 Bc)
Compressive strength development
500 psi [3.4 MPa] (UCA) after 23:42
1000 psi [7 MPa] (UCA) after 72:58
783 psi [5.4 MPa] (crush); 512 psi
[3.5 MPa] (UCA) after 24:00
1316 psi [9 MPa] crush (996 psi
[6.9 MPa] (UCA) after 72:00
Tensile strength*
1.9 MPa
*Cement was cured for 7 days at 53° C. and 20 MPa before measuring tensile strength.
[0041] The composition of the slurry containing SIS is given in Table 5, and the test results are presented in Tables 6 and 7. The slurry density was 1606 kg/m 3 , and the solid volume fraction (SVF) of the slurry was 51.7%.
[0000]
TABLE 5
Composition of Test Cement Slurry Containing SIS
as Self-Healing Particle.
Component
Type
Quantity (kg/m 3 )
Cement
Class G Portland cement
694
Self-healing additive
SIS #1
208
Antifoam
Polypropylene Glycol
5
Silica
200 mesh (74 μm)
219
Water
Fresh
393
Dispersant
Polymelamine Sulfonate
8
Antisettling
Biopolymer
1
Fluid loss
RHODOFLAC ™, available from
81
Rhodia Nederland
[0000]
TABLE 6
Rheological Properties of Test Cement Slurry Containing
SIS as Self-Healing Particle.
Mixing
20-min Conditioning
PV: 119 cP
PV: 107 cP
Ty: 6.7 KPa (14 lbf/100 ft 2 )
Ty: 9.1 KPa (19 lbf/100 ft 2 )
[0000]
TABLE 7
Additional Properties of Test Cement Slurry Containing
SIS as Self-Healing Particle.
Measurement
Results
Free water
0.3%
Thickening time
4:13 (to 70 Bearden consistency)
Compressive strength development
500 psi [3.4 MPa] after 11:52
(measured by UCA)
1000 psi [7 MPa] after 32:00
867 psi [6 MPa] after 24:00
1260 psi [8.7 MPa] after 72:00
Example 3
[0042] Various cement formulations containing SIS or SBS were evaluated for their self-healing properties. The slurry compositions are presented in Table 8. The formulation that contains acrylonitrile-butadiene copolymer rubber (ABCR) was included as a control with no self-healing capability.
[0000]
TABLE 8
Slurry Compositions for Self-Healing Tests.
SBS
Particle type
Unit
ABCR
SIS #1
SIS #2
SBS #1
SBS #2
SBS #3
#4
Density
(kg/m 3 )
1571
1498
1606
1498
1498
1498
1606
SVF
(%)
55
50.3
52.3
50
50.6
50
52
Particle
(kg/m 3 )
286
240
210
243
239
243
213
Cement
616
560
645
555
563
553
641
Silica
219
199
281
197
200
196
279
Water
436
494
459
498
491
497
463
Antifoam*
3
4
3
4
4
6
3
Dispersant*
5
0
5
0
0
3
5
Antisettling*
1
1
1
1
1
1
1
Retarder*
5
0
0
0
0
0
0
*Antifoam Agent: polypropylene glycol; Dispersant: polymelamine sulfonate; Antisettling Agent: 90% crystalline silica, 10% polysaccharide biopolymer; Retarder: calcium lignosulfonate.
[0043] Each cement slurry was prepared according to the method described in ISO Publication 10426-2, and samples were prepared in the manner required to perform a Brazilian tensile-strength test. This test is also described in ISO Publication 10426-2. The cement-core samples were 66 mm long and 22 mm in diameter. The samples were cured at room temperature and atmospheric pressure. The curing times are presented in Table 9. Columns with two numbers indicate that two tests were performed.
[0000]
TABLE 9
Curing times.
Particle
SBS
name
ABCR
SIS #1
SIS #2
SBS #1
SBS #2
SBS #3
#4
Curing
40/121
48
104
101
79/77
78/105
100
time
(days)
[0044] The samples were fractured by the Brazilian method, then transferred to a steel tube and secured by a sealing cement. As shown in FIG. 2 , the steel tube 101 is 180 mm long. There are two 90-mm sections—one with an internal diameter of 31.5 mm in diameter, the other with an internal diameter of 29.5 mm. The fractured cement sample 102 is placed inside the tube and the sealing cement 103 is applied around the sample. Midway along the cement sample, owing to the different tube diameters, there is an edge 104 to prevent the cement sample from sliding.
[0045] The composition of the sealing cement was a 1.88-kg/m 3 Portland cement slurry containing 2.7 mL/kg polynaphthalene sulfonate dispersant, 2.7 mL/kg polysiloxane antifoam agent, 178 mL/kg styrene butadiene latex and 2.1% by weight of cement calcium chloride accelerator.
[0046] Pure methane was then injected through the fractured samples for 24 hours at 21 MPa backpressure and at ambient temperature (20°-23° C.). Flow-rate and pressure variations were recorded, and normalized flow rates were calculated. The results are shown in FIG. 3 .
[0047] The cement matrices incorporating SIS particles demonstrated normalized flow-rate reductions greater than 98%. The performance of cement matrices incorporating SBS particles demonstrated flow-rate reductions between 49% and 97%. The control did not show a flow-rate reduction.
[0048] Example 4
[0049] Using the methods described in Example 3, the effect of slurry density on the performance of set cements containing SIS#1 or SBS#3 was investigated. The slurry compositions are shown in Table 10.
[0000]
TABLE 10
Slurry Compositions for Self-Healing Tests
Density
(kg/m 3 )
1606
1606
1498
1498
SVF
(%)
52
51.5
50.3
50.7
Particle type
SIS#1
SBS#3
SIS#1
SBS#3
Particle
(kg/m 3 )
213
216
240
242.5
Class G cement
641.5
635.5
560
554.3
Silica
280
277
199
196
Water
462.5
467.5
494
496.5
Antifoam
5
5
4
4
Dispersant
3
3
0
3
Antisettling
1
1
1
1
[0050] The cement slurries were cured for 7 days at 53° C. and 20 MPa. The self-healing test results are presented in FIG. 4 . For both cement matrices, density variation does not affect performance in terms of flow-rate reduction.
Example 5
[0051] Using the methods described in Example 3, the effect of pressure on the performance of set cements containing SIS#1 or SBS#3 was investigated. The 1606-kg/m 3 formulations from Table 9 were tested.
[0052] The samples were cured for 7 days at 53° C. and 20 MPa. Flow-rate-reduction measurements were performed at four methane pressures: 3.5 MPa, 7 MPa, 13.7 MPa and 20 MPa. The results, presented in FIG. 5 , indicate that flow-rate reduction was achieved at 3.5 MPa for the set cement containing SIS, and at 7 MPa for the set cement containing SBS.
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A self-adaptive cement formulation includes cement, water and thermoplastic block-polymer particles. The set cement demonstrates self-healing properties when exposed to methane, and is particularly suited for well-cementing applications. After placement and curing, the self healing properties help maintain zonal isolation should bonding be disrupted between the set cement and the formation or a casing string, should cracks or defects appear in the set-cement matrix, or both.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a semiconductor device and, more particularly, to a semiconductor device which includes a semiconductor chip bonded to an insulating substrate such as a film carrier.
A smiconductor device is proposed in U.S. Pat. No. 3,763,404, "SEMICONDUCTOR DEVICES AND MANUFACTURE THEREOF" patented on Oct. 2, 1973, wherein a semiconductor chip is bonded to lead electrodes formed on a flexible carrier made of, for example, a polyimide film. In the film carrier system, electrodes formed on the semiconductor chip are arranged so as to confront finger lead electrodes formed on the flexible carrier, and the electrodes formed on the semiconductor chip are simultaneously connected to the corresponding finger lead electrodes formed on the flexible carrier through the use of a bonding method.
Therefore, the above-mentioned film carrier system is suited for mass production. Moreover, the film carrier system has great advantages. For example, the film carrier system facilitates the fabrication of thin and small semiconductor devices.
However, the film carrier system of the prior art can not show a sufficient yield. And the semiconductor device formed by the film carrier system of the prior art can not tolerate the mechanical shock. The present inventors have discovered that the above defects are caused by the following facts. Generally, in the film carrier system, wiring patterns essentially made of copper are formed on the film carrier. In order to enhance the tight connection between the film carrier and the wiring patterns, it is necessary that roughness of three to fifteen micron (3-15μm) amplitude be formed on the surface of the copper film confronting the film carrier. One method for forming the roughness on the copper film surface is to mechanically rub the copper film surface. However, when the copper film is formed through the use of plating techniques, roughness of the three to fifteen microns (3-5μm) amplitude is unavoidably formed on the plated surface. Therefore, in the film carrier system, the copper film formed through the use of plating techniques is used to form the wiring patterns.
Accordingly, the finger lead electrode surfaces also have a roughness of the three to fifteen microns (3-5μm) amplitude. This roughness on the finger lead electrodes causes a capillary phenomenon during the bonding treatment Therefore, there is a possibility that an eutectic alloy created during the bonding treatment will flow along the rough surfaces by capillary action to form undersirable short circuits between the finger lead electrodes and the semiconductor chip. The thus formed short circuits will damage the semiconductor chip.
Accordingly, an object of the present invention is to provide an improved thin semiconductor device.
Another object of the present invention is to provide a semiconductor device carried on a film carrier.
Still another object of the present invention is to provide a semiconductor device carried on a film carrier, which shows accurate and stable operation.
Yet another object of the present invention is to provide a semiconductor device carried on a film carrier, which shows a good yield.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
To achieve the above objects, pursuant to an embodiment of the present invention, the surface of the finger lead electrodes is smoothed, as compared with that of the wiring patterns, through the use of a mechanical polishing method, a press method, an electrolytic polishing method, or a slight etching method. By smoothing the finger lead electrode surface, the undersirable capillary phenomenon is prevented and, therefore, the semiconductor device can show accurate operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detiled description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein,
FIG. 1 is a sectional view of a film carrier carrying wiring patterns and finger lead electrodes formed thereon in accordance with the prior art;
FIG. 2 is a sectional view of a semiconductor device of the prior art, wherein a semiconductor chip is bonded to the finger lead electrodes of FIG. 1;
FIG. 3 is a sectional view of one step for forming an embodiment of a semiconductor device of the present invention;
FIGS. 3(A) to 3(C) illustrate the resulting articles or products at three separate stages of performance of the method of the present invention;
FIG. 4 is a perspective view of a finger lead electrode included within the semiconductor device of the prior art; and
FIG. 5 is a perspective view of a finger lead electrode included within an embodiment of the semiconductor device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings, and to facilitate a more complete understanding of the present invention, a semiconductor device carried on a film carrier of the prior art will be first described with reference to FIGS. 1 and 2.
A copper film 10 is attached to a film carrier 12 made of a polyimide film. The copper film 10 is formed through the use of a plating method and, therefore, one surface thereof, which confronts the film carrier 12, has a roughness 14 of the three to fifteen microns (3-15μm) amplitude. An aperture 16 is formed in the film carrier 12, in which a semiconductor chip is secured. The copper film 10 is shaped in a desired pattern through the use of etching techniques so as to form wiring patterns formed on the film carrier 12 and finger lead electrodes 18 extended toward the aperture 16. The surface of the finger lead electrodes 18, to which the semiconductor ship is bonded, also has the roughness 14.
FIG. 2 shows a condition, where a semiconductor chip 20 is bonded to the finger lead electrodes 18 shown in FIG. 1. The surface of the wiring patterns and the finger lead electrodes 18 is coated with tin 22 through the use of a plating method. Bumps 24 made of, for example, gold are formed on the semiconductor chip 20 at positions corresponding to the finger lead electrodes 18. When the bonding operation is carried out to connect the bumps 24 to the finger lead electrodes 18, an eutectic alloy, for example, the eutectic alloy of Au-Sn is formed, whereby the semiconductor chip 20 is electrically and mechanically connected to the finger lead electrodes 18.
The eutectic alloy shows fluidity because of heat created during the bonding operation. The molten alloy will flow along the roughness 14 formed on the finger lead electrodes 18 due to capillary attraction and will reach the position where the bumps 24 are not formed as shown by the reference numeral 26 in FIG. 2. The eutectic alloy thus formed after undesirable flow will create undesirable short circuits, so called the chip touch phenomenon, whereby the semiconductor chip 20 is damaged.
FIG. 3 shows one step for forming an embodiment of a semiconductor device of the present invention. Like elements corresponding to those of FIG. 1 are indicated by like numerals.
The semiconductor device of the present invention is fabricated in the following manner. In this example, the semiconductor chip is mounted on a film carrier. However, the semiconductor device of the present invention can be formed on either the film carrier or a rigid substrate such as a glass substrate.
A strip of flexible film made of, for example, a polyimide film is first painted with adhesive. The flexible film is transported by a suitable means, whereby sprocket holes are formed in the both sides of the flexible film through the use a press method. Thereafter, the flexible film is transoprted through the use of the sprocket holes, whereby an aperture for securing a semiconductor chip and holes for cutting outer connection electrodes are formed at desired positions as is well known in the art.
A copper film is attached to the flexible film via the adhesive through the use of thermo press rollers. As is already discussed above, the copper film is preferably fabricated by a plating method, The surface of the copper film has roughness of three to fifteen microns (3-15μm) amplitude, which ensures tight connection between the flexible film and the copper film.
FIG. 3 shows a condition where the copper film 10 is attached to the film carrier 12. One surface of the copper film 10 has the roughness 14, which is exposed to the ambient at the aperture 16 where the semiconductor chip is to be secured. The flexible film 12 carrying the copper film 10 is supported by a supporting table 28 in such a manner that the roughness 14 formed at the aperture 16 faces upward. The roughness 14 formed at the aperture 16 is smoothed through the use of a mechanical polishing method, a press method, an electrolytic polishing method, or a slight etching method. The resulting smoothed article is illustrated in FIG. 3(A). The respective methods will be described in detail hereinbelow.
(1) MECHANICAL POLISHING
The surface of the copper film 10 exposed to the ambient at the aperture 16 is rubbed by a polishing tool 30 as shown in FIG. 3.
(2) PRESS
The surface of the copper film 10 exposed to the ambient at the aperture 16 is smoothed through the use of a coining tool to which a predetermined pressure is applied.
(3) ELECTROLYTIC POLISHING
The polyimide film carrying the copper film is dipped into an electrolyte made of phosphoric acid, or phosphoric acid including chromium trioxide, glue and/or propionic acid. The copper film is connected to the positive terminal to be dissolved, thereby smoothing the copper film surface.
(4) SLIGHT ETCHING
The copper film surface is slightly dissolved within the solvent of the following composition.
H 2 SO 4 :7
HNOS 3 :3
HCl: 1-5
H 2 O: 0-6
The electrolytic polishing method and the slight etching method are suited for mass production, since a batch treatment can be applied to either method.
The thus formed copper film 10 is shaped in a desired configuration through the use of a conventional etching method to form wiring patterns formed on the film carrier 12, finger lead electrodes extended to the aperture 16, to which the semiconductor chip is bonded, and terminal electrodes for connecting the semiconductor device to the outer circuitry. The resulting product from this step of the method is illustrated in FIG. 3(B).
FIG. 4 shows the surface condition of the finger lead electrode of the prior art. FIG. 5 shows the surface condition of the finger lead electrode included within the semiconductor device of the present invention. It will be clear from FIGS. 4 and 5 that the roughness is considerably smoothed or decreased so that the above-mentioned erroneous short circuits will not occur. The finger lead electrode surface shown in FIG. 5 was smoothed through the use of the slight etching method referred to hereinbefore. The thus shaped copper film surface is then coated with tin through the use of a plating method. The semiconductor chip is arranged within the aperture 16 in such a manner that bumps formed on the semiconductor chip confront the finger lead electrodes and, thereafter, heat is applied so as to connect the bumps to the finger lead electrodes by forming the eutectic alloy. The resulting article from these steps is illustrated in FIG. 3(C).
In the foregoing embodiment, the etching treatment for shaping the finger lead electrodes is conducted after smoothing the copper film surface exposed at the aperture. However, the finger lead electrodes can be first shaped and, thereafter, the finger lead electrode surface can be smoothed. Moreover, the electrodes are not limited to be made of copper but other suited material can be applied.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.
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A semiconductor device comprises an insulating substrate such as a film carrier having wiring patterns formed thereon, lead electrodes connected to the wiring patterns, and a semiconductor chip bonded to the lead electrodes. The surface of the lead electrodes, to which the semiconductor chip is bonded, is smooth as compared with that of the wiring patterns, thereby ensuring accurate operation of the semiconductor device.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 12/243,374, filed on Oct. 1, 2008, now U.S. Pat. No. 7,553,242 which is a continuation of U.S. patent application Ser. No. 11/938,883, filed on Nov. 13, 2007, now U.S. Pat. No. 7,431,664, which is a continuation of U.S. patent application Ser. No. 11/510,791, filed on Aug. 25, 2006, now U.S. Pat. No. 7,297,072, which is a divisional of U.S. patent application Ser. No. 10/799,118, filed on Mar. 12, 2004, now U.S. Pat. No. 7,214,142, which is a continuation-in-part of U.S. patent application Ser. No. 10/428,061, filed on May 1, 2003, now U.S. Pat. No. 7,029,403, which is a continuation-in-part of U.S. patent application Ser. No. 09/551,771, filed on Apr. 18, 2000, now U.S. Pat. No. 6,605,007. The disclosures of all the parent patent applications are incorporated herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to an improved golf club head. More particularly, the present invention relates to a golf club head with an improved striking face and improved shock absorption between the mating portions making up the body of the club head.
BACKGROUND
The complexities of golf club design are well known. The specifications for each component of the club (i.e., the club head, shaft, hosel, grip, and sub-components thereof) directly impact the performance of the club. Thus, by varying the design specifications, a golf club can be tailored to have specific performance characteristics.
The design of club heads has long been studied. Among the more prominent considerations in club head design are loft, lie, face angle, horizontal face bulge, vertical face roll, face progression, face size, sole curvature, center of gravity, material selection, and overall head weight. While this basic set of criteria is generally the focus of golf club engineering, several other design aspects must also be addressed. The interior design of the club head may be tailored to achieve particular characteristics, such as the inclusion of hosel or shaft attachment means, perimeter weights on the face or body of the club head, and fillers within hollow club heads.
Golf club heads must also be strong to withstand the repeated impacts that occur during collisions between the golf club and the golf ball. The loading that occurs during this transient event can accelerate the golf ball to several orders of magnitude greater than gravity. Thus, the club face and body should be designed to resist permanent deformation or catastrophic failure by material yield or fracture. Conventional hollow metal wood drivers made from titanium typically have a uniform face thickness exceeding 0.10 inch to ensure structural integrity of the club head.
Players generally seek a metal wood driver and golf ball combination that delivers maximum distance and landing accuracy. The distance a ball travels after impact may be dictated by variables including: the magnitude and direction of the ball's translational velocity; and, the ball's rotational velocity or spin. Environmental conditions, including atmospheric pressure, humidity, temperature, and wind speed, further influence the ball's flight. However, these environmental effects are beyond the control of the golf equipment manufacturer. Golf ball landing accuracy is driven by a number of factors as well. Some of these factors are attributed to club head design, such as center of gravity and club face flexibility.
The United States Golf Association (USGA), the governing body for the rules of golf in the United States, has specifications for the performance of golf balls. These performance specifications dictate the size and weight of a conforming golf ball. One USGA rule limits the golf ball's initial velocity after a prescribed impact to 250 feet per second ±2% (or 255 feet per second maximum initial velocity). To achieve greater golf ball travel distance, ball velocity after impact and the coefficient of restitution of the ball-club impact must be maximized while remaining within this rule.
Generally, golf ball travel distance is a function of the total kinetic energy imparted to the ball during impact with the club head, neglecting environmental effects. During impact, kinetic energy is transferred from the club and stored as elastic strain energy in the club head and as viscoelastic strain energy in the ball. After impact, the stored energy in the ball and in the club is transformed back into kinetic energy in the form of translational and rotational velocity of the ball, as well as the club. Since the collision is not perfectly elastic, a portion of energy is dissipated in club head vibration and in viscoelastic relaxation of the ball. Viscoelastic relaxation is a material property of the polymeric materials used in all manufactured golf balls.
Viscoelastic relaxation of the ball is a parasitic energy source, which is dependent upon the rate of deformation. To minimize this effect, the rate of deformation must be reduced. This may be accomplished by allowing more club face deformation during impact. Since metallic deformation may be purely elastic, the strain energy stored in the club face is returned to the ball after impact thereby increasing the ball's outbound velocity after impact.
A variety of techniques may be utilized to vary the allowable deformation of the club face, including uniform face thinning, thinned faces with ribbed stiffeners and varying thickness, among others. These designs should have sufficient structural integrity to withstand repeated impacts without permanent deformation of the club face. In general, conventional club heads also exhibit wide variations in the coefficient of restitution depending on the impact location on the face of the club. Furthermore, the accuracy of conventional clubs is highly dependent on impact location.
It has been reported in F. Werner and R. Greig, “How Golf Clubs Really Works and How to Optimize Their Designs”, Ch. 4, pp. 17-21 (2000) that a typical distribution of golf ball hits on the face of a driver club follows an elliptical pattern with its major axis orientating in a direction from high toe to low heel. The size of the hit distribution depends on the handicap of the golfer. Players with low handicap have smaller elliptical distribution and players with high handicap have larger elliptical distribution. These authors also patented golf clubs that have an elliptical outer hitting face that aligns in the direction of high toe to low heel. See U.S. Pat. No. 5,366,233, entitled “Golf Club Face for Drivers,” issued on Nov. 22, 1994. However, there is no teaching to align the coefficient of restitution of the golf club head to the ball impact pattern.
SUMMARY OF THE INVENTION
The present invention relates to a golf club head adapted for attachment to a shaft. The head includes a hitting face and a body. The hitting face is configured and dimensioned so that it includes at least an inner zone and a concentric intermediate zone. The inner zone has relatively high flexural stiffness and the intermediate zone has lower flexural stiffness. Preferably, the inner zone has a shape that comprises a major axis and a minor axis and the major axis aligns substantially in the direction of high heel to low toe. The inner zone can have an elliptical shape or a substantially parallelogram shape. The inner zone and intermediate zone may have same shape or different shape.
This arrangement of inner and intermediate zones forms an area of relatively high flexural stiffness in the direction of high heel to low toe, thereby creating high resilience in the direction of high toe to low heel. In other words, this arrangement creates a gradient of flexural stiffness in the direction of high toe to low heel, and produces a desirable effect of manipulating resilience or higher coefficient of restitution (COR) in that direction. This area of improved coefficient of restitution advantageously coincides with the ball impact pattern that golfers typically make on the hitting face.
The inventive club head encompasses a measurement zone that exhibits high COR where the lowest COR is at least 93% of the peak COR within this measurement zone. The measurement zone is defined by a rectangle having the dimensions of 0.5 inch by 1.0 inch, and the COR values are measured at the corners of the rectangle, the mid-points of the sides and the geometric center of the rectangle. The geometric center of the measurement zone preferably coincides with the geometric center of the face of the club.
The above is accomplished by providing the inner zone with a first flexural stiffness and the intermediate zone with a second flexural stiffness. Flexural stiffness is defined as Young's modulus or elastic modulus (E) times the zone's thickness (t) cubed or Et 3 . The first flexural stiffness is substantially higher than the second flexural stiffness. As a result, upon ball impact, the intermediate zone exhibits substantial elastic deformation to propel the ball.
In one embodiment, the first flexural stiffness is at least three times the second flexural stiffness. In other embodiments, the first flexural stiffness is six to twelve times the second flexural stiffness. More preferably, the first flexural stiffness is greater than 25,000 lb-in. Most preferably, the first flexural stiffness is greater than 55,000 lb-in. Preferably, the second flexural stiffness is less than 16,000 lb-in. More preferably, the second flexural stiffness is less than 10,000 lb-in.
Since the flexural stiffness is a function of material properties and thickness, the following techniques can be used to achieve the substantial difference between the first and second flexural stiffness: 1) different materials can be used for each portion, 2) different thicknesses can be used for each portion, or 3) different materials and thicknesses can be used for each portion.
The golf club head may further include a perimeter zone disposed between the intermediate zone and the body of the club. In one embodiment, the perimeter zone has a third flexural stiffness that is at least two times greater than the second flexural stiffness
In the club heads discussed above, the inner, intermediate and optional perimeter zones can have any shape that has a major axis and a minor axis, such as elliptical, rhombus, diamond, other quadrilateral shapes with one or more rounded corners and the like. The zones may also have a substantially parallelogram shape. Furthermore, the club head inner cavities can have a volume greater than about 100 cubic centimeters, and more preferably a volume greater than about 300 cubic centimeters. In other words, the club head in accordance to the present invention can be used in driver clubs and/or fairway clubs. In addition, the inner, intermediate, and perimeter zones can each have variable thickness.
Another feature of the present invention is locating the center of gravity of the club head with respect to a Cartesian coordinate system. The origin of the Cartesian coordinate system preferably coincides with the geometric center of the hitting face. The X-axis is a horizontal axis positioned tangent to the geometric center of the hitting face with the positive direction toward the heel of the club. The Y-axis is another horizontal axis orthogonal to the X-axis with the positive direction toward the rear of the club. The Z-axis is a vertical axis orthogonal to both the X-axis and Y-axis with the positive direction toward the crown of the club. The center of gravity is preferably located behind and lower than the geometric center of the face.
In one preferred embodiment, the center of gravity is spaced from the geometric center along the Z-axis by about −0.050 inch to about −0.150 inch, and more preferably by about −0.110 inch. The center of gravity is preferably spaced about ±0.050 inch, and more preferably about +0.015 inch from the geometric center along the X-axis. The center of gravity is preferably spaced about +2.0 inches and more preferably about +1.35 inches from the geometric center along the Y-axis.
The hitting face may comprise a face insert and a face support. The face support defines a cavity adapted to receive the face insert. The hitting face may further comprise at least one side wall, which can be a partial crown portion or a partial sole portion. Preferably, the inner zone is located on the face insert, and the intermediate zone may partially be located on the face insert and partially on the face support.
Another aspect of the invention provides for a crown portion to be composed of a material having a lower density than a body portion. The material for the crown portion selected from such materials as composite, thermoplastic or magnesium, and preferably graphite composite. The crown portion having an inner surface layer integrally composed of a vibration dampening or acoustical attenuating material. One embodiment would include a titanium mesh material.
An embodiment of the invention includes a non-integral dampening material, juxtaposed between the body and crown portions.
A preferred embodiment would be a gasket juxtaposed between the body and the crown portions
Yet still another embodiment of the invention is comprised of a body and light weight crown with a vibration dampening gap there between. The gap is preferably filled with putty or other shock absorption material such as a rubber based structural adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein:
FIG. 1 is a toe side, front, perspective view of an embodiment of a golf club head of the present invention;
FIG. 2 is a heel side, rear, perspective view of the golf club head of FIG. 1 ;
FIG. 3 is a front, elevational view of the golf club head of FIG. 1 ;
FIG. 3A is a cross-sectional view of the face of the golf club head of FIG. 1 along line 3 A- 3 A;
FIG. 3B shows a cross-sectional view the face of the golf club head of FIG. 1 along line 3 B- 3 B;
FIGS. 3C and 3D are alternative embodiments of FIGS. 3A and 3B , respectively;
FIG. 4 is a top view of the golf club head of FIG. 1 ;
FIG. 5 is a bottom, perspective view of the golf club head of FIG. 1 ;
FIG. 6 is a schematic view of substantially parallelogram shaped the inner and intermediate zones;
FIG. 7 is a schematic view of the inner and intermediate zones with substantially parallelogram and elliptical shape;
FIG. 8 is a front, exploded view of another embodiment of the present invention;
FIG. 9 is a front, exploded view of another embodiment of the present invention;
FIGS. 10( a )- 10 ( c ) illustrate the results from a comparative example, which compares iso-COR contour lines of conventional golf club head and of an embodiment of the present invention;
FIG. 11 is a top view of an embodiment of the invention wherein the crown is composed of a composite material;
FIG. 12 a is a cross-section view of the crown portion attached to the lip section of the outer portion;
FIG. 12 b is a plan view showing the layer of titanium mesh material integral with the inner surface of the crown portion;
FIG. 12 c is a cross-section view of another embodiment of the crown portion wherein a titanium mesh ring is integral about the perimeter edge of the crown portion;
FIG. 12 d is a plan view showing a ring of titanium mesh about the perimeter edge of the crown portion;
FIG. 12 e is a cross-section view of an embodiment of the invention wherein a gasket is disposed between the lip section of the outer portion and the crown portion;
FIG. 12 f is a plan view of the gasket of FIG. 12 e;
FIG. 12 g is a cross-section view of an embodiment of the invention having a gap filled with a shock absorption material between the crown portion and lip section;
FIG. 12 h is a cross-section view of an embodiment of the invention having an “L” shaped gasket composed of a shock absorption material between the crown portion and lip section;
FIG. 12 i is a cross-section view of an embodiment of the invention having a “Y” joint on the crown portion;
FIG. 12 j is a plan view of the inner side of the crown portion showing the plurality of “Y” joints about the perimeter;
FIG. 13 is a schematic of the front face of an embodiment of the invention depicting the location of the center of gravity;
FIG. 14 a is a front schematic depicting a 9 point spin variance across the front face of an embodiment of the invention; and
FIG. 14 b is a front schematic depicting a 9 point spin variance across the front face of a prior art club head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-5 , a first embodiment of a golf club head 10 of the present invention is shown. Club head 10 includes shell 12 with body 14 , hitting face 16 , toe portion 18 , heel portion 20 , sole plate 22 , hosel 24 , bottom portion 26 , crown portion 28 , and rear portion 29 . The sole plate 22 fits in a recess 30 (as shown in FIG. 5 ) in the bottom portion 26 of body 14 . The shell 12 and sole plate 22 create an inner cavity 31 (as shown in FIG. 5 ). The hitting face 16 has an exterior surface 32 and an interior surface 34 . The exterior surface 32 is generally smooth except for external grooves (which are omitted for clarity). Preferably, interior surface 34 has elevated or depressed areas to accommodate the varying thickness of hitting face, as discussed below and shown in FIGS. 3A-3D .
A golf club shaft (not shown) is attached at hosel 24 and is disposed along a shaft axis SHA. The hosel may extend to the bottom of the club head or may terminate at a location between the top and bottom portions of the head. The hosel can also terminate flush with the top portion or extend into the cavity within the head.
Inner cavity 31 of club head 10 may be empty, or alternatively may be filled with foam or other low specific gravity material. It is preferred that the inner cavity 31 has a volume greater than 100 cubic centimeters, and more preferably greater than 300 cubic centimeters. In other words, the club head design in accordance to the present invention can be used with any driver club, as well as any fairway club. Preferably, the mass of the inventive club head is greater than 150 grams but less than 250 grams.
Referring to FIGS. 1 and 3 - 3 D, the face 16 includes an inner zone or portion 36 , an intermediate zone or surrounding portion 38 adjacent the inner zone 36 , and an optional perimeter zone or outer portion 40 . The intermediate zone 38 preferably surrounds inner zone 36 , and the perimeter zone 40 preferably surrounds the intermediate zone 38 . The inner zone 36 is a contiguous zone located on the hitting face 16 and contains a geometric center (“GC”) of the hitting face. As shown, inner zone 36 and its concentric zones have a generally elliptical shape with a major axis in the direction of high heel to low toe. As used herein, the term “ellipse” or “elliptical” refers to non-circular shapes that have discernable major axis and minor axis, and include, but are not limited to, any quadrilateral shapes, geometrical ellipses, quadrilateral shapes with one or more rounded corner(s) and unsymmetrical elliptical shapes. Also, the term “concentric” refers to shapes that substantially encircle or surround other shapes. The “major axis” is defined as the axis coinciding with the longest length that can be drawn through the non-circular shapes without intersecting the perimeter of the shapes at more than two locations, i.e., at the start and end points of said length. The “minor axis” is orthogonal to the major axis at or near its midpoint.
The major axis of inner portion 36 forms an angle, θ, with the shaft axis, SHA. Preferably, angle θ is between about 10° to about 60°, more preferably between about 20° and about 50°, and most preferably between about 25° and about 45°. Additionally, the ratio of the length of the major axis to the length of minor axis is preferably greater than 1.0 and more preferably less than about 6.0.
Preferably, zones 36 , 38 and 40 are concentric to each other within hitting face 16 . The inner zone 36 has a first thickness T 1 . The intermediate zone 38 has a second thickness T 2 . The first thickness T 1 is greater than the second thickness T 2 . Typically, when the club head is cast, the perimeter zone 40 is thicker than the intermediate zone 38 . Alternatively, the hitting face may also be forged. However, the present invention is not limited to any manufacturing technique. T 1 may range from about 1.5 mm to about 7.5 mm and T 2 may range from about 0.8 mm to about 3.0 mm. Preferably, the first thickness T 1 is equal to about one and a half (1.5) times the thickness T 2 to about four (4) times the thickness T 2 .
The thickness relationships between the zones 36 , 38 , and 40 are provided so that a predetermined relationship exists between flexural stiffness exhibited by each of the zones.
For clubs that have a hitting face made from a single material, such as titanium or titanium alloy, the area of highest thickness corresponds to the portion with the highest flexural stiffness. Flexural stiffness (FS) of each portion is defined as:
FS=E(t 3 ),
where:
E is the elastic modulus or Young's modulus of the material of the portion, and
t is the thickness of the portion.
Young's modulus of titanium is about 16.5×10 6 lbs/in 2 , and thickness is typically measured in inch. Hence, FS as used in this application has the unit of lb·in.
The inner zone 36 has a first flexural stiffness FS 1 . The intermediate zone 38 has a second flexural stiffness FS 2 . The perimeter zone 40 has a third flexural stiffness FS 3 . The predetermined relationship between the portions is that the first flexural stiffness FS 1 is substantially greater than the second flexural stiffness FS 2 , and the optional third flexural stiffness FS 3 is substantially greater than the second flexural stiffness FS 2 . Preferably, the first flexural stiffness FS 1 is at least three times greater than the second flexural stiffness FS 2 , i.e., (FS 1 /FS 2 )≧3. When the above ratio of flexural stiffness is less than three, the inner zone sustains excessive deformation during impact and accuracy of the club is diminished. More preferably, the first flexural stiffness FS 1 is about six (6) to twelve (12) times greater than the second flexural stiffness FS 2 . Most preferably, the first flexural stiffness FS 1 is about eight (8) times greater than the second flexural stiffness FS 2 . Preferably, the third flexural stiffness FS 3 is at least two times greater than the second flexural stiffness FS 2 , i.e., (FS 3 /FS 2 )≧2.
Alternatively, the flexural stiffness, FS 1 , FS 2 or FS 3 , can be determined for two combined adjacent zones, so long as the preferred ratio (FS 1 /FS 2 )≧3 or (FS 3 /FS 2 )≧2 is satisfied. For example, FS 1 , can be calculated to include both zones 36 and 38 , and FS 3 can be calculated to include both zones 38 and 40 .
The thickness of the zones, T 1 and T 2 , may be constant within the zone as illustrated in FIGS. 3A and 3B , or may vary within the zone as illustrated in FIGS. 3C and 3D . For the purpose of determining FS, when the thickness varies, a weighted average thickness is calculated. The determination of FS when the thickness varies or when the material is anisotropic is fully discussed in the parent patent application, which has already been incorporated by reference in its entirety.
In club head 10 (as shown in FIGS. 3-3D ), the above flexural stiffness relationships are achieved by selecting a certain material with a particular elastic modulus and varying the thickness of the zones. In another embodiment, the flexural stiffness relationships can be achieved by varying the materials of the zones with respect to one another so that the zones have different elastic moduli and the thickness is changed accordingly. Thus, the thickness of the zones can be the same or different depending on the elastic modulus of the material of each zone. It is also possible to obtain the required flexural stiffness ratio through the use of structural ribs, reinforcing plates, and thickness parameters.
Quantitatively, it is preferred that the first flexural stiffness FS 1 is greater than 25,000 lb-in. When the first flexural stiffness is less than 25,000 lb-in excessive deformation of the inner region can occur during impact and accuracy is diminished. More preferably, the first flexural stiffness FS 1 is greater than 55,000 lb-in. Preferably, the second flexural stiffness FS 2 is less than 16,000 lb-in. When the second flexural stiffness is greater than 16,000 lb-in, the resultant ball velocity is reduced. More preferably, the second flexural stiffness FS 2 is less than 10,000 lb-in and, most preferably, less than 7,000 lb-in.
Referring to FIG. 3 , it is preferred that inner zone 36 has an area that is between about 15% and about 60% of the exterior surface area 32 . The percentage of face area is computed by dividing the area of each zone 36 , 38 , or 40 by the total face area of exterior surface 32 . It should be noted that the face area of exterior surface 32 is equivalent to the total area of zones 36 , 38 , and 40 . When the inner zone 36 is less than 15% of the total face area, then accuracy can be diminished. When inner portion 36 is greater than 60% of the face area 32 , then the coefficient of restitution can be diminished.
Referring again to FIG. 1 , the club head 10 is further formed so that a center of gravity of the club head has a predetermined relationship with respect to a Cartesian coordinate system with its center located on hitting face 16 and coincident with the geometric center GC of the face 16 . The hitting face 16 includes a vertical centerline VCL and a horizontal centerline HCL perpendicular thereto. The geometric center (GC) of hitting face 16 is located at the intersection of centerlines VCL and HCL. The VCL and HCL are co-linear with the X-axis and the Z-axis of a Cartesian coordinate system, described below. Preferably, the GC of the inner zone 36 is spaced from the GC of hitting face 16 by a distance of less than about 0.10 inch, more preferably less than about 0.05 inch and most preferably less than about 0.025 inch. The GC of inner zone 36 may be coincident with the GC of hitting face 16 . The GC of inner zone 36 can be defined as the intersection between the major axis and the minor axis of the zone.
The Cartesian coordinate system is defined as having the origin coincident with the geometric center of the hitting face. The hitting face is not a rectilinear plane, but due to the bulge and roll radii it is a curvilinear surface. The X-axis is a horizontal axis lying tangent to the geometric center of the hitting face with the positive direction toward the heel of the club. The Y-axis is another horizontal axis orthogonal to the X-axis with the positive direction toward the rear of the club. The Z-axis is a vertical axis orthogonal to both the X-axis and Y-axis with the positive direction toward the crown of the club.
The center of gravity is preferably located both behind and lower than the geometric center of the face, when the club head is resting on a flat surface (i.e., at its natural loft). In one preferred embodiment, the center of gravity of club head 10 is spaced from the geometric center along the Z-axis between about −0.050 inch and about −0.150 inch, more preferably about −0.110 inch. The center of gravity is preferably spaced about ±0.050 inch, more preferably about 0.015 inch, from the geometric center along the X-axis. The center of gravity is preferably spaced about 2.0 inches or less and more preferably about 1.35 inches or less from the geometric center along the Y-axis.
The center of gravity for the club head can be achieved by controlling the configuration and dimensions of the club head in addition to adding predetermined weights to the sole plate or to the club head. Other known methods of weight manipulation can be used to achieve the inventive center of gravity location as set forth above.
FIG. 6 illustrates another embodiment of the present invention. Central zone 36 has a generally parallelogram shape, such that the opposite sides are generally parallel and the angles formed between adjacent sides are rounded. More specifically, the acute angle α of central zone 36 is preferably between 40° and 85°. Additionally, the major axis of central zone 36 , as shown, forms an angle β with the HCL, which preferably is between 5° and 45°. The major axis is the line connecting the two acute angles of the parallelogram. Similar to the embodiments disclosed above, intermediate zone 38 surrounds central zone 36 , and the relative thickness and ratio of FS between zone 36 and zone 38 follow the relationships discussed above.
As shown in FIG. 7 , central zone 36 can be an ellipse while intermediate zone 38 can have a generally parallelogram shape. Conversely, central zone 36 can have a generally parallelogram shape, while intermediate zone 38 can be an ellipse. Furthermore, as illustrated intermediate zone 38 may have varying width.
In accordance to another aspect of the present invention, hitting face 16 may comprise a face insert 42 and face support 44 , as shown in FIG. 8 . In this embodiment, hitting face 16 is delineated from crown 28 , toe 18 , sole 22 and heel 20 by parting line 46 . Central zone 36 is preferably disposed on the back side of face insert 42 , and, as shown, has a generally parallelogram shape. Intermediate zone 38 , designated as 38 1 and 38 2 , can be disposed partially on face insert 42 and partially on face support 44 . A transition zone 37 having variable thickness is disposed between central zone 36 and intermediate zone 38 . Preferably, the thickness of central zone 36 is reduced to the lesser thickness of intermediate zone 38 within transition zone 37 . This reduces any local stress-strain caused by impacts with golf balls due to abrupt changes in thickness. Face support 44 defines hole 48 , which is bordered by rim 50 . Face insert 42 can be attached to face support 44 by welding at or around rim 50 . For the purpose of determining the FS ratio for this embodiment, the FS 1 of the inner zone includes both zone 36 and zone 37 .
In accordance to another aspect of the invention, the face insert may include one or more side walls, wherein the side walls may form part of the crown and/or part of the sole. As shown in FIG. 9 , face insert 52 comprises central zone 36 , transition zone 37 , a portion of intermediate zone 38 , partial crown portion 54 and partial sole portion 56 . Club head 10 correspondingly defines cavity 58 sized and dimensioned to receive face insert 52 . Face insert 52 is preferably welded to club head 10 . Face insert 52 together with face support 60 forms hitting face 16 . Similar to the embodiment illustrated in FIG. 8 , intermediate zone 38 , designated as 38 1 and 38 2 , can be disposed partially on face insert 52 and partially on face support 60 .
EXAMPLE
In this example, hitting face 16 has the following construction. The central zone 36 has a substantially parallelogram shape, as shown in FIG. 10( a ), with a major axis measuring about 3 inches and a minor axis about 0.75 inches with a thickness T 1 , of about 0.120 inch. The central zone 36 has a concentric transition zone 37 with a similar shape as the central zone 36 . The intermediate zone 38 surrounds the central and transition zones with a thickness T 2 of 0.080 inch and comprises the remainder of the face hitting area. There is no perimeter zone 40 included in this example. The major axis of zone 36 substantially coincides with the major axis of zone 38 , and these two major axes form angle theta (θ) of about 50° with the shaft axis. Furthermore, zones 36 and 37 comprise about 18% of the total face surface area. A single homogeneous material, preferably a titanium alloy, with a Young's modulus (E) of approximately 16.5×10 6 lbs/in 2 is used. In this example, the (FS 1 /FS 2 ) ratio is 3.4 when FS 1 includes both zones 36 and 37 and FS 2 includes zone 38 .
The test results were generated using computational techniques, which include finite element analysis models. In the computer model, the following assumptions were made: club head loft of 9°; club head mass of 195 grams; and club head material is 6AL-4V titanium alloy. The golf ball used in the model was a two-piece solid ball. Finite element models were used to predict ball launch conditions and a trajectory model was used to predict distance and landing area. The impact condition used for club coefficient of restitution (COR) tests was consistent with the USGA Rules for Golf, specifically, Rule 4-1e Appendix II Revision 2 dated Feb. 8, 1999.
Distributions of coefficient of restitution (COR) are shown in FIGS. 10( b ) and 10 ( c ). The lines indicate contour lines, similar to the contour lines in topography maps or weather maps, and indicate lines of constant COR (hereinafter iso-COR lines). The innermost contour line indicates the highest COR region on the hitting face and outer contour lines indicate lower COR regions on the hitting face. FIG. 10( b ) represents the iso-COR contours for a conventional club having a hitting face with uniform thickness, and FIG. 10( c ) represents the iso-COR contours of the inventive club described in this Example.
COR or coefficient of restitution is one way of measuring ball resiliency. COR is the ratio of the velocity of separation to the velocity of approach. In this model, therefore, COR was determined using the following formula:
(v club-post −v ball-post )/(v ball-pre −v club-pre )
where,
v club-post represents the velocity of the club after impact; v ball-post represents the velocity of the ball after impact; v club-pre represents the velocity of the club before impact (a value of zero for USGA COR conditions); and v ball-post represents the velocity of the ball before impact.
COR, in general, depends on the shape and material properties of the colliding bodies. A perfectly elastic impact has a COR of one (1.0), indicating that no energy is lost, while a perfectly inelastic or perfectly plastic impact has a COR of zero (0.0), indicating that the colliding bodies did not separate after impact resulting in a maximum loss of energy. Consequently, high COR values are indicative of greater ball velocity and distance.
The iso-COR contour lines generated by the computational analysis are shown within a rectangle having dimensions of 0.5 inch by 1.0 inch, as typically used in the art. Within this rectangle, the inventive club head exhibits relatively high and substantially uniform COR values. The COR values are measured at nine points within this rectangle, i.e., the corners of the rectangle, mid-points of the sides and the geometric center of the rectangle. Additionally, the geometric center of this rectangular measurement zone preferably coincides with the geometric center of the hitting face of the club. In this example, the lowest COR within this measurement zone is 0.828 and the peak COR is 0.865. According to the present invention, the lowest COR is within 93% of the peak COR. This advantageously produces a hitting face with a substantially uniform COR and large “sweet spot.”
The iso-COR contour lines of the conventional club shown in FIG. 10( b ) follow a substantially elliptical pattern. Furthermore, the center of the innermost iso-COR contour line, which has the highest COR value, is offset from the geometric center of the rectangular measurement zone, indicating a reduction in COR. The major axis of these contour lines is substantially horizontal.
The iso-COR contour lines for the inventive club also follow an elliptical pattern, and as shown in FIG. 10 ( c ), the major axis of the pattern does not coincide with the horizontal center line, HCL, of the hitting face. The test results indicate that the major axis of the iso-COR pattern makes an angle, delta (δ), with the HCL. The angle δ is at least 5°, and more preferably at least 7° in the direction from high toe to low heel. While the major axis of central zone 36 with the highest FS runs substantially from high heel to low toe, the major axis of the iso-COR contours runs substantially in a different direction, i.e., from high toe to low heel, which advantageously coincides with the typical hit distribution that golfers make on the hitting face, discussed above. Furthermore, the center of the innermost iso-COR contour line is closer to the geometrical center of the rectangular measurement zone, indicating a higher peak COR value.
Without being limited to any particular theory, the inventors of the present invention observe that when an elliptical area of high thickness or high FS is present at or near the center of the hitting face with areas of less thickness or lower FS surrounding it, the iso-COR contour lines generally form an elliptical shape where the major axis of the iso-COR contours forms an angle with the major axis of the areas of high thickness or high FS. This arrangement of inner and intermediate zones forms a zone of relatively high flexural stiffness in the direction of high heel to low toe thereby creating high resilience in the direction of high toe to low heel. In other words, this arrangement creates a gradient of flexural stiffness in the direction of high toe to low heel and produces a desirable effect of manipulating resilience or higher coefficient of restitution (COR) in that direction. This area of improved coefficient of restitution advantageously coincides with the ball impact pattern that golfers typically make on the hitting face.
As shown is FIG. 11 , a club head embodiment of the invention is depicted having a club head 10 , which includes a body portion 60 , a composite crown portion 61 , and a hosel 24 for attaching to a shaft (not shown). The body portion 60 comprises an outer portion 40 that includes a lip section 63 , as shown in FIGS. 12 a, c, e, g, h , and i . The transverse surfaces of the lip section 63 define a cutout 65 . As shown in FIG. 12 a , the crown portion 61 attaches to the first body portion 60 by an outer ledge section 62 being attached to the lip section 63 . The outer ledge section 62 substantially forms a perimeter edge of the crown portion 61 . An inventive aspect of the present invention is the inclusion of a shock absorption layer 66 integral with the inner surface 64 of the crown portion 61 . For an embodiment shown in FIG. 12 a , the shock absorption layer 66 covers substantially the entire inner surface 64 of the crown portion 61 , as depicted by FIG. 12 b . This shock absorption layer 66 is preferably composed of titanium mesh material. Although the crown portion is shown herein as only encompassing the crown of the club head 10 , it is appreciated that it could also include parts of the skirt or hosel sections of the club head 10 . The crown portion 61 may be cast, formed, injection molded, machined or pre-preg sheet formed.
The density range for crown portion 61 is from about 0.1 g/cc to 4.0 g/cc. Preferably the crown portion 61 may be formed from materials such as magnesium, graphite composite, a thermoplastic, but the preferred material for the crown portion 61 is graphite composite. Preferably, the crown portion 61 has a thickness in the range of about 0.1 mm to about 1.5 mm, and more preferably less than about 1.0 mm.
An embodiment of the invention is shown in FIGS. 12 c and 12 d . In this embodiment, the titanium mesh layer 66 is integral with the inner surface 64 of the crown portion 61 is in the shape of a ring, such that it is juxtaposed the outer ledge 62 and the lip section 63 .
Another embodiment of the invention is described on FIGS. 12 e and 12 f , wherein, the shock absorption material is a separate gasket 67 , and is disposed between the outer ledge section 62 and the lip section 63 . Other materials, such as a viscoelastic material or an aluminum foil, may be substituted in lieu of the titanium gasket.
Another way to dampen vibrations according to the invention is shown in FIG. 12 g , wherein a gap 68 is created between the transverse surfaces of the body portion 60 and the crown portion 61 . In FIG. 12 g , this gap 68 has a substantially rectangular shape, while in FIG. 12 h , an L-shaped gap 69 , creates the bond between the transverse surfaces. However, both are preferably filled with a shock absorbing material such as putty or a rubber based structural adhesive, such as those provided by PPG Industries, Inc. under the trade name CORABOND®HC7707.
The materials for forming the body portion 60 may be stainless steel, pure titanium or a titanium alloy. The more preferred material comprises titanium alloys, such as titanium 6-4 alloy, which comprises 6% aluminum and 4% vanadium. The body portion 60 may be manufactured through casting with a face insert, or formed portions with a face insert. The face insert is made by casting, machining sheet metal or forming sheet metal. Another embodiment can be created by forming a wrapped face, from forging, stamping, powdered metal forming, or metal-injection molding.
Tests were conducted on each of two golf clubs of the present invention. The only physical difference between the two clubs was that one of the clubs was manufactured with the shock absorption layer 66 , as shown in FIGS. 12 a and 12 b , and the other club was made without any such shock absorption layer. Identical shaft specifications were used for both test clubs, and the ball was a Pinnacle Gold, as manufactured by Titleist®. Test data taken over a frequency range of 3,000 to 12,000 Hz indicated swing speed is a variable in the percentage of dampening that was achieved. At a swing speed of 90 mph, the noise was dampened between a range of about 28% to 50% over a frequency range of about 3800 Hz to 10,000 Hz, while at a swing speed of 105 mph the noise was dampened about 20% to 32% over the same Hz range.
An embodiment of the invention provides an improvement in the percentage of club area relative to the head volume. With the composite crown portion 61 being considerably lighter than titanium, weight is removed from the crown and may then be redistributed into weight inserts in the body and face. The weight relocation helps to position the center of gravity lower. As seen in FIG. 13 , an embodiment of the present invention provides a club head with the center of gravity located between 50 to 55% of the face height with a face area greater than 50 cm 2 . The combination of shaft characteristics with the present invention provides for dynamic results. The shaft used in the embodiment is a lightweight rayon Model SL-45, as manufactured by Mitsubishi. It has a weight that is less than 50 grams and preferably less than 48 grams. The shaft torque is greater than about 3.5° and preferably greater than about 4°. The shaft tip stiffness is less than 900 cpm and greater than 600 cpm as measured 320 mm from the tip. The face is closed at an angle greater than 1°, preferably 2°, and the face has an effective hitting area greater than 7.0 in 2 and preferably greater than 7.25 in 2 . Combining this center of gravity location with the ultra-light shaft design and low tip stiffness, a high right to left trajectory is promoted with increased swing speed. The lower center of gravity promotes a high launch, a larger head size yields a higher moment of inertia, and the larger face area allows for more forgiveness.
As suggested above, FIG. 13 shows the position of the center of gravity as it relates to face height for the King Cobra 454 COMP driver as manufactured by The Acushnet Company and depicts a face area of 48.4 cm 2 , overall club weight of 290 (with a Mitsubishi Rayon SL-45 shaft having a weight of 45 grams, and a length of 45.5″). The magnitude of the effective hitting area of the King Cobra 454 COMP golf club is shown in FIGS. 14 a and 14 b . The effective hitting area of the King Cobra 454 is about 7.5 in 2 versus an effective hitting area of about 5.0 in 2 for an ERC Fusion golf club, as manufactured by the Callaway Golf Company of Carlsbad, Calif.
A significant performance criteria in the design of a golf club is the club's “forgiveness” or its ability to provide near optimum hitting for golf hits that are not struck right on the perfect “sweet spot” of the club. The “sweet spot” of a golf club is usually referred to as that spot on the club face wherein maximum Coefficient of Restitution is obtained. The golf club of the present invention provides a “sweet zone” or nine (9) points across the club face, in which the club will deliver near maximum COR, at not just one particular point on the club face, but at any point within the sweet zone.
FIGS. 14 a and 14 b make a 9 point comparison of the club faces of a model 454 Cobra versus the ERC Fusion club of Callaway Golf Company. The spin of the golf ball coming off the club face is an important parameter and in a perfect situation, the spin would be the same for the entire club face. In the design of a club face, having a minimum variance of spin across a large area of the face is a highly desired performance characteristic. The performance data shown on FIGS. 14 a and 14 b are based on striking the golf ball at an 11° launch angle and a club speed of 90 mph. The spin imparted to the ball coming off the King Cobra 454 face is much higher across the entire face (average spin of 2375 rpm) than that of the ERC Fusion club (average spin of 2070 rpm), the variance across the “sweet zone” of the King Cobra 454 club is only 475 rpm to 850 rpm for the ERC Fusion club. This demonstrates a club face that will consistently yield shots more consistent over a greater surface area.
While various descriptions of the present invention are described above, it should be understood that the various features of each embodiment can be used alone or in any combination thereof. Therefore, this invention is not to be limited to only the specifically preferred embodiments depicted herein. Further, it should be understood that variations and modifications within the spirit and scope of the invention may occur to those skilled in the art to which the invention pertains. For example, the face and/or individual zones can have thickness variations in a step-wise or continuous fashion. Other modifications include a perimeter zone that has a thickness that is greater than or less than the adjacent, intermediate zone. In addition, the shapes of the central, intermediate, and perimeter zones are not limited to those disclosed herein. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is accordingly defined as set forth in the appended claims.
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A metal wood golf club head adapted for attachment to a shaft, comprising of a body portion and a crown portion, each portion constructed of a different density material. Combining a high-density material in the body portion, with a low-density material in the crown portion, creates an ultra-low center of gravity relative to the geometric face center, resulting in higher launch angles and spin rate ratios. The material for the crown portion is preferably a composite. A vibration dampening gasket is disposed between the ledge and lip sections of the body and crown respectively.
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TECHNICAL FIELD
This invention relates to a digital switch for setting up numerical data and so on in electronic equipment in general, and in particular to a digital switch of a very simple and advantageous structure.
BACKGROUND OF THE INVENTION
Recently an increasingly large number of electronic devices are equipped with so-called digital switches for setting up values and parameters in place of conventional means such as potentiometers and so on which may be considered as analog set up means. A digital switch has the advantage that an input may be made in terms of discrete numbers. This development may be compared to the transition from slide rules to electronic calculators.
Since a digital switch requires an electric part which may be consisting of a more or less conventional switch element and a mechanical part which activates the switch element. The ratchet mechanism is most commonly used for such a mechanical part. Therefore, a digital switch is a fairly complex device and has been often too expensive for practical applications in spite of a strong demand for the use of digital switches.
Conventionally, a digital switch has been comprised of a case, a indicator wheel having a ratchet gear integrally formed therewith, a push rod having a pawl at its inner end so that the pawl may cooperate with the ratchet gear so as to turn the ratchet gear, along with the indicator wheel, in a step-wise manner. The indicator wheel is further connected to a switch element having movable contact pieces and fixed contact pieces which may be arranged in a pattern so as to produce a desired combination of output signals at the output terminals depending on the rotational angle of the indicator wheel.
Recently, development in micro-electronics has created a need for extremely compact design of digital switches, but, because of the basic mechanical complexity, there have been no digital switches which are of sufficient compact design and both economical and reliable. Following are some of the problems which engineers have encountered in designing such a digital switch.
First, because the ratchet and pawl mechanism requires a large number of component parts and, therefore, assembly work tends to be cumbersome and it is difficult to assure sufficient mechanical strength to each component part.
Secondly, a digital switch is generally equipped with a stopper mechanism which determines the range of the values which may be set up and, in order to indicate it to the user that a limit has been reached, the stopper mechanism must have a sufficient mechanical strength to withstand the force the user may apply to the digital switch without knowing that the limit has been reached. Conventional, pins are pressure fitted into the holes in the ratchet gear and the rotational limit of the indicator wheel has been determined by the engagement of the pins with a projection on a fixed member. However, as the size of the ratchet gear is reduced, it becomes difficult to obtain enough areas on the ratchet gear for fitting metallic pins thereinto with sufficient mechanical strength.
Thirdly, as the size of the digital switch is reduced, so the size of the switch element must be reduced. As a result, a small misalignment in the pattern of contact pieces may cause errors in the operation of the digital switch. Conventionally, printed circuit boards have been widely used as contact pieces having various patterns, but such printed circuits may lack necessary durability on one hand, and may lack sufficient dimensional precision on the other hand. Additionally, manufacturing a printed circuit requires special materials and special facilities, resulting in a relatively high cost for manufacture.
Alternatively, an electro-conductive pattern has been made by forming a V-groove corresponding to the pattern in the side surface of the circular base plate at the time of molding the same and pressure-fitting an electro-conductive member made of a printed circuit into the V-groove. However, because the electro-conductive pattern comprises a continuous contact surface having a circumferential portion, a radial portion and another concentric circumferential portion and a plurality of isolated contact surfaces, manual labor required for fitting the electro-conductive members into the V-grooves of the indicator wheel has been so substantial that it has been a major factor for the high cost of such a switch and increasingly compact design of switches tends to reduce the efficiency of such work.
OBJECT OF THE INVENTION
In view of such shortcomings of conventional digital switches, a primary object of this invention is to provide a digital switch of substantially compact design which is simple to assembly and durable.
Another object of this invention is to provide a digital switch which can operate in a smooth manner and is reliable.
Yet another object of this invention is to provide a digital switch equipped with a stopper mechanism which is compact enough to be accommodated in a digital switch of very compact design and strong enough to withstand rough handling.
SUMMARY OF THE INVENTION
In order to achieve such objects, according to this invention, there is provided a digital switch, comprising a indicator wheel supported in a freely rotatable manner and carrying symbols on its outer circumference, a ratchet gear formed on the indicator wheel in a coaxial manner, actuating means having pawls for rotating the ratchet wheel in step-wise manner by being operated by external force, and switching means connected to the indicator wheel so as to produce different signals on an output terminal depending on the rotational angle of the indicator wheel, wherein: the actuating means comprises a pair of substantially parallel main bodies, push-botton portions formed on first ends of the main bodies, a pair of advance pawls formed on free ends of a pair of first arms integrally extending from opposing surfaces of the main bodies toward the ratchet gear, a pair of stop pawls formed on free ends of a pair of second arms extending from the opposing sides of the main bodies towards the ratchet gear at an oblique angle relative to the main bodies, spring portions which are integrally formed on second ends of the main bodies, and a mounting member which interconnects the other ends of the spring portions and engaged to a fixed casing member.
According to a certain aspect of the invention, the indicator wheel is integrally provided with an outer ring and a stopper piece is fitted between the inner surface of the outer ring and the ratchet gear. The stopper piece may be adapted to cooperate with a stopper integrally formed in the casing member or, alternatively, to cooperate with part of the stop pawl.
According to another aspect of the invention, the indicator wheel comprises a main body made of molded synthetic resin, and a metallic member which is insert molded in the main body according to a desired electro-conductive pattern; and the contact unit comprises a plurality of contact pieces which cooperate with the electro-conductive pattern. It is even more preferable if the metallic member is a single plate which is embossed according to the desired electro-conductive pattern, elevated surfaces of the metallic plate being exposed for cooperation with the contact pieces of the contact unit while the depressed surfaces of the metallic plate is embedded in the main body made of synthetic resign so as to be insulated from the contact pieces of the contact unit.
Such an electro-conductive patterns is advantageously manufactured by a method comprising the steps of: forming the electro-conductive pattern by embossing an electro-conductive metal plate and forming a through hole in the bottom of an embossed depression, an embossed elevated surface serving as the isolated contact surface and the continuous contact surface; and inserting the metal plate into a mold forming cavity so that the electro-conductive pattern may come into contact with a die surface and performing insert molding by filling molten synthetic resin into a V-groove space between the two contact surfaces through the cavity and the through holes.
According to yet another aspect of the invention, the indicator wheel comprises a main body made of molded synthetic resin and cams formed integrally with the main body in a concentric partial arcuate manner on the side opposite to the ratchet gear; and the contact unit comprises at least one moveable contact piece which cooperates with the cams and at least one fixed contact piece connected to an output terminal, the moveable contact being biased away from the fixed contact piece and engageable to the fixed contact piece upon engagement with the cams.
BRIEF DESCRIPTION OF THE DRAWINGS
Now this invention is described in the following with reference to the appended drawings, in which:
FIG. 1 is an exploded perspective view of an embodiment of the digital switch according to this invention;
FIG. 2 is a sectional view of the digital switch of FIG. 1;
FIG. 3 is a partially broken away perspective view of the indicator wheel of the digital switch shown in FIGS. 1 and 2;
FIGS. 4 to 6 are plan views of the internal structure of the digital switch illustrating the action thereof;
FIG. 7 is a view similar to FIG. 3 for showing another embodiment of the indicator wheel;
FIGS. 8 and 9 are views similar to FIGS. 4 to 6 for showing the action of a digital switch incorporating the indicator wheel of FIG. 7;
FIG. 10 is a perspective view showing an embodiment of an electro-conductive pattern which may be incorporated into the digital switch of this invention;
FIG. 11 is a front view of the indicator wheel carrying the electro-conductive pattern of FIG. 10;
FIG. 12 is a sectional view taken along line 12--12 of FIG. 11;
FIG. 13 is a magnified view of a part of FIG. 12;
FIG. 14 is an exploded perspective view of another embodiment of the digital switch according to this invention;
FIG. 15 is a front view of the contact unit used in the embodiment of FIG. 14; and
FIG. 16 is a sectional view taken along line 16--16 of FIG. 15.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows the internal structure of a digital switch according to this invention. This digital switch comprises a case 1 made of synthetic resin in the form of a rectangular box having an open end on one side thereof and includes a side wall 11 opposite to the open end, a front wall 12, a rear wall 13, a top wall 14 and a bottom wall 15.
The side wall 11 is provided with a pivot shaft 19 integrally formed therewith on its inner surface in a position which is generally in the middle but is slightly closer to the front wall 12. The front wall 12 has a display window 16 in its center fitted with a transparent acrylic plate 16a and a pair of through holes 17 above and below the display window 16 in symmetric manner. The rear wall 13 extends in parallel with the front wall 12 and has a linear projection 18 extending laterally in the middle part of its inner surface. The inner surfaces of the top and bottom walls 14 and 15 are conveniently contoured to accommodate internal structure.
A push rod member 2 comprises a pair of main body protions 2a and 2b extending generally in parallel with the top and the bottom walls 14 and 15, a pair of push-button portions 23a and 23b integrally formed on the front ends of the main body portions in a shape adapted to be passed through the through holes 17 of the front wall 12. The rear ends of the main body portions 2a and 2b are formed as spring portions 21 which are substantially U-shaped by curving towards each other and the rearmost ends of the spring portions 21 are joined together by a mounting plate 22 which is generally planar and extends in parallel with the rear wall 13. The rear surface of the mounting plate 22 is provided with a groove 27 which is adapted to snugly receive the linear projection 18 on the rear wall 13.
A pair of arms extend from the parts of the main body portions 2a and 2b adjacent to the push-botton portions 23a and 23b towards each other in an oblique manner, and the free ends of the arms are formed as advance pawls 24a and 24b. Another pair of arms 25a and 25b extend from the main body portions 2a and 2b, slightly rear to the first arms, in a manner similar to the first arms, and their free ends integrally carry stop pawls 26a and 26b, respectively.
Thus, the push rod member 2 integrally comprises the push-button portions 23a and 23b, the main body portions 2a and 2b, the advance pawls 24a and 24b, the stop pawls 26a and 26b, the spring portions 21 and the mounting plate, and is adapted to be fitted into the case 1 by passing the push-button portions 23a and 23b through the through holes 17 of the front wall from inside and engaging the groove 27 with the linear projection 18 of the rear wall 13. The push-button portions 23a and 23b thus protrude from the through holes 17 and shoulders 28 of the push-button portions determine the extent to which the push-button portions protrude from the front wall 12.
An indicator wheel 3 is generally shaped as a disc and is made of molded synthetic resin material. The indicator wheel 3 comprises a central pivot hole 29 which is adapted to be pivoted on the pivot shaft 19 of the side wall 11, a central tubular portion 32 surrounding the pivotal hole 29, a ratchet gear 36 formed on the free end of the tubular portion 32, and an outer ring 33 whose outer surface carries numerals 35 formed therein, for instance, by hot stamping.
When this indicator wheel 2 is pivoted on the pivot shaft 19, the numerals 35 on the outer circumferential surface show through the window 16 and the pawls 24a, 24b, 26a and 26b engage with the teeth of the ratchet gear 36 as will be described in greater detail hereinafter.
The side surface 31 of the indicator wheel 3 facing the open end of the case 1 carries an electro-conductive pattern 34 thereon. The inner surface of the outer ring 33 is provided with a number of notches 39 and a pair of stopper pieces 51 of a generally triangular cross-section are fitted into an annular space 37 defined between the central tubular portion 32 and the outer ring 33 by the broader ends of the stopper pieces 51 being engaged by the notches 39 of the outer ring 33 on one hand and the narrower ends of the stopper pieces 51 being engaged by grooves 38 between the teeth of the ratchet gear 36, as shown in FIGS. 2 and 3 in greater detail. These stopper pieces 51 define the range the indicator wheel 3 can rotate by engaging to a stopper 52 which is integrally formed on the side wall 11. As can be readily seen, these stopper pieces 51 may be inserted into the annular space 37 as desired and may be selectively placed therein according to the need of the user of the digital switch.
The axial length of these stopper pieces 51 is shorter than the axial length of the space 37 so that they do not interfere with the action of the pawls 24a, 24b, 26a and 26b. And they have axial through holes 54 so that they are elastic enough to be able to absorb any impulsive force they may receive upon contact with the stopper 52 and also to be snugly received between the ratchet gear 36 and the notches 39. These stopper pieces 51 have the additional utility as members for reinforcing the indicator wheel 3.
The open end of the case 1 is closed by a contact unit 4 consisting of a wall member having a central opening 42 and a plurality of terminals 43 in the rear end of the wall member. A plurality of contact pieces 41 are connected to the corresponding terminals 43 and project into the opening 42. These contact pieces 41 and terminals 43 are advantageously placed into the wall member by insert molding. When this contact unit 4 is fitted over the open end of the case 1, the contact pieces 41 engage the electro-conductive pattern 34 and can produce different electric signals on the terminals 43 depending on the angular position of the indicator wheel 2. The contact unit 4, when assembled, is further covered by a cover plate 44 for the protection of the contact pieces 41 from external interferences.
Now, the action of the above-described digital switch is described in the following with reference to FIGS. 4 to 6.
In the assembled state of the digital switch, the push rod member 2 is fitted into the case 1 by the engagements of the shoulder 28 with the front wall 12 and of the mounting plate 22 with the rear wall 13, and the push rod member 2 is so dimensioned that, in this assembled state, the spring portions 21 are slightly compressed. Therefore, the push rod member 2 is tightly fitted into the case 1 and is capable of withstanding vibrations without any play or looseness.
When either one of the push-button portions, for instance 23a, is depressed against the spring force of the corresponding spring portion 21, the stop pawl 26a comes out of the gear groove 38 and the advance pawl 24a pushes the ratchet gear 36 by one step. As the ratchet gear 36 rotates, the gear tooth pushes against the other stop pawl 26b but, due to the lateral flexibility of the arm 25b, the stop pawl 26b yields and rides over the gear tooth, as shown in FIG. 5.
As the push-button portion 31a is pushed further, the stop pawl 23b snugly fits into the next gear groove 38 under the biasing force produced from its own elasticity and holds the ratchet gear 36 at this position.
As a result, the indicator wheel 2 rotates by a predetermined angle and, by virtue of a suitable arrangement of the electro-conductive pattern, the contact pieces pick up a corresponding electric signal and produce it on the terminals 43. At the same time, the numeral which has been showing through the window 16 is now replaced by the next one.
When the push-button portion 23a is released, the main body portion 2a returns to its original position under the biasing force of the spring portion 21 and the stop pawl 26a fits into the next gear groove 38, thus firmly securing the ratchet gear 36 in cooperation with the other stop pawl 26b. Because the arms 25a and 25b is more rigid against the force directed from the front to the rear than the force directed from the bottom to the top or from the top to the bottom, the ratchet gear 36 is now very firmly secured.
The action is identical when the other push-button 23b is depressed but, of course, the ratchet gear 36 rotates in the reverse direction.
According to this invention, because it is the U-shaped and integral spring portions 21 which undergo deformation when the push-button portions 23b, 23b are depressed, the mounting plate 22 merely engages the case rear wall 13 without being deformed or displaced due to the positioning effect of the engagement between the linear projection 18 and the groove 27.
FIG. 7 shows another embodiment of the stopper piece 51. An axial extension 53 is provided in the broader end or the end engaged by the notch 39 so that the mechanical strength of the engagement between the stopper piece 51 and the notch 39 may be increased. According to this embodiment, the stopper 52 is eliminated and when the limits of the rotation of the indicator wheel 3 are reached the axial extension 53 engage with the stop pawls 26a and 26b (FIGS. 8 and 9). The stopper pieces 51 otherwise do not interfere with the action of the pawls 24a, 24b, 26a and 26b.
FIGS. 10 to 13 show another embodiment of the electro-conductive pattern.
According to this embodiment, a desired pattern corresponding to the electro-conductive pattern to be formed is formed by the method of embossing, which may included a press-forming process, in an electro-conductive metal plate 62, and through holes 64 are formed in the bottoms of V-grooves 63 so that an electro-conductive pattern 67 may be formed from elevated surfaces serving as isolated contact surfaces 65 and V-grooves 63 serving as continuous contact surfaces 66. The metallic plate 62 is inserted into a cavity of a metallic molding die (not shown in the drawings) and molten synthetic resin is filled into the cavity including the V-groove space 63 between the two contact surfaces 65, 66 from the through holes 64. When the synthetic resin has solidified, the indicator wheel 3 having an electro-conductive pattern 67 on the base plate 60 is completed and the surface of the base plate 60 is flush with the surfaces of both the contact surfaces 65, 66.
This structure and the method of manufacture are quite advantageous because considerable saving of labor is achieved on one hand and the dimensional accuracy of the electro-conductive pattern 67 can be improved on the other hand. Additionally, the electro-conductive pattern 67 of this structure is mechanically highly integral and is indeed quite durable.
FIGS. 14 to 16 show another embodiment of the digital switch of this invention.
According to this embodiment, the digital switch generally comprises a case 101, an actuating rod 110, a indicator wheel 120, a contact unit 130 and a case cover 140.
The case 101 is a box made of synthetic resin and is provided with a display window 103 and an actuating rod mounting hole 104 on its operating surface 102. Further, the case 101 is provided with a pivot shaft 106, for pivotally supporting the indicator wheel 120 as will be described in greater detail hereinafter, protruding from the center of a bottom surface 105 of the case 101 and a pair of springs 107, 108 are integrally formed in the bottom surface 105 so as to laterally oppose the pivot shaft 106 therebetween from below and above. The spring 107 is provided with a positioning pawl 107a, at its free end, which restrains the free rotation of a ratchet gear 122 by engaging thereto as will be described hereinafter while the spring 108 is provided with a protrusion 108a, at its free end, which engages the bottom surface of the actuating rod 110 to apply a restoring force thereto.
The display window 103 is fitted with a window cover 109, for instance, made of a transparent acrylic plate for shutting out dust and one can see the symbols on the indicator wheel 120 through this window 103.
Numerals 101a and 101b denote an engagement projection and an engagement hole, respectively, which are for connecting neighboring switches when the digital switches of this embodiment are used in a number more than one.
The actuating rod 110 has a push-button portion 111 protruding from the mounting hole 104 of the case at its upper end and a drive portion 113 which is shaped as latter "U" and formed integral with a drive pawl 114 on the free end at its lower end. When this actuating rod 110 is pushed down, the drive pawl 114 advances the ratchet gear 122 in a step-wise manner. The proximal end of the push-button portion 111 is provided with a stopper surface 112 for determining the uppermost position of the push-button portion 111.
The indicator wheel 120 is shaped as a disc carrying numerals or letters on its outer circumferential surface 121 which are formed, for instance, by hot stamping at equal intervals and supported by the pivot shaft 106 in a freely rotatable manner. One side of the indicator wheel 120 is provided with the ratchet gear 122, as mentioned previously, which may be rotated in a step-wise manner by the drive portion 113, and the other side of the indicator wheel 120 is provided with cam portions 123a to 123d on concentric circles of different diameters so as to correspond to the numerals, surrounded by an annular groove 124.
The contact unit 130 has a contour which is adapted to close the case 101, and an annular projection 131, which fits into the annular groove 124, is integrally provided in the inner side surface of the contact unit 130, with a central opening 132 being formed in the center of the annular groove 131. This central opening 132 accommodates a fixed contact piece 134 formed integral with a common terminal 133 and moveable contact pieces 135a to 135b formed integral with corresponding terminals 136a to 136d and in contact with the cam portions 123a to 123d, these contact pieces being accurately positioned by insert molding.
Contact portions 137a to 137d which are to contact the cam portions 123a to 123d are integrally formed with the moveable contact pieces 135a to 135d by being made of synthetic resin (FIGS. 15 and 16). The moveable contact pieces 135a to 135d may be made by press-forming or bending, but, because of the difficulty to obtain required dimensional accuracy, performance may be impaired and adjustment work during assembly may be too cumbersome. However, according to this embodiment, dimensional accuracy is very favorable and no adjustment is required during assembly.
The case cover 140 is attached over the outer surface of the contact unit 130 to close the central opening 132.
Now the action of the digital switch of the above described structure is described in the following:
First, when the push-button portion 111 of the actuating rod 110 is pushed down and the actuating rod moves downwardly against the biasing force of the spring 108, the drive pawl 114 engages with a tooth of the ratchet gear 122, and the indicator wheel 120 integral with the ratchet gear 122 is rotated. When the positioning pawl 107a of the spring 107 has come off the corresponding tooth as the ratchet wheel 122 turns, then the positioning pawl 107a again engages with the space between the next two teeth under its restoring force, thus preventing any further rotation of the ratchet gear 122. Therefore, the indicator wheel 120 turns by one step and then stops at that position.
When the pressure on the push-button portion 111 is removed, the actuating shaft 110 restores its original position under the biasing force of the spring 108 and disengages from the teeth of the ratchet gear 122.
Every time this is repeated, the ratchet gear 122 along with the indicator wheel 120 rotates by one step and the numeral showing in the display window 103 through the transparent window cover 109 increases by one. At the same time, the cam portion 123a to 123d corresponding to the displayed numeral engages the corresponding contact portion 137a to 137d and brings the moveable contact pieces 135a to 135d into engagement with the fixed contact piece 134 to produce a signal corresponding the displayed numeral.
Thus, according to the digital switch of this embodiment, a cam portion is insert molded on one side of a symbol wheel in place of a conventional printed circuit board while a contact portion for engagement with the cam portion is insert molded on a moveable contact piece in place of a conventional metallic member, by doing so, much higher dimensional accuracy has become possible as opposed to the case in which a conventional printed circuit board is used and, therefore, a digital switch of more accurate performance can be obtained.
Furthermore, elimination of the work required for positioning a printed circuit board greatly simplifies the manufacturing process. Moreover, elimination of an expensive printed circuit board can provide a digital switch having a low cost contact mechanism.
This invention may be applied not only to digital switches as described above, but also to other electric component parts, such as switches, and has practical advantages.
Although the present invention has been shown and described with reference to the preferred embodiments thereof, it should not be considered as limited thereby. Various possible modifications and alterations could be conceived of by one skilled in the art to any particular embodiment, without departing from the scope of the invention. Therefore, it is desired that the scope of this invention should be defined not by any of the perhaps purely fortuitous details of the shown preferred embodiments, or of the drawings, but solely by the scope of the appended claims, which follow.
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A digital switch may have an advantageous actuating member including, in addition to pawls for a ratchet mechanism, a pair of main bodies and spring portions integrally formed therewith, whereby the mechanical integrity of the actuating member and smooth operation are assured. The spring portions are interconnected by a mounting plate which is in turn engaged to a casing member. The switch may include an advantageous electro-conductive pattern which is made by insert molding an embossed metallic plate into synthetic resin, whereby the dimensional accuracy of the pattern is assured and the production may be facilitated. Further, the switching element may make use of a set of concentric cams which selectively drive movable contact pieces onto fixed contact pieces according to the step-wise rotation of a ratchet wheel.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The present invention relates to thin film resistors and more particularly to thin film resistors with high resistivity and low temperature coefficient of resistance.
BACKGROUND: THIN FILM RESISTORS IN INKJET PRINTERS
[0002] The demand for inkjet printers has steadily increased in recent years due to the growth of the PC market. Recently, the release of high-resolution digital imaging products, such as 2M-pixel digital cameras, has increased the demand for high resolution printing. To meet this demand, inkjet printers are shifting to high resolution printers capable of producing photo-quality prints. Such print quality requires continuing reduction of ink droplet and ink nozzle size. The resolution of current printers is up to 1200-1400 dpi, which corresponds to 17-21 micron per droplet. Yet the demand for higher quality and faster printing speeds calls for even smaller devices.
[0003] Thermal inkjet printers generally comprise a printer head mounted on a moveable cartridge which slides back and forth across the width of a page as it prints. The cartridge contains a reservoir for ink. Ink is ejected in controlled patterns during printing via nozzles in the printer head. The nozzles are in fluid communication with the reservoir.
[0004] A printer head typically consists of a resistive thin film heating material in contact with a conductor deposited on a thermally and electrically insulated substrate. The conducting layer may be deposited atop the insulating layer first. The conductor is then etched by conventional mask techniques in preparation for the resistor layer, which is deposited next. Alternatively, the resistor layer may be deposited first and etched. The conductive material is then deposited over the resistive material. The individual heating elements are then defined by etching the conducting layer with the usual mask techniques. The resulting configuration allows the heaters to be activated by current applied to the conductors.
[0005] Each heating element is positioned beneath an ink chamber with a nozzle that contains the ink to be deposited on the page. The ink chamber and nozzle are formed from resin or polymer material in a separate process and glued to the rest of the printer head. The ink chamber typically communicates with the ink reservoir in the printer cartridge by shared or individual ink feed slots.
[0006] Thermal inkjet printers use the heaters to shoot ink droplets onto a page. A microprocessor addresses the resistors via the conducting layer with current pulses according to the patterns to be printed. The current heats the resistors, which in turn vaporize the nearby ink, producing a bubble in the chamber. The growth and collapse of the bubble forces an ink droplet from the nozzle onto the paper surface. The droplets collectively form the printed image.
[0007] To meet the requirements for size and speed, the next generation thermal inkjet printers need smaller printer heads. This requires greater resistivity in the heaters to reach the necessary temperatures. Present materials used for thin film resistors can be made to exhibit the required resistivity, but not the necessary stability due to unacceptable temperature coefficient of resistance. Thus, there is a need for thin film resistors with high resistivity and small temperature coefficient of resistance (TCR). Resistivity needs to reach 1000 μΩcm and the absolute value of TCR must remain less than 200 ppm/C.
[0008] Improving the TCR is also important for homogeneous heating of the resistor. The temperature at the edge of the heater is often lower than that at the center. If the TCR is large and negative, the resistivity of the center will become smaller than at the edge. This causes more current to flow through the center, further raising the temperature there. This creates a feedback cycle, and the temperature difference between the center and edges becomes very large.
[0009] Many materials are known as heater materials, including NiCr, Ta, TiSiN, AlTiN, and TaxN. Among these, TaxN is widely used in thermal inkjet printers because of its high resistivity and stability at high temperatures. For example, commonly used Ta 2 N have high resistivity around 180-300 μΩcm, and low TCR of around −100 ppm/C. However, it is hard to raise the resistivity higher, because increasing N, which raises resistivity, also raises TCR.
[0010] In order to achieve higher resistivity, Si is often added to TaxN. These films have a large resistivity while maintaining a relatively low TCR. For example, a TaSiN film with around 16% composition ratio Si has resistivity of about 280 μΩcm and TCR of −120 ppm/C. However, increasing the resistivity (to, say, greater than 500 μΩcm) also increases the TCR to unacceptable limits (e.g., TCR>500 ppm/C).
[0011] [0011]FIG. 1 shows resistivity and TCR of TaSiN films of various Si and N compositions. Silicon content of 0%, 15%, 29%, and 45% are each plotted according to their nitrogen composition ratios. Nitrogen percentages range from 8% to 30%. From FIG. 1 it can be seen that in general, larger N content decreases TCR and increases resistivity, and adding silicon also increases resistivity. However, these compositions have unacceptably large absolute values for TCR.
[0012] The rise in TCR is currently considered inevitable and no suggestion for improvement has been reported.
[0013] It is therefore an object of the present invention to develop a thin film resistor to act as a heater with large resistivity and small TCR simultaneously.
[0014] Production Method of Fine Resistor Thin Film with Very Low TCR for Inkjet Printer
[0015] The present application discloses a heater made from TaSiN with large Si composition ratio. The addition of large amounts of Si to the film greatly increases the resistivity, but also increases absolute value of TCR to unacceptable limits. The thin film resistor is therefore heat treated or “pre-operated” as a printer head before actual operation. During this process, the film is heated up to approximately 900 C, substantially the same temperature at which the resistor operates. This drastically reduces the TCR of the thin film, while leaving the resistivity high. This method thus produces thin film resistors with the necessary large resistivity and small TCR.
[0016] During production, the TaSiN thin film is deposited by some method (for example, sputtering) onto an insulating layer. In a preferred embodiment, the Si composition ratio of the thin film (Si/(Si+Ta)) is between 40% and 80%, and the N composition ratio is between 2.5% and 50%. Next, the TaSiN thin film is patterned by conventional means, and the rest of the printer head is completed, which includes a conducting layer in electrical contact with the thin film, an ink chamber, and a nozzle. The thin film is heated in a furnace, or by applying current to the conducting layer (and therefore the thin film) in the same manner as in actual printing operations. During this process, the TaSiN film is heated to around 900 C by its own joule heat. This process improves the TCR of the TaSiN film without reducing its high resistivity.
[0017] The disclosed innovations, in various embodiments, provide one or more of at least the following advantages:
[0018] high resistivity;
[0019] low absolute value of TCR;
[0020] homogeneous heating of the heater material.
BRIEF DESCRIPTION OF THE DRAWING
[0021] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0022] [0022]FIG. 1 is a graph showing the resistivity and TCR of TaSiN films with varying composition.
[0023] [0023]FIG. 2 shows a printer pen that includes a printer head according to the preferred embodiment.
[0024] [0024]FIG. 3 shows a perspective view of a printer head.
[0025] [0025]FIG. 4 shows a cross section view of the layers within a printer head.
[0026] [0026]FIG. 5 shows a cross section view of the layers within a printer head of an alternative design.
[0027] [0027]FIG. 6 shows the resistivity and TCR of the TaSiN films with large Si composition ratios before and after annealing.
[0028] [0028]FIG. 7 shows a composition diagram for the innovative thin film resistor material.
[0029] [0029]FIG. 8 shows a process flow for creation of a printer head substructure employing the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
[0031] [0031]FIG. 2 shows a thermal inkjet printer pen that includes a printer head according to the preferred embodiment. The printer pen includes a pen body 202 that contains a reservoir (not shown). The reservoir contains the ink supply for printing. The pen body 202 contains a printer head 204 on its bottom that is used to control the ejection of ink from the pen. The printer head includes many minute nozzles 206 on its surface that direct ink from firing chambers 308 (shown in FIG. 3) onto the surface of a page. Each firing chamber 308 is positioned beneath or adjacent to a heater made from a thin film resistor 302 that is selectively heated by current pulses to drive ink from the chamber 308 through the nozzle 206 onto the page.
[0032] Conducting lines for each thin film resistor component 302 are part of a flexible circuit 208 mounted on the exterior of the pen body 202 . Contact pads 210 at the ends of the conducting lines are designed to contact corresponding pads on a matching circuit within the printer carriage. A microprocessor and drivers generate the signals for activating the resistors 302 .
[0033] [0033]FIG. 3 depicts a typical printer head substructure incorporating presently disclosed innovations. A thin film resistor 302 is located on an insulator 303 , which covers a substrate material 304 . The thin film resistor 302 contacts a conductor 306 . The conductor 306 is connected to receive current pulses from a controller or microprocessor (not shown). An ink firing chamber 308 formed out of a barrier material 310 is located above the resistor 302 . A channel 312 supplies ink from a reservoir (not shown) to the chamber 308 . Current pulses through the conductor 306 generate heat in the resistor 302 , which vaporizes ink in the chamber 308 , creating a bubble. The expansion and collapse of the bubble ejects an ink droplet through the nozzle 314 .
[0034] The process of making the innovative printer head 400 is described in FIG. 4. A substrate 402 is covered by an insulating material 404 , preferably silicon oxide. The thickness of the insulating layer 404 must be enough to electrically isolate the heater. In the case of a Si substrate and silicon oxide insulating layer, the typical thickness of the insulating layer is several micrometers. A thin film 406 is deposited on the insulating layer 404 by conventional methods, such as RF sputtering. The thickness of the thin film resistor layer 406 depends on the required resistance. Typical thickness ranges from 500-700 Angstroms. The thin film resistor 406 is made from TaSiN, and is deposited using RF-reactive co-sputtering method with Ta and Si targets. In the preferred embodiment, the Si composition ratio, defined as Si/(Si+Ta), is between 40% and 80%. The composition of the Si is adjusted by changing the RF power on each target during deposition. The N composition ratio, defined as N/(N+Si+Ta), is between 2.5% and 50%, and is adjusted by changing the N 2 partial pressure during film deposition.
[0035] A first mask layer is used to etch the TaSiN thin film 406 in preparation for the conducting layer 408 . The conducting layer 408 is formed using conventional means, and is made from Al (though other metals can also be used). A second mask is needed to pattern the conducting layer 408 . Typical thickness for the conducting layer is around 1 micrometer.
[0036] Alternatively, the conducting layer can be formed before the thin film resistor is formed, resulting in a slightly different layer configuration as shown in FIG. 5. In such a case, the substrate 502 and insulator 504 remain the same. The conducting layer 506 is formed next, and a mask is used to pattern the conducting layer 506 in preparation for the thin film resistor 508 . Regardless of the exact configuration, the conduction layer 506 and the resistor layer 508 must be in electrical contact such that current applied to the conductor 506 generates heat in the resistor 508 .
[0037] Referring back to FIG. 4, the ink chamber and nozzle 410 , composed of resin or polymer material, are fabricated during a separate process and glued to the rest of the printer head substructure 400 . This completes assembly of the printer head substructure 400 .
[0038] The resistivity and TCR of the thin films depend in part on the composition ratios of N and Si in the thin film. Both resistivity and TCR increase as N and Si composition ratios increase. However, adding an annealing step wherein the printer head is heat treated drastically improves the TCR of the annealed thin film. The effect of the annealing depends on the composition ratios of the Si and N. The experimental results discussed below detail the process and results of the heat treatment.
[0039] Experimental Results
[0040] Films with varying Si and N composition ratios were deposited using RF-reactive co-sputtering method with Ta and Si targets. Composition ratios of Si were adjusted by changing RF power on each target. N composition ratios were adjusted by changing N 2 partial pressure during film deposition. Four different thin film compositions were tried, with Si composition ratios of 60% and 70% each deposited at different N 2 partial pressures of 5.0% and 7.5%. Thermal treatment at 900 C was applied to the films in diluted H 2 ambient for 20 minutes at atmospheric pressure.
[0041] The N composition ratio range was determined from the N composition ratios of films deposited in N2 partial pressure of 8%, with varying Si content. The following experimental results were obtained:
Si ratio 0% 12% 28% 45% N ratio 48% 53% 45% 37%
[0042] These results lead to the conclusion that TaSiN films with Si composition ratios of 60% and 70% deposited in N 2 partial pressures of 5.0% and 7.5% have N composition ratios smaller than 50%. This indicates an N composition ratio range narrower than 0-50%. However, TaSiN with 0% N composition is tantalum silicide, which is quite different from TaSiN, so a lower N composition ratio boundary of 2.5% was used.
[0043] [0043]FIG. 6 shows the resistivity and TCR of the TaSiN films with large Si composition ratios before and after annealing. In non-heat treated films, resistivity and TCR both increase as N and Si composition ratios increase, making TCR values in films with large resistivity very large. In contrast, the TCR is greatly improved in heat treated films without significant reduction of resistivity. As FIG. 6 shows, the film with 60% Si composition ratio deposited in 7.5% N 2 had large resistivity (2400 μΩcm) after annealing, and the TCR improved drastically from −620 ppm/C to −180 ppm/C. For thin films of 60% Si composition ratio deposited in 5.0% N 2 , resistivity was slightly reduced by annealing, and the TCR was raised to a large positive value (400 ppm/C). The change in TCR due to heat treating was greater in films with Si composition ratio of 70%, as shown in the graph. The TCR of these films increased to a large positive value.
[0044] Samples with Si values of 16% were also tested. The change in their TCR value was not significant, indicating that the annealing step must be coupled with large Si content in order for the TCR to be reduced significantly by heat treatment. Noting FIG. 6, the TCR of the 60% Si was changed by roughly 400-600 ppm/C (depending in part on the N2 partial pressure at deposition). However, the annealing step affected the 70% Si material more profoundly, changing the TCR by nearly 1000 ppm/C.
[0045] Referring back to FIG. 1, it can be seen that the TCR of TaSiN thin film with fixed Si composition ratios can be gradually reduced by changing N composition. This effect is also seen in FIG. 6, where the films with greater N composition have consistently lower TCR. Specifically, the TaSiN film with 60% Si composition ratio after thermal treatment had a positive TCR (about 400 ppm/C) for N 2 partial pressure of 5.0%, and a negative TCR (about −180 ppm/C) for N 2 partial pressure of 7.5%. Thus, any TCR value between two samples with the same Si composition ratios and different N compositions can be realized by varying the N 2 partial pressure at deposition. This, coupled with the fact that TCR values both above and below zero can be achieved with materials of the same Si content and different N content, indicates that any TCR value near zero can be realized.
[0046] [0046]FIG. 7 is a composition diagram for the thin film resistor. The composition ranges of the three materials, Si, Ta, and N, form an area on the graph of acceptable heater material compositions. Si/(Si+Ta) ranges from 40% to 80%, while N ranges from 2.5% to 50%. The crosshatched area shows compositions within the specified ranges. Within this area, the 60% and 70% Si lines are also shown (corresponding with the stated experimental results).
[0047] [0047]FIG. 8 depicts an overview of the construction process of a printer head employing the preferred embodiment. In process 1, the TaSiN thin film is deposited on a substrate. Process 2 patterns the thin film in preparation for completion of the printer head substructure. In process 3, the other parts of the printer head (including the firing chamber and nozzle) are glued on. In process 4, the completed printer head is run through a dummy printing operation, which causes the thin film to be heated to approximately 900 C by its own joule heat.
[0048] Definitions:
[0049] Following are short definitions of the usual meanings of some of the technical terms which are used in the present application. (However, those of ordinary skill will recognize whether the context requires a different meaning.) Additional definitions can be found in the standard technical dictionaries and journals.
[0050] Composition Ratio: Atomic ratio, or the number of atoms of a given material present in a certain volume. In the present application, the Si percent composition is expressed only in terms of Si and Ta as Si/(Si+Ta). The percent composition of N is defined as N/(N+Si+Ta).
[0051] Modifications and Variations
[0052] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0053] Additional general background, which helps to show the knowledge of those skilled in the art regarding variations and implementations, may be found in the following publications, all of which are hereby incorporated by reference: THIN FILM PROCESSES by Vossen, John; Kern (1978); THE SCIENCE AND ENGINEERING OF MICROELECTRONIC FABRICATION by Campbell, Stephen; Oxford Press (1996), PHYSICAL VAPOR DEPOSITION OF THIN FILMS by Mahan, John, 1999; HANDBOOK OF PHYSICAL VAPOR DEPOSITION (PVD) PROCESSING by Mattox, Donald, 1998; HANDBOOK OF SPUTTER DEPOSITION TECHNOLOGY: PRINCIPLES, TECHNOLOGIES, AND APPLICATION by Wasa, Kiyotaka; Hayakawa, Shigeru, 1992.
[0054] The material of the resistor can be replaced by a combination of amorphous insulating nitride and crystalline conductive nitride, such as TiSiN, WSiN, HfSiN, NbSiN, MoSiN, and ZrSiN.
[0055] Thermal printer heads, which use thin film heaters, can incorporate the presently disclosed innovations which are also applicable to fine resistors used in printed circuits and semiconductor devices.
[0056] The heat treating process of the thin film may be replaced by various heating methods, such as heating by laser radiation.
[0057] Likewise, other process steps may be varied without deviating from the disclosed innovations, such as varying the composition percentages or materials used to create the thin film, or varying the order or number of process steps used in making the printer head.
[0058] The structure of the printer head may be modified. There can be a thin insulating layer on the heater, and the upper part of the printer head (the chamber and nozzle) may be fabricated directly on the lower part using micro-machining technology as is known in the art.
[0059] The thin film may be formed i various ways, such as CD sputtering, CD magnetron sputtering, or RF sputtering with one composition target. Or, CVD technology may be used.
[0060] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
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A thin film resistor ( 302 ) for use in inkjet printer heads that has high resistant and low absolute value of TCR.
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BACKGROUND OF THE INVENTION
This invention relates generally to kaolin clays, and more specifically relates to a process for beneficiating a kaolin clay to improve the rheological properties of a high solids suspension subsequently formed from the beneficiated clay, thereby rendering same more suitable for paper and paperboard coating applications.
Kaolin clay coating pigments having very fine particle size and high brightness characteristics, are widely utilized in the coating of merchant grade papers and various types of paperboard wherein high gloss and smoothness of coating is required. Typically, these pigments are applied as a high solids aqueous suspension, i.e., a suspension including from approximately 60-75% by weight of clay solids. The size distribution of prior art pigments used for such purposes are usually such that of the order of 90-100% by weight thereof are of less than 2 microns equivalent spherical diameter (E.S.D.). Typically, further, the brightness characteristics, as measured by the standard specification established by TAPPI procedure T-646m-54, are of the order of at least 90.
Among the further qualities of a high solids coating clay slurry, which are of paramount importance for achieving high quality coatings, are the viscosity characteristics of same. It may be noted in this connection that the term "viscosity" as used herein with respect to clay slurries, refers to such characteristics as determined by the procedures of TAPPI Method T 648 su-72, as revised in 1972. This method sets forth specific procedures for determination of both the "low shear" and "high shear" viscosity. The latter, i.e. the high shear viscosity, is considered of special importance in evaluating a high solids clay slurry for the aforementioned coating purposes.
While numerous products are known and commercially available which are quite adequate (and in many instances of excellent quality) with respect to brightness, and to a lesser extent, particle size distribution, the high shear rheological qualities of these coating clays are less than would be ideally sought for. Efforts have therefore been made over the years to improve the rheological properties of such clays; but by and large, little direct success has been achieved. In general, the rheological properties have been accepted as those which are inherent in the particular starting materials used.
In accordance with the foregoing, it may be regarded as an object of the present invention, to provide a method for beneficiating a kaolin clay to improve the high shear viscosity of a high solids suspension subsequently formed from the beneficiated pigment.
It is a further object of this invention to provide a method as aforesaid, which simultaneously improves the size characteristics of the clay, to markedly decrease the proportion of the clay particles which may have deleterious size or shape characteristics.
SUMMARY OF INVENTION
Now, in accordance with the present invention, the foregoing objects and others as will become apparent in the course of the ensuing specification, are achieved in a method wherein a 10 to 20% solids aqueous suspension of a kaolin clay is subjected to a selective rheological separation, by mixing the suspension with from about 0.001% to 0.1% by weight of dry clay, of a high molecular weight anionic polymer. The treated suspension is then allowed to separate into a sedimented phase, and a supernatant phase which is found to be substantially free of aggregates. The supernatant phase containing the beneficiated kaolin pigment in suspension is then separated from the sedimented phase. The suspended product of the process can then be conventially processed, e.g., bleached, flocced, filtered and washed, then re-dispersed and dried or mixed with previously prepared dry material, to yield a high solids (e.g. 60% to 75% solids) coating slurry.
In a typical procedure wherein the initial starting material is a crude sedimentary kaolin clay including from about 1-2% titania, the said crude is first subjected to a separation process to reduce the titania content to below 0.8% by weight--more generally the titania will be reduced to the range of from about 0.2 to 0.8%. Where a froth flotation process is used for such purposes, the clay may be initially blunged and conditioned by forming an aqueous alkaline dispersion of the clay (pH adjusted to about 7-10 with ammonium hydroxide). The dispersion may include as a deflocculating agent, various compounds known to be useful for such purposes. A preferred agent for such purposes is sodium silicate. Other useful agents include a water soluble salt of a polyacrylic acid or polymethacrylic acid, preferably having an average molecular weight in the range of 500-10,000. Oleic acid or other collector agent is added during the conditioning process. Reference may be had to U.S. Pat. No. 3,974,067 for further details of flotation procedures which may be utilized in this aspect of the invention.
Further aspects of flotation treatment of the aforementioned type can be found in numerous places in the prior art, including in Cundy, U.S. Pat. No. 3,450,257; and in U.S. Pat. Nos. 2,990,958 and 3,138,550.
The purpose of the froth flotation in the foregoing sequence is to remove titania; and accordingly other techniques can be utilized in place of, or to supplement flotation, including by passing the slurry in relatively dilute form (typically at about 30% solids) through a high intensity magnetic field, e.g. via a magnetic separator of the type disclosed in Marston, U.S. Pat. No. 3,627,678. Such device comprises a canister packed with stainless steel wool, at which enveloping magnets are capable of of providing a high-intensity field of 12 kilogauss or higher.
Reference may further be had in the above connection to the cited U.S. Pat. No. 3,974,067 to Alan J. Nott, which patent is assigned to the assignee of the present application. In this patent a method is disclosed for brightening a kaolin clay to remove discloring contaminants, including titania, by subjecting the clay as an aqueous slurry to a froth floatation treatment, and subsequently to a magnetic separation in a slurry-pervious ferromagnetic matrix of the type described in the aforementioned patent to Marston.
The fraction obtained from the previously described process is, if necessary, diluted to less than 20% solids by weight (preferably to 10% to 15% solids), and is then subjected to the central step of the present process, i.e. to a selective rheological separation, utilizing an appropriate high molecular weight anionic polymeric flocculant. Typically the said anionic polymeric flocculant is added at a dose in the range of from about 0.001% to 0.1% by weight (of dry clay in the suspension), with agitation just sufficient to completely disperse the polymer throughout the clay slip.
Within minutes (typically less than 5 minutes per inch of slurry depth), the slip is found to separate into two phases: a fluid and dispersed supernatant phase, and a flocculated, sedimented phase. The supernatant phase, which includes the beneficiated kaolin, is readily separated from the sediment and may be processed separately. The subsequent treatment of this separated phase is then relatively conventional, and may typically include acid flocculation, bleaching with sodium hydrosulfite, filtration, washing, redispersing, and drying or mixing with previously beneficiated dry material.
When a high solids slurry based upon the refined clay of the supernatant phase is examined from a rheological viewpoint, it is unexpectedly and surprisingly found to have extremely low values of high shear viscosity relative to the starting clay, and particularly relative to the clay in the sedimented phase. Examination of the beneficiated clay by electron microscopy establishes that it is substantially free of aggregates, which structures have apparently been relegated to the sedimented phase by the process of the invention. As will be discussed further hereinbelow, this is hypothesized to be at least one of the mechanisms responsible for the remarkable improvements enabled by the invention.
In a further aspect of the invention it is found that where the starting dilute suspension includes a 100% less than 5 micron clay, the fraction of clay rerecovered in the supernatant phase has extremely fine particle size. Typically 90% to 100% by weight of the particles thereof have an E.S.D. less than 2 microns. Thus the process of the invention also serves to beneficially alter the size characteristics of the suspension as to improve the coating properties of the clay.
It is important to observe here that the size separation which occurs as an incident of the polymer treatment, and which is normally highly beneficial, can in no way fully account for the remarkable rheological improvements yielded by the invention. Thus, and as will be hereinafter illustrated, a given kaolin clay can be classified by centrifuging to provide a fraction having a size distribution as above; yet such fraction will lack the rheological characteristics yielded when the same clay is processed by the method of the invention.
The anionic polymeric flocculants which are advantageously used in the method of the invention, are preferably characterized by charge densities of 25% or higher and a molecular weight of over 10 7 . Typical such molecular weights are, e.g., of the order of 10 to 15 million. Typical such compounds utilizable in the invention include highly anionic polymers such as polyacrylamides or derivatives of same. Among the compounds of this type commercially available and utilizable in the invention are those produced by Nalco Chemical Company, Oak Brook, Ill., and commercially available in the U.S. under designation such as Nalco 7873, and Nalco 9UD120; and the Percol 156 product, produced by Allied Colloids Incorporated, Ridgewood, N.J.
It may be noted here that in Rowland, U.S. Pat. No. 2,981,630, poly-aliphatic-hydroxy polymers or carbohydrate polymers, and most especially water suspensible derivatives such as manno-galactans, are disclosed for separating a clay suspension into components having different viscosities by selectively flocculating one or more said components. In this teaching, however, the low viscosity component is precipitated, while the more viscous fraction remains in the supernatant liquid. There is no indication that high shear rheology is improved. The mechanism of the Rowland disclosure is believed to differ fundamentally from the present invention, with the distinctions being partially due to the chemically distinct nature of the polymers used in the two instances.
It may be further noted, that it has heretofore been known to utilize high molecular weight anionic polymeric flocculants of the general type used in the present invention, including certain polyacrylamides, in the course of treatment of clay slurries to effect certain separations in same. However, it is noteworthy to observe that such prior art treatments have considered solely the utility of such flocculants for removal of discoloring contaminants from the clay slurry. None have taught the utility or application of the said flocculants for the separation of clay fractions from clay fractions, wherein such fractions are further, possessed of markedly different rheological properties.
Reference may be had in the foregoing connection to U.S. Pat. No. 3,808,021 to R. N. Maynard, wherein a kaolin slurry which has previously been reflocculated by use of excess peptizing agent, is treated with an anionic high molecular weight polymer to form flocs of purified kaolin clay, which settle, leaving titanium and iron contaminants in suspension. Reference may also be had to the same inventor's U.S. Pat. No. 3,857,781, wherein a similarly reflocculated and aged kaolin slurry, is treated with an anionic high molecular weight polymer in the presence of specified inorganic salts. In this instance, the flocs which settle out from the suspension include the titanium and iron contaminants, leaving the brightened kaolin in suspension.
The precise mechanisms at work in achieving the highly beneficial results yielded by the present invention are, at present, only imperfectly understood. While applicant does not intend to be bound by any theory of the invention, evidence thus far gathered (in part by use of scanning electron photomicroscopy) suggests that the highly anionic polymer functions in the present invention to selectively flocculate aggregates of very minute kaolin platelets, thereby removing these elements from the suspension to render same substantially free of aggregates, and leaving substantially discrete kaolin platelets remaining in the suspension, with the highly improved rheological properties being thereby yielded.
In the terminology set forth in the preceding paragraph, applicant intends the phrase "aggregates" to refer to two types of kaolin structures wherein groups of kaolin platelets are associated. In the type "A" aggregate, the clay platelets are substantially arranged in neatly stacked, one-atop-the-other order. In the type "B" aggregate, the stacks of platelets are skewed, i.e., a relatively complete overlap between successive overlying platelets is absent. In this type "B" aggregate a certain amount of edge-to-edge contact in the platelets thus occurs. An analogy might be made with a deck of ordinary playing cards. If the deck is perfectly squared off, the arrangement is comparable to the "A" aggregate. If the same deck is spread out or skewed about, then an arrangement results which is more nearly akin to the type "B" aggregate.
In any event, in the instance of both the type "A" and "B" aggregates, it will be clear that, in comparison to the situation where relatively small numbers of platelets are bound to each other, or where platelets are substantially free from one another, one effectively has an increased collection of platelet edges relative to outwardly accessible faces. In view of the known fact that kaolin platelet faces carry negative charges, while the edges thereof carry positive charges, it will be clear that the aggregates will possess a higher proportion of positive-to-negative charge than will isolated platelets or small collections of platelets. Therefore, using an anionic high molecular weight polymer, the aggregates are attracted to the long-chain polymer, which polymer tends to tie up a large number of such aggregates, in consequence of which the resultant flocs settle out of the suspension.
In accordance with a further aspect of the invention, it is found that the benefits of the present process are applicable to a kaolin clay which has already been highly refined, i.e., refined to the extent of being of relatively fine particle size, and which by virtue of low titania and iron content, already constitutes a highly whitened and brightened pigment. Thus, it is possible, in accordance with this aspect of the invention, to utilize as a "starting material" the already highly brightened and purified pigment produced by prior art processes, which may have included flotation and/or magnetic separation treatment of crude kaolins and/or various classification and bleaching steps--to have already resulted in a pigment of relatively good coating qualities. By use of the present invention, however, i.e., by subjecting such materials to a selective rheological separation by the method of the invention, the high shear viscosity is greatly improved and the size distribution properties, i.e. the fineness of the clay, may be substantially further improved.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 herein is an electron photomicrograph of a clay suspension, representing the supernatant phase resulting from treatment of a kaolin clay by the process of the present invention;
FIG. 2 is a further electron photomicrograph, showing type "A" aggregates which have accumulated in the sedimented phase resulting from treatment of a kaolin clay by the process of the invention;
FIG. 3 is a yet further electron photomicrograph, showing type "B" aggregates which have accumulated in the sedimented phase resulting from treatment of a kaolin clay by the process of the invention; and
FIG. 4 is a graph plotting percentage of clay flocculated against polymer dose-rate for several polymers of differing degree of ionic charge and molecular weight.
DESCRIPTION OF PREFERRED EMBODIMENT
The invention is further illustrated by the following Examples:
EXAMPLE I
In this Example the selective rheological separation method of the present invention was practiced, utilizing as starting material samples obtained from a plant processing stream normally utilized to produce a high quality, fine particle size, and highly brightened coating clay from a mixture of relatively fine particle size sedimentary soft Georgia kaolin crudes. The mixture of crudes initially included by weight approximately 1.5% titania and 0.75% of iron expressed as Fe 2 O 3 .
These crudes, in the usual plant processing procedure, are subjected to blunging, refining, and conditioning as aforementioned, and, thence, to a froth flotation, which reduces the titania content to between 0.2 and 0.4%. A product from such processes was diverted from the plant processing stream for use in the present Example. Normally such material would proceed through the conventional flocculating, bleaching, filtering, and redispersion steps, which would result in a final product brightness exceeding 90%. The size distribution resulting from this conventional processing would generally be such that 95% by weight of the particles are of less than 2 microns E.S.D.
Initially, a sample (A) was so diverted, and processed as to constitute a control. In particular, the said sample was flocced with H 2 SO 4 , then reductive bleached, and then filtered and washed. The filter cake was dispersed and the sample was then screened, and spray-dried.
A second portion of the above starting material was diluted to 11.0% solids using deionized water. The diluted slip was then treated with 0.01% of an anionic acrylamide polymer, viz. the Nalco 9UD120 polymer. The treated suspension was allowed to age 5 minutes per inch of slip. After aging, the sediment (Sample B) and supernatant (Sample C) phases were separated by siphoning off the supernatant phase.
The recovery of clay in the supernatant phase totaled approximately 54.5%. The sediment (Sample B) and the supernatant phase (Sample C) were then individually flocced with H 2 SO 4 to pH 3.0, bleached with 0.35% sodium hydrosulfite, filtered, washed and then spray dried. In Table I, hereinbelow, the results yielded for each of the three samples A, B, and C are set forth. More specifically, surface area, PSD, and viscosity data is tabularized for each of the said samples:
TABLE I__________________________________________________________________________ VISCOSITY* SURFACE PARTICLE SIZE DISTRIBUTION (PSD) Brookfield High Shear AREA (in microns) in cps in High Shear+SAMPLE in m.sup.2 /g -10 -5 -2 -1 -1/2 -1/4 at 20 rpm Dyne-cm × 10.sup.5 in cps__________________________________________________________________________A 19.43 100 100 95 86 74 53 380 18 @ 3380 rpm 101.7(control)B 19.11 100 100 90 73 56 35 540 18 @ 620 rpm 554.5(sediment)C 25.58 100 100 100 96 88 64 510 6.2 @ 4400 rpm 26.9(supernatant)__________________________________________________________________________ *Viscosity measurements are in accordance with TAPPI Method T648 su72 (revised1972). ##STR1##
To be noted in Table I is that a most substantial improvement in all significant coating characteristics has been achieved in the sample C, which has been processed in accordance with the invention. This in comparison to sample A, which sample already represents a very high quality product. Thus, the considerable improvement in particle size distribution (PSD) is evidenced by the much higher surface area achieved in sample C. The PSD shows that 96% by weight of the sample C particles are of less than 1 micron E.S.D., with 100% less than 2 microns, as compared to the 86% and 95% for control sample A. Also to be noted is the extremely fine particle sizes in sample C: 88% by weight are less than 1/2 micron E.S.D. and 64% by weight are of less than 1/4 micron E.S.D., as compared to 74% and 53% for the same properties in sample A.
But perhaps the most dramatic and startling improvement may be noted in the viscosity data. Here it is emphasized that it is the high shear viscosity which is of particular significance for present (coating) purposes. And in this instance, it is seen that the high shear viscosity in centipoise for sample C is of the order of 1/3 that of sample A. It should, incidentally, be pointed out that the increase in Brookfield viscosity, which sample C displays in comparison to sample A, is not considered of significance for present purposes.
Table I also illustrates that the separated sedimented phase (sample B) indeed possesses properties for coating purposes which are of comparatively less value than those of the control sample, and far inferior to those of sample C. Thus, it will be evident, in accordance with the invention, that a true selective separation of clay from clay has been effected, with the separated fractions having markedly different properties in regard to viscosity properties as same are measured by the critically important high shear viscosity test, and also different properties as respects the PSD and surface area.
The electron photomicrograph of FIG. 1, shows a portion of the supernatant phase recovered from a selective rheological separation conducted on samples processed in accordance with the procedure set forth in this Example. The photomicrograph (which incorporates a size scale) clearly depicts the substantial absence of aggregates in the supernatant phase, which is thus seen to be comprised essentially of individual clay platelets.
The electron photomicrograph of FIG. 2, shows a portion of the sedimented phase recovered from the said selective rheological separation. Again in this instance, the scale of the photomicrograph is set forth in the Figure. The very large body appearing at the right center of the photomicrograph, is a type "A" aggregate, consisting of neatly stacked individual platelets. Among other features to be noted is the occurrence of the small negative plates attached to the positive edges of this large aggregate.
FIG. 3 is a further electron photomicrograph which shows another portion of the sedimented phase recovered from the selective rheological separation. In this photomicrograph, a large type "B" aggregate is very clearly depicted. The skewed relationship of the individual platelets which comprise this aggregate may be clearly seen.
EXAMPLE II
In this Example the selective rheological separation method of the invention was practiced, again utilizing as starting material specimens diverted from a plant production stream normally utilized to produce a high quality fine particle size and highly brightened coating clay from a mixture of fine particle-size sedimentary soft Georgia kaolin crudes.
A first said specimen of the floated and refined slip, was processed exactly as was sample A in Example I, i.e. in this Example the resulting sample A served as a control in exactly the manner of sample A in Example I.
A second said specimen was diluted to 11.0% solids using deionized water. The diluted slip was then treated with 0.0075% of the aforementioned Nalco 9UD120 polymer. This was then allowed to stand unagitated for 1 hour. Afterwards, the supernatant phase and the sediment phase were separated by siphoning off the supernatant phase. The supernatant phase (Sample B) was flocced to 3.0 pH using H 2 SO 4 , then bleached with 0.35% sodium hydrosulfite, filtered, washed, dispersed and spray dried.
A portion of the sediment phase obtained from the above procedure (sample C), was treated as was sample B in Example I.
A further portion of the sediment from the selective rheological separation step of this Example was also treated with gaseous ozone, by bubbling the ozone as a fine dispersion through a well-agitated suspension of the sediment. Thus further sample (D) was then processed exactly as was the sediment in sample C.
In Table II hereinbelow, the results yielded for each of the five samples, A, B, C, and D are set forth. More specifically, there is tabularized surface area, PSD, and viscosity data for each of said samples:
TABLE II__________________________________________________________________________ PARTICLE SIZE DISTRIBUTION (PSD) VISCOSITY SURFACE (in microns) Brookfield High Shear AREA -10 -5 -2 -1 -1/2 -1/4 in cps in High ShearSAMPLE in m.sup.2 /g % at 20 rpm Dyne-cm × 10.sup.5 in cps__________________________________________________________________________A 22.63 100 96 87 76 66 47 450 18 @ 1880 rpm 182.8(Control)B 26.70 100 100 99 93 85 68 790 18 @ 3160 rpm 108.7(Supernatant)C 18.66 99 95 71 53 44 32 690 18 @ 280 rpm 1227.8(Sediment)D 18.17 100 96 71 52 41 30 580 18 @ 280 rpm 1227.8(Sediment& Ozone)__________________________________________________________________________ Notes:- All test procedures are as in Example I. Recovery of clay in the supernatant phase was 56.7%.
The data of Table II clearly supports the findings of Table I, and further illustrates the remarkable improvement in high-shear viscosity which is yielded by practice of the present invention.
The objective of the ozone treatment in preparing sample D was to destroy the organic polymeric flocculant in order to demonstrate that the relatively poor rheology of the sedimented phase is not due to residual effects of the polymeric flocculant. Comparison of sample C with sample D in Table II, will bear out that this is indeed the case; i.e. this further confirms that a true rheological separation is achieved by the process of the invention.
EXAMPLE III
The present Example illustrates that simple classification of particle size by sedimentation, in no way results in a product having viscosity characteristics similar to those yielded by the selective rheological separation technique of the present invention.
In this Example, a floated No. 2 clay fraction was diverted from the plant processing stream. A first said sample thereof (A) was processed as were the (A) samples in prior Examples.
A further sample (B) of the starting material was processed as was sample A, except that the product was refined to 90% less than 2 micron fraction by centrifuging prior to floccing, bleaching, filtration, washing, redispersion and spray-drying. Subsequently, the viscosity, PSD, and surface area were determined for the sample.
A further sample (C) of the starting material was processed as sample B, except the sample in this instance was cut by the centrifuge to 98% less than 2 microns.
A further portion of the original sample was diluted to 11.0% solids, then subjected to a selective rheological separation by treating with 0.0075% of the aforementioned Nalco 9UD120 polymer (0.25% weight/volume solution). The sample was then allowed to sit and age quiescently for 5 minutes per inch of slip. After aging, the supernatant phase was siphoned off into a separate container, leaving the sediment undisburbed.
A portion (sample D) of the supernatant phase was flocced to a 3.0 pH using a 10% weight-to-volume solution of sulfuric acid, then bleached using 0.35% by weight sodium hydrosulfite, then allowed to age for 30 minutes, filtered, and washed. The filtered cake was dispersed as with prior samples, then screened, diluted and spray-dried, after which the said characteristics for prior samples were determined.
A portion of the sediment phase sample (E), was flocced to a 3.0 pH using sulfuric acid and bleached, filtered and washed as with prior samples. Following filtration the filter cake was dispersed as with prior samples, screened, spray dried and the aforementioned viscosity, PSD, and surface area characteristics determined.
In Table III hereinbelow, the results yielded for each of the samples (A through E) of this Example are set forth:
TABLE III__________________________________________________________________________ PARTICLE SIZE DISTRIBUTION (PSD) VISCOSITY (in microns) Brookfield High Shear SURFACE AREA -10 -5 -2 -1 -1/2 -1/4 in cps in High ShearSAMPLE in m.sup.2 /g % at 20 rpm Dyne-cm × 10.sup.5 in cps__________________________________________________________________________A 18.83 98 94 81 71 57 36 210 18 @ 2380 rpm 144.4(Control)B 18.79 100 99 89 79 65 43 270 18 @ 2280 rpm 150.7(Centrifuged)C 22.61 100 φ 99 95 83 56 580 18 @ 2200 rpm 156.2(Centrifuged)D 24.29 100 100 99 96 86 64 500 9.2 @ 4400 rpm 39.9(Supernatant)E 12.31 95 83 57 42 29 17 250 18 @ 420 rpm 818.5(Sediment)__________________________________________________________________________ Notes:- All test procedures are as in Example I.
The data in Table III further illustrates that the remarkable improvement in viscosity characteristics yielded by the present invention, are in no way dependent solely upon the particle size distribution changes achieved by the invention.
EXAMPLE IV
In this Example, selective rheological separations in accordance with the invention were effected at substantially lower polymer concentrations than in prior examples.
An initial sample of plant floated fine No. 1 fraction clay slip was flocced with acid, filtered, washed, then dispersed and spray-dried. This material constituted a control sample (sample A).
A portion of the slip above described, was treated with 0.001% by weight of dry clay of the aforementioned Nalco polymer 9UD120. The treated material was allowed to separate, and the dispersed supernatant phase was recovered, flocced, bleached, filtered, washed, dispersed and dried as was the control sample A. The resulting material is identified as sample B.
A third sample (C) was prepared as described for sample B, except that the polymer dose was 0.002%.
A fourth sample (D) was prepared as were the previous samples, except that the polymer dose was 0.003%.
Table IV sets forth the resulting measurement data for the samples, where the measured parameters are as discussed in prior Examples. It will be particularly noted that the polymer dose is effective over the entire range utilized in these Examples:
TABLE IV__________________________________________________________________________ Particle Size Distribution Viscosity Recovery % < stated size (μ) Brookfield HerculesSample Brightness % 5 2 1 1/2 1/4 cps dynes @ rpm cps__________________________________________________________________________A 90.3 -- 99 94 87 73 44 430 18 @ 2820 122(Control)B 89.6 82 100 98 92 73 53 390 11.8 @ 4400 51(.001% polymer)C 89.7 74 100 98 92 79 58 410 11.3 @ 4400 49(.002% polymer)D 90.1 73 100 98 95 84 60 420 7.7 @ 4400 33(.003% polymer)__________________________________________________________________________
EXAMPLE V
Whereas many of the prior Examples herein utilize relatively fine particle sized input materials for treatment by the selective rheological process of the present invention, this Example considers treatment of somewhat coarser materials.
In particular, samples of a No. 2 grade plant floated slip, as described in the prior Example, were classified to (A) 83; (B) 93; and (C) 100% finer than 2 microns. These samples A, B, and C, were subsequently flocced, bleached, filtered, washed, dispersed and dried. In each instance brightnesses, particle size distribution and viscosities were determined, whereby to serve as controls.
Utilizing further portions of plant floated slip which had been classified to 83% less than 2 microns, further samples D, E, F, and G were prepared by treating such slip portions with the Nalco polymer 9UD120, then allowing the slip to separate, recovering the supernatant phase, then floccing, bleaching, filtering, washing, dispersing and drying--as in the controls. The polymer doseages were D--0.001%; E--0.003%; F--0.005%; and G--0.0075% Nalco 9UD120 by weight of the dry clay. The resulting data is set forth in Table V, from which it will be evident that the selective rheological separation of the invention is fully effective with the coarser slip. To be noted is that the high shear vicosity characteristics are substantially better for all of samples D, E, F, and G, as compared even to control sample C. Also to be observed is that the size distribution for the samples D through G indicates coarser materials than e.g., control sample C; but nonetheless highly significant improvements in viscosities are evidenced. This again demonstrates that the rheological improvements yielded by the invention are in no way a simple consequence of the size separation which is an incident of the present selective rheological separation process.
TABLE V__________________________________________________________________________ Particle Size Distribution Viscosity Recovery % < stated size (μ) Brookfield HerculesSample Brightness % 5 2 1 1/2 1/4 cps dynes @ rpm cps__________________________________________________________________________A 89.9 85 97 83 74 61 41 280 18 @ 1920 179(83% < 2μ)B 91.1 70 100 93 80 70 52 630 18 @ 1600 215(93% < 2μ)C 90.6 40 100 100 100 96 67 1060 18 @ 1400 246(100% < 2μ)D 90.4 72 100 90 80 67 46 480 18 @ 3000 115(.001% polymer)E 90.6 67 100 94 84 71 48 520 18 @ 3320 104(.003% polymer)F 90.7 65 100 96 87 73 47 620 18 @ 3300 104(.005% polymer)G 90.9 63 100 97 88 74 57 600 18 @ 3620 95(.0075% polymer)__________________________________________________________________________
EXAMPLE VI
In this Example, three different polymers were evaluated to determine the effects of the ionic charge and molecular weight upon the selective rheological separation process of the present invention. In particular, the steps of the process were carried out using a nonionic, a moderately anionic, and a very highly anionic polymer.
Pursuant to the above, a sample product was diverted from the plant processing stream, and was treated with three different polymers, viz. Nalco 7871, a nonionic polymer with average molecular weight of 8 million; with Nalco 8UD574, a 100% anionic polymer, further characterized as having an average molecular weight of 15 million; and with Nalco 9UD120, a 26% anionic polymer, which has been described in prior Examples.
Differing dosage levels of the three polymers were utilized in order to generate the curves of FIG. 4 herein, which shows the relationship between the specific polymer dose and the percentage of flocculation of the treated clay suspension.
Thus, in the first instance, a floated No. 2 clay fraction product was diluted to 11% solids, and 500 ml (58.9 g) of such product was treated with a 0.25% solution of the aforementioned 7871 polymer, utilizing dose rates of 0.0025%, 0.005%, 0.01%, 0.03%, 0.04%, 0.05%, 0.1%, 0.15%, 0.2% and 0.225%--all by weight of dry clay. The supernatant phase was siphoned off, then flocced, filtered and washed. The cake was dispersed for particle size distribution analysis, as described for the previous Examples.
A further such specimen was treated as described above, but with the Nalco 8UD574 polymer, also at various dosage rates.
A further sample was treated as above, but with the Nalco 9UD120 polymer.
In Tables VI(A), VI(B), and VI(C), data is tabulated for the three runs, i.e., using the different polymers:
TABLE VI(A)______________________________________Nonionic Polymer/Nalco 7871 PARTICLE SIZERECOVERY DISTRIBUTION (%)(% of clay (in microns)DOSE % treated) -5 -2 -1 -1/2 -1/4______________________________________.0 100 95 82 72 58 38.0025 86.7 -- -- -- -- --.005 87.2 98 91.0 82 68 42.01 78.6 -- -- -- -- --.03 63.9 -- -- -- -- --.04 60.0 -- -- -- -- --.05 51.8 -- -- -- -- --.10 20.7 100 96 84 70 36.15 16.6 -- -- -- -- --.20 6.9 -- -- -- -- --.225 3.6 100 98 96 90 44______________________________________
TABLE VI(B)______________________________________100% Anionic Polymer/Nalco 8UD574 PARTICLE SIZERECOVERY DISTRIBUTION (%)(% of clay (in microns)DOSE % treated) -5 -2 -1 -1/2 -1/4______________________________________.0 100 95 82 72 58 38.000625 58.0 -- -- -- -- --.00125 53.7 -- -- -- -- --.0025 44.9 100 99 98 88 60.005 36.1 -- -- -- -- --.01 23.9 100 99 98 92 65.02 22.1 -- -- -- -- --.04 21.8 100 100 99 95 66.05 21.5 -- -- -- -- --.10 17.5 100 100 99 98 80.11 10.9 -- -- -- -- --______________________________________
TABLE VI(C)______________________________________ 26% Anionic Polymer/Nalco 9UD120 PARTICLE SIZE RECOVERY DISTRIBUTION (%) (% of clay (in microns)DOSE % treated) -5 -2 -1 -1/2 -1/4______________________________________.0 100 95 82 72 58 38.000625 67.6 99 94 86 72 48.00125 59.1 -- -- -- -- --.0025 56.7 -- -- -- -- --.005 50.7 -- -- -- -- --.01 50.1 -- -- -- -- --.03 46.1 100 99 98 94 62.04 43.2 -- -- -- -- --.05 40.8 -- -- -- -- --.075 36.2 -- -- -- -- --.10 18.5 100 98 97 94 74.11 0.0 -- -- -- -- --______________________________________
In each instance the dosage, recovery, percentage flocculated of the solids, and the particle size distribution for the supernatant phase is set forth.
FIG. 4 plots the percentage by weight of dry clay flocculated against the polymer dose rate (on a semi-log scale) for the data tabulated in each of the aforementioned Tables, thus showing the effects on flocculation of each of the three polymers. From these plots it is readily seen that the nonionic polymer is nonselective, as the percent flocculation increases at a rate proportional to dose rate.
However, it is equally clear that the 26% anionic and 100% anionic polymers were selective--as is shown by the plots of dose rate versus flocculation. It is readily seen that with the 26% anionic polymer, a plateau was obtained, where further increase in dose resulted in very little additional flocculation. This plateau was particularly evident in the range of from about 0.006 to 0.03% by weight of the polymer. A relatively broad plateau and higher recovery are clearly advantageous under commercial processing conditions. Among other things, the broad plateau implies that doseage is not extremely critical over a fairly wide range.
EXAMPLE VII
In this Example, the effects of selective rheological separation pursuant to the invention were compared for two very different polymers, viz., the substantially nonionic Nalco polymer 7871 previously referenced in Example IV, and the 26% anionic Nalco polymer 9UD120. Each of these polymers are classified as flocculants.
Samples of a fine No. 1 clay fraction were diverted from the plant processing line as referenced in the earlier Examples. A first such sample (A), was flocced to 3.0 pH using sulfuric acid, then bleached with 0.35% by weight sodium hydrosulfite, filtered, and washed with deionized water. The resulting filter cake was dispersed and spray dried. Following spray drying, PSD, surface area, and viscosity characteristics were determined for the resultant product.
A further sample (B) of the original fraction was diluted to 11% solids. The diluted slip was then treated with 0.02% of the mentioned Nalco 7871 polymer, based on dry clay. The polymer was mixed into the sample by pouring the treated slip from one container to another several times. The treated slip was then allowed to stand unagitated for 5 minutes per inch of slip. After this, the supernatant phase was siphoned off into a separate container, flocced to 3.0 pH using sulfuric acid, and bleached with 0.35% sodium hydrosulfite and allowed to age for 30 minutes, then filtered and washed. The filter cake was dispersed, screened, diluted and spray-dried, all as in the instance of Sample A, and thereupon the same characteristics of PSD, surface area, and viscosity were determined.
The same procedure as was used for Sample B was used for a third sample (C); but in this instance, the treating polymer was the aforementioned anionic Nalco 9UD120 at a dose rate of 0.0075%.
In Table VII hereinbelow, the data obtained pursuant to the above procedures for the three samples, A, B, and C, is tabulated:
TABLE VII__________________________________________________________________________ PARTICLE SIZE DISTRIBUTION (PSD) VISCOSITY (in microns) BrookfieldSURFACE AREA -10 -5 -2 -1 -1/2 -1/4 in cps High shear High ShearPRODUCT in m.sup.2 /g % at 20 rpm in Dyne-cm × 10.sup.5 in cps__________________________________________________________________________A 22.2 100 100 96 88 78 57 340 18 @ 3780 rpm 90.9(control)B 22.54 100 100 96 89 77 52 370 18 @ 4200 rpm 81.8(non-ionic)C 24.93 100 100 99 98 92 69 380 5.8 @ 4400 rpm 25.2(anionic)__________________________________________________________________________ Notes:- Supernatant phase recovery for Sample B was 86.5%; for Sample C, 54.1% Test procedures are all as in prior Examples.
The data of Table VII establishes that the product B of treatment with the non-ionic polymeric flocculant, differs very little, if at all, from the control product A. Particle size distribution was substantially not affected, nor was rheology by treatment with the non-ionic polymeric flocculant. On the other hand, the anionic polymer yielded a selective separation treatment, resulting in the recovery (product C), of a product with extremely desirable rheological characteristics, i.e., with a very low high-shear viscosity; the very fine size characteristics are also deemed most desirable for coating purposes.
While the present invention has been particularly set forth in terms of specific embodiments thereof, it will be understood in view of the instant disclosure, that numerous variations upon the invention are now enabled to those skilled in the art, which variations yet reside within the scope of the present teaching. Accordingly, the invention is to be broadly construed, and limited only by the scope and spirit of the claims now appended hereto.
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A method is disclosed for beneficiating a kaolin clay pigment to improve the rheological properties of a high solids suspension subsequently formed therefrom. According to the method, a 10 to 20% solids aqueous suspension of a kaolin clay is subjected to a selective rheological separation, by mixing the suspension with from about 0.001% to 0.1% by weight of dry clay, of a high molecular weight anionic polymer, and allowing the thereby treated suspension to separate into a sedimented phase, and a supernatant phase which is substantially free of aggregates; and separating the supernatant phase containing the beneficiated kaolin pigment in suspension. The suspended product of the process can then be conventionally processed, as by reductive bleaching, floccing, filtering, washing, dispersing, and drying.
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PRIORITY INFORMATION
This application claims the benefit of U.S. Provisional Application No. 60/809,378, filed on May 30, 2006.
FIELD OF THE INVENTION
The field of the invention is well cleanup tools that allow a tubular top to be dressed, the mud conditioned or displaced in the liner, and above the liner through lateral ports, as well as setting a packer to test integrity of the cementing of the tubular.
BACKGROUND OF THE INVENTION
In well completions a liner is typically inserted in the drilled wellbore and cemented. Thereafter the integrity of the cementing needs to be tested and that is accomplished with a pressure test using a packer set above the liner top. To avoid damage to tools that may be later set in the liner, the top of the liner needs to have a relatively burr free internal surface. Typically, a mill is used to dress the liner top. It is advantageous to condition the mud above the liner and to do it with relatively high circulation rates. To accomplish that a tool with a lateral port has been used that can open, when needed to allow conditioning.
Typically, these ported tools involve a ported mandrel in a ported housing where the ports can be selectively put into alignment for flow and misalignment to close off flow. In the past the required relative movement to go between the open and closed positions has been accomplished with j-slot mechanisms that involve relative movement between a pin on one part and a slot on the other. Progress of the pin in the slot could be obtained by cycling pressure on and off that forced relative movement between a j-slot sleeve and a lug to advance the lug in a j-slot track or by mechanical movement of the pin or slot with the other held supported. For example a mandrel with a pin extending into a slot on a surrounding housing that is supported in the well could allow the mandrel to take several positions with respect to the surrounding housing. That relative movement could result in aligning or misaligning of ports. The limitations of such j-slot mechanisms are that the pin continues to progress in the slot if there is reciprocating movement of the tool for other purposes. In that case if aligned ports were needed to stay aligned during reciprocating tool movement for another purpose such as conditioning the mud through a lateral port while reciprocating the tool the length of tubulars that can be assembled on a rig floor, for example about 90 feet, the j-slot mechanisms would not assure that the aligned ports would not go to a misaligned position and thus nullify the mud conditioning effort that was in progress. Thus, one advantage of the present invention allows the lateral port to remain open for conditioning by having a barrier to the progress of the lug out of a desired slot in the j-slot while mud is conditioned above a liner top.
Tools in the past have included bearings so that when weight was set down on the bearing the mandrel could rotate with ports in the mandrel selectively aligned with ports in the housing, as long as weight was set down. This rotation of the mandrel feature allowed better agitation of the mud as different outlets around the circumference of the outer housing saw flow in turn as the mandrel rotated. The problem was that if the tool was moved longitudinally back and forth from the position it took to align the ports such as if the span of the conditioning zone was 90 feet, for example, the j-slot device would cycle and the ports may no longer stay aligned.
What was needed in a cleanup and test tool of this type is an ability to open the lateral ports and hold them open while the tool is cycled up and down for a long distance and then later be able to close them. Another desirable feature was to be able to later still open the ports and circulate and swivel before pulling the tool out of the hole. These and other features of the present tool and associated method of the present invention will be more readily apparent to those skilled in the art from a review of the detailed description and the associated drawings and the claims below that define the full scope of the invention.
SUMMARY OF THE INVENTION
A tool and associated method allows a liner top to be dressed. Then while maintaining a lateral port closed the tool can be used to circulate while being rotated and reciprocated. The tool features discrete j-slot mechanisms. The upper j-slot allows the lateral port to initially open while the lower j-slot keeps the lateral port open despite movement of the tool in opposed directions in the hole due to a barrier to the pin in the lower j-slot. When enough weight is set or the barrier is otherwise removed, the lateral port can be closed and the test packer set by set down weight with the lateral port closed. After the packer is unset the lateral ports can be reopened and circulation and swiveling on a bearing can occur even if the packer is temporarily actuated from the setting down motion that reopened the lateral ports.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 c show the tool in the run in position;
FIGS. 2 a - 2 c shows the tool with the lateral port open position where the tool can be swiveled, reciprocated and circulated with the lateral ports remaining open;
FIGS. 3 a - 3 c show the tool with the lower j-slot disabled and the tool in position to swivel on the bearing to displace mud from above the packer;
FIG. 4 is a section through the upper pin of the upper j-slot taken along lines 4 - 4 of FIG. 1 a;
FIG. 5 is a layout of the upper j-slot;
FIG. 6 is a layout of the lower j-slot;
FIG. 7 show a section of a snap ring alternative, in the run in position, to the lower j-slot shown in FIG. 6 ;
FIG. 8 is the view of FIG. 7 with the snap ring securing the ports open position and the mandrel picked up;
FIG. 9 is the view of FIG. 7 with the mandrel set down;
FIG. 10 is the view of FIG. 9 with weight set down moving the shear ring and allowing the snap ring to snap in further for a release between the mandrel and the outer assembly so the ports can close;
FIG. 11 shows an alternative to using the shear ring 114 pinned by pins 116 in a design that lets the lateral flow ports be held open more than a single time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 a - 1 c the tool has a multipart mandrel M made up of top sub 10 having a thread 12 to which the work string (not shown) is attached for manipulation of the mandrel M. Upper mandrel 14 is connected to top sub 10 at thread 16 that is sealed with seal 18 . Upper mandrel 14 has a bushing 15 that rides inside of upper sleeve 54 . Port sub 20 is connected to upper mandrel 14 at thread 22 that is sealed by seal 24 . Port sub 20 has one or more ports 26 around its circumference and ports seals 28 and 30 straddle ports 26 . Lower mandrel 32 is attached to port sub 20 at thread 34 that is sealed by seal 36 . Bottom sub 40 is secured to lower mandrel 32 at thread 38 that is sealed by seal 39 and retains one or more radially inwardly oriented lugs 42 that extend through the lower mandrel 32 . Referring back to FIG. 1 a and FIG. 4 , upper mandrel 14 has one or more radially outwardly oriented lugs 44 that are part of the upper j-slot assembly as will be later described. Lugs 42 are part of the lower j-slot assembly as will be later described. The various parts of the mandrel M have now been described. Next, the outer assembly O will be described in great detail.
The outer assembly O begins with a top sub 46 that has a bushing 48 that rides on upper mandrel 14 . Upper sleeve 54 is secured at thread 52 to top sub 46 . Upper j-slot sleeve 56 is secured at thread 58 to top sub 46 . FIG. 5 shows a rolled flat view of upper j-slot sleeve 56 with lug 44 in the several positions that it can take along track 60 . In the section view of FIG. 1 a the upper j-slot sleeve 56 is seen disposed on both sides of lug 44 . Upper sleeve 54 has a series of openings 62 , 64 , 66 and 68 that prevent liquid lock between the mandrel M and the outer assembly O. Seals 28 and 30 on the mandrel M engage surface 70 on upper sleeve 54 to keep port 26 closed for run in. Upper sleeve 54 also has a port 72 that is capped shut for run in by sleeve 74 retained by a shear pin 76 .
Lower sleeve 78 is connected to upper sleeve 54 at thread 80 and sealed at 82 . Lower sleeve 78 traps retainer 84 between itself and sleeve 54 . Retainer 84 supports part of a z-shaped shear ring 86 to sleeves 54 and 78 while a shoulder 88 on lower mandrel 32 rests on shear ring 86 for run in for reasons that will be explained below. Bottom sub 90 is secured to lower sleeve 78 at thread 92 and sealed by seal 94 . Opposed surfaces 96 on bottom sub 90 and 98 on lower sleeve 78 contain bearing assembly B that will be described below.
The lower j-slot sleeve 100 has a track 102 that is shown in rolled out form in FIG. 6 along with lug 42 that travels track 102 . Bearing retainer 104 is secured to lower j-slot sleeve 100 at thread 106 . Retainer 104 has a rib 108 with bearings 110 and 112 above and below rib 108 respectively. A shear ring 114 is pinned by pin 116 to lower j-slot sleeve 100 for purposes that will be explained when the operation is reviewed.
The major parts of the tool now having been described, the operation will be reviewed in greater detail. While not shown, those skilled in the art will appreciate that supported at thread 118 on bottom sub 90 is a string that extends into the liner that has been hung off a higher casing that has been cemented. That string supports the mill by extending through it and goes to close to the liner bottom. That string also supports a packer above the mill that is used to dress the liner top so that it later can accept a packer connected to a production string. The packer that is used with this tool is set in the casing above the liner for a test to determine if there is fluid loss into the formation when pressure is applied against the set packer.
In operation, the tool shown in FIGS. 1 a - 1 c is lowered into position and the mill (not shown) is used to dress the liner top. After that the tool with the pipe extending from thread 118 is rotated and reciprocated while fluid in the liner is conditioned. During this operation the outer assembly O may be put into a supported position off the liner top but care is taken to avoid loading the mandrel M to the point that shoulder 88 shears the z-shaped shear ring 86 . With ring 86 intact, the mandrel M cannot move with respect to the outer assembly O. The next step is to condition the mud above the liner top. For this operation, the outer assembly O is lowered to a supported position off the liner top and weight is set down on the mandrel M to the point that shoulder 88 breaks the shear ring 86 . The downward movement to break the shear ring 86 has lug 44 moving from position 120 to position 122 in track 60 . There the weight of the string above the tool is on lugs 44 as position 122 traps lugs 44 in upper j-slot sleeve 56 . At the same time lug 42 simply moves down in track 124 but not quite to the point shown in FIG. 6 .
Next the mandrel M is picked up and rotated right while being let down. This movement takes lug 44 along the slanted path shown at the top of FIG. 5 and out of upper j-slot sleeve 56 to let the mandrel M descend further since lugs 44 are free from being trapped in position 122 . The mandrel can then descend until its bottom sub 40 engages the shear ring 114 but does not break the shear pins 116 that retain it to lower j-slot sleeve 100 . While this movement is going on, the lugs 42 continue their descent in track 124 shown in FIG. 5 . The turning of the mandrel M to get lugs 44 out of upper j-slot sleeve 56 simply has the effect of rotation of lower j-slot sleeve 100 by lugs 42 as they travel down track 124 . At the time when bottom sub 40 of mandrel M hits the shear ring 114 , the lugs 42 have just reached ramp 128 at the bottom of track 124 , as shown in FIG. 6 . There is still enough mandrel movement left at that point before engaging the shear ring 114 so as to allow lugs 42 to go down ramp 128 into track 126 that is a very short track parallel to track 124 . Those skilled in the art will appreciate that the movement of the mandrel M to the just described position aligns ports 72 and 26 so that high flow circulation can take place through those aligned ports while the tool is reciprocated and rotated. There is no rotation of the outer assembly O because bearings 110 and 112 allow for such relative rotation. With the shear ring 114 in place lugs 42 can't escape track 126 and despite the relative longitudinal motion allowed by lugs 42 moving from one end to the other of track 126 , the ports 26 and 72 maintain sufficient longitudinal alignment for high flow rate circulation despite tool reciprocation and rotation of mandrel M. This position of the tool is shown in FIGS. 2 a - 2 c . In this position the mud above the liner top can be conditioned as the tool is used for circulation while it is picked up and set down with the mandrel M rotating. Again there is the assurance of aligned ports 72 and 26 to permit circulation despite the up and down movements or mandrel M rotation.
Those skilled in the art will appreciate that the present invention encompasses other ways to retain the tool in the desired position during this step than using a j-slot with a feature to temporarily trap a lug in a j-slot. In fact, the use of a temporary block of a lug in a j-slot is not limited to circulation tools discussed above but rather has broad applications to other downhole tools. Additional features can be added to the above described tool to protect the shear pins 116 from breaking early. For example, another sleeve with a ball seat can be placed in a supporting position to the ring 114 so that pins 116 can't shear until a ball lands on a seat of a supporting sleeve to move it away from supporting ring 114 so that impact can then break pins 116 in the manner that will be described below. Yet other types of temporary retaining devices can be used instead of the ring 114 interfering with movement of lug 42 in j-slot sleeve 100 as will be described below. The procedure being described herein can be modified to even eliminate the lower j-slot sleeve 100 and the associated lug 42 , if desired.
When the conditioning of the mud above the liner top is concluded, weight is set down on mandrel M to break shear pins 116 and doing so lets the shear ring 114 drop down onto the bearing 110 , as shown in FIG. 3 c . Because the ring 114 is displaced, the lug 42 can exit short track 126 as shown in the bottom of FIG. 6 . At that point a pickup force on mandrel M will bring lug 42 up the next track 124 ′. As that is happening, lug 44 will enter track 60 guided by tapered surfaces 130 and 132 , as shown in FIG. 5 . Lug 42 will first hit the upper position 120 and after weight is set down on mandrel M will settle into position 122 . At this point the ports 26 and 72 will be misaligned and isolated as the tool assumes the run in position of FIG. 1 , with the main difference being that shear pins 116 and shear ring 86 are now both broken.
However, before setting down weight to get lug 44 in position 122 displacing fluid can be pumped through the tool into the liner to displace the mud out of it and position the displaced mud at a location above where the packer (not shown) will be set to test the cement integrity of the liner. When the displacing is done then the mandrel is lowered without rotation to set the packer. Here lug 44 will be in position 122 . After the test with the packer is completed, the packer is unset by picking up on mandrel M which engages surface 134 of upper mandrel 14 to top sub 46 of the outer assembly O pulling up the outer assembly O and stretching out the packer to release it. This engagement can be seen in the run in position in FIG. 1 a . The liner can then be circulated through the string extending through it that is supported at threads 118 . The mandrel M can then be set down while being rotated right to allow lug 44 to exit track 60 . At this point the tool will be in the position of FIGS. 3 a - 3 c . The ports 72 and 26 will be aligned and the mandrel M will rest on ring 114 which in turn will rest on bearing 110 . At this point the mud that was earlier conditioned above the packer can be displaced from the hole while the mandrel M is rotated on bearing 110 without being picked up since at this point picking up will misalign ports 72 and 26 . The tool can then be pulled out of the hole.
Those skilled in the art can appreciate that the tool can save the operator rig time in that the mud conditioning can be done above the liner top in a shorter period of time if the drill string is rotated and reciprocated up and down during circulation while still retaining the flexibility to close the ports for mud displacement from the liner and open them again for displacement of mud from above the packer after the cement integrity test.
Referring now to FIGS. 7-10 there is illustrated an alternative embodiment to the use of the lower j-slot sleeve 100 . In this embodiment the bottom sub 40 of mandrel M has a recess 136 that carries a snap ring or equivalent device that stores energy 138 . In the run in position that this Figure illustrates, the snap ring 138 is prevented from collapse by sleeve 100 ′ that this time has a single straight slot (not shown) that lug 42 rides in. When lug 44 is brought out of upper j-slot sleeve 56 as previously described, the bottom sub 40 of mandrel M brings down lug 42 and snap ring 138 until the snap ring 138 lines up and snaps into groove 140 that is defined by shoulder 142 and the lower end of sleeve 100 ′. This position is illustrated in FIG. 8 . In this position, the mandrel M including the lug 42 is prevented from moving up the not shown groove in sleeve 100 ′ by shoulder 142 . The mandrel M is prevented from moving down by the presence of shear ring 114 held by shear pins 116 . In FIG. 8 the mandrel M is pulled up showing a gap between bottom sub 40 and ring 114 . In FIG. 9 weight is set down on the mandrel M closing that gap with the pins 116 still intact. After the conditioning step above the liner top is concluded involving circulation, picking the mandrel M up and setting it down while rotating it, the mandrel M is set down hard enough to break shear pins 116 to allow ring 114 to move down as shown in FIG. 10 . In this position, snap ring 138 is clear of surface 146 on the mandrel M since it is in lower groove 144 in sleeve 100 ′.
Referring now to FIG. 11 there is shown a structure that can replace the ring 114 and associated pins 116 . With the ring and pins design, the lug 42 can be trapped in track 126 to hold the ports 26 and 72 aligned while the mandrel M is picked up or set down and rotated. It isn't until the pins 116 are broken that lug 42 can exit track 126 to allow the mandrel to come up to the point where the ports 26 and 72 are no longer in flow communication. In that version, once the pins 116 are broken, the alignment of ports 26 and 72 can no longer be secured. Thus only weight being set down on mandrel M after pins 116 are broken will keep those ports aligned. The FIG. 11 design operates to keep the lug 42 in track 126 by landing bottom sub 40 of mandrel M on ring 148 that is biased by a stack of Belleville washers or an equivalent bias force 150 . The operation to retain the lug 42 in track 126 is the same as using the ring 114 . As long as the contact force on ring 148 is not excessive, it will not move and lug 42 will not be able to exit from track 126 . However, if enough downward force on mandrel M is applied, the ring 148 is displaced as washers 150 are compressed and the lug 42 can move out of short track 126 . The difference is that the washers 150 force the ring 148 back to its original position against shoulder 152 to allow the trapping of lug 42 in track 126 a multiple number of times rather than just once as the design using ring 114 with pins 116 would allow.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below.
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A tool and associated method allows a liner top to be dressed. Then while maintaining a lateral port closed the tool can be used to circulate while being rotated and reciprocated. The tool features discrete j-slot mechanisms. The upper j-slot allows the lateral port to initially open while the lower j-slot keeps the lateral port open despite movement of the tool in opposed directions in the hole due to a barrier to the pin in the lower j-slot. When enough weight is set or the barrier is otherwise removed, the lateral port can be closed and the test packer set by set down weight with the lateral port closed. After the packer is unset the lateral ports can be reopened and circulation and swiveling on a bearing can occur even if the packer is temporarily actuated from the setting down motion that reopened the lateral ports.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of co-pending application Ser. No. 07/968,182, filed Oct. 29, 1992, to be issued on Aug. 10, 1993, under U.S. Pat. No. 5,234,525, said application Ser. No. 07/968,182 being a continuation of application Ser. No. 07/914,871, filed Jul. 16, 1992, said application Ser. No. 07/914,871 having issued on May 4, 1993, under U.S. Pat. No. 5,208,313.
FIELD OF THE INVENTION
The present invention relates generally to waterproof breathable polyurethane membranes, to a coating method and system for producing same on porous substrates and to waterproof breathable porous substrates, particularly fabrics, comprising such membranes.
BACKGROUND OF THE INVENTION
A well known waterproof breathable textile laminate of commerce, sold under the brandname, GORE-TEX, is technically based upon the use of a membrane of hydrophobic, microporous, expanded polytetrafluoroethylene (hereinafter "PTFE") as an essential functional component thereof. For most purposes, the microporous PTFE membrane of the laminate is sandwiched between inner and outer fabric layers, the membrane generally, although not necessarily, being continuously bonded and/or adhered to one or both fabric layers. Such hydrophobic microporous PTFE membranes and the preparation thereof are described in U.S. Pat. Nos. 3,953,566, Robert W. Gore, issued Apr. 27, 1976 and 4,187,390, Robert W. Gore, issued Feb. 8, 1980. The preparative method broadly comprises the uniaxial or biaxial stretching of an unsintered highly crystalline PTFE sheet, prepared by paste extrusion, at a rate exceeding 10% per second while maintaining the temperature thereof at between about 35° C. and the crystalline melt point of the polymer. The resulting membranous PTFE product of this process has a microstructure characterized by nodes interconnected by fibrils and is possessed of an interesting and useful combination of properties which befits it for use in the preparation of waterproof breathable textile systems. More specifically, the hydrophobic, microporous, expanded PTFE membranes of the above Gore patents are sufficiently hydrophobic and the micropores small enough such that the membrane can function as a barrier to the passage of bulk water therethrough at significant hydrostatic pressures. On the other hand, due to the microporous character thereof, said membranes also possess the capacity to allow diffusion of water vapor therethrough. Thus, these desirable properties of waterproofness and water vapor transmissibility or "breathability" are imparted to textile laminates in which such a membrane comprises a component layer.
Despite its relative success in the marketplace, the waterproof breathable textile laminate systems based on the hydrophobic microporous expanded PTFE membrane of the above-identified Gore patents are, nevertheless, possessed of certain deficiencies. Firstly, such expanded PTFE membranes are relatively expensive. Secondly, because waterproof breathable textile laminates utilizing such microporous expanded PTFE membranes are necessarily constructed by some form of physical lamination of the previously prepared PTFE membrane to at least one previously prepared fabric layer, equipment and operative techniques must be provided to handle the membrane and the fabric, to properly index them and to secure the PTFE membrane layer to the fabric layer. Thus, the techniques used to prepare such laminates are generally substantially more complex, arduous and expensive as compared to conventional liquid coating and curing techniques known in the fabric coating art. Thirdly, PTFE materials are generally known to be of adhesion resistance character. Therefore, where it is desired to prepare a waterproof breathable textile laminate by means of a continuous bonding of the PTFE membrane layer to a fabric layer, such as by interposition of a continuous adhesive layer between the microporous expanded PTFE membrane layer and the fabric layer, the resulting bond strength, albeit usually adequate, is generally relatively low and the selection of a suitable adhesive which can accomplish the necessary bonding without substantial adverse affect upon the breathability of the system can be a problem. Another problem associated with the use of the microporous expanded PTFE membranes in textile laminate systems resides in the finding that such membranes, over a period of use, can crack sufficiently as to provide sites for bulk water leakage or seepage therethrough. Apparently, the many micropores necessarily embodied in the polymer matrix can act as crack propogation loci and this, coupled with the crystalline nature of the polymer, result in a membrane whose flexure life is somewhat limited. Finally, the expanded microporous membranes of the above-identified Gore patent are apparently susceptible to significant loss of their waterproof characteristics when contacted with such surface active agents as are inherently contained in human perspiration. Obviously, this can be a serious detriment where textile laminates employing these membranes are employed as garment materials. This problem, as well as a solution therefor, is disclosed in U.S. Pat. No. 4,194,041, Gore et al., issued Mar. 18, 1980. The solution therein disclosed resides in the interposition of a continuous, hydrophilic, water vapor transmissible layer between the microporous hydrophobic membrane surface and the surfactant source. Thus, with respect to garments fabricated with a waterproof breathable textile laminate prepared in accordance with the aforementioned Gore et al. patent, the microporous hydrophobic membrane layer faces the exterior of the garment while the continuous hydrophilic layer faces the interior of the garment. In this role, the continuous hydrophilic layer functions as a barrier to the surfactant contaminants in human perspiration and prevents contact thereof with the hydrophobic microporous PTFE membrane, thereby to preserve the waterproof character of the membrane. As disclosed, the continuous hydrophilic layer of the construction can be in the nature of a hydrophilic polyurethane based on a reactive crosslinkable prepolymer having an isocyanate terminated branched polyoxyethylene backbone. Attachment of the continuous hydrophilic layer to the microporous hydrophobic membrane can be discontinuous, such as in the nature of sewing or adhering together of the edges of the respective layers by thread or adhesive. The use of a continuous adhesive bond between the hydrophobic and hydrophilic layers is apparently believed by the patentees to be potentially detrimental to the water vapor transmission properties of the laminate and so is not discussed or disclosed. Where continuous bonding of the respective layers of the laminate is desired, patentees disclose a technique whereby direct bonding of the one layer to the other is achieved. Said technique involves the casting of the hydrophilic layer directly onto the surface of the microporous hydrophobic membrane layer with application of sufficient hydraulic pressure as to force the hydrophilic layer into the surface voids of the hydrophobic layer. Thus, while the Gore et al. patent may provide a second generation solution for the surfactant contamination problem disclosed to exist with respect to garment applications involving the first generation hydrophobic microporous expanded PTFE membranes disclosed in U.S. Pat. Nos. 3,953,566 and 4,187,390, it is obvious that the solution is achieved at the expense of added complexity and, of course, cost.
In U.S. Pat. No. 4,532,316, Robert L. Henn, issued Jul. 30, 1985, there is generally disclosed a phase separateed polyurethane prepolymer having hard and soft segments and elastomers prepared therewith. The prepolymer comprises the product of reaction of (a) a polyol having a number average molecular weight of between 600 and 3500, (b) a polyisocyanate having a functionality of at least 2, and (c) a chain extender having a molecular weight of no greater than 500, these components of the prepolymer being present within a specified range of proportions. It is further disclosed that, where the polyol component employed is poly(oxyethylene) glycol, the prepolymer can be formed into cured films having superior moisture vapor transmission properties and that such prepolymer can thus be formed as a composite with various textiles for use in rain protective garments. Example 10 of the patent discloses the preparation of breathable coated textiles by melt coating of a fabric with poly(oxyethylene) glycol based prepolymers prepared in accordance with the invention followed by moisture curing of the coating. Said breathable coated textiles were found to be durably waterproof under scoring and flexing tests and were stated by patentee as being suitable for use in rain protective wear. In Example 11, a hydrophilic phase separated non-porous film of hydrophilic polyurethane was directly bonded to an expanded PTFE membrane in the manner of the aforementioned U.S. Pat. No. 4,194,041. A poly(oxyethylene) glycol based prepolymer different from those employed in Example 10 was utilized and roll coated onto the PTFE membrane under pressure, followed by ambient moisture curing of the coating. The resulting PTFE/polyurethane composite was discontinuously adhered to a textile fabric to form a breathable textile laminate, the PTFE layer being being sandwiched between the fabric and polyurethane layers. The patentee discloses this textile construction as being suitable for the fabrication of excellent rain protective wear therefrom. From the disclosure it is suggested that Henn regards the attainment of acceptable moisture vapor transmissions rate for clothing purposes as being absolutely dependent upon the use of a poly(oxyethylene) glycol based prepolymer and, to a lesser extent, upon the extent of phase separation attained between the hard and soft segments of the cured polymer.
In accordance with the present invention there is provided a waterproof breathable polyurethane membrane whose waterproofness and breathability properties are not dependent upon the presence of microporosity and in which at least several of the problems related to the known microporous membranes of the prior art have been solved or substantially ameliorated. In another aspect of the invention, the polyurethane membranes hereof are disposed over porous substrates, particularly as coatings applied to fabrics, thereby to confer waterproofness and breathability to such substrates,
OBJECTS OF THE INVENTION
It is a principal object of the invention to provide a novel polyurethane composition which, in non-porous membranous form, is waterproof and water vapor transmissible.
It is another object of the invention to provide a novel non-porous polyurethane membrane which is waterproof and water vapor transmissible.
It is another object of the invention to provide the novel non-porous, waterproof and water vapor transmissible polyurethane membrane hereof in the form of an adherent coating.
It is another object of the invention to provide porous material substrates to which waterproof and water vapor transmissive properties have been conferred by disposition of the polyurethane membrane of the invention thereover.
It is still another object of the invention to provide a novel waterproof and water vapor transmissible coated fabric.
It is another object of the invention to provide a novel waterproof and water vapor transmissible textile laminate construction.
It is yet another object of the invention to provide a novel solvent based polyurethane coating system whereby porous material substrates, such as fabrics, may be rendered waterproof and water vapor transmissible by conventional coating techniques.
Other objects and advantages of the present invention will in part be obvious and will in part appear hereinafter.
SUMMARY OF THE INVENTION
The polyurethane membrane of the invention is a cured polyurethane film arising as a reaction product of: (a) an organic polyisocyanate, (b) a polyalkylene ether glycol wherein the number of carbon atoms of the alkylene radical is 2, in other words a poly(oxyethylene) glycol, (c) at least one polyalkylene ether glycol wherein the number of carbon atoms defining the alkylene radical is at least 3, and (d) a reactive hydroxy group-containing polydimethylsiloxane having a functionality of at least 2. The mole ratio of the polyalkylene ether glycol of (a) to the polyalkylene ether glycol of (b) can be within the range of 1.5:0.5 to 0.5:1.5. The mole ratio of the reactive polydimethylsiloxane of (d) to the total glycols of (b) and (c) can be within the ranges of 0.1:1 to about 0.3:1. The polyurethane composition can be prepared utilizing the well known prepolymer or one-shot routes although, in applicant's belief the prepolymer route is more versatile and is, therefore, preferred. Utilizing the prepolymer route, a single NCO-terminated prepolymer can be prepared bearing the compositional requirements set forth above and then chain extended to provide a curable composition suitable for preparation of the cured membrane of the invention. Alternatively, two NCO- terminated prepolymers can be separately prepared, each prepolymer chain extended and the chain extended prepolymers blended in the appropriate amounts prior to or during formation of the membrane and prior to curing thereof. Using this scheme the first prepolymer is formed from the polyethylene glycol and reactive hydroxyl group-containing polydimethylsiloxane to form an isocyanate terminated random block urethane copolymer of polyethylene oxide and polydimethylsiloxane. The second prepolymer is performed from the polyoxyalkylene glycol(s) of (c). Each of these prepolymers is chain extended in the conventional manner, utilizing low molecular weight chain extenders having terminal labile hydrogen atoms. These chain extended prepolymers may then be suitably blended in the amounts required to bring the blended composition within the foregoing combination of compositional parameters prior to or during formation of the membrane and at any time prior to curing thereof. A particularly flexible system for accomplishing the blending of the chain extended prepolymers resides in preparing separate solutions thereof in inert fugitive solvents, coating the surface of a porous substrate desired to be rendered waterproof with the first (block copolymer) extended prepolymer solution and driving off the solvent therefrom, overcoating the dried, uncured first coating with the second extended prepolymer solution, thereby to cause diffusion of at least a portion of said second prepolymer solution into the dried uncured first coating, driving off the solvent, and curing the resulting membranous coating.
The cured non-porous polyurethane membranes of the invention may be prepared separate and apart from the porous substrate over which they may ultimately be disposed, such as by forming of the uncured membrane on a release surface followed by curing thereof. Moreover, the membranes of the invention can be disposed over a porous substrate to render same waterproof and water vapor transmissive in any suitable manner, such as by discontinuously securing the membrane to the substrate surface using mechanical securing elements. However, it is much preferred that the membrane be continuously bonded to the substrate surface, and this can generally be achieved by a direct solution coating technique such as outlined above and/or by adhering the membrane to the substrate surface by means of a compatible continuous water vapor transmissible adhesive interposed between the substrate surface and the membrane of the invention.
Many porous articles, such as woven and non-woven fabrics, natural and poromeric artificial leathers, papers and ceramics can be rendered waterproof and water vapor transmissible by disposition of the membranes of the invention thereover. The direct solution coating and continuous adhesive techniques mentioned above are particularly amenable to the preparation of waterproof and water vapor transmissible fabrics and fabric laminates utilizing the membranes of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Utilizing the preferred prepolymer route for preparing the polyurethane membranes of the invention, the prepolymers are produced in accordance with conventional methodology whereby the polyols and reactive polydimethylsiloxane are reacted with a stoichiometric excess of the polyisocyanate and the resulting isocyanate terminated prepolymer is then reacted with a relatively low molecular weight difunctional chain extender.
Polyalkylene ether glycols generally suitable for preparation of the prepolymers of the invention are those known in the polyurethane preparative art. The polyalkylene ether glycols of interest are generally those prepared from ethylene oxide (polyoxyethylene glycol), propylene oxide (polyoxypropylene glycol), butylene oxide (polyoxybutylene glycol), copolymers and mixtures thereof and preferably have average molecular weights of between about 450 and 2000 since such glycols are either liquids at room temperature or may be readily liguified by mild heating thereof. I generally prefer that the starting material polyalkylene ether glycols employed by difunctional, that is to say having a functionality of 2. Where a prepolymer of the invention is prepared from polyalkylene ether glycols have functionalities of substantially greater than 2, for instance 2.2 or greater, the resulting polyurethane prepolymers tend to be excessively branched, thereby to exhibit viscosities which are excessive for further polymer preparation and handling.
It is known that non-porous hydrophilic breathable polyurethane coatings and membranes can be produced utilizing polyoxyethylene glycols as the primary polyol. However, hydrophilic polyurethanes whose backbones are composed entirely or nearly entirely of ethylene oxide units tend to swell greatly upon contact with water and the wet physical properties of such polyurethanes are generally wholly inadequate for practical use as membranous breathable waterproofing materials. In the present invention, the polyalkylene ether glycol(s) used in combination with the poly(oxyethylene) glycol, that is to say, those polyalkylene ether glycols wherein the number of carbon atoms of the alkylene radical is at least 3, serve to confer sufficient wet strength properties to the cured polyurethane composition as to permit the practical use thereof in the form of a breathable waterproofing membrane. In order to assure this result, the molar ratio of the poly(oxyethylene) glycol to the other polyalkylene ether glycols in the compositions of the present invention should be within the range of 1.5:0.5 to 0.5:1.5 and is preferably about 1:1. In general, it can be said that, all other factors being equal, the higher the molar ratio of the poly(oxyethylene) glycol component to the other polyalkylene ether glycol(s) in the composition, the greater the water vapor transmission properties and the lower the wet physical properties in a cured membrane prepared therewith. Conversely, the lower the molar ratio of the poly(oxyethylene) glycol component to the other polyalkylene ether glycols in the composition, the lesser the water vapor transmission properties and the higher the wet physical properties in a cured membrane prepared therewith. Indeed, based on the relatively high concentration of the polyalkylene ether glycol component whose alkylene groups comprise at least 3 carbon atoms in the compositions of the invention, it would be predicted that the water vapor transmission rates attainable in cured membranes prepared therewith would be too low for practical utility, particularly in such textile applications as rainwear fabrics where a moisture (or water) vapor transmission rate as determined by the Upright Cup Test Method of ASTM-E96-B 66B, hereinafter referred to as "MVTR", of at least 500 gms/m 2 /24 hours is considered necessary for maintaining the comfort of a wearer of a garment manufactured from the fabric. In the membrane compositions of the invention the attainment of MVTR values of at least 500 gms/m 2 /24 hours and substantially higher in the cured membrane is markedly facilitated, despite the relatively high concentration of the C 3 and higher polyalkylene ether glycol component, by the additional presence of a relatively minor proportion of a reactive polydimethylsiloxane component which apparently forms a hydrophobic, water vapor transmissive block in the polymer backbone of the cured composition.
The reactive polydimethylsiloxane starting materials of interest are those which comprise a linear or lightly branched polydimethylsiloxane backbone and which further comprise at least two reactive, usually terminal, hydroxyl groups per molecule, that is to say, a functionality of at least 2. Such reactive polydimethylsiloxanes are commercially available in various average molecular weight fractions from such sources as Dow Chemical Company, Midland, Michi. and General Electric Company, Silicones Division, Schenectady, N.Y. In general, I prefer that the average molecular weight of the reactive polydimethylsiloxane utilized as a starting material in the preparation of the polyurethane compositions of the invention reside within the range of from 800 to 3500. As previously mentioned, the mole ratio of the reactive polydimethylsiloxane to the total polyalkylene ether glycol content of the final composition should be within the range of 0.1:1 to 0.3:1. Generally speaking, all other factors being equal, the higher the mole ratio of the reactive polydimethylsiloxane within the foregoing range the greater will be the MVTR values attainable in the cured polyurethane membranes prepared therewith.
Polyisocyanates useful in the preparation of the polyurethane compositions of the invention generally include any of the diisocyanates conventionally employed in the preparation of polyurethanes. Exemplary of these are: toluene diisocyanate, diphenylmethane diisocyanate, napththalene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, dimethoxydiphenyl diisocyanate, p-xylene diisocyanate, hexamethylene diisocyanate, tetramethylxylene diisocyanate and the like. Where the preferred prepolymer route is employed, and as is known practice in the preparation of polyurethane prepolymers, the quantity of the polyisocyanate employed in preparing the prepolymer is in stoichiometric excess relative to the reactive hydroxyl group population of the polyalkylene ether glycol and reactive polydimethylsiloxane components, thereby to ensure that the resulting prepolymer macromolecular product will be terminated with reactive -NCO groups. Thus, the quantity of the polyisocyanate employed in the preparation of the prepolymers of the invention will be sufficient to provide at least 100% of the -NCO groups necessary to react with the hydroxyl groups of the polyalkylene ether glycols and reactive polydimethylsiloxane components of the prepolymer reaction mixture. As a matter of convenience, the amount of polyisocyanate introduced to the polyalkylene ether glycol and polydimethylsiloxane components can be sufficiently in excess to handle the needs of the subsequent chain extension of the prepolymer wherein a relatively low molecular weight bifunctional chain extender is incorporated in and reacted with the NCO- terminated prepolymer.
Suitable chain extenders are well known in the polyurethane preparative art and generally comprise organic molecules having a molecular weights of between 200 and 600 and having two terminal groups comprising labile hydrogen atoms, such as hydroxyl or amino groups. Glycols, diamines, alkanolamines and hydroxy acylamines are typical classes of such chain extenders. Specific examples are: 1,4-butanediol, phenylene diamine, ethanolamine, ethylene diamine, butane diamine, 1,4-cyclohexane dimethanol, bis(hydroxyethyl)bisphenol A, bis(2-hydroxyethyl)carbamate and the like.
In addition to the foregoing components, the polyurethane compositions of the invention may also have incorporated therein various additives and modifiers conventional in the polyurethane formulation art. Such additives and modifiers may take the form of curatives, pigments, colorants, antiblocking agents, antioxidants, catalysts, flatting agents, anticurling agents and the like. Where the prepolymer route is employed such additives and modifiers other than catalysts are usually incorporated into the polymer system only after chain extension of the prepolymer has been achieved.
The viscosity of the prepolymers of the invention and of the chain extended products thereof can range from that of a water thin liquid to the consistency of a thick, slow pouring grease or semi-solid. Generally speaking, in those instances wherein the prepolymer or chain extended polymer viscosity is likely to become excessive for subsequent operations, such as for chain extension of the prepolymer or for utilization of the chain extended polymer product in conventional textile coating techniques, such as by spraying, doctor blading, roll coating and the like, the viscosity of the prepolymer or the chain extended polymer can be readily reduced to an acceptable level by dissolution of the prepolymer or polymer in one or more suitable solvents. Indeed, as is demonstrated in certain of the working examples hereof, the viscosities of the prepolymer and chain extended polymer systems can be controlled by addition of suitable inert organic solvents to the prepolymer subsequent to its formation and by carrying out the prepolymer chain extension polymerization step in the presence of suitable inert organic solvents.
Where the membranes of the invention are to be applied to a fabric surface utilizing a solvent coating technique without lamination of the coated fabric to another fabric, it can be desirable to afford physical protection of the exposed surface of the solvent coated waterproof and water vapor transmissible polyurethane membrane by overcoating the exposed surface thereof with a protective water vapor transmissible polyurethane topcoat composition. Said topcoat composition may also be applied by a solvent coating technique to the dried, but uncured, membrane, the solvent driven off from the topcoat and the resulting composite coating cured. Where a first fabric layer is to be laminated to a second fabric layer with the cured waterproof and water vapor transmissible membrane of the invention interposed therebetween, the first of the fabric layers can be first directly coated with a precursor membrane solution comprising a chain extended polyurethane prepolymer prepared from the poly(oxyethylene) glycol and reactive polydimethylsiloxane components and the solvent driven off from this as yet compositionally incomplete coating. Then, a coating solution containing a water vapor transmissible chain extended polyurethane adhesive solute which also contains the polyalkylene ether glycol component required to complete the membrane coating is overcoated onto the precursor membrane coating and the solvent driven off therefrom. Next, the second fabric layer is brought into contact with the coated adhesive of the first fabric layer under sufficient pressure as to establish the fabric laminate structure and to cause sufficient intermingling the adhesive coating into the precursor membrane coating so as to establish in the membrane coating the compositional requirements of the invention.
There follow a number of illustrative non-limiting examples.
EXAMPLE 1
Preparation of Basecoat Formulation Urethane Chain Extended Prepolymer
The following ingredients are employed, in the stated weight percentages.
______________________________________Ingredient Weight Percent______________________________________Isophorone diisocyanate (IPDI) 15.786CARBOWAX 1450, a poly(oxyethylene) glycol 46.690having an average molecular weight of 1450and a functionality of 2 (Union CarbideCorp., Danbury, CT)Silicon Q4-3667, a polydimethylsiloxane 7.762having functional hydroxyl groups, and afunctionality of about 2 (Dow ChemicalCompany, Midland, MI)COSCAT 83, a catalyst (Cosan Chemcal 0.024Company, Carlstadt, NJ)Toluol 29.738______________________________________
The apparatus employed to prepare the prepolymer is an assiduously predried reaction kettle equipped with heating and stirring means. At about room temperature the IPDI is first charged into the kettle and, with constant stirring, there are then slowly added at proportionate rates the poly(oxyethylene) glycol and polydimethylsiloxane. Since the poly(oxyethylene) glycol employed is a solid at room temperature it is heated to melting and charged into the kettle in the liquid state. The relative quantities of these ingredients provides a reaction mixture having a stochiometric excess of IPDI, the NCO:OH ratio thereof being about 2:1. Upon completion of the addition of the poly(oxyethylene) glycol and polydimethylsiloxane, the kettle is heated to and maintained at a temperature of 160°-180° F. Upon attainment of this goal temperature the catalyst is added and the resulting reaction mixture stirred for a period of between about 4 and 6 hours. Next, the toluol is added and stirred into the prepolymer product of reaction and the kettle cooled to below about 100° F. The reaction product is sampled and tested for free NCO and is found to have a free NCO content of about 3%, by weight. Upon analysis of the polymeric reaction product it is found that it comprises an isocyanate capped copolymer polyurethane having random polyethylene oxide and polymethyldisiloxane blocks. The prepolymer is then chain extended as follows.
Chain Extension of Prepolymer
The following ingredients are employed, in the stated weight percentages.
______________________________________Ingredient Weight Percent______________________________________Prepolymer solution 52.025Toluol 11.653Methyl ethyl ketone 12.741Isopropyl alcohol 11.653Chain Extender (20 wt. % solution 11.928of isophorone diamine in toluol)(IPD Solution)______________________________________
The prepolymer mixture is charged into an assiduously predried, moisture-free stirred reaction kettle maintained at about room temperature. Next, the toluol, methyl ethyl ketone and isopropyl alcohol solvents are stirred into the prepolymer mixture in order to provide a reaction mixture having a water thin viscosity and a 35-40 wt. % prepolymer solids content. Next, the chain extender solution is trickled into the water thin reaction mixture with agitation. Over the period of the chain extender addition the viscosity of the mixture increases to between about 100,000 and 110,000 cps at 25° C. as measured with a Brookfield Viscometer using a #6 spindle at 20 revolutions per minute.
EXAMPLE 2
Preparation of Basecoat Formulation Urethane Chain Extended Prepolymer
In a stirred reaction kettle of the type utilized and in the general manner disclosed in Example 1, a prepolymer is prepared utilizing the following ingredients, in the stated weight percentages.
______________________________________Ingredient Weight Percent______________________________________CARBOWAX 1450 23.335TERATHANE 2000, a polytetramethylene ether 32.659glycol having an average molecular weight of2000 and a functionality of 2 (E. I. du Pontde Nemours, Inc., Wilmington, DE)Isophorone diisocyanate (IPDI) 12.096COSCAT 83 0.024Toluol 31.886______________________________________
The prepolymer reaction mixture is heated and stirred at a temperature within the range of from about 165° F. to about 180° F. for a period of about 4 hours, followed by addition of the toluol solvent and cooling of the resulting prepolymer solution to below about 100° F. Said prepolymer solution has a free NCO content of 1.42 wt. %.
Chain Extension of Prepolymer
The prepolymer of this Example is chain extended in a manner similar to that of Example 1 utilizing the following ingredients, in the stated weight percentages.
______________________________________Ingredient Weight Percent______________________________________Prepolymer solution 56.457Methyl ethyl ketone 12.340Toluol 13.266Isopropyl alcohol 12.168Chain extender (IPD solution) 5.767______________________________________
Upon completion of the trickled addition of the chain extender the resulting chain extended polymer solution has a Brookfield viscosity of between 100,000 and 110,000 cps at 25° C.
EXAMPLE 3
Preparation of Thermosettable Breathable Basecoat Coating Formulation Suitable for Direct Coating of Fabrics
Into a stirred kettle are mixed the following ingredients, in the stated weight percentages.
______________________________________Ingredient Weight Percent______________________________________Chain extended polyurethane solution 65.020of Example 2Chain extended polyurethane solution 27.821of Example 1SANTOLITE MHP, an anti-curl additive 2.128(Monanto Co., St. Louis, MO)CYMEL 380, a melamine anti-blocking 3.179agent (American Cyanamid, Inc., Bridgeport,CN)20 wt. % solution of a triethylamine 1.852blocked ethyl acid phosphate catalystdissolved in toluol______________________________________
This formulation, once it has been completed by incorporation of the acid catalyst therein, is in the nature of a promoted resin system which, upon long standing, ultimately thickens and gels. Accordingly, at least for direct coating applications, once the acid catalyst has been added the completed formulation should normally be utilized within about 24 hours of its preparation. The mole ratio of poly(oxyethylene) glycol (derived from the chain extended prepolymer of Example 1) to polytetramethylene ether glycol (derived from the chain extended prepolymer of Example 2) contained in this formulation is 1:1. The mold ratio of the polydimethylsiloxane constituent (derived from the prepolymer of Example 1) to the total glycols (derived from the prepolymers of Examples 1 and 2) contained in the formulation is 0.1:1.
EXAMPLE 4
Preparation of Thermosettable Breathable Basecoat Coating Formulation Suitable for the Preparation of Laminated Fabrics
The following ingredients, in the stated weight percentages. are stirred in a kettle at room temperature until uniformly mixed.
______________________________________ WEIGHTINGREDIENT PERCENT______________________________________Chain extended prepolymer solution of 95.00Example 1CYMEL 380 melamine anti-blocking agent 4.00Catalyt solution consisting of 40 wt. % 1.00ethyl acid phophate dissolved in toluol______________________________________
The resulting basecoat formulation has a Brookfield viscosity of between 30,000 and 35,000 cps at 25° F.
EXAMPLE 5
Preparation of Thermosettable Breathable Topcoat Formulation Suitable for Topcoating of Dried Basecoat of Example 3
This formulation comprises a blend of polyester and polyether chain extended urethane prepolymer solutions each of which is prepared in a manner similar to that described in previous examples. The first chain extended urethane prepolymer solution is prepared utilizing the following ingredients, in the stated weight percentages.
______________________________________9337 Preparation of First Urethae Prepolymer SolutionPREPOLYMER (1)INGREDIENT WEIGHT PERCENT______________________________________MILLESTER VII-110, 1,4 Butandiol 50.099adipate (Polyurethane SpecialtiesCo., Inc., Lyndhurst, NJ)Isophorone diisocyanate 20.291COSCAT 83 .001173Butylated Hydroxy Toluene .002346Toluol 29.573______________________________________
The reaction mixture, minus the toluol, is heated and stirred overnight at about 160° F. The mixture is cooled to below about 100° F. and the toluol then mixed thereinto to form a prepolymer solution.
Chain Extension of First Urethane Prepolymer
The above prepolymer solution is chain extended by addition thereto of the following ingredients, in the stated weight percentages.
______________________________________CHAIN EXTENDED PREPOLYMER (I)INGREDIENT WEIGHT PERCENT______________________________________Prepolymer solution (1) 39.858Toluol 21.166Isopropyl alcohol 28.239IPD chain extender solution 10.737______________________________________
As previously, the chain extender solution is trickled into the system only after the addition and admixture of the toluol and isopropyl alcohol solvents therein. The resulting chain extended polymer solution has a Brookfield viscosity within the range of 45,000-60,000 cps at 25° F. The chain extension reaction is then shortstopped or terminated with morpholine.
The second urethane prepolymer solution is prepared utilizing the following ingredients, in the stated weight percentages.
______________________________________PREPOLYMER (2)INGREDIENT WEIGHT PERCENT______________________________________CARBOWAX 1000, a poly(oxyethylene) 48.467glycol having an average molecularweight of about 1000Isophoron diisocyanate 21.483COSCAT 83 .001189Toluol 30.038______________________________________
The reaction mixture, minus the toluol solvent, is heated and stirred for 3 to 4 hours at a temperature of about 180° F. Thereafter, the mixture is cooled to below about 100° F. and the toluol mixed thereinto.
Chain Extension of Second Prepolymer
Chain extension of the second prepolymer is achieved using the following ingredients, in the stated weight percentages.
______________________________________CHAIN EXTENDED PREPOLYMER (2)INGREDIENT WEIGHT PERCENT______________________________________Prepolymer solution (2) 45.700Toluol 20.259Isopropyl alcohol 19.41520 wt. % IPD chain extender solution 14.626______________________________________
As previously, the IPD chain extender solution was trickled into the stirred formulation only after addition and admixing of the toluol and isopropyl alcohol solvents thereinto. The resulting chain extended prepolymer solution was then shortstopped with morpholine.
Preparation of Topcoat Formulation
The final topcoat formulation is prepared by admixing the foregoing prepolymer solutions along with additional ingredients. The ingredients of the topcoat formulation are given below in their order of mixing, along with the weight percentages thereof.
______________________________________TOPCOAT FORMULATIONINGREDIENT WEIGHT PERCENT______________________________________Chain Extended Prepolymer solution (1) 36.819Isopropyl alcohol 12.269Toluol 5.724CAB 381-0.5, a cellulose acetate butyrate 2.935film hardener (Eastman Chemicals,Kingsport, TN)Chain Extended prepolymer solution (2) 37.731AEROSIL TS100, a hydrophobic 2.525pyrogenic silica flatting agent (Degussa,Inc., Ridgefield Park, NJ)50 wt. % solution of petrolatum in toluol .396CYMEL 303 melamine anti-blocking 1.071agentCatalyst solution consisting of 45 parts .529by weight of Catalyst 4040, a p-toluenesulfonic acid solution (AmericanCyanamid, Inc.) reduced in 55 parts byweight isopropyl alcohol______________________________________
This topcoating formulation has a Brookfield viscosity at 25° F. of between 10,000 and 15,000 cps.
EXAMPLE 6
Preparation of Breathable Thermosettable Polyurethane Adhesive Suitable for Bonding of Membrane Composed of Dried Basecoat of Example 4 to a Fabric
Into a dry reaction kettle equipped with stirring, heating and cooling means there are charged the following ingredients, in the stated weights:
______________________________________INGREDIENT WEIGHT (LBS)______________________________________TERATHANE 2000, polytetramethylene 23.037ether glycolMONDUR M, methylene diisocyanate 5.799(Miles, Inc., Pittsburgh, PA))Stabilized 1,1,1-trichloroethane 14.022______________________________________
These ingredients are heated to about 110° F., with constant mixing, for about 1/2 hour at which time the heating means of the kettle is deactivated. Then, 15.024 lbs of M-Pyrol solvent (GAF chemicals Corp., Wayne, N.J.) and 0.010 lb of Fomrez C-2 tin based catalyst (Witco Chemical Corp., Chicago, Ill.) are charged into the kettle and the cooling means activated to maintain the temperature of the contents at between 115° and 120° F. for about one hour. Then, there are added to the reaction mixture 16.026 lbs of stabilized 1,1,1-trichloroethane and 1.042 lbs of 1,4-butanediol chain extender with constant mixing and maintenance of the resulting reaction mixture at a temperature of between 115° and 125° F. The Brookfield viscosity of the mixture is monitored and, upon attainment of a viscosity (at the reaction temperature) of about 80,000 cps, there is charged thereinto an additional 25.040 lbs of stabilized 1,1,1-trichloroethane and, upon completion of its admixture, the chain extension reaction is then terminated or shortstopped with methanol. The viscosity of this polyurethane solution at 25° F. is between about 100,000 and about 120,000 cps. The viscosity is reduced to about 40,000 cps by mixing the polymer solution with additional 1,1,1-trichloroethane in an 85:15 weight ratio, thereby to provide an unpromoted polyurethane adhesive formulation which, prior to use, must be admixed with a sufficiency of a polyisocyanate having a functionality of at least three in order to promote cross linking thereof.
EXAMPLE 7
Direct Coating of Fabric
Coating is achieved by a multiple serial doctor blading station apparatus comprising an elongate flat trough bed to support a textile passed therethrough and having feed and take-off ends. Preceding the feed end of the trough is a feed reel to feed a textile to be coated into the feed end of the trough. Positioned above the trough at spaced apart locations along the length thereof are three doctor blade stations, each comprising a liquid coating delivery system by which to deliver liquid coating material to the upper surface of a textile running through the trough followed by an adjustable doctor blade running across the width of the trough. Following each doctor blade station is a solvent flashing and vapor recovery station. Immediately following the take-off end of the doctor blading apparatus is a thermostatically controlled curing over having feed and take-off ends, said oven being adapted to receive into the feed end thereof a coated textile from the take-off end of the doctor blading apparatus and to discharge the cured coated textile to a take-up reel located downstream therefrom.
A bolt of tightly woven 3 ounce/yd. 2 nylon cloth having a thickness of about 8 mils is treated utilizing the above-described apparatus. The basecoat formulation of Example 3 is fed to the first and second doctor blading stations, the doctor blades thereof each being set at a spacing of 2-3 mils above the cloth surface. The delivery rate of the basecoat coating formulation to each of the doctor blading stations is metered to provide a coating weight of between 1 and 1.5 ounces basecoat/yd 2 of cloth. The topcoat formulation of Example 5 is fed to the third doctor blading station, the doctor blade of this station being set to a spacing of 2-3 mils above the basecoat coated cloth surface and the rate of delivery of the topcoat formulation being metered to provide a coating weight of between 1 and 1.5 ounces of the topcoat formulation/yd 2 of cloth. After passing through the last of the solvent flashing and recovery stations the thusly multiply coated cloth is passed through the curing oven maintained at a temperature of about 325° F., the residence time of the cloth therein being controlled by the take-up reel to between 1 and 2 minutes. After passing from the curing oven and, prior to being taken up on the take-up reel, the bottom or uncoated side of the cloth is treated with a water repelling fluorocarbon composition such as that marketed under the brand name ZEPEL (E.I. du Pont de Nemours & Company, Wilmington, Del.).
Upon visual inspection, the cured polyurethane coating is noted to be smooth, uniform an devoid of structural defects. Attempts to strip the coating from the cloth reveal that the coating is strongly adherent to the nylon fabric substrate, the mode of failure, when achieved at all, tending to be in the nature of failure in cohesion rather than adhesion. Specimens of the coated cloth are subjected to waterproofness and moisture vapor transmission tests. Waterproofness is assessed by use of the Mullin's Burst Test (Fed. Std. 191, Method 5512) and failure of the coated textile occurs at an average hydrostatic pressure of about 120 p.s.i. Moisture vapor transmission rate is determined by the Upright Cup Test Method of ASTM-E96-66B and is found to be within the range of 500-600 gms/m 2 /24 hours. However, the upright cup method of ASTM-E96-66B is considered by those of skill in the art to be deficient in determining high range moisture vapor transmission rates due, in large part, to the fact that the test inherently places an interfering air gap between the bulk water contained in the upright cup and the test material sealed to the mouth of the cup. Moreover, where the specimen is a fabric believed to have utility in applications wherein direct contact thereof with bulk water is anticipated, the Upright Cup method does not simulate such a direct wetting condition. Accordingly, it is conventional practice to test specimens believed to possess high water vapor transmission rate capabilities by means of a modified test wherein the specimen is sealed to the mouth of the upright cup containing the charge of water and the cup then inverted in order to avoid altogether the air gap between specimen and water charge and to thereby place the bulk water in direct contact with the specimen material. The coated textile of this example is also tested by this inverted cup modification of the ASTM-E96-66B method and the moisture vapor transmission rate thereof is found to be within the range of 6000 to 7000 gms/m 2 /24 hours. In handling of the coated textile it is noted that the hand and stiffness thereof is little changed, if at all, from that of the uncoated cloth. From the foregoing results, it is apparent that the coated textile of the present example would make an excellent shell material for waterproof garments or other waterproof textile applications wherein water vapor transmissibility, as well as waterproofness, are essential or desirable traits.
EXAMPLE 8
Preparation of Fabric Laminate Comprising Breathable Waterproof Basecoat Sandwiched Between Fabric Layers
A doctor blading line similar to that employed in the previous example is utilized. However, interposed between the take-off end of the doctor blading trough and the curing oven are a nip roll and, in opposition thereto, a calendering roll equipped with pressure adjustment means by which to adjust the pressure of the one roll against the other. In addition, a second feed reel is stationed upstream of the calender and nip rolls, thereby to provide means by which a second cloth may be applied to the coated cloth entering the calender and nip rolls.
The textiles employed in this example are each a tightly woven 3 oz/yd 2 nylon cloth. The cloth fed by the first feed reel through the coating line is coated at the first station and recoated at the second station with the basecoat polyurethane formulation of Example 4, the coating delivery rates at each station being metered at 0.4 to 0.5 oz/yd 2 . At the third coating station the basecoat coated cloth is overcoated with the adhesive formulation of Example 6 which has been freshly promoted by admixture thereof with 3 parts by weight/100 parts of the adhesive solution of a crosslinker polyisocyanate such as MONDUR CB-75 (Miles, Inc., Pittsburgh, Pa.) or its equivalent. The promoted adhesive formulation is delivered to the basecoated cloth at a rate of about 0.3 oz/yd 2 and is doctor bladed at the third coating station to a thickness of about 2 wet mils. After passing the third solvent flashing station, the second cloth from the second feed roll is applied to the adhesively coated upper surface of the first textile and both are passed through the nip of the opposed nip and calender rolls under a roll pressure of several tons, thereby to effect continuous laminating contact of the second cloth to the adhesively coated surface of the first cloth and, further, to cause sufficient intermingling of the polytetramethylene ether glycol based adhesive formulation with the poly(oxyethylene) glycol and reactive polydimethylsiloxane based basecoat formulation such that an intermediate composition falling within the compositional parameters of the invention is formed therebetween. The resulting cloth laminate is then passed through the curing oven held at a temperature of about 350° F. and at a residence time of between about 1 and 2 minutes.
Specimens of the cloth laminate are tested for waterproofness and moisture vapor transmission rate (MVTR) in accordance with the Mullin's Burst Test Procedure of Federal Standard 191, Method 5512 and ASTM-E96-66B, respectively. The average burst strength is determined to be 150 p.s.i. and the average MVTR is determined to be 500 gms/m 2 /24 hours. On the bases of these waterproofness and MVTR values, the laminated cloth product of this example is assessed as suitable for use as a material of construction of rain protective garments and in other textile applications wherein the qualities of waterproofness and water vapor transmissibility are necessary or desirable.
The foregoing description and examples are illustrative in character and demonstrate certain embodiments and techniques for implementation and use of the present invention. It should be recognized and understood, however, that said description and examples are not to be construed as limiting of the invention because many changes, modifications and variations may be made therein without departing from the scope, spirit or intention of the invention, as will be obvious to those skilled in the art.
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Disclosed herein are polyurethane compositions specifically adapted to produce non-porous membranes exhibiting waterproof and water vapor transmissible characteristics. The membranes can be produced as free standing products or can be produced as coatings on porous substrates to confer similar properties to such substrates. Also disclosed are coated fabrics and fabric laminates utilizing the membranous coatings of the invention and exhibiting waterproof and water vapor transmissible characteristics. Such coated fabrics and fabric laminates find utility in the fabrication of tenting, rainwear and other garments where waterproofness, coupled with breathability, are important features.
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FIELD OF THE INVENTION
The present invention relates to a method for rendering font characters and, in particular, a method for reducing the height of a font character when rendering.
BACKGROUND OF THE INVENTION
The appearance and layout of a typical text document, e.g., a word processing document or a media presentation document, is determined by the selection of fonts used to display the characters which comprise the text document. To accurately render a text document, often it is necessary to vary the size or resolution of the font, depending on the display or printer used to view the contents of the document.
Mathematical algorithms are used to scale font characters and render the font characters at various sizes and resolutions. One mathematical scheme used to render font characters at various sizes and resolutions while maintaining character aesthetics is referred to as hinting. Hinting corrects the pixels of a font character scaled to a given size and resolution using any number of techniques for restoring the native shape, aesthetics and legibility of the character. Hinting consists of making minor corrections to the outline of a font character to preserve the “spirit” of a typeface throughout all of its characters or glyphs for all font sizes.
One type or family of fonts, which are mathematically scalable, are TrueType fonts. Other scalable fonts include PostScript, TrueType or OpenType font. In TrueType fonts, each glyph or character form contains a respective hint data program, such as a script or algorithm, which includes instructions for manipulating various control points of the respective glyph outline just prior to rasterization. As a result, the outline of the glyph is mathematically altered by the respective glyph's hinting instruction to surround only the pixels that produce a desired bitmap image of the glyph.
Typically, the outline and hint data are executed using a hint instruction processing program which interprets hint instructions that are embedded within each character in a TrueType font set. The hinting program is typically written in C programming language, which recognizes on the order of 256 hinting instructions. Many of these instructions move two dimensional coordinates of a point either horizontally, vertically or in a diagonal direction, called the “freedom vector.” Some instructions calculate the distance between points. Some interpolate collections of points between two moved points. The TrueType hint program inspects each hint instruction in the glyph and performs the operation specified by the hint instruction. PostScript uses a similar hint interpreter and hinting scheme.
Often it is necessary to adjust the height of text to fit within a fixed space. However, sometimes the characters which comprise the text are too tall to fit within a fixed space and, therefore, the characters need to be adjusted in a vertical or y direction. This could be achieved by scaling the characters linearly in the y direction. One disadvantage with using linear scaling is that depending on the character and the extent to which the character height is to be reduced, the scaling produces characters which are distorted or do not appear correctly. Moreover, linear scaling may produce characters which affect readability.
SUMMARY OF THE INVENTION
The present invention involves a novel method for automatically reducing the height of a character by using an iterative process and a pixel removal criteria, whereby pixels are removed during the iterative process from selected portions of the character while maintaining a preset minimum pixel spacing relative to various on pixels, e.g., black spaces, and off pixels, e.g., white spaces, which comprise a bitmap of the font characters by using a predetermined removal criteria. As a result of the present method, font characters are reduced in a non-linear process, whereby the readability and recognition of the characters are maintained while simultaneously reducing an overall height of the font characters. Thus, the present method preserves as much of the integrity of the font characters as possible while reducing its overall height.
The present method, in one form, reduces the height of a character by adapting hinting technology used in rendering a font character. The method uses the hint instructions and adds adjustments at key or relevant hinting instructions to reduce the overall height of a font character while preserving the font character integrity as much as possible.
For example, for TrueType fonts, the present method may be implemented by making two passes in executing the TrueType instructions. During a first pass, information pertaining to instruction which affects the y component of a point is stored as the instruction is executed. Instructions altering any components of the points which comprise an outline of a font character are identified as “key instructions.” A new y position for each of the points comprising the character outline is determined so that the outline does not exceed the present boundaries for the character. An adjustment value is set for each instruction and then the instructions are executed a second time, now applying the adjustment value for each relevant instruction.
With regard to identifying new y positions, the y positions are identified by using an iterative process, in order to remove pixels, e.g., black or white spaces from various portions of a bitmap which comprises the font character until a desired font height is achieved, while maintaining a removal criteria. The removal criteria maintains a predefined spacing between off or white pixels and on or black pixels comprising a bitmap of the font, thereby allowing the height of the font to be disproportionately or nonlinearly scaled to achieve the desired height reduction while maintaining as much of the integrity of the font character as possible.
The present invention, in one form, comprises executing font character instructions for rendering a font character to produce a font outline; determining points which comprise an outline for a font character to be rendered based on the font character instruction; calculating new y positions for various points which comprise the outline so that the outline does not exceed preset boundaries for the character, calculating a new y position using a pixel removal criteria in which pixels are removed in an iterative process until a desired font height is achieved, the removal criteria comprising: maintaining at least one off pixel between zones, defined as areas in the font character separated by a horizontal stripe of off pixels, and at least three on pixels between two points when removing pixels during the iterative process, if possible, and, if not possible; eliminating the one off pixel between zones, and reducing the number of on pixels between points in succession, from three to two to one, during the iterative process; setting an adjustment value for each instruction; and executing the font instruction while applying the adjustment value to each point.
The present invention, in another form, comprises executing font character instructions for rendering a font character to produce a font outline; determining an outline for a font character to be rendered based on the font character instruction; determining whether a y component of a character outline is to be adjusted and, therefore, the freedom vector in the y direction is not zero; storing instruction code, a point number, and, optionally, a parent number, if there is a parent number for a respective point number, and any other point number, if the point number is an interpolation; storing the x and y coordinate values of each point, a respective part number to which the instruction belongs, and a status value, indicating whether or not the instruction applies to a single character part or to a composite character; identifying key points from the outline of the character corresponding to points having instructions applied thereto, to adjust their respective position; constructing a data structure comprising a set of trees where roots of the tree correspond to points which do not have parents, and each parent has a branch for each of its children; identifying a set of zones as areas in a bitmap of the character separated by a horizontal stripe of off pixels within the character; defining a y line by data added to the typeface, which sets a baseline point which does not move; calculating a number of pixels needed to be removed from above or below the baseline; removing pixels, one at a time, in an iterative process, until the number of pixels to be removed is reached, the iterative process comprising: removing off pixels between zones comprising the font, until the number of pixels to be removed is reached, or until there is only one off pixel separating one zone from another zone; if there is only one zone; shifting the character towards the baseline if there is only one zone in the character bitmap, and the character lies entirely above or below the baseline; removing an on pixel between composite parts which comprise the character, if any; removing an on pixel from the topmost or bottommost portion of the character; removing an on pixel between the instruction trees previously constructed; removing a pixel from the largest on pixel portion of the character; wherein removing pixels occurs based on removal criteria setting an amount of off pixels between regions and an amount of on pixels between points; setting an adjustment value for each instruction; and executing the font instruction while applying the adjustment value to each point.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a bitmap of a font character prior to height reduction.
FIG. 1B is the character of FIG. 1A having its height linearly scaled using a prior art height restriction method.
FIG. 1C is the character of FIG. 1A having its height reduced in accordance with the present method.
FIGS. 2A and 2B depict a flowchart of a method for reducing a font character height in accordance with the present invention.
DETAILED DESCRIPTION
Referring now to FIGS. 1A-1C , font character 10 is depicted in FIG. 1A as an original height font character. FIG. 1B depicts character 20 , which represents the character 10 reduced, using a prior art height reduction method in which the height of character 10 is linearly scaled. FIG. 1C depicts character 30 , which represents character 10 reduced in height, in accordance with the present automatic height reduction method.
A comparison of original character 10 with the reduced height character 30 in accordance with the present invention, and the linearly scaled font character 20 , exemplifies the result of using the present automatic height restriction method over the prior linear scaling height restriction method. The automatic height restricted character 30 maintains the integrity of character 10 , while simultaneously reducing its height to the same extent as linearly scaled character 20 . Moreover, the automatic height restriction character 30 maintains the appearance and integrity of the original character 10 . Conversely, character 20 is distorted.
Referring now to FIGS. 2A and 2B , automatic height restriction method 100 comprises executing font character instruction for rendering a font character to thereby produce a character outline (step 110 ). For example, the font character instruction may be from TrueType font instructions or other scalable font instructions. The instructions are used to determine an outline of a font character to be rendered, including the points which comprise the outline of the character to be rendered (step 120 ).
Based on the font character instructions, it is determined whether a y component of each point of the character outline is to be adjusted during font rendering (step 130 ). For example, if the font instruction is for a scalable TrueType font, the freedom vector in the y direction will not be zero for any y component for a point which is to be adjusted.
After determining a y component for each point to be adjusted, instruction code, a point number, a parent point number (if there is a parent for the point), and other parent point number (if there is an interpolation) are stored for a subsequent execution during a second execution of the font instruction during step 230 , as discussed below (step 140 ).
As used herein, a point number is the index of the point on the outline, i.e., the number is simply an identifier of a point on the outline. The parent point number is the index or identifier of the parent of the point. Interpolated points have two parents, the coordinate of the interpolated point is computed by interpolating the point between the two parent points. Interpolated points do not produce point numbers.
X and y coordinate values are stored for each point of the character, in addition to respective part numbers to which the instruction belongs (step 150 ). In addition, a status value, indicating whether or not the instruction applies to a single character part or to a composite character, is also stored (step 150 ).
True Type fonts contain two types of characters, simple characters and composite characters. Simple characters contain the outline and the hints for the particular character. Composite characters are created by combining one or more simple characters into one character. The individual characters which make up the composite characters are called parts. Each part is identified by a part number which is the index to that part in a list of parts which comprise the composite character.
Key points are identified from the outline of the character, corresponding to points having instructions applied thereto, to adjust their respective positions during font rendering (step 160 ). When the font instruction is a TrueType font instruction, the key points are ones which have instructions applied to them, such as Move Indirect Absolute Point (MIAP), Move Direct Absolute Point (MDAP), Move Indirect Relative Point (MIRP), Move Direct Relative Point (MDRP), SHift Point (SHP), SHift Contour (SHC), SHift by PIXel amount (SHPIX) and DELTA (step 160 ).
A data structure is constructed comprising a set of trees where roots of the trees correspond to points which have no parents and where each parent has a branch for each of its children (step 170 ).
In one form, the data structure created comprises a set of trees comprising roots corresponding to points which do not have parents, since the instruction to be applied to the points are Move Indirect Relative Points (MIRP) or Move Direct Absolute Points (MDAP) (step 170 ).
Next, the font character is examined to determine whether the character comprises zones, defined as on pixels separated by a horizontal strip of off pixels spanning across the entire width of the character (step 180 ). If the character does contain zones, a set of zones are so identified (step 180 ).
Next, a y line is defined, setting a baseline point which does not move (step 190 ). The y-line value is added to data which comprises the typeface data.
Optionally, two additional y lines may be defined (step 190 ). The additional y lines identify a second reference line and a minimum or maximum value to which the lines can be moved. The additional y lines prevent upper case characters which have accent marks from appearing smaller than lower case accents. The additional y lines are also specified by data added to the typeface data.
Next, a number of pixels needed to be removed from above or below the baseline, in order to reduce the character to a desired height, is calculated (step 200 ).
Subsequently, points or pixels are removed, one at a time, in an iterative process from the bitmap of the character while maintaining a removal criteria (step 210 ). The removal criteria includes first maintaining at least one off or white point or space between zones if zones are present in the character, and at least three on or black pixels or spaces between two points when removing pixels during the iterative process (discussed below), if at all possible. If not, the removal criteria eliminates the one off or white pixel between zones and reduces the number of on or black pixels or spaces between two points, in succession, from three to two to one, during the iterative process (step 210 ).
The iterative process, applying the removal criteria, removes one pixel at a time in succession, as follows. First, an off pixel between zones is removed. If there is only one zone and the character lies entirely above or below the baseline, the character is shifted toward the baseline. Next, a pixel is removed between composite parts, if any are present.
Next, an on or black pixel is removed from the topmost or bottommost portion of the font outline, followed by the removal of a pixel from between the instruction trees that were computed in step 170 . Finally, a pixel is removed from the largest on pixel or black space comprising the font character. The iterative process is allowed to proceed until the desired height of the font is achieved, thereby producing all final y positions for each of the points being computed (step 210 ).
Using the final y positions, an adjustment value is computed for each point to be adjusted in the reduced height character (step 220 ). Instructions for points which do not have parents act to determine the amounts to move the respective points. Conversely, instructions for points which do have parents need to be adjusted in order to factor in the amount that the parent will be shifted, which in turn determines how much that point needs to be shifted (step 230 ). Accordingly, for pixels with parents, it is determined how much the point needs to be shifted, factoring that the parent point will itself be shifted (step 230 ).
It will now be clear to one of ordinary skill in the art that the present automatic height restriction method provides features and advantages not found in prior linearly scaled height restriction methods. The present method produces a font nonlinearly reduced in height, which maintains the integrity of the font character, while reducing its height as desired. Furthermore, the present method preserves the overall appearance and integrity of a character as much as possible while reducing its height.
Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.
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A method is provided for reducing a height of a font character in a nonlinear scaling process. The method includes reducing the height of the character by interacting with hinting instruction to adjust relevant instructions to thereby reduce the overall height of a font character while preserving as much of the integrity of the character as possible. The method includes an iterative process which selectively removes various pixels, defining an outline of a font character while maintaining a removal criteria, which results in a nonlinear height reduction in order to produce a font of a desired height.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved evaporator section for a capillary pumped loop, and more particularly to an evaporator section for a capillary pumped loop using a inorganic/organic composite wick.
2. Description of the Related Art
Passive cooling systems, unlike conventional refrigerators, do not require the use of mechanical pumping to circulate the coolant. They are typically used in applications where one or more of the features of conventional refrigerators (power demand by the pump, heating from the pump, vibration from the pump, size and weight of the pump) are unacceptable.
A capillary pumped loop (CPL) is a particular type of passive cooling system. A simple CPL is depicted in FIG. 1. In a CPL 10, a waste heat source 11 is in thermal contact with one or more evaporators 12. The liquid coolant 13 absorbs heat from the waste heat source 11, and undergoes a liquid-to-vapor phase change in the evaporator 12. Coolant vapor 14 from the evaporator 12 travels through the vapor line 15 to the condenser 16, where the vapor 14 condenses to the liquid phase 13, transferring heat to the heat sink 17 (typically some type of radiator). The liquid coolant 13 then travels through the liquid line 18 back to the evaporator(s) 12, where the cycle repeats.
A critical component in the CPL 10 is the evaporator 12, a typical example of which is shown in cross section in FIG. 2. The evaporator 12 has a porous wick 20 separating the liquid phase 13 of the coolant (typically ammonia) from the vapor phase 14 of the coolant. The liquid coolant 13 moves from the center 21 of the evaporator 12 through the porous wick 20 by capillary force. Upon reaching the outer surface 22 of the wick 20, the fluid vaporizes, absorbing heat. The capillary force through the wick 20 provides the pumping for the coolant through the CPL 10. Between the wick 20 and the evaporator tube wall 23 are one or more channels 24 (typically longitudinal to the evaporator, as shown) for the vapor phase 14 of the coolant to flow out of the evaporator 12, and into a vapor line, and subsequently to the condenser.
To date, the largest hurdle to the wide-scale implementation of CPL technology has been the lack of satisfactory wicks. In the U.S., the most common wick material in use is polyethylene, with an average pore diameter of 15 μm. This pore size is too large to maintain an adequately large pressure gradient across the wick. Consequently, these wicks suffer from poor performance. These wicks also have low porosity, on the order of 30%-50%. They have poor thermal stability, to only about 80° C. They also have poor plasticity and machinability, both of which are desirable properties for fabricating wicks. Furthermore, production of these porous polyethylene wicks has proven to be inconsistent.
Metal wicks are also in use. These metal wicks typically have average pore sizes of 1 to 2 μm, resulting in 15 times greater pressure head than has been achieved with polyethylene (pressure head through the wick is proportional to the inverse of the pore diameter in the wick). However, these wicks are much heavier than polyethylene wicks, and are thermally conductive. Thermal conductivity can lead to vaporization of the coolant within the core of the evaporator, rather than only at the outer surface of the wick. Vapor formation within the core of the evaporator can lead to "deprime" of the CPL, and loss of pumping action. Another disadvantage of the metal wicks is their rigidity. Frequently, it is desired to have evaporators with irregular shapes, to fit into relatively confined spaces near heat sources. Fabricating these evaporators is much simpler if the wick material is at least partially flexible.
Thus, a desirable wick material would have small pores, with pore sizes that could be selected for appropriateness for particular applications. A desirable wick material would also be flexible, light weight, thermally stable (greater than the 80° C. stability of polyethylene), thermally insulating, and compatible with the coolant used in the CPL. The desirable wick material would also be highly porous (greater than the 50% porosity of polyethylene), to minimize weight and maximize coolant throughput (and thus cooling action) without sacrificing pressure head across the wick. This desirable wick material would also have good plasticity and machinability. Finally, since this wick material should fit snugly into an evaporator tube, it would be advantageous for the wick material to be slightly expandable in some manner after it is inserted into the evaporator tube.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide an improved evaporator for a capillary pumped loop, where this evaporator has an improved wick, the wick having small pores, the size of the pores being controllable, high porosity, high thermal stability, low thermal conductivity, low density, good plasticity and machinability, and compatibility with the working fluid of the capillary pumped loop.
These and additional objects of the invention are accomplished by the structures and processes hereinafter described.
The present invention is an evaporator for a capillary pumped loop, having: (a) a tubular wick for containing a coolant liquid flow centrally therein, the body of the wick being saturated with the coolant liquid; (b) a tubular heat exchanger for receiving the wick; and (c) one or more vapor channels between the wick and the heat exchanger, for transporting a vapor of the coolant out of the evaporator; where this tubular wick comprises a porous organic/inorganic composite.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention will be obtained readily by reference to the following Description of the Preferred Embodiments and the accompanying drawings in which like numerals in different figures represent the same structures or elements, wherein:
FIG. 1 is a schematic view of a typical capillary pumped loop cooling system.
FIG. 2 is a cross sectional view of an evaporator section of a capillary pumped loop cooling system.
FIG. 3 is a structural diagram of a typical organic/inorganic composite for use in a wick for an evaporator according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following are incorporated by reference herein, in their entireties, for all purposes:
(a) U.S. Pat. No. 5,116,703, "Functional hybrid compounds and thin films by sol-gel process", issued May 26, 1992 to Badesha et al.;
(b) U.S. Pat. No. 5,316,855, "High abrasion resistance coating materials from organic/inorganic hybrid materials produced by the sol-gel method", issued May 31, 1994 to Wang et al.;
(c) U.S. Pat. No. 5,384,376, "Organic/inorganic hybrid materials", issued Jan. 24, 1995 to Tunney et al.;
(d) J. E. Mark et al., "Polymer-modified silica glasses", Polymer Bull. 18 259-64 (1987);
(e) S. Kohjiya et al., "PREPARATION OF INORGANIC/ORGANIC HYBRID GELS BY THE SOL-GEL PROCESS", J. Non-Crystalline Solids 119 132-35 (1990).
As depicted in FIG. 3, organic/inorganic composites have a network structure, where finely-defined regions of inorganic material are bonded to finely defined regions of organic polymers. The composites form a three-dimensional network.
The inorganic phase of the organic/inorganic composites will typically be in the form of metal oxides, such as silica, alumina, zirconia, titania, and combinations thereof. They will typically have precursors with repeating units of the structure: ##STR1## where M is a metal, and where R 1 and R 2 are independently selected. R 1 and R 2 are typically H or OH, but they may also be small organic ligands bonded to the inorganic backbone, such as aliphatic groups having 10 or fewer carbons, and aromatic groups having 10 or fewer carbons, and combinations thereof. In the later case, typical small organic ligands include CH 3 , CH 2 CH 3 , propyl, isopropyl, phenyl, and vinyl groups, and combinations thereof.
The organic phase of the organic/inorganic composites will typically be in the form of linear polymers, most typically polydimethylsilane. Other typical polymers for the organic phase include polyethylene glycol, poly(alkylmethacrylate), dialkoxysilanes, trialkoxysilanes, and combinations thereof.
Morphologically, these composites cam form gels having pores ranging in average size from about 0.1 μm (or less), to about 20 μm. The pore size is controllable within this approximate range by selection of the processing conditions, as shown below. The porosity of the composites (void volume/sample volume) will typically be between about 20% and about 80%. Larger porosity will increase the coolant throughput, and thus the cooling capacity, of the wick, but will decrease the strength of the wick. The porosity is likewise controllable within this approximate range by selection of the processing conditions.
Preferred pore sizes for the composites of the invention are preferably less than 20 μm, more preferably less than 5 μm, still more preferably less than 1.0 μm, and most preferably less than 0.7 μm. Pore sizes of 0.3 μm, 0.2 μm, and 0.1 μm are achievable by the present invention. As noted above, decreasing wick pore size is associated with improved pressure inventory, and hence improved evaporator performance.
Porosities greater than the 30%-50% available from polyethylene are achievable by the present invention. As a practical matter, however, there will be an upper limit on porosity due to the need for a certain minimum strength to the wick. Accordingly, porosities for the composites of the present invention are typically between about 50% and about 95%, more typically between about 55% and about 90%, preferably between about 60% and about 85%, and more preferably between about 65% and about 80%.
Skilled practitioners will recognize that organic/inorganic composites may be made by the sol-gel method. In this method, an organic precursor and an inorganic precursor (for the respective organic and inorganic phases) undergo concurrent hydrolysis and polycondensation reactions. For example, the hydrolysis and polycondensation of tetraethoxysilane (TEOS) and polydimethylsiloxane (PDMS) will proceed as:
Hydrolysis:
Si(OR.sup.1).sub.4 +Si(CH.sub.3).sub.2 (OR.sup.2).sub.2 +6 H.sub.2 O→Si(OH).sub.4 +Si(CH.sub.3).sub.2 (OH).sub.2 +4 R.sup.1 O+2 R.sup.2 O
Polycondensation:
Si(OH).sub.4 +HO--(Si(CH.sub.3).sub.2 --O--)--H→--(--O--)Si--O--(Si(CH.sub.3)--O--).sub.y --Si(--O--).sub.3 + . . .
The gels made by this process are typically translucent when wet, and turn an opaque white when dried. The gels made by this process typically shrink slightly when dried. A unique and useful feature of wicks made from these gels is that they are wettable by alcohols, and swell by a few vol % upon wetting by alcohols (swelling up to 4 vol % has been observed), despite being hydrophobic. This feature is exploitable in making CPL evaporators, in that a wick for a CPL evaporator may be made with an outside diameter (OD) that is slightly (a few %) smaller than the inner diameter (ID) of the evaporator tube. Thus, the wick is easily inserted into the evaporator tube. After insertion, the wick is wet by alcohol, to cause the wick to swell slightly, forming a snug fit between the wick and the evaporator tube.
It has been discovered that by varying the processing conditions, in particular by varying the acid treatment during the sol-gel process, composites of varying pore size and porosity can be made. Generally speaking, additional acid treatment leads to composites with composites with very fine particle sizes and high porosity. Also, additional acid treatment speeds up the reaction. Also, varying the reaction temperature will affect the morphology of the samples. Generally, finer grained composites are made at lower processing temperatures.
Varying the ratio of inorganic to organic material will affect the material properties of the composite. Generally speaking, the resiliency of the composite will increase with the fraction of the composite that is organic, and the brittleness of the composite will increase with the fraction of the composite that is inorganic. Typically, composites according to the invention will be between about 20% and about 80% inorganic. More typically, composites according to the invention will be between about 40% and about 70% inorganic. Most typically, composites according to the invention will be between about 55% and about 65% inorganic.
It has been discovered that the composites of the present invention are much more thermally stable than polyethylene wicks. Stability to 200° C. has been observed, a 120° C. improvement over polyethylene. This opens up the possibility to the use of other working fluids that have boiling points above 80° C.
Having described the invention, the following examples are given to illustrate specific applications of the invention, including the best mode now known to perform the invention. These specific examples are not intended to limit the scope of the invention described in this application.
EXAMPLE 1
Solution A: 30 grams of tetraethoxyorthosilicate was mixed with 20 grams of polydimethylsilane. 15 ml of isopropanol was added to the mixture, followed by 10 ml of tetrahydrofuran. This solution was mixed at room temperature and then stirred in a water bath at a constant elevated temperature (50° C. and 70° C. in various runs).
Solution B: 25 ml of isopropanol, 7.77 grams of deionized water, and 1.2 ml of 12M HCL were mixed together, and added to Solution A, gradually.
The mixture was stirred at constant 70° C. temperature for a reaction time that varied from 10-50 minutes for various runs. In some runs, additional acid, in the form of concentrated hydrofluoric acid (less than a gram) was added to the solution.
After reaction, the solution was poured into molds and kept in a 70° C. oven for 48 hours. The solution gelled in the oven. The solution was taken out of the oven, and kept at room temperature for an extended period (up to two weeks). The gels were taken out of the molds and dried at room temperature for several days, and then at elevated temperature (120° C.).
The properties of three samples of organic/inorganic composite wicks according to the present invention are tabulated below, with the properties of a conventional polyethylene wick for comparison.
TABLE 1______________________________________Properties of a Polyethylene Wick and Gel Wicks. Bulk Apparent Density.sup.1 Density.sup.2 Porosity Pore Size SwellingSample (K/m.sup.3) (K/m.sup.3) (%) (μm) (vol %)______________________________________polyethylene 650 880 27 15-20 0R20 330 1150 71 3-5 2R30D 280 1200 77 10-15 3R50 530 1180 55 0.2-0.5 2______________________________________ .sup.1 Measured density of porous gel. .sup.2 Inherent density of the material porosity is 1 BD/AD).
Sample R20 was prepared by reacting the organic and inorganic components in the hot bath for 20 minutes, and was catalyzed with only one acid (HCL). Sample R30D was prepared by reacting the organic and inorganic components in the hot bath for 30 minutes, and was catalyzed with two acids (HCL and HF). Sample R50 was prepared at a lower temperature than the other samples (50° C. vs. 70° C.). It was reacted for 50 minutes, and was catalyzed with one acid (HCL).
Scanning electron microscopy of the samples show a microstructure that varies with processing conditions. Samples R20 and R30D, prepared at higher temperatures, had coarser morphologies than sample R50. However, all the gel-wick samples had much finer structures than the polyethylene wick.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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An evaporator for a capillary pumped loop, has: (a) a tubular wick for containing coolant liquid centrally therein, the body of the wick being saturated with the liquid coolant; (b) a tubular heat exchanger for receiving said wick; and (c) one or more longitudinal vapor channels between said wick and said heat exchanger, for transporting a vapor of the working liquid out of the evaporator; where this tubular wick comprises a porous organic/inorganic composite made by the sol-gel process. By replacing the conventional polyethylene wick with the composite wick, smaller pores, greater porosity, greater thermal stability, and other advantages are secured.
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[0001] The present invention relates in general to baffle vibration reducing and more particularly concerns novel apparatus and techniques for reducing vibration transmitted to structures attached to loudspeaker drivers.
BACKGROUND OF THE INVENTION
[0002] When an electroacoustic transducer, such as a loudspeaker driver, is mounted to a structure, such as a package shelf, the door of a vehicle, the wall of an enclosure, other wall or other baffle, where attachment is usually on the periphery of the transducer frame, an energized transducer motor develops forces in response to an energizing electrical signal. The forces generated by the motor cause the diaphragm of the transducer to move relative to the transducer frame. These forces will also be transmitted through the frame to the structure through the attachment points of the frame. Package shelves and door panels of vehicles are often made of thin material, such as thin sheet metal. Such structures typically have insufficient stiffness to resist vibration and are typically lightly damped. As a result, forces applied to the structure around modal resonance frequencies of the structure may result in excessive vibration of the structure, acoustically perceived as unwanted buzzes and rattles, or degraded frequency response of the radiated sound.
[0003] It is an important object of the invention to reduce these structurally transmitted vibrations.
SUMMARY OF THE INVENTION
[0004] According to the invention, a first electroacoustical transducer incorporating a movable diaphragm is seated in and structurally coupled to a panel. The transducer is mechanically connected to a device containing a compensating moveable mass driven out of phase with the movement of the diaphragm of the first electroacoustical transducer, to significantly reduce the resultant force applied to the panel. Typically the device with compensating mass is a second electroacoustical transducer identical to the first transducer. According to another feature of the invention, the acoustic output from the first side of the first transducer is directly coupled to a listening environment, such as a vehicle passenger compartment or living room. The acoustic output from the side of the second transducer facing away from the first transducer is also coupled to the listening environment through an acoustical element or elements such as compliant volume and/or port so that the acoustical output into the vehicle compartment from the facing away side of the second transducer is effectively in phase with the output into the vehicle compartment from the first side of the first transducer, over a desired frequency range. The acoustic elements are arranged such that the output from the away facing side of the second transducer is not acoustically coupled to the output from the second side of the first transducer or the output from the first side of the second transducer. Thus, the invention achieves both significant reduction in unwanted mechanical vibration of the supporting structure with enhanced acoustic output from the second transducer.
[0005] Other features, objects and advantages of the invention will become apparent from the following description when read in connection with the accompanying drawing in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0006] [0006]FIG. 1 is a diagrammatic representation of an embodiment of the invention with the assembly carried by an infinite baffle, such as a vehicle rear deck or door; and
[0007] [0007]FIG. 2 is a graphical representation showing the force exerted on the structure as a function of frequency for various systems; and
[0008] [0008]FIG. 3 is a diagrammatic representation of an alternative embodiment of the invention with the assembly carried by an infinite baffle, such as a vehicle rear deck or door; and
[0009] [0009]FIG. 4 is a diagrammatic representation of an alternative embodiment of the invention with the assembly carried by an infinite baffle, such as a vehicle rear deck or door, incorporating transducers with inverted motor structures.
DETAILED DESCRIPTION
[0010] With reference now to the drawing and more particularly FIG. 1 thereof, there is shown a diagrammatic representation of an embodiment of the invention with structure carried by infinite baffle 11 , typically a vehicle rear shelf or door panel carrying a first transducer, such as loudspeaker driver 12 , mechanically connected to a second transducer, such as loudspeaker driver 13 , preferably identical to loudspeaker driver 12 , through mechanical link 14 . The two transducers are ideally mounted in substantially parallel planes such that the diaphragms move in the same axial direction. The front side of transducer 12 is directly coupled to listening area 18 . If baffle 11 is the rear package shelf of a vehicle, listening area 18 will be the passenger compartment of the vehicle. The second side of transducer 12 is coupled to volume 30 , which would be the vehicle trunk if baffle 11 is the rear package shelf. The second side of diaphragm 22 of driver 13 is coupled to the listening area 18 through compliant column 15 and port tube 16 . The front of diaphragm 22 of transducer 13 is coupled to volume 30 . Power amplifier 17 energizes first loudspeaker driver 12 and second loudspeaker driver 13 with the same signal but drives them in opposite polarity. The system is arranged such that when diaphragm 21 of first driver 12 is moving up, diaphragm 22 of second driver 13 is moving down, which significantly reduces the forces applied to and unwanted resultant vibrations of baffle 11 . Meanwhile, the output from the rear of second driver 13 is coupled by compliant volume 15 and port tube 16 for emission substantially in phase with the output from the front surface of first driver 12 . The output from the rear of second driver 13 could also be coupled through a conduit of substantially constant or smoothly varying cross section to listening area 18 without loss of generality.
[0011] The second transducer need not be an identical transducer. All that is required for significant reduction in vibration is for the moving mass and generated motor force of the second transducer to approximately equal the moving mass and generated motor force of the second transducer to approximately equal the moving mass and generated motor force of the first transducer. Such a component could be made at lower cost than the cost of a transducer identical to the first transducer. It is still desirable for the frames of the two transducers to be similar so that the second transducer may be attached to the first transducer at the same attachment points where the first transducer is attached to the baffle. An alternative means of assembly would be to rigidly attach the top of the motor structure of the first driver to the rear of the motor structure of the second driver, using a rigid connecting member such as a threaded metal rod.
[0012] [0012]FIG. 3 shows an alternative construction. Driver 13 is now physically inverted with respect to driver 12 . FIG. 3 shows the rear of the motor structure of driver 12 rigidly attached to the rear of the motor structure of driver 13 through spacer 20 , although spacer 20 is not required. Structural coupling of the two transducers could also be accomplished through attachment around the periphery of the transducer frames, as shown in the system of FIG. 1. The arrangement of FIG. 3 would also work equally well if each of transducers 12 and 13 were inverted compared to what is shown. In this case, structural connection would be more easily accomplished through attachment around the periphery of the transducer frames.
[0013] Since drivers 12 and 13 are physically inverted with respect to each other, cancellation of vibration will occur when signals of the same relative polarity are applied to each transducer. Each driver is attached to the output of amplifier 17 such that when the signal provided to driver 12 causes diaphragm 21 of driver 12 to move down, signal output from amplifier 17 which is connected to driver 13 causes diaphragm 22 of driver 13 to move up, in the opposite direction to the motion of diaphragm 21 .
[0014] Above a certain frequency, output from the second transducer will not be in phase with the output from the first transducer. The frequency response of the combined system may exhibit a comb filter behavior with the first null occurring when the path length difference between the front of the first transducer and the listening position and the rear of the second transducer and the listening position is a half wavelength.
[0015] One approach for reducing the effects of this comb filter behavior is by using a low-pass filter to restrict the spectral components delivered to both drivers to spectral components below the first null and using other transducers for reproducing higher frequency spectral components. The low-pass filters used could be identical for both drivers, or they may have different orders and/or corner frequencies. The output from one of the drivers could be restricted to being below a predetermined cutoff frequency while the other was allowed to operate over a wider frequency range. Preferably, the first transducer operates over a wider frequency range than the second transducer. This result can be achieved by placing a low-pass filter in the signal path of the second transducer only, or by having a low-pass filter in the signal path of the first transducer with a higher corner frequency and/or lower order than a low-pass filter in the second transducer signal path. The result can also be achieved either in combination with or solely by the appropriate design of the acoustic elements connecting the second driver to the listening region such that the acoustic elements, in combination, form a low pass filter.
[0016] It may also be advantageous to include a low-pass filter in the signal path of the second transducer and a complementary all-pass filter in the signal path of the first transducer. A complementary all-pass filter has the same phase response as a function of frequency as a corresponding low-pass filter. This feature can be accomplished, for example, by using a second order critically damped low-pass filter in the second transducer signal path, and a first order all-pass filter in the first transducer signal path, where the corner frequencies of the low-pass and all-pass filters are substantially identical.
[0017] According to another embodiment, a fourth order low-pass filter in the second transducer signal path and a second order all-pass filter in the first transducer signal path may be used. Other examples of complementary all-pass filter/low-pass filter combinations will be evident to those skilled in the art.
[0018] The use of complementary all-pass filters and low-pass filters as described above can be combined with other signal processing as disclosed in U.S. Pat. No. 5,023,914, incorporated by reference herein, to simultaneously achieve improved system frequency response and reduce vibration.
[0019] Referring to FIG. 2, there is shown a graphical representation of force upon a baffle as a function of frequency for various structures. Curve 21 shows the resultant response of using two Bose eight-inch Nd drivers in an acoustic system having a low-pass filter. Curve 22 shows the applied force when using only a single eight-inch Nd driver with a low-pass filter. Curve 23 shows the applied force when using just two eight-inch Nd loudspeaker drivers connected according to the invention without the low-pass filter. Curve 24 shows the applied force with just a single eight-inch Nd loudspeaker driver. These graphical representations demonstrations the significant reduction in force applied to the baffle with the invention and the advantage of incorporating the low-pass filter into the system.
[0020] The embodiments shown in FIGS. 1 and 3 show use with infinite baffle 11 . Although the arrangements are described having region 18 as the listening area, this is not required. The invention can be adapted to work equally well with volume 30 or region 18 operating as the listening area without loss of generality.
[0021] [0021]FIG. 4 shows use of the invention with transducers of an alternate construction. Transducers 32 and 33 have motor structures that are inverted with respect to the motor structures of transducers 12 and 13 . FIG. 4 shows transducers 32 and 33 physically inverted with respect to each other use of inverted motor structure transducers is not limited to the orientation shown. Any of the previous arrangements described for non-inverted motor transducers is also applicable for transducers with inverted motor structures. Use of inverted motor structure transducers in the current invention can significantly reduce the overall thickness of the multiple transducer assembly, which can reduce intrusion into a vehicle trunk or allow a system to fit within a wall space where an arrangement using traditional transducers would not fit. Note also that mechanical links 14 can be made much thinner than links 14 shown in FIG. 1 in the embodiment using transducers without inverted motor structures.
[0022] It is evident that those skilled in the art may now make numerous uses and modifications of and departures from the specific apparatus and techniques herein disclosed without departing from the inventive concepts. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features present in or possessed by the apparatus and techniques herein disclosed and limited only by the spirit and scope of the appended claims.
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a vibration reducing apparatus comprising, a baffle subject to vibration, a first electroacoustical transducer characterized by a first mass seated in the baffle, a second electromechanical transducer mechanically connected to said first transducer or said baffle in the vicinity of the periphery of the first transducer. The rear sides of the diaphragms of the first and the second transducer are not connected to the listening area. The first transducer and the second transducer are constructed and arranged to receive a common electrical signal so that the movable element in the first transducer and the movable element in the second transducer move in phase opposition in response to the common electrical signal to significantly reduce the vibrating force imparted to the baffle.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention pertains to a document sheet or a business form that is formed as a single sheet or part of a continuous web of interconnected sheets, where an indentation(s) are pressed into a front surface of the sheet and an object, such as a card, label or coin, is releasably adhered to the sheet in the indentation enabling the simultaneous printing of both the document sheet and object.
(2) Description of the Related Art
It is well known in the prior art to provide document sheets and business forms with removable labels and cards adhered to the sheets and forms. The various different types of sheets and forms with adhered cards range from business forms with removable, adhesive free data cards secured to the front surface of the forms such as that disclosed in U.S. Pat. No. 4,890,862, to business forms with removable, self-stick labels fabricated within the thickness of the forms as disclosed in U.S. Pat. No. 4,379,573.
Prior art document sheets and business forms of the type having data cards adhered to their front surfaces have been found to be disadvantaged in that the projecting height or thickness of the data card from the front surface of the sheet will at times cause the sheet to jam in a printing apparatus. Business forms and document sheets of the type where a self-adhesive label is fabricated within the thickness of the sheet often require the addition of an underlayment beneath the self-stick label. The cost of the underlayment and its attachment to the underside of the label and sheet contribute significantly to the overall cost of the document sheet.
SUMMARY OF THE INVENTION
The document sheet of the present invention avoids the above set forth disadvantages of prior art document sheets and business forms by providing a document sheet with a removably attached object thereon having simplified, inexpensive construction and having a reduced cross sectional thickness enabling use of the sheet in printers without the risk of jamming the printer.
The document sheet of the present invention is basically comprised of a sheet of material, preferably paper stock, having an indentation recessed in its front surface and an object secured in the indentation. The sheet material is continuous within the peripheral boundaries of the sheet. In variant embodiments, the document sheet is provided as a single sheet, and as a sheet of a continuous web of sheets wherein each individual sheet is separated by a transverse frangible line such as a perforation line. The individual sheets of the continuous web of sheets may also be provided with left and right side margins separated from the document sheets by frangible lines such as perforation lines and having pluralities of tractor holes provided therein as a conventional continuous web of computer printer paper.
The indentation(s) in the front surface of the sheet is formed by compressing the material of the sheet from the front surface down into the thickness of the sheet. The configuration of the indentation may vary to complement the configuration of an object to be adhered to the sheet in the indentation. The depth of the penetration of the indention into the document sheet and the thickness of the object to be adhered to the sheet in the indentation may vary depending on the thickness of the stock material employed in constructing the sheet.
The object is adhered within the indentation on the indentation surface of the sheet. Preferably, the object is releasably adhered in the indentation to permit its easy removal from the sheet. The thickness of the object is at least as large as the distance of the indentation into the sheet thickness from the sheet top surface. This is to enable both the front surface of the document sheet and the front surface of the object to be simultaneously printed when running the document sheet through a printer. Alternatively, an object having a greater thickness than the distance of penetration of the indentation into the thickness of the document sheet may be employed. With the object being adhered to the indentation surface, a portion of the object's thickness is recessed into the indentation depth so that only a fraction of the object's thickness projects above the front surface of the sheet. This reduces the projection of the object from the front surface of the sheet and lessens the risk of the sheet and object jamming a conventional printer than heretofore has been available with prior art document sheets having cards affixed to their front surfaces. By forming the indentation in the sheet front surface by compressing the material of the sheet, the document sheet of the invention may be produced more economically than prior art document sheets and business forms comprising underlayment layers beneath cards or labels cut into the thickness of the document sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the present invention are revealed in the following detailed description of the preferred embodiments of the invention and in the drawing figures wherein:
FIG. 1 is a view of the front surface of the document sheet and affixed object of the present invention;
FIG. 2 is a partial view, in section, of the document sheet taken along the line 2--2 of FIG. 1;
FIG. 3 is a front view of an alternative embodiment of the document sheet of the invention; and
FIG. 4 is a front view of a still further embodiment of the document sheet of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show the document sheet 12 of the present invention constructed in accordance with the method of the present invention. The document sheet is basically comprised of a sheet of material 14 and an object 16 adhered to the front surface 18 of the sheet. The sheet of material 14 is shown in solid lines in FIG. 1 as a single sheet. However, in variant embodiments of the invention, the sheet of material 14 may be one of a continuous web of material sheets with a second 22 and additional like sheets connected along a top peripheral edge 24 of the sheet and a third 26 and additional like sheets connected along a bottom peripheral edge 28 of the sheet. The variant embodiment of the sheet in which it is one sheet of a continuous web is represented in dashed lines in FIG. 1. The top peripheral edge 24 connecting the sheet 14 to the second sheet 22 may be a frangible edge such as a fold line or a line of perforations that facilitate the separation of the two sheets along the line. Likewise, the bottom peripheral edge 28 of the sheet provides a frangible connection between the sheet 14 and the third sheet 26 with the frangible connection being provided by a fold line or a line of perforations. In a still further variant embodiment of the invention, the left 32 and right 34 peripheral edges of the document sheets may be frangible connections to left 36 and right 38 margins with tractor holes 42 provided therethrough as in conventional computer printer paper. The material of the sheet is continuous within the sheet peripheral edge, meaning that there are no holes or areas of different materials within the sheet's peripheral edge. Although not shown, in variant embodiments the sheet 14 may also be provided with fold lines or tear lines within the peripheral edges 24, 28, 32, 34 of the sheet. The material of the sheet 14 is preferably paper stock and the thickness of the sheet between the front surface 18 and back surface 44 of the sheet may vary depending on the particular application desired for the document sheet.
An indentation 46 is provided in the front surface of the sheet. As shown in FIG. 1, the indentation 46 has a rectangular configuration conforming to the rectangular configuration of the object 16. However, the configuration of the indentation boundary 48 may take on a variety of shapes complementary to the configuration of a particular object to be secured to the front surface of the sheet. At the bottom of the indentation 46 is an indentation surface 52 of the sheet recessed below the sheet front surface 18 and into the thickness of the sheet by a desired distance, the distance being dependent on the thickness of the sheet material and the thickness of the object to be adhered to the sheet front surface. According to the method of the invention, the indentation 46 is formed into the thickness of the sheet 14 by pressing the material of the sheet, for example by using a conventional rotary press. It can also be seen in FIG. 2 that by forming the indentation 46 into the thickness of the sheet 14, a projecting surface 54 is formed in the sheet back surface 44 projecting about the same distance from the back surface that the indentation surface 52 extends into the sheet thickness from the front surface 18, there being a slight difference in these differences due to compression of the sheet material forming the indentation surface 52.
In the illustrative example shown in the drawing figures, the object 16 to be adhered to the sheet front surface 18 is a rectangular identification card. However, various different types of objects may be employed with the document sheet of the invention. For example, self-adhesive labels, coins, tokens, keys, and a variety of different types of objects may be adhered to the front surface of the sheet in the indentation 46, the only requirement being that the objects have a limited thickness. The object 16 has a top surface 56 and a bottom surface 58, with the bottom surface being adhered to the indentation surface 52. An adhesive 62 is employed to secure the object bottom surface 58 to the indentation surface 52. The adhesive may be applied to the object bottom surface or the indentation surface prior to the object being received in the indentation and pressed against the indentation surface. The adhesive 62 may be a permanent adhesive, or preferably may be a releasable adhesive, enabling the object 16 to be easily removed from the indentation surface 52 and the document sheet 14 when so desired.
It can be seen in FIG. 2 that by forming the indentation 46 into the front surface 18 of the sheet, the thickness or the projecting height that the object 16 would project above the sheet front surface 18 is lessened by the distance that the indentation surface 52 is recessed into the thickness of the document. Any additional distance that the object thickness would project above the sheet front surface 18 if it were not received in the indentation 46 is the distance that the projection surface 54 of the sheet projects from the sheet back surface 44, less the change in sheet thickness due to compression of the sheet material when the indentation is formed. In this manner, the document sheet of the present invention distributes the thickness of the object 16 adhered to the sheet 14 between the front surface 18 and back surface 44 of the sheet so that the object 16 may be adhered to the sheet 14 while presenting a very small protuberance from the sheet front surface 18 and back surface 44. Distributing the thickness of the object on the front and back surfaces of the sheet enables the document sheet of the invention to provide an inexpensive document having an attached object, the both of which can be printed simultaneously by a conventional printer without risking jamming the printer.
Although the document sheet and method of the invention are described above with reference to only a single object 16 adhered in the indentation 46 of the sheet 14, it should be understood that a plurality of objects may be secured in indentations in a variety of positions of the indentations on the document sheet. Some possible variations are illustrated in FIGS. 3 and 4 where like component parts have like reference numerals followed by a prime (') in FIG. 3 and a double prime (") in FIG. 4. The variant document sheets of FIGS. 3 and 4 are constructed in the same manner as the first described embodiment shown in FIGS. 1 and 2.
While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.
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The present invention pertains to a document sheet or a business form formed as a single sheet or part of a continuous web of interconnected sheets where an indentation is pressed into a front surface of the sheet and an object such as a card, label or coin is releasably adhered to the sheet in the indentation, whereby recessing the object in the sheet indentation enables the simultaneous printing of both the document sheet and object.
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BACKGROUND OF INVENTION
1. Technical Field
This invention relates to modem technology, and more particularly, to a modem that adjusts for missed code samples during transmission of data.
2. Related Art
During transmission of data, modems typically buffer digitized data representing the analog transmission for that transmission. This buffered data is originally processed by the main central processing unit of a host computer and transferred to the modem via a link over an internal bus in the computer.
The data to be transmitted to the remote unit is processed by the host computer into digital samples representing the outgoing analog signal and are stored in the memory of the host computer, awaiting transfer to the modem. Upon transfer to the modem, the digitized samples are stored within a transmit buffer in the modem. When the data is to be transmitted to a remote modem, the modem performs a digital to analog conversion on these digitized samples. The modem then outputs the resulting analog waveform across the communication link to the other modem.
On the other end, when the modem receives analog signals from another modem, the receiving modem typically digitizes the analog waveform as samples and store these samples in an internal buffer. The modem then ships the digitized samples of the analog waveform to the host computer's memory via an internal bus, where the host computer processes the samples to recover the embedded data in the original analog signal.
However, in a typical host computer system, instant and timely access the memory across the bus is not always present. Since the digitized data must be shipped across a bus shared with numerous devices and peripherals associated with a computer a delay in the use of the bus can cause the transfer of the digitized samples to take longer than expected. This delay can cause a disruption in the flow of digitized samples from the host computer memory to the modem.
When this delay occurs, the modem may exhaust all of the data in the transmit buffer. When the transmit buffer has exhausted the supply of digitized samples representing the output analog signal, an indeterminate signal can be output by the modem.
The sending of the unspecified signal across the communication link could result in abnormal noise in the transmitted audio waveform. In a worst case scenario, the abnormalities may include a disruption in the phase of the audio waveform. Different varieties of abnormal waveforms are diagrammed in FIGS. 1 a and 1 b.
FIG. 1 a is a timing diagram of an analog signal 100 output by a modem when the transmit buffer is in an underflow condition. In the period before a time T 1 , the transmit buffer is not in an underflow situation and has valid data corresponding to samples of a valid transmitted waveform. However, at the time T 1 the transmit buffer enters into an underflow situation, perhaps caused by a delay in receiving digitized samples from a main memory. The resulting analog signal transmitted by the modem at the time T 1 is very noisy, due to the fact that no coherent data is being output.
FIG. 1 b is a diagram of an even worse case scenario. The modem is outputting an analog signal 150 to a remote modem. The transmit buffer of the modem is operating normally until a time T 2 . However, at the time T 2 an underflow in the transmit buffer occurs, again perhaps caused by the delay in receiving the digitized samples representing the output analog waveform 150 from a main memory or other peripheral device. This described delay is among other types of delays inherent in computer systems that could cause the transmit buffer to underflow.
At the time T 2 , the modem cannot transmit valid, coherent data over the communication link. As such, the modem proceeds to transmit an out of phase signal.
An out of phase, non-coherent, or noisy signal is extremely destructive in terms of a modem session. The transmissions of extremely noisy data, such as depicted in FIG. 1 a , or the transmission of a non-coherent, discontinuous signal, such depicted as in FIG. 1 b may lead to lower performance in the modem. In fact, even more destructively, these types of signals may cause a termination of a communication link between another modem.
Other aspects of the present invention, as well as shortcomings of the prior art will become apparent with further reference to the drawings and specification that follow.
BRIEF SUMMARY OF THE INVENTION
In short, the invention relates to a modem that is able to adapt to missed transmission samples by supplying a patch signal for the missing samples. The patch samples do not affect the operation of the modem in a communication session that it is currently engaged.
In one embodiment, the modem is made up of a conversion circuitry, a buffer for storing samples from the conversion circuitry, and a second buffer containing samples of a substitute signal. The modem recieves digital samples from a main computer, which are then stored a transmission buffer. The modem transforms the digital samples into an analog signal, which it then outputs. The digital samples are transformed into the analog signal by the conversion circuitry
A second buffer contains digital samples of a substitute analog signal. When the modem determines that no further valid digital samples are available in the transmission buffer, the digital samples from the second buffer are substituted as input to the conversion circuitry. The conversion circuitry transforms the digital samples contained in the second buffer into an analog output coherent with the prior output signal. Thus, the output of the modem is uninterrupted due to the lack of digital samples in the transmission buffer, and transmits a coherent analog signal that will not impair the communication session.
In one embodiment, the contents of the second buffer are tracked or synchronized with the output of the digital samples from the first buffer to the conversion circuitry. As such, a related digital sample from the second buffer may be substituted seamlessly with the prior digital samples sent form the transmission buffer. Thus, the resulting analog signal output from the conversion circuitry is seamless as well.
In another exemplary embodiment, the digital samples in the second buffer are indicative of a signal coherent with the signal as represented by the samples in the transmission buffer. Thus, the substitution of a sample from the second buffer for a missing sample in the transmission buffer results in a coherent output from the conversion circuitry.
In another embodiment, the second buffer stores samples of a cyclical signal. Further, the second buffer stores samples indicative of at least one cycle of the cyclical signal. In this way, a patch from the second buffer is readily available at any point in the output cycle. This gives the modem the ability to graft the delayed signals from the computer onto the ongoing output analog signal.
Other aspects of the present invention will become apparent with further reference to the drawings and specification that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b are timing diagrams of analog signals output by a modem when the transmit buffer has experienced an underflow or signals representative of missed samples from an overflow condition in a reception buffer.
FIG. 2 is a timing diagram of an analog output of a modem with missing samples, a patch analog output tracked by the modem to compensate for the missing signal samples, and a resulting composite signal output by the modem according to the invention.
FIG. 3 is a schematic block diagram of an embodiment of a device that performs a phase coherence adjustment for missed code samples according to the invention.
FIG. 4 is a timing diagram showing the interaction of an outgoing analog signal, and the coherent phase buffer of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is a timing diagram of an analog output of a modem with missing samples, a patch analog output tracked by the modem to compensate for the missing output signal samples, and a resulting composite signal output by the modem according to the invention. Assume that a modem is transmitting data, exemplified by an analog signal 200 . Samples corresponding to the analog signal 200 are present in a transmit buffer of a modem. The samples are converted to the analog signal 200 and output on a communication line.
At a time T 1 , the transmit buffer experiences an underflow situation. As, such no valid data samples are present in the transmit buffer to be converted and transmitted. However, the data sample stream is resumed at a time T 2 , at which time the underflow situation in the transmit buffer is corrected. As such, an analog output signal 204 may be resumed at that time. However, the in the time between the time T 1 and the time T 2 , no valid samples of an analog output signal are present in the transmit buffer that may be converted and output by the modem.
However, the modem may compensate for the lost transmission samples by patching the output signal with an in-phase, non-noisy, coherent waveform, as indicated by an analog waveform 212 . The modem stores digitized samples of a patching waveform.
In this case, the modem tracks the output waveform. This enables the modem to patch the output waveform in the proper location. Thus, the modem may supply a patching waveform 212 by supplying alternate digital samples corresponding to the patching waveform 212 to the output in lieu of the invalid digital samples in the transmit buffer. This substitution continues while the transmit buffer is in an underflow situation. In one exemplary embodiment, the patching waveform corresponds to a “dataless” waveform; thus no information is transmitted in the patch.
As such, the modem, upon the indication of an underflow situation in the transmit buffer, supplies a patching waveform 212 to the output until the underflow situation is corrected. Thus, the modem supplies an uninterrupted, continuous, coherent, and non-noisy waveform 230 as the analog output to the communication link.
The modem supplies the samples corresponding to the waveform in the time before the time T 1 from the transmit buffer, as indicated by the waveform segment 220 . In the time between the time T 1 and the time T 2 , the analog output generated by the modem is derived from those samples corresponding to the patch waveform generated internally, as indicated by the waveform segment 222 . The patch waveform is continued until the underflow situation is corrected at the time T 2 . At the time T 2 , the samples of the delayed new data flowing into the transmission buffer are resumed. At this point, the transmission from the delayed data may be resumed, as indicated by the waveform segment 224 .
Thus, an analog output waveform 230 is a composite waveform. The composite waveform is made up of the waveform segments 200 , 212 , and 204 . In this manner the communication session is not affected by the absence of samples in the period of time between the time T 1 and the time T 2 . FIG. 3 is a schematic block diagram of an embodiment of a device that performs a phase coherence adjustment for missed code samples according to the invention. FIG. 3 is an internal schematic of a host computer containing a modem 3300 . The host computer contains a computer bus 350 , a memory 360 , and another device 370 operably coupled to the computer bus 350 and possibly requiring access to the memory 360 .
Within the memory 360 is a digital input stream buffer 362 and digital output stream buffer 364 . The digital output stream buffer 364 is an area of memory in which digital samples corresponding to an output analog transmission signal is stored before sending to the modem 330 for final transmission.
When transmitting data, the modem may utilize the digital output stream buffer 364 of the memory 360 to create digitized samples of output analog signal. Or, the modem may output these digitized samples from a digital signal processor.
Periodically, the modem 300 requests a block of the digitized samples contained in the digital output stream buffer 364 in the memory 360 for output to a remote modem as an analog output signal. Or, these digitized samples may be requested from a specialized piece hardware, such as a digital signal processor.
In either case, this requested block of samples is transferred across the computer bus 350 and into the transmit buffer 324 contained within the modem 3300 . There, the digitized samples of the analog output signal are sent to the conversion circuitry 320 . The conversion circuitry 320 converts the digitized samples of the analog output signal to a resulting analog output signal. This analog signal is output through the input/output port to a remote modem.
However, when the computer peripheral device 370 requests data from the memory 360 , that request may block the modem 3300 from obtaining the digitized samples stored in the memory 360 . Or, the computer peripheral device 370 may request another peripheral device supply some data using the computer bus 350 . Again, access to the computer bus 350 would be blocked from the modem 3300 . As such, the digitized samples corresponding to the output of the modem 300 might be delayed.
When other devices are using the computer bus 350 , or when other devices block access to the memory 360 , this causes the digitized samples to be blocked from the modem 3300 . When this situation occurs, the transmission buffer 324 may enter an underflow state.
Additional control circuitry 340 may also present with the modem 3300 . This control circuitry 340 may be onboard to the modem. Or the control circuitry may be a remote processor running the functional protocol of the modem, as might exist in a software modem. Thus, the control circuitry 340 controls the functional aspects of operating the transmission buffer.
The modem 300 also contains a coherent phase buffer 330 . This coherent phase buffer 330 contains data corresponding to samples of an analog signal that the modem may use in patching an output analog signal as it waits for delayed data from the main computer.
The processing circuitry 340 allows the modem to direct the introduction and matching of the phase coherent samples to the output signal. As such, when the digitized samples are delayed from the memory 360 , the modem may use the digitized samples in the coherent phase buffer 330 to adjust for any missed samples because of these delays.
In an embodiment of the invention, the representation of the signal contained in the coherent phase buffer 330 is “dataless”, meaning that it is representative of a carrier wave containing no embedded data. With such a wave, the contents of the coherent phase buffer may be used in the “patching” functions in building a phase coherent analog signal that adjusts for missed code samples.
For example, in the case where the transmission buffer 324 experiences an underflow due to a lack of samples from the memory 360 , the modem 300 can compensate for this situation by providing digitized samples from the coherent phase buffer 330 to the conversion circuitry 320 . These samples from the coherent phase buffer 330 represent an analog signal that is in phase, coherent with, and non-discontinuous from the ongoing output signal.
First, an underflow condition in the transmission buffer 324 is detected by the modem 300 . Upon an indication that this event had occurred, the modem 300 would send the samples from the coherent phase buffer 330 corresponding to an analog signal coherent with the ongoing output signal to the conversion circuitry 320 . Upon an indication from the modem 300 that the underflow condition in the transmission buffer 324 no longer exists, the modem 300 ceases sending the samples in the coherent phase buffer 330 to the conversion circuitry 320 .
As such, for the time that the underflow condition exists, the sample stream from the coherent phase buffer 330 replaces a sample stream from the transmission buffer 324 . When the underflow condition lifts, the samples from the transmission buffer 324 replace those from the coherent phase buffer 330 , since valid digital samples of an analog output signal are now present in the transmission buffer 324 and are available for output to the conversion circuitry 320 .
It should be noted that the portions of the modem 300 may exist in hardware, or in software, or in some combination thereof. For example, the coherent phase buffer 330 or the transmission buffer 324 may be implemented in software, as well as being implemented in physical embodiments.
The coherent phase buffer may also be used in another manner. The modem 300 may monitor the status of the transmission buffer 324 . When the level of the outgoing samples in the transmission buffer 324 reaches a predetermined low level, the modem 300 may start to use the appropriate samples out of the coherent phase buffer 330 . In this manner, the level of valid samples in the transmission buffer always remains positive. When the level of valid samples reaches a level in which the modem can operate in a normal manner again, the modem 300 will again substitute back to using the samples from the transmission buffer 324 .
FIG. 4 is a timing diagram showing the interaction of an outgoing analog signal, and the coherent phase buffer of FIG. 3 . First, a modem produces an outgoing analog transmission signal 400 . The modem receives digitized samples of the outgoing data, represented by the solid arrows within the signal 400 , from a computer memory. The modem puts these samples into a transmission buffer, from where the samples are sent to a conversion circuitry. The conversion circuitry converts the digital samples into the signal 400 .
A coherent phase buffer 410 contains samples 412 a-n of a signal that correspond to the output carrier signal of the modem. As the samples in the transmission buffer are sent to the conversion circuitry and later output as an analog signal, a pointer 420 marks the sample in the coherent phase buffer 410 containing a corresponding sample of the analog output signal coherent with the outgoing signal. As each sample in the analog signal is sent to the conversion circuitry, the pointer 420 into the coherent phase buffer is incremented. As such, the modem tracks the appropriate point in the coherent phase buffer 410 corresponding to a proper start of a potential patch wave.
At a time T 1 , the transmission buffer has gone into an underflow condition. As such, no valid samples are available in the transmission buffer that may be processed into a proper analog output signal. However, when this condition occurs, the pointer 420 into the coherent phase buffer 410 will mark an appropriate start point from which the modem may make available to the conversion circuitry a coherent patch waveform. While the transmission buffer is still in an underflow condition, the modem will output samples from the coherent phase buffer 410 to the conversion circuitry. The conversion circuitry then transforms the samples from the coherent phase buffer into an analog signal which is then output to the remote modem over a communication link.
The coherent patch signal is denoted as a dashed analog signal 490 , and the samples from the coherent phase buffer 410 making up the coherent patch signals are denoted as dashed arrows beneath the coherent patch signal. Each of the samples making up the coherent patch signal is taken the coherent phase buffer 410 , denoted as shaded.
Assume that the underflow condition ceases at the time T 2 . Outputting the next valid sample in the transmission buffer at that time would not be coherent. Thus, the patch waveform from the coherent wave buffer must be continued until the valid samples contained in the transmission buffer may be coherently reattached to the outgoing analog signal.
As such, the samples from the coherent phase buffer must be supplied to the conversion circuitry until a suitable reattachment of the next valid sample in the transmission buffer is possible. Thus, the shaded samples in the coherent phase buffer 410 must be output, allowing attachment of the next valid data sample in the transmission buffer to the coherent patch signal. As such, the coherency and stability of an outgoing analog signal is maintained in presence of missed samples.
As such, a system describing the addition of phase coherent samples to make up for lost samples is described. In view of the above detailed description of the present invention and associated drawings, other modifications and variations will now become apparent to those skilled in the art. It should also be apparent that such other modifications and variations may be effected without departing from the spirit and scope of the present invention as set forth in the claims which follow.
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The present invention envisions the use of a coherent signal to make up for lost or delayed samples to a modem. The modem contains a coherent phase buffer containing samples of at least a cycle of a coherent signal corresponding to an outgoing signal. When, for any reason, the samples for the outgoing signal are lost or delayed, the modem adaptively patches the outgoing signal with samples from the coherent phase buffer. The modem tracks the outgoing signal, and synchronizes a pointer into the coherent phase buffer outgoing signal. Thus, when the outgoing signal samples are delayed or lost, the modem may replace the invalid samples from the samples of the outgoing data signal with a patch of an appropriate sample or samples from the coherent phase buffer. As such, disruptions of the modem session associated with an incoherent signal during modem communications are avoided.
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FIELD OF THE INVENTION
This invention is directed to spinning toys, and particularly aerodynamic spinning toys wherein the toy carries a reservoir and centrifugally discharged water.
BACKGROUND OF THE INVENTION
Many spinning toys are known, from hula hoops to aerodynamic discs. The spinning of such toys is essential to their operation because it provides dynamic stability. This invention is directed to the concept of employing that spinning to achieve the secondary benefit of discharging water out of an onboard reservoir by way of the pressure generated by spinning through one or more radially outward positioned discharge nozzles.
SUMMARY OF THE INVENTION
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a spinning toy with water discharge wherein the spinning toy carries a water reservoir thereon and the water reservoir has an outlet opening positioned radially outward from the spinning axis so that, when the toy is spinning, water is discharged from the opening. A preferred embodiment is an aerodynamic disc.
It is, thus, an object and advantage of this invention to provide a spinning toy with water discharge wherein the spinning toy spins about an axis. A reservoir carried on the spinning toy has a discharge opening positioned radially outward from the axis so water in the reservoir is discharged upon spinning of the toy.
It is a further object and advantage of this invention to provide a spinning toy with water discharge which enhances the play value of the spinning toy.
It is another object and advantage of this invention to provide a spinning toy with water discharge which is economic of manufacture and which is easily used so that the spinning toy can be widely enjoyed.
Other objects and advantages of this invention will become apparent from a study of the following portion of the specification, the claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the first preferred embodiment of the spinning toy with water discharge in accordance with this invention.
FIG. 2 is a side-elevational view thereof.
FIG. 3 is a transverse section through the spinning toy on its spinning axis.
FIG. 4 is an isometric view of the second preferred embodiment of the spinning toy with water discharge of this invention.
FIG. 5 is a plan view thereof.
FIG. 6 is a section taken generally along line 6--6 of FIG. 5.
FIG. 7 is an enlarged section, with parts broken away, taken generally along line 7--7 of FIG. 5.
FIG. 8 is an enlarged section, with parts broken away, through the filling port of the reservoir, showing the filling plug in exploded position.
FIG. 9 is an enlarged section taken generally along line 9--9 of FIG. 5.
FIG. 10 is a view similar to FIG. 9, showing the toy body before the reservoir cover is attached.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1, 2 and 3 illustrate a first preferred embodiment of the spinning toy with water discharge of this invention where it is generally indicated at 50. The spinning toy has a body 52 which is disc-shaped with a convex top 54, concave bottom or under surface 56 and a down-turned rim 58. The body 52 is configured in the form of a well-known aerodynamic spinning toy. The structural difference of the body 52 is that it is molded of open, self-substantially rigid synthetic polymer composition material. This open self-foam material is positioned interiorly of the body and is generally indicated at 60 in FIG. 3. It comprises a foam layer throughout the dome-shaped body and down into the rim thereof. Upper and lower skins 62 and 64 are naturally formed on the film during the molding process and form the convex top and concave bottom surfaces.
The foam layer 60 serves as a reservoir. To permit water to flow into and out of the reservoir, at least one outlet opening is provided on the rim 58. Outlet openings 66 are specifically indicated in FIG. 1, outlet opening 68 is specifically indicated in FIG. 2, and outlet opening 66 is specifically identified in FIG. 3. As is seen in FIGS. 1 and 2, there is a series of outlet openings around the outer periphery at the downturned rim. The downturned rim forms a wall which is radially outward from the spinning axis. The spinning axis is the geometric center of the toy 50. When there is water in the reservoir formed by the foam layer and the toy 50 is launched, the spinning induced by the launch causes the water in the reservoir to be moved to the outlet openings by the pressure caused by the centrifugal force resulting from spinning. Water is thus discharged from the outlet openings to spray those along the flight path. The reservoir can be recharged by submerging the body 52 in water, preferably edgewise, so that air can bubble out while the water enters most of the openings. If desired, a separate inlet could be provided. This would mean removing the skin from the body, either the upper skin or lower skin on the axis so that water entry could be faster, but the water would move radially outward due to centrifugal force to move toward the outlet openings rather than be discharged from the axially located central filling opening. The outlet openings 66 and 68 and their companion openings may be punched into the rim 58, preferably in a radial direction. Another way to provide these openings is to remove the entire outer skin in sections around the rim or completely around the rim. In this way, the open self-foam core would be exposed in certain limited areas, and the foam openings themselves would serve as the outlet openings.
FIGS. 4, 5 and 6 illustrate a second preferred embodiment of the spinning toy with water discharge of this invention where it is generally indicated at 10. The toy 10 may be any type of spinning toy and, in the preferred embodiment shown, it is an aerodynamic disc. However, other types of spinning toys can incorporate the water reservoir and discharge nozzles, in accordance with this invention. The toy has a body 12 which is circular, as seen in plan view in FIG. 5. The body has an axis which is perpendicular to the sheet in FIG. 5 at the center of the circular body. As seen in FIG. 6, the circular body has a downwardly directed lip 14 which is part of the aerodynamic design. The body is of thin wall construction, as seen in FIG. 6, and may be molded of thermoplastic synthetic polymer composition material. The dome 16 of the body is upwardly convex. Toward the center, the body has a downwardly curved lower reservoir wall 18. As seen in FIG. 10, the dome 16 and lower reservoir wall 18 are contiguously formed and preferably have a cylindrical wall 20 therebetween. The cylindrical wall is concentric about the axis and terminates in a shoulder 22.
Reservoir cover 24 is a circular domed structured, generally a surface of revolution around the same axis. It has a downwardly extending lip 26, see FIG. 9, which engages inside the cylindrical wall 20 and against the shoulder 22 to substantially enclose the reservoir space 28. On the axis, reservoir cover 24 has an inlet opening 30, see FIG. 8. Cap 32 can engage in the opening to substantially close the opening, as shown in FIGS. 4, 2 and 3. The cap 32 can be removed, as shown in FIG. 8, to permit the pouring of water into the reservoir space. Ears 34 on the cap resiliently engage below the inlet opening to releasably retain the cap in place. The reservoir cover is domed to define a compatible curvature with the dome of the body.
As thus far described, with the reservoir cover sealed into the body around lip 26, a reservoir without an outlet has been described. However, nozzle housings are formed on the reservoir cover. Nozzle housings 36, 38, 40 and 42 are formed upward from the dome of the reservoir cover so that they provide a nozzle wall which is above the dome 16. Nozzle wall 44 is illustrated for nozzle housing 36 and is seen in FIG. 7. The nozzle wall 44 is preferably in line with lip 26, as shown in FIG. 4. In any event, the nozzle wall 44 extends above dome 16 to permit outlet openings or nozzles therein. Outlet nozzle 46 is shown in nozzle wall 44 in FIG. 7. Outlet nozzles 48 and 49 are shown with respect to nozzle housing 42 in FIG. 1. Only one nozzle may be provided in each nozzle wall, or more than two may be provided if more droplets are desired. Furthermore, while four nozzle housings are illustrated, more may be employed, but it is thought that more than four nozzle housings and more than eight outlet nozzles are not required. The number and size of outlet nozzle openings is a function of the desired droplet size of how quickly the discharge of water is desired.
The toys 10 and 50 are toys which spin when they are played with. The spinning causes spinning of the water in the reservoir space, and the spinning of the water causes centrifugal force at the nozzle openings since the nozzle openings are radially outward from the axis of spinning. Water pressure builds up within the reservoir space at the outlet nozzle as a function of rotational speed and radius. When the toys 10 and 50 have water in their reservoir spaces and are played with in the normal manner, the spinning of the toys causes discharge of the water from the outlet nozzles. This adds an additional pleasure factor in playing with the spinning toys. When the spinning toys are aerodynamic discs, as indicated in the preferred embodiment, the discs are designed so that they fly a substantially straight and level flight when properly thrown. The water discharge is thus delivered substantially horizontally along its flight path, giving water droplet sensations to the persons along its path.
This invention has been described in its presently contemplated best embodiment, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
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Spinning toy carries a reservoir thereon with radially outward positioned discharge openings. When the reservoir is spun, water is discharged due to centrifugal forces resulting from the rotation of the spinning toy. A preferred embodiment is an aerodynamic disc.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/823,430, filed Jun. 27, 2007, which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present development relates generally to stent or graft devices for implantation in an anatomical structure and, more particularly, to intravascular catheter deliverable branched stent or graft devices and methods of fabrication. Embodiments include unique branched stent or graft devices for the treatment of abdominal aortic aneurysms (AAA) involving the aorta-iliac bifurcation by reinforcing, excluding, bridging, or lining the diseased vessel, and to methods of fabrication of such as stent or graft devices involving a unique braiding technique using a single plurality of filaments to form two hinged legs and the common body or trunk portion of the device.
[0004] II. Related Art
[0005] An aortic aneurysm is a weak area in the wall of the aorta, the main blood vessel that carries blood from the heart to the rest of the body. The aorta extends upwards from the heart in the chest and then arches downwards, traveling through the chest (the thoracic aorta) and into the abdomen (the abdominal aorta). The normal diameter of the abdominal aorta is about one inch (2.5 cm).
[0006] Aortic aneurysms are frequently caused by the breakdown of the muscular layer and the elastic fibers within the wall of the aorta. The breakdown usually occurs over time, frequently in patients over 40 years of age, and can be caused by prolonged high blood pressure, effects from smoking or a genetic predisposition. As the vessel tissues deteriorate, the vessel wall strength decreases, and the high blood pressure causes the aortic wall to stretch beyond its normal size, forming an aneurysm. The weak aneurysm bulges like a balloon over time and can burst if the wall becomes too thin and weak to hold the blood pressure.
[0007] Most commonly, aortic aneurysms occur in the portion of the vessel below the renal artery origins. The aneurysm may extend into the aorta-iliac bifurcation and into the iliac arteries supplying the hips, pelvis and legs.
[0008] Once an aneurysm reaches 5 cm (about 2 in.) in diameter, it is usually considered necessary to treat to prevent rupture. Below 5 cm, the risk of the aneurysm rupturing is lower than the risk of conventional surgery in patients with normal surgical risks. The goal of therapy for aneurysms is to prevent them from rupturing. Once an AAA has ruptured, the chances of survival are low, with 80-90 percent of all ruptured aneurysms resulting in death. These deaths can be avoided if the aneurysm is detected and treated before it ruptures and ideally treated at an early stage (smaller aneurysm) with a lower risk procedure.
[0009] AAA can be diagnosed from their symptoms when they occur, but this is often too late. They are usually found on routine physical examination, through use of ultrasound, or by chest and abdominal X-rays. On examination, a doctor may feel a pulsating mass in the abdomen. If the doctor suspects an aneurysm, he/she will probably request that an ultrasound scan be carried out. Other scans, such as computerized tomography (CT) and magnetic resonance imaging (MRI) may also be performed. These scanning techniques are very useful for determining the exact position of the aneurysm.
[0010] The surgical procedure for treating AAA involves replacing the affected portion of the aorta with a synthetic graft, usually comprising a tube made out of an elastic material with properties very similar to that of a normal, healthy aorta. This major operation is usually quite successful with a mortality of between 2 and 5 percent. The risk of death from a ruptured AAA is about 50%, even during surgery.
[0011] More recently, instead of performing open surgery in undertaking aneurysm repair, vascular surgeons have installed an endovascular stent/graft delivered to the site of the aneurysm using elongated catheters that are threaded through the patient's blood vessels. Typically, the surgeon will make a small incision in the patient's groin area and then insert a delivery catheter containing a collapsed, self-expanding or balloon-expandable stent/graft to a location bridging the aneurysm, at which point the stent/graft is delivered out from the distal end of the delivery catheter and allowed or made to expand to approximately the normal diameter of the aorta at that location. The stent/graft, of course, is a tubular structure allowing blood flow through the lumen thereof and removing pressure from the aneurysm. Over time, the stent/graft becomes endothelialized and the space between the outer wall of the stent and the aneurysm ultimate fills with clotted blood. At this time, the aneurysm is no longer subjected to aortic pressures and thus will not continue to grow.
[0012] In treating AAAs that involve the aorta-iliac bifurcation, various stent or grafts designs have been placed to support, bridge or reline the vessels in the aneurysm segments. This has often involved multiple self expanding stents or stent grafts such as a large diameter stent or graft in the aortic segment and two smaller stents or grafts placed in each of the iliac arteries. In other designs the stent or graft has been designed to extend from the aortic segment into one branch of the iliac artery. In this case a hole is provided in the stent or graft to accommodate blood flow to the other iliac artery. A second stent or graft may be optionally placed into the other iliac artery and extending into the hole in the first stent or graft provided for iliac branch blood flow.
[0013] It has become apparent through use and clinical experience that the junctions of multiple stents or grafts presented placement problems of component alignment within the body. The stents or grafts being independent of each other caused components to rub against each other causing metal fatigue and flow discontinuities or thrombosis could occur where one component was not aligned with another and protruded into the blood flow. Use of multiple components also caused uneven vessel support such as where overlapping components may have an excess in vessel support as well as unsupported portions of the vessel where gaps occur between components. In the case of grafts, gaps between components cause leaks and may result in continued blood pressure exposure to the aneurysm.
[0014] As a result there remains a need for an alternative one piece stent or graft designs that covers the entire aneurysm segments including the main aortic segment as well as both iliac artery segments. It is also desirable that such a design be collapsible for percutaneous catheter delivery to the treatment site as well as self expandable when deployed from the delivery catheter.
[0015] U.S. Pat. No. 6,409,750 to Hyodoh et al. discloses woven bifurcated and trifurcated stents together with methods of fabrication. Those devices include a first plurality of wires defining a first leg having a first portion and a second plurality of wires defining a second leg having a second distal portion, and a common body having a distal end and a proximal portion, the common body being formed from at least the first and second plurality of wires, the proximal portion of the common body being adjacent to the distal portions of both legs, and both ends of at least one wire from both of the pluralities being located proximate the distal end of the common body. In this design the braided legs are connected only by the common body portion and gaps in metal coverage occur near the juncture of the legs.
[0016] U.S. Pat. No. 7,004,967 to Chouinard et al. describes a process for manufacturing a braided bifurcated stent. The process involves the use of two or more braiding machines in which a first discrete plurality of filaments are braided to form a first leg, and a second discrete plurality of filaments are braided to form a second leg. The process involves braiding the first plurality of filaments and the second plurality of filaments together to form the body using another braiding machine. That design results in metal coverage gaps occurring at the outside top portion of each leg and the process requires the use of multiple braiding machines. As with other concepts, the legs are not connected except to the common body portion. There are no common wires from one leg connecting to the other leg so a gap occurs between them.
[0017] There exists a need for a one piece branched stent or graft device that has improved metal coverage for uniform properties and a manufacturing process that is simple and produces a one piece design from a single discrete plurality of wires. There is a need for an improved bifurcated stent or graft that incorporates wires from one leg into the other leg creating a wire hinge and reinforcing the crotch area of the device. There is also a need for a device having the improved characteristics as above and which is also deliverable using a percutaneous intravascular catheter approach having a collapsed configuration for delivery through a catheter and a self expanding configuration when released from the catheter confines. The present development provides such a device.
SUMMARY OF THE INVENTION
[0018] The present concept includes embodiments of catheter-deliverable, endovascular, one piece, multi-region stent or graft devices. Embodiments include bifurcated stent or graft devices for treating abdominal aortic aneurysms involving the aorta-iliac bifurcation. An important aspect of the concept includes a braiding fabrication technique that enables a single bundle or a single plurality of filaments to be used to form a plurality of regions, such as distinct regions of a device including a first region, a second region and a third region.
[0019] One preferred embodiment, for example, includes three regions: the first region and second region form two hinged legs and a third region forms a common body or trunk portion of the device. The third region is braided from a subset of the same single plurality of filaments forming the two hinged legs. In this manner, the stent or graft structure includes a single plurality of resilient filaments that are braided to define a pair of hinged legs and a common body or trunk. The stent or graft has a filament hinge in the crotch area connecting the legs. The filaments are preferably a shape memory metal such as nitinol wire but may be or may include other metals that have an elastic heat settable shape. A polymer filament overlaying version can be used as part of a grafted device.
[0020] As used herein the terms “filament” and “wire” are used interchangeably to describe strands of any suitable type of material including metal and non-metal materials used in aspects of the devices. As used herein, the term “braiding” includes interweaving where appropriate. It will be appreciated the term includes any braid or weave which enables elongation of the device with corresponding reduction in diameter so that the device may be delivered by vascular catheter.
[0021] One preferred method of fabrication includes braiding a plurality of highly elastic filaments supplied from a plurality of braiding spools onto an assembled two-piece or two-part mandrel. The filaments are braided onto a first part of the mandrel to form a first leg. The braiding is stopped and the braid is secured around the mandrel at the first leg distal end (last braided portion) using tape or other clamping means.
[0022] Long loops are formed from each filament exiting the tape/clamp above the distal end of the leg except for filaments that are intended to be the crotch or hinge filaments or wires connecting the legs. The filament loops created are made long enough to later be braided into the common body portion or trunk of the stent or graft. Once the loops are formed, they are coiled or spooled and secured to be out of the way so as not to become entangled in continued braiding. The loop end is taped/clamped to the mandrel on top of the loop starting point. The braiding process is restarted and a second leg is braided over a second part of the mandrel using the same plurality of filaments that were used to braid the first leg.
[0023] Once the second leg has been braided to a desired length, the filaments are taped/clamped to the mandrel and cut from the braiding spools. The braid and mandrel are removed from the braiding machine. The two parts of the two-piece assembled mandrel are separated and the legs and first and second mandrel parts are manipulated in relation to each other to position the legs adjacent each other connected by the hinge filaments. Next, a common body portion or trunk mandrel is attached using leg extensions designed to be inserted into the top of each leg mandrel. The loops that were formed and coiled or spooled are then made available for braiding the common body portion or trunk of the stent/graft.
[0024] At this point, a plurality of trunk braiding options are available and a decision is now required to determine which variation of braiding the trunk is to be selected. One option or choice is to leave the spooled loops intact and braid both filaments of each loop along the same path. A second choice is to unwind the loops, sever the end of each loop and rewind the two filaments onto separate braiding spools. The two braided loop filaments can then be wound in opposite helical directions.
[0025] In either braiding choice the filaments are spooled and placed on the braiding machine spool carriers and the new mandrel assembly is installed in the braiding machine. The common body portion or trunk is then braided using a major portion of the same plurality of filaments used to braid the legs. The remaining portion of the plurality of filaments or those not used to braid the trunk, are the filaments selected to form the hinge connecting the legs. The braiding machine for braiding the trunk will require a different number of spool carriers as compared to the leg braiding. In the case of the loops being severed into two pieces, for example, the number of braiding machine spool carriers will be much higher in number than if the loops are left intact.
[0026] Aspects of the inventive concept encompass both the method of fabrication of the branched stent or graft device and also the medical device that results from use of the process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic illustration of the braiding of both legs of a branched stent or graft device over an assembled two-part mandrel and showing the formation of loops between the leg segments;
[0028] FIG. 2 is side view of two legs of the device of FIG. 1 after braiding and separation of the two-piece mandrel;
[0029] FIG. 3 is a top view of the device shown in FIG. 2 illustrating the filaments available for braiding the trunk portion of the device;
[0030] FIG. 4 is a perspective drawing of a trunk mandrel prior to assembly to the leg mandrels;
[0031] FIG. 5 is a top view of the legs indicating an area for optional manual braiding;
[0032] FIG. 6 is a side view of one embodiment of a final device;
[0033] FIG. 7 is a side view of an alternative embodiment; and
[0034] FIG. 8 is a schematic top view illustrating a 32 filament braider showing the spool carriers 1 - 32 .
DETAILED DESCRIPTION
[0035] Embodiments will next be described with reference to the drawing figures. Such figures and the accompanying detailed description are meant to be illustrative rather than limiting and are included to facilitate the explanation of aspects of the inventive concepts, including devices and methods of fabrication of the devices.
[0036] Two preferred final device configurations of a branched stent/graft are shown in FIGS. 6 & 7 . These embodiments consist of two leg portions formed with a common body or trunk portion.
[0037] One aspect of the development involves the materials of construction of a device contemplated by the present invention. The device is fabricated from a single plurality of filaments which in the preferred embodiment should include a material which is both resilient and which can be heat treated to substantially set a desired shape. Materials found suitable for this purpose include a cobalt-based low thermal expansion alloy referred to in the field as Elgeloy, nickel-based high temperature high-strength “superalloys” commercially available from Haynes International under the trade name Hastelloy, nickel-based heat treatable alloys sold under the name Incoloy by International Nickel, and a number of different grades of stainless steel. The important factor in choosing a suitable material for the filaments or wires is that the filaments retain a suitable amount of the deformation induced by a molding surface when they are subjected to a predetermined heat treatment.
[0038] One class of materials which also meet these qualifications includes so-called shape memory alloys such as nitinol, an approximately stoichiometric alloy of nickel and titanium, which may also include minor amounts of other metals to achieve desired properties. Such alloys tend to have a temperature induced phase change which will cause the material to have a preferred configuration which can be fixed by heating the material above a certain transition temperature to induce a change in the phase of the material. When the alloy is cooled back down, the alloy will “remember” the shape it was in during the heat treatment and will tend to assume that configuration unless constrained from so doing.
[0039] As an example, without limitation, the device can be illustrated being fabricated from 32 braided nitinol wires having a diameter ranging from 0.0015-0.008 inch (0.0381-0.203 mm), preferably 0.002-0.005 inch (0.051-0.127 mm). The number of wires to be braided may range from 4-200 or more, preferably from 8 to 144 and, more preferably, from 16-72 depending on the particular device characteristics desired. FIG. 8 shows a schematic top view illustrating 32 numbered spool carriers on a braiding machine 100 . All the even numbered spool carriers travel in one direction (clockwise) and all the odd numbered spool carriers travel in the opposite direction (counter-clockwise). In addition, as the spool carriers travel in a circular direction, they also change radius of travel about the center of the braider passing inside of one spool carrier and outside of the next spool carrier, thereby forming wires wrapped about a center mandrel that are woven over and under each other in a braided configuration. As the spool carriers are moving, the mandrel is slowly moved in a vertical direction at a controlled speed relative to the braider speed to set the pitch of the braided wires. A typical pitch angle may range from 30-70 degrees from the longitudinal axis of the braided tube in the, as braided, relaxed tube prior to heat treatment. The pitch, pick count (number of wire crossovers per inch, or other lineal measure) and wire diameter, are all variables that can be altered to change the device characteristics as well as the heat set shape.
[0040] Referring now to FIG. 1 , there is shown a tubular mandrel consisting of two parts 20 and 22 . The two-piece mandrel may be assembled together by sliding the two parts over a close fitting shaft and holding them in place with removable end caps (not shown) or by any number of other known suitable means. The braiding of a first region or leg 24 begins at the bottom of the mandrel as indicated in the illustration. The braid starts by attaching, as by taping or clamping, the thirty-two filaments or wires 25 to the mandrel as at 26 . The braiding is begun at a controlled pitch until a desired sufficient length is generated for the first leg 24 near the center of the assembled mandrel The braiding is stopped and the braided wires are next taped or clamped in place on the mandrel at location 28 .
[0041] After the braiding of the first leg 24 , a hinge zone 30 that represents the portion of the circumference of the first braided leg 24 to be connected directly to the second braided leg 36 is designated. In a preferred arrangement using the illustration of a thirty-two filament or wire braid, this will typically range between about 4 to 8 wires or from 4/32 to 8/32 (⅛ to ¼ of the total) of the circumference of the legs based on the thirty-two filament braid. As an example, 4 wires may be designated as the hinge area 30 . That leaves (32−4) or 28 remaining wires of the braid that will be configured differently.
[0042] Each of the remaining 28 wires leading from the spool carriers as at 32 will have a specific length of filament or wire drawn off the spool to form a loop as at 34 of wire, the loop beginning at the taped mandrel at 28 (end of leg one) and ending back at the same spot at the mandrel. The loop length is predetermined and is at least the length needed to braid the common body portion plus leader length for a braiding machine. The loops 34 are taped to the mandrel over the first tape at location 28 such that the wire leading back to the spool carrier as at 32 is at the same position as it was prior to the forming of the loop. After each loop 34 is secured, the loop material may be spooled or otherwise routed away from the braiding action to prevent the filament or wire from becoming entangled with the next braiding process.
[0043] It will be appreciated that all 32 wires are still oriented radially about the mandrel to begin braiding the second leg 36 from taped filaments as also shown in FIG. 1 . The braiding is started at about mid point on the assembled mandrel and continues until the desired braided length for the second leg 36 has been completed. At this point, both ends of the leg 36 braid are secured to the mandrel by tape 38 and 40 ( FIG. 2 ) or other clamping means. Next, the 32 wires from the spool carriers may be cut about 2 inches (5.1 cm) from the mandrel and the assembled mandrel and braided legs may be removed from the braiding machine along with the 28 loops of braid filament or wire. A typical filament feed spool is shown at 44 mounted on a spool carrier device 42 in a well known manner.
[0044] In FIG. 2 , the central shaft of the mandrel has been removed so that the two halves of the mandrel may be separated and manipulated relative to each other to assume the relative positioning shown in the Figure. For example, the upper mandrel for the second leg may be turned upside down and pivoted about the hinge 30 as shown. The wire loops 34 are shown in the top view in FIG. 3 . Note that the hinge area 30 has no loops as none were formed in this region.
[0045] As indicated, there are several options involving different procedures for forming the body or trunk portion of the device. Versions of preferred embodiments and examples will be discussed next.
[0046] In a first embodiment, the distal ends of the wire loops are not cut or severed and each of the loops 34 is wound with the two wires together onto a spool for braiding the common body or trunk of the stent/graft using double strands. Thus, in the example, 28 spools of two filaments or wires each are available to be placed onto a braider that has at least 28 spool carriers.
[0047] In an alternate embodiment, the wire loops are severed toward the ends to form two wires of substantially equal length from each original loop. The two wires are wound on separate spools for placement on a braider including at least (2 times 28) or 56 spool carriers.
[0048] FIG. 4 illustrates one shape of a mandrel at 50 , which may be solid or hollow, for forming the common body or trunk of the stent or graft. There are two pilot diameters or leg extensions 52 and 54 for insertion into the corresponding two-leg mandrels. The now three-part mandrel is secured together by fasteners or other known means and mounted into the braider in a well known manner for braiding the third region or common body or trunk configuration of the device. The corresponding spools are loaded onto the spool carriers as well.
[0049] FIG. 5 illustrates an area of transition between the stent/graft leg diameter and the trunk diameter where it may be advisable to optionally hand braid about 4-8 wires of each side of the device as at 60 and 62 to bridge the diameter transition prior to beginning of the machine braiding for the trunk. To do this, the spools involved in the hand braiding are removed from the carrier and then returned to the carrier prior to full machine braiding. This optional process provides smaller openings in the stent/graft between wires in the leg to crotch to trunk transition and makes for a less open device lattice.
[0050] As indicated in one embodiment, the 28 pairs of wires are braided together over the mandrel in FIG. 4 for the desired length of the trunk. The braiding is stopped and the filaments or wires are taped or clamped to the mandrel. The wires leading to the spools are cut and the mandrel assembly and braided device are removed from the braider. A finished device in accordance with the embodiment is shown in FIG. 6 . The trunk portion with the mesh of double filament loops is shown at 72 .
[0051] In an alternative embodiment, the severed loops on 56 individual spools of wire are braided together over the trunk mandrel 50 in FIG. 4 for the length of the trunk shown in the embodiment 80 in FIG. 7 as 82 . The braiding is then stopped and the wires are taped or clamped to the mandrel. The wires leading to the spools are cut and the mandrel assembly and braided device are removed from the braider. The finished device 80 has a trunk portion braided from single filaments or wires as is shown in FIG. 7 .
[0052] In the embodiment with the loop braid, the final braiding of the trunk may be accomplished on the same original 32 carrier braider used for braiding the legs, but four of the spools, i.e., every 8th spool, would be empty. However, this would cause the final device to exhibit gaps between some of the braided wires. This is not as desirable as using a braider with the exact number of needed spool carriers. The gaps can be manually spaced more evenly prior to the final device heat treatment to be discussed in the following. Braiders are available in a wide variety of spool carrier numbers such as 4-200 or more in increments of four carriers as offered, for example, by Steeger USA, Spartanburg, S.C.
[0053] The heat treatment process follows the braiding of the device. In the case where the braiding process was accomplished on a mandrel that equals the final device size, the braid may remain on the mandrel if the mandrel was made of metal or a material able to adequately handle the temperature of the device heat treatment. Heat treatment techniques are generally known to those skilled in the art.
[0054] U.S. Pat. No. 5,725,552 to Kotula et al., incorporated herein in entirety by reference, for example, describes in great detail the heat treatment of braided medical devices made of nitinol wire and the process of confining the device in a mold of the desired final device shape during the heat treatment to set the final device shape in memory. In this regard, it has been found that holding a nitinol fabric or braid at 500-550° C. for a period of about 1-30 minutes, depending on the hardness or softness desired, will tend to set the braid in the shape held during the heat treatment. The materials used to hold the braid in place must be suitable for the temperature range of the heat treatment. For example, the tape if used to hold the braid down may not be suitable, so a metal clamp may be substituted or other means known in the art.
[0055] The devices shown in FIGS. 6 & 7 show a slight amount of flare at the trunk as at 74 and 84 and the leg ends as at 76 and 78 ( FIG. 6 ) which can be molded in during a heat set process by holding the braid in the flared condition during the heat set. Any gaps between wires, such as occurring from braiding 28 wires on a 32 spool carrier braiding machine may also be manually repositioned as desired. After heat treatment, they will retain the repositioned shape.
[0056] If the braiding mandrel is not the desired final heat set shape for the device, the braided device may be removed from the mandrel and placed in a separate mold to produce the desired shape for heat treatment. After heat treatment and shape setting, the braid will resist unraveling without the need for clamps or other retention means. The flared ends of the trunk and legs have been found to assist the device in seating against the artery walls and, in addition, help prevent the wires from catching on other devices that may be passed through the stent or graft. Preferably, the trunk and legs are sized to be somewhat larger (example 5-30%, preferably 15-20%) in the stent/graft relaxed state than the size of the artery in which they are to be placed, to thereby exert outward pressure on the arterial wall to aid in device seating and retention.
[0057] Heat set stents or grafts fabricated by the present braiding process are easily collapsed to a small diameter for delivery through an intravascular catheter lumen by pulling on the trunk and leg ends and stretching the braided wires along the longitudinal axis of the device. Once the device is positioned within the catheter and delivered to the treatment site, the stent/graft may be urged out of a catheter lumen end opening. The released device will self expand to its heat set memorized size or against the arterial wall if the artery is smaller. It will be appreciated that the design of the delivery catheter is somewhat more complex for a branched stent or graft. Examples of such delivery devices are illustrated in detail in U.S. Pat. No. 6,409,750 to Hyodoh et al. and U.S. Pat. No. 6,953,475 to Shaolian et al.
[0058] The branched braided configuration may be used as a stand alone stent or the braid may be a component of a graft whereby a polyester or other braided polymer or woven fabric may be added to the outside of the braided metal structure to serve as a sealing surface to the graft. In this type of configuration, the braided metal expansion characteristics urge the graft fabric out against the arterial wall. The fabric may be attached to the braid by suture as an example or by other means known in the graft art. Alternatively, the polyester or other braided polymer or woven fabric may be added to the inside of the braided metal structure and attached by suture.
[0059] Another embodiment of the graft consists of braiding a separate polyester filament using the same techniques as described for the metal filaments or wires. In this embodiment, the braided polymer branched graft material is placed over the heat set metal braid structure and the polymer braid sutured to the metal braid for retention. Alternatively, the branched graft material may be placed within the metal braided structure and sutured to the metal structure. By using similar pitch and pick count for both the metal braid and polymer braid the device can easily collapse and self expand as a unitary device. It should be noted that the underlaying or overlaying polyester or other braided polymer may be fabricated of multiple independent components attached to the metal structure.
[0060] In still another embodiment the graft is made using the same braiding process but the single plurality of filaments used to fabricate the graft consists of a combination of metal and polymer filaments braided together in a single operation. The number of metal and polymer filaments and the ratio of metal to polymer may be altered as desired to obtain sufficient self expansion force and adequate polymer density for sealing of the graft. The process allows for a great deal of flexibility in graft design.
[0061] The present stent or graft braiding process, unlike other techniques, provides for fabrication of a one piece tubular framework device whereby the legs are connected by a hinge and the legs and trunk are fabricated from a single plurality or array of filaments. It will be appreciated that the legs may be the same or unequal in length, the same or unequal in diameter and of a constant (uniform) or vary in diameter along the length thereof (longitudinal axis) as desired in a particular application.
[0062] Although the example device illustrated is for the treatment of an abdominal aortic aneurysm involving the iliac bifurcation, it will be appreciated that the process for braiding and the resulting device is more broadly applicable and not limited to a branched stent or branched graft and a process for fabricating a branched stent or graft for treating a particular condition. There are numerous locations within the body where such a branched stent or graft may be needed and the process is suitable for other configurations as well as the inverted Y stent or graft illustrated. For example, it is anticipated that a side branch can be fabricated off a main braided tubular body in the manner of this invention by creating loops of filaments in a circular pattern at the location of the intended side branch. Such a process involves stopping the braiding machine as braid wires cross the side branch location, creating the loops, and repeating the process until the branch take off area is passed by the braiding. Once the main tube is braided, the loops may be used to braid the side branch.
[0063] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the example as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself.
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Branched braided stent or graft devices and processes for fabrication of the devices are disclosed in which a trunk portion and two hinge leg portions are fabricated in one piece braided from a single plurality of filaments, whereby the legs contain the full plurality of filaments and the trunk portion contains a subset of the same plurality of filaments. The fabrication process involves braiding the hinged legs on a mandrel while retaining loops of filament between the hinged leg portions for subsequent braiding of the trunk portion of the stent or graft.
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FIELD OF THE INVENTION
[0001] This invention relates to an improvement in both oil/grease and water sizing of cellulosic materials, especially paper products, through the use of a polyvinylamine in combination with both oil and water sizing agents.
BACKGROUND OF THE INVENTION
[0002] Sizing agents are used in papermaking processes to repel water or grease; i.e., oils, from adhering or penetrating into the paper, thus weakening and/or staining the paper. Sizing agents can be classified into reactive agents or non-reactive agents. They can also be classified into internal sizing agents or as surface sizing agents. Reactive sizing agents bond with the paper fibers and are usually used for internal sizing.
[0003] Sizing agents can be added to the paper furnish before the furnish enters the wet end of the papermaking machine. Alternatively, same sizing agents can be sprayed or nipped onto the newly formed paper as the paper passes through. If the sizing agent is added to the pulp slurry (i.e., the furnish) it must adhere to the pulp or it will not be retained in the paper. This can be achieved by using an agent that is oppositely charged from the pulp. Sizing agents in paper prevent excess penetration of water or grease into the paper. They are used where water or grease resistance is needed in the paper end use. There are no sizing agents that have adequate resistance properties of both. The most efficient oil-sizing agents for cellulosics, such as paper, contain long, linear fluorocarbons chains. Fluorocarbons in general have low surface energies and are not wetted easily by oil-based materials. Conversely, agents that contain non-fluorinated hydrocarbon chains are good water sizing agents.
[0004] However, when a combination of a fluorocarbon-based agent for oil resistance and a hydrocarbon based product for water resistance are both employed in paper making processes, each has an adverse affect on the other's performance. Accordingly, more material or product must be used to compensate for the adverse loss of resistant properties.
[0005] As described by Bottorff in U.S. Pat. No. 5,252,754, long chained fluorocarbons are efficient oil sizing agents for cellulosic materials such as paper due to their low surface energy. However, these fluorocarbon-based sizing agents are generally inefficient for water resistance, especially if they contain hydrophilic salt groups. On the other hand, hydrocarbon-based size products such as alkyl ketene dimer (AKD), are effective water sizing agents but are inefficient for oil sizing purposes. When combinations of both hydrocarbon and fluorocarbon-based materials are used, they have a negative impact on each other's performance in paper. This adverse relationship generally results in inefficient treatment schemes because elevated product levels are required to achieve both adequate oil and water resistance properties in the same paper.
[0006] It has now been discovered that the presence of a polyvinylamine in a paper or board furnish which furnish contains both oil (or grease), and water-sizing agents, the adverse effect is surprisingly counteracted.
SUMMARY OF THE INVENTION
[0007] In one aspect, the invention is a papermaking or board making process in which a furnish contains both an oil sizing agent and a water sizing agent. The improvement being that the furnish also contains a polyvinylamine.
[0008] Another aspect of the invention is the order of addition of the agents to the furnish. A water sizing agent is added to a paper furnish. The polyvinylamine is then added to the paper furnish either before or after the water sizing agent is added, followed by adding the oil sizing agent.
[0009] In addition the invention provides a paper furnish which contains at least one polyvinylamine, a water sizing agent and an oil sizing agent.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Adding a water-soluble cationic polyvinylamine when both an oil size and a water size are used in the papermaking process is an important aspect of the invention.
[0011] The furnish (i.e., pulp) is passed through a paper machine consisting of a head box, a sheet forming section and a drying section, all in sequence.
[0012] Polyvinylamines useful in this invention include but are not limited to ones produced through free radical solution polymerization of n-vinylformamide. The resulting nonionic polyvinylformamide can then be base-hydrolyzed, creating a primary amine cationic functionality on the polymer and sodium formate as a byproduct. Products effective for the purpose include, but are not limited to, vinylamine polymers that have been reacted to a hydrolysis level of 35-100% velocity 50-100% with molecular weight ranging from 300,000-400,000 via size exclusion chromatography (SEC) Copolymers of polyvinylamine can be used. Comonomers include vinyl acetate or vinyl propionate monomers.
[0013] The polyvinylamine polymers can be incorporated into the aqueous suspension of fibers used to form the web, i.e., the furnish.
[0014] By furnish is meant the mixture of various materials that are blended in the stock suspension from which paper or board is made; the chief constituents are fibrous material (pulp), sizing or strength materials, or other additives such as fillers and dyes.
[0015] By pulp is meant fibrous materials prepared from wood, cotton, grasses, etc, by chemical or mechanical processes for use in making paper, board, or cellulose products.
[0016] By wire is meant a woven material made of plastic or metal for use in forming the web of paper or board from the dilute pulp slurry.
[0017] By headbox is meant a flow control chamber that receives the dilute paper stock or furnish from the stock preparation system and acts to spread the flow uniformly across the full width of the forming wire.
[0018] By sheet forming is meant the process by which the dilute fiber furnish is formed into a wet web through vacuum and gravity drainage effects.
[0019] By drying section is meant the part of the papermaking process that involves the removal of excess water from the wet web of paper or board through direct contact with heated-drying cylinders.
[0020] By web is meant the sheet of paper or board coming from a paper machine in its full width.
[0021] Suitable water sizing agents include alkyl ketene dimers (AKD) or alkenyl ketene dimer (AKD), alkenyl succinic anhydride (ASA), rosin-based sizes such as rosin soap, dispersed rosin, and the like.
[0022] Suitable oil sizing agents include fluorocarbon-containing polymers such as those which have fluorinated alkyl groups.
[0023] In a preferred process aspect of the invention, the oil size and water size can be added to the furnish in amounts of 0.005% to 1.0% (weight percent) active treatment solids based upon total furnish solids, and the polyvinylamine can be present in an amount of between 0.001% and 1% active treatment solids based on upon total furnish solids.
[0024] The following Example A highlights the typical adverse relationship between oil and water sizing agents in cellulose-based systems requiring high levels of water and oil sizing.
EXAMPLE A
[0025] To make handsheets of paper, a Noble and Wood laboratory former was used to prepare 20 cm×20 cm handsheets at a basis weight of 160 grams/square meter.
[0026] A furnish containing bleached softwood Kraft pulp and bleached chemi-thermomechanical pulp were obtained from a commercial specialties manufacturer requiring significant water and oil sizing properties. The pulps were blended at a 1:1 ratio and refined in a laboratory cycle beater to 470 ml Canadian Standard Freeness (CSF). As outlined in Table A, commercial water and oil sizing agents were added sequentially to aliquots of the pulp. Stock agitation was accomplished with an overhead mixer assembly set at 1,400 rpm. The oil size treatment was added to the pulp (furnish), 30 seconds after the addition of the water sizing agent. Handsheet preparation commenced after an additional 30 seconds of mix time following the oil size treatment. Handsheets were formed on a 100 mesh screen, passed through a felted roll press set at 35 psi (single pass), and dried to 3-4% moisture using a drum dryer.
[0027] Performance testing was conducted with both a Hot Water Cobb test and a Hot Oil Cobb test to demonstrate water and oil resistance properties in the finished paper. The procedures for these tests are set forth below. The Hot Water Cobb test involves paper samples cut to 12.5 cm×12.5 cm, weighed to the nearest 0.01 g, and subsequently clamped inside a 100 ml Cobb ring apparatus. A 50 ml sample of water at 180° F. is then poured into the Cobb ring and on top of the paper. After exactly two (2) minutes of contact time with the paper sample, the water is quickly poured from the ring. The wetted paper sample is removed from the apparatus and placed between two pieces of blotting paper (wetted side up). The excess water is removed from the paper specimen by moving a Cobb hand roller once back and forth over the sample without exerting any additional force. The wetted paper sample is immediately reweighed to the nearest 0.01 g. The weight of water absorbed in grams per square meter is calculated by subtracting the conditioned weight of the sample from its final weight and multiplying by 100.
[0028] The Hot Oil Cobb test is identical to the Hot Water Cobb Test except that oil (Wesson® Corn Oil) is used at 220° F. in place of the water. The only other difference in the oil testing is that the Cobb hand roller is not used to remove the excess oil but rather the wetted paper sample is pressed by hand between blotter paper before the sample is gently wiped with a clean Kimwipes® towel. The Hot Oil Cobb test quantifies the weight of the hot oil absorbed in grams/square meter using the same calculation described under the Hot Water Cobb test.
[0029] In both the Hot Water and the Hot Oil Cobb tests, a higher test result indicates a greater degree of absorption by the paper sample. Conversely, a lower Cobb test value is indicative of low surface welting and penetration and better sizing properties. The data in Table A shows the typical negative impact of a water sizing agent on the performance of an oil sizing product. For example, as the treatment level of the water size is increased, the water sizing improved while the oil size property is reduced. The water sizing agent is comprised of alkyl ketene dimer while the oil size is a perfluoroalkyl-containing product.
TABLE A Water and Oil Sizing Results Commercial Water Commercial Oil Hot Water Hot Oil Size Size Cobb Cobb (wt. %) (wt. %) (g/m 2 ) (g/m 2 ) 0.132 0.225 162 89 0.155 0.225 71 118
[0030] The following definitions apply for Table A:
Commercial AKD Water Size: Hercon® 79—Hercules Incorporated Commercial Oil Size: imPress® FP-100—Hercules Incorporated Weight %: % Addition of Active Treatment Solids Based Upon Total Furnish Solids
[0034] The following Examples are illustrative of the surprising beneficial effect of polyvinylamine on both water and oil resistance in cellulose-based systems requiring high levels of water and oil sizing.
EXAMPLE 1
[0035] The data from Example 1 is summarized in Table 1. In this study, handsheets were prepared using the same papermaking procedure described in Example A with the exception that the furnish was comprised of 60% southern bleached softwood Kraft and 40% northern bleached hardwood Kraft commercial market pulps refined to 480 ml Canadian Standard Freeness (CSF). The target basis weight was 248 grams/square meter. The chemical addition sequence was as described in Example A except that when polyvinylamine was included in the testing, it was added to the mixing furnish 30 seconds prior to the addition of the water sizing agent. Handsheet performance testing was conducted using the same procedures as described in Example A except that a 2% Ambient Saline Cobb test was conducted in place of the Hot Water Cobb test. The saline used in the test is at ambient temperature and is derived from deionized water treated with NaCl at 2% by weight. Aside from these differences, the test procedure is identical to the Hot Water Cobb test method described in Example A.
[0036] The data summarized in Table 1 shows the simultaneous positive effect of polyvinylamine on both water and oil sizing test results. The low Saline and Hot Water Cobb test values demonstrate that an effective balance in water and oil resistance is achieved through the addition of the polyvinylamine. The water sizing agent is comprised of alkyl ketene dimer while the oil size is a perfluoroalkyl-containing product. The polyvinylamine is a solution polymer that has been reacted to a hydrolysis level of 50%.
TABLE 1 Water and Oil Sizing Results Commercial Commercial Commercial 2% Ambient Hot Oil Polyvinylamine Water Size Oil Size Saline Cobb Cobb (wt. %) (wt. %) (wt. %) (g/m 2 ) (g/m 2 ) 0 0.075 0.15 51 134 0.013 0.075 0.15 35 116 0 0.075 0.20 111 111 0.013 0.075 0.20 31 33
[0037] The following definitions apply for Table 1:
Commercial Polyvinylamine: Hercules® PPD M-1189—Hercules Incorporated Commercial AKD Water Size: Hercon® 80—Hercules Incorporated Commercial Oil Size: imPresse FP-100—Hercules Incorporated Weight %: % Addition of Active Treatment Solids Based Upon Total Furnish Solids
EXAMPLE 2
[0042] The data from Example 2 is summarized in Table 2. In this work, handsheets were prepared to 160 grams/square meter using the same papermaking procedure and furnish blend described in Example A. The target Canadian Standard Freeness for pulp refining was 470 mls. The chemical addition sequence was consistent with the description provided in Example A except that when an anionic polymer was included in the testing, it was added to the mixing furnish 30 seconds after to the addition of the water sizing agent and 30 seconds prior to the addition of the oil size material. When polyvinylamine was included in the testing, it was added to the mixing furnish 30 seconds prior to the addition of the water sizing agent. Handsheet performance testing was conducted using the same procedures as described in Example A.
[0043] The data in Table 2 further demonstrates the beneficial effect of polyvinylamine on both water and oil sizing properties as low Cobb values are achieved with the addition of polyvinylamine to the test furnish. The water sizing agent is comprised of alkyl ketene dimer. The oil size is a perfluoroalkyl-containing product, and the polyvinylamine is a solution polymer that has been reacted to a hydrolysis level of 50%. The anionic polymer is a solution copolymer of acrylamide and acrylic acid (Hercobond 2000). Anionic polymer is used as a retention aid to enhance the retention of fine solids in the web during the sheet forming process.
TABLE 2 Water and Oil Sizing Results Commercial Commercial Commer- Hot Hot Poly- Commercial Anionic cial Water Oil vinylamine Water Size Polymer Oil Size Cobb Cobb (wt. %) (wt. %) (wt. %) (wt. %) (g/m 2 ) (g/m 2 ) 0 0.35 (1) 0 0.24 74 40 0 0.35 (1) 0.2 0.24 99 51 0.1 0.35 (1) 0.2 0.24 49 39 0.05 0.125 (2) 0 0.24 255 53 0.1 0.125 (2) 0 0.24 82 39 0.2 0.125 (2) 0.1 0.24 43 35
[0044] The following definitions apply for Table 2:
Commercial Polyvinylamine: Hercules® PPD M-1189—Hercules Incorporated Commercial Water Size (1): 60:40 Blend ReTen® 204LS/Hercon® 70—Hercules Incorporated Commercial Water Size (2): Hercon® 70—Hercules Incorporated Commercial Anionic Polymer: Hercobond® 2000—Hercules Incorporated Commercial Oil Size: imPress® FP-100—Hercules Incorporated Weight %: % Addition of Active Treatment Solids Based Upon Total Furnish Solids.
EXAMPLE 3
[0051] The data from Example 3 is summarized in Table 3. In this study, handsheets were prepared using the same papermaking procedure described in Example A with the exception that the furnish was comprised of 70% southern bleached softwood Kraft and 30% northern bleached hardwood Kraft commercial market pulps refined to 405 ml Canadian Standard Freeness. The target basis weight was 149 grams/square meter. The chemical addition sequence was consistent with the description provided in Example A except that when either the polyvinylamine or branched polyamine were included in the testing, it was added to the mixing furnish 30 seconds prior to the addition of the water sizing agent. In addition, the anionic polymer and colloidal silica were added in sequential order 30 seconds after the addition of the water size and 30 seconds prior to the addition of the oil sizing agent with 30 seconds of mix time between each product addition. Handsheet performance testing was conducted using the same procedures as described in Example A
[0052] The data in Table 3 summarizes the positive effect of polyvinylamine on water and oil sizing results. The trends associated with the polyvinylamine further demonstrate that it is possible to reduce the addition level of the water and oil sizing agents while maintaining an effective low balance of Cobb test values indicative of high water and oil resistance properties. The test data associated with the branched polyamine indicate that it is difficult to achieve the same effective balance in water and oil sizing properties as compared to the test conditions involving polyvinylamine.
[0053] In this example, the branched polyamine is a solution polymer with quaternary amine functionality. The polyvinylamine is a solution polymer that has been reacted to a hydrolysis level of 50% with a predominantly linear structure and primary amine functionality. The water sizing agent is comprised of alkyl ketene dimer, while the oil size is a perfluoroalkyl-containing product. The anionic polymer is an emulsion copolymer of acrylamide and acrylic acid. The silica component is an aqueous dispersion of colloidal silica particles. The anionic polymer and colloidal silica are added to the furnish with the purpose of increasing the retention of fine solids in the paper web in the forming process.
TABLE 3 Water and Oil Sizing Results Commercial Commercial Commercial Commercial Hot Hot Branched Poly- Commercial Anionic Colloidal Commercial Water Oil Polyamine vinylamine Water Size Polymer Silica Oil Size Cobb Cobb (wt. %) (wt. %) (wt. %) (wt. %) (wt. %) (wt. %) (g/m 2 ) (g/m 2 ) 0.35 0 0.14 0.29 0.09 0.15 49 95 0.35 0 0.14 0.29 0.09 0.17 51 55 0.35 0 0.14 0.29 0.09 0.19 47 39 0.35 0 0.14 0.29 0.09 0.21 51 41 0.35 0 0.14 0.29 0.09 0.23 76 39 0.30 0 0.14 0.29 0.09 0.19 49 36 0.40 0 0.14 0.29 0.09 0.19 57 39 0 0.15 0.14 0.29 0.09 0.19 39 47 0 0.20 0.14 0.29 0.09 0.19 39 36 0 0.20 0.12 0.29 0.09 0.17 39 34 0 0.20 0.10 0.29 0.09 0.15 40 33
The following definitions apply for Table 3:
Commercial Branched Polyamine: Nalco 7607—Nalco Commercial Polyvinylamine: Hercules® PPD M-1189—Hercules Incorporated Commercial Water Size: Hercon® 79—Hercules Incorporated Commercial Anionic Polymer: PerForm® PA8137—Hercules Incorporated Commercial Colloidal Silica: Positek 8691—Nalco Commercial Oil Size: imPress® FP-100—Hercules Incorporated Weight %: % Addition of Active Treatment Solids Based Upon Total Furnish Solids
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The presence of both a water sizing agent and an oil sizing agent in a paper making furnish is detrimental in that each has an adverse effect on the sizing property of the other. It has now been found that this adverse effect can be counteracted or lessened by the presence in the furnish of a polyvinylamine.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Aspects of the present invention relate to an intake manifold for an internal combustion engine and, more particularly, to a manifold having interchangeable parts capable of disassembly and reassembly.
[0003] 2. Background of the Technology
[0004] Internal combustion engines generally include an intake manifold. The intake manifold directs air or a fuel and air mixture into the cylinders of the engines where the fuel and air mixture is combusted, releasing mechanical energy to power the engine.
[0005] Intake manifolds have been traditionally made by either casting metals into a single component or by forming plastics or polymers into several different pieces that are then permanently bonded together, by, for example, friction welding. Subsequent attempts to disassemble either of the traditional types of manifolds results in severe damage to the intake manifold. Therefore, these construction types have precluded the intake manifold from being tuned to alter individual engine performance, or allowing clearing or removal of excess metal or other material, for example, without completely removing and discarding the current intake manifold and obtaining and installing a new intake manifold. Such replacement is both costly and wasteful. Additionally, removal of the traditional intake manifold destroys the seal between the intake manifold and the engine, exposing internal components of the engine to external debris and contamination. Thus, in order to tune engine performance by means of the intake manifold, e.g., adjusting runner length, a user must essentially purchase an entirely new intake manifold part and subject the engine to potential damage from external contamination, among other things.
[0006] Prior art patents disclosing multipiece intake manifolds capable of being disassembled are known, such as U.S. Pat. No. 3, 831,566 issued to Thomas and U.S. Pat. No. 4,279, 224 issued to Szabo, et al., the entirety of each of which is hereby incorporated by reference. However, among other things, none of these patents provides for a manifold comprising easily removed and replaced components having different characteristics, such as air inlet size and internal runner shape, to alter engine performance. U.S. Pat. No. 7,021,263 issued to Agnew et al., the entirety of which is hereby incorporated by reference, provides an improved intake manifold for an internal combustion engine that permits disassembly, replacement or substitution, and reassembly without detriment to the individual intake manifold components. The Agnew manifold has a multiple piece construction comprising, for example, a lower base member, a center runner section, and an upper shell, wherein the upper shell and center runner section fixably attach to the lower base member in such a way that the components can later be disassembled. The center runner section is formed with runner cavities of different shapes that work with the upper shell and the lower shell to change the airflow within the intake manifold and, hence, the way in which the air is delivered to the engine. However, among other things, Agnew does not provide for interchangeable individual runners that function independently from the manifold shell, wherein the runners can be easily removed and replaced without requiring an associated removal and replacement of an upper shell and/or a lower shell in order to alter the air intake qualities, and hence the performance, of an internal combustion engine.
SUMMARY OF THE INVENTION
[0007] Aspects of the present invention provide for an intake manifold for an internal combustion engine that permits efficient disassembly, replacement and/or substitution, and reassembly of an intake manifold, in which variably dimensioned independent runners are easily removed and replaced to alter engine performance, for example, without the requirement of replacing an upper shell and/or a lower shell due to permanently formed or attached flow pathways therein. As a result, the intake manifold in accordance with aspects of the present invention may be disassembled and assembled with a new runner configuration without causing damage to the component parts of the intake manifold. Similarly, the intake manifold may be disassembled and assembled with a new shell configuration, permitting a larger (or smaller) and/or different length air inlet, for example, and thus permitting transmittal of different volume(s) of air through the intake manifold and/or transmittal of air with different flow characteristics.
[0008] The modularity and ease of assembly/disassembly of the intake manifold allows for the efficient mixing and matching of component parts, e.g., the shell, base member, and/or individual runners, to achieve targeted performance goals for an engine at significant advantage, including at lower cost and with less waste. The ability to simply unfasten the shell and remove, replace and/or exchange one or more of the individual runners with runners of different lengths and/or shapes, for example, facilitates the efficient fine tuning of a particular engine's performance characteristics. For example, different runners may be used with the same or different base members to serve different engine displacements and revolution per minute (rpm) ranges. The ability to disassemble the shell from the base member to access and/or exchange the runners, and then simply reassemble the intake manifold, eliminates the complete replacement and/or welding, gluing, and other cumbersome requirements typical with most intake manifold repairs and/or modifications.
[0009] Furthermore, the modular construction of the intake manifold permits the shell and/or the runners to be changed, for example, without having to disassemble the base member from the engine. Therefore, the seals between the intake manifold and the cylinder heads can remain intact. Accordingly, there is less risk of debris entering into the engine and, therefore, less risk of internal engine damage while removing and/or replacing various components of the intake manifold.
[0010] In some variations, constructing the various components of the intake manifold from an advanced polymer material, for example, provides the added benefits of lighter weight, increased strength and improved heat dissipating characteristics. The injection molded design of the various components, among other things, also allows perfect bolt-on fitment of various factory accessories without modification or clearance concerns, including, for example, integrated nitrous bungs and provisions for various Positive Crankcase Ventilation (PCV) features, vacuum nipples, fuel rails, and throttle body linkages.
[0011] Additional advantages and novel features of aspects of the invention will be set forth in part in the description that follows, and in part will become more apparent to those skilled in the art upon examination of the following or upon learning by practice of the invention.
BRIEF DESCRIPTION OF THE FIGURES
[0012] In the drawings:
[0013] FIG. 1 shows an exemplary intake manifold assembly, in accordance with aspects of the present invention;
[0014] FIG. 2 shows an exploded view of an intake manifold assembly, in accordance with aspects of the present invention
[0015] FIG. 3 corresponds to view A-A of FIG. 2 and is a bottom view of an intake manifold assembly, in accordance with aspects of the present invention;
[0016] FIG. 4 shows an exemplary air outlet, in accordance with aspects of the present invention;
[0017] FIGS. 5A-5C show exemplary shapes for inlet ports for different engines, in accordance with aspects of the present invention;
[0018] FIG. 6 is an isometric view of an exemplary shell for a modular intake manifold assembly, in accordance with aspects of the present invention;
[0019] FIG. 7 is a cross-sectional view of an intake manifold assembly, in accordance with aspects of the present invention;
[0020] FIG. 8 corresponds to view S-S of FIG. 3 and is another cross-sectional view of the intake manifold assembly, in accordance with aspects of the present invention;
[0021] FIG. 9 corresponds to view E-E of FIG. 2 and is a top view of an intake manifold assembly, in accordance with aspects of the present invention;
[0022] FIG. 10 shows a front view of an intake manifold assembly, in accordance with aspects of the present invention;
[0023] FIGS. 11A-11E show various views and cross-sectional views of an exemplary intake manifold assembly, in accordance with aspects of the present invention;
[0024] FIGS. 12A-12G show various views and cross-sectional views of an exemplary intake manifold assembly, in accordance with aspects of the present invention; and
[0025] FIGS. 13A-13K show various views and cross-sectional views of an exemplary intake manifold assembly, in accordance with aspects of the present invention.
DETAILED DESCRIPTION
[0026] FIG. 1 shows an exemplary intake manifold assembly 10 for an eight-cylinder internal combustion engine in accordance with aspects of the present invention. However, it is understood that aspects of the invention are applicable to an internal combustion engine having any number of cylinders. The intake manifold assembly 10 has a shell 20 , individual runners 30 (see FIG. 2 ), and a base member 40 . As shown in FIG. 1 , the shell 20 is the upper component and the base member 40 is the lower component of the intake manifold assembly 10 . The intake manifold assembly 10 , or components thereof, may be constructed from a state-of-the-art polymer material for cooler airflow operations, compared to an aluminum manifold, for example, which aluminum may tend to act as a heat-sink, reducing an engine's power. The shell 20 secures to a mating surface 50 of base member 40 with the individual runners 30 enclosed between the shell 20 and the base member 40 .
[0027] FIG. 2 is an exploded view of an intake manifold in accordance with aspects of the present invention. One individual runner 30 may be secured to the base member 40 for each cylinder of the engine 100 . For example, an eight cylinder engine may have eight individual runners 30 secured to the base member 40 . Each runner 30 may be designed to be very similar or essentially identical, for example, or each runner 30 may be individually tuned for each cylinder of a particular engine 100 . The individual runners 30 may be formed to be of varying dimensions, including different shapes and lengths, for example, and limited only by the dimensions of the plenum chamber formed between the shell 20 and the lower base 40 into which the runners 30 are fitted. For example, a set of short runners may be installed for higher horsepower applications and easily exchanged for a set of longer runners for low-end torque applications.
[0028] As shown in FIG. 2 , the base member 40 may include right 60 and left 70 mating faces that abut mating surfaces on right 80 and left 90 cylinder heads of an engine 100 . A semicircular flange 180 having an upper surface 190 and rounded surfaces 200 may be formed at the front of base member 40 to create a semicircular front opening 210 .
[0029] FIG. 3 corresponds to view A-A of FIG. 2 and is a bottom view of the intake manifold assembly 10 . As shown in FIG. 3 , air outlets 110 are provided within the base member 40 . The air outlets 110 are formed to correspond to inlet ports (not shown) provided in the cylinder heads 80 and 90 . A raised pad 112 and a seal groove 114 may be provided around the perimeter of the air outlet 110 . As shown in FIG. 3 with respect to the right mating face 70 of the base member 40 , a rope style o-ring type seal 116 , for example, may be press fit into the seal groove 114 surrounding the raised pad 112 in order to provide a sealed connection when the base member 40 is attached to the engine 100 . As shown in FIGS. 3 and 4 , a series of through-holes 230 may be provided from the mating surface 50 of the base member 40 that extend through the entire thickness of the base member 40 .
[0030] FIG. 4 shows an exemplary air outlet 110 in accordance with aspects of the present invention. The air outlet 110 with raised pad 112 may have an upper edge 120 relative to a lower edge 130 , as well as an interior surface 140 extending from the upper edge 120 to the lower edge 130 . The air outlets 110 are formed to correspond to the inlet ports (not shown) provided in the cylinder heads 80 and 90 . As illustrated in FIGS. 5A-5C , for example, inlet ports may be shaped and sized differently for different engines. Accordingly, the base member 40 may be designed with air outlets 110 of varying shape, size and/or location to mate properly with a designated engine 100 . Once the base member 40 is mounted onto the engine 100 , the air outlets 110 mate with the inlet ports of cylinder heads 80 and 90 to form passages extending through the entire thickness of base member 40 , allowing communication between the interior of the intake manifold 10 and the inlet ports of cylinder heads 80 and 90 .
[0031] As shown in FIGS. 3 and 4 , surfaces 150 may be provided within an outer periphery of the air outlets 110 near the outer periphery of the base member 40 . An opening 160 may extend from each surface 150 through the entire thickness of the base member 40 .
[0032] Referring to FIG. 4 , a witness mark 170 may be formed into the interior surface 140 of the air outlets 110 . The witness mark 170 may, among other things, allow removal of material from the interior surfaces 140 of the air outlets 110 in a practice referred to herein as “porting”. The depth of the witness mark 170 defines the depth of material that may be safely removed by porting without the risk of damaging the seal between the intake manifold assembly 10 and the engine 100 .
[0033] FIG. 6 is an isometric view of the shell 20 that illustrates a continuous lower mating surface 530 , comprised of a lower surface of the mating flange 440 , a lower semicircular surface 540 , and rounded surfaces 550 .
[0034] The shell 20 may enclose the intake manifold assembly 10 from above, for example. The shell 20 may be formed as a single piece component, for example, manufactured by any number of well-known casting or molding techniques. As shown in FIG. 6 , the shell 20 may comprise a throttle body mounting boss 420 , an inlet 430 , a peripheral mating flange 440 , an upper portion 450 , and an interior cavity 460 . The inlet 430 communicates with the interior cavity 460 and may be circular in shape. However, the inlet 430 , in accordance with aspects of the instant invention can be of any suitable shape. As illustrated in FIG. 6 , a series of openings 470 may extend through the throttle body mounting boss 420 from a front face and accept heat staked inserts used to attach a throttle body or other fasteners to the shell 20 . Similarly, the openings 470 may be threaded and accept bolts, for example, to attach a throttle body to the shell 20 . A series of openings 480 extend through the mating flange 440 from an upper surface, as shown in FIG. 6 . The upper portion 450 may comprise a series of contours that extend from an edge of the mating flange 440 to an opposing edge on the mating flange 440 . The contours may be formed to efficiently accommodate the runners 30 , while maintaining specified clearance parameters for an engine 100 within a specific engine compartment. A sealing ridge 560 may extend from a surface of the mating flange 440 .
[0035] The components of the intake manifold assembly 10 may be assembled as follows. As shown in FIG. 2 , the base member attaches to the engine 100 between the cylinder heads 80 and 90 . The mating faces 60 and 70 may engage corresponding mating surfaces on the cylinder heads 80 and 90 with a series of gaskets 570 or other sealing mechanisms provided there between. When the base member 40 is properly positioned on the engine 100 , openings 160 align with corresponding openings in the cylinder heads 80 and 90 of the engine 100 . Securing features 580 , such as bolts, may insert through the openings 160 and attach, e.g., screw into corresponding threaded opening(s), to the cylinder heads 80 and 90 , creating a sealable interface of the mating faces 60 and 70 , e.g., via the gaskets 570 , and the mating surfaces of the cylinder heads 80 and 90 . Further, as previously described, the air outlets 110 align with the corresponding inlet ports in the cylinder heads 80 and 90 of the engine 100 , allowing communication between the interior of both the intake manifold 10 and the engine 100 .
[0036] The individual runners 30 may then be inserted into and attached to the base member 40 . FIG. 7 is a cross-sectional view of an intake manifold assembly 10 in accordance with aspects of the present invention. As shown in FIG. 7 , each runner 30 may be formed with a flange section 31 , a tube section 35 , and a plenum section 37 . The flange section 31 may be formed to mate with the edge 120 of the air outlet 110 . The edge 120 may thus seat the runner 30 when an outlet 32 of the runner 30 is inserted into the air outlet 110 . The flange portion 31 of the runner 30 has a peripheral groove 33 into which a runner tube seal 34 , e.g., a rope style o-ring type seal, may be inserted to provide a seal between the outlet 32 of the runner 30 and the base member 40 . An additional sealant, such as silicone gel, for example, may be applied to the flange portion 31 of the runner 30 prior to seating the outlet 32 of the runner 30 into the base member 40 .
[0037] The tube section 35 may be formed in virtually limitless variations within the dimensions available to create variations in the air flow pattern, while maintaining a compact design. For example, the runner 30 may vary in length by increasing or decreasing the radius of curvature of the tube section 35 . The runners 30 may be designed as shown in FIG. 7 , with smooth contours, for example, to create more predictable air flow patterns without the associated pressure drops that occur in runners with more abrupt changes in shape and/or contour.
[0038] As shown in FIG. 7 , bosses 290 may be provided on an interior surface 250 of the base member 40 . Attendant features, such as threaded openings 295 may be formed on or used in connection with the bosses 290 and extend into the base member 40 . A tube shell fastener 590 , such as a bolt, may be used to attach the runner 30 to the base member 40 , which may be by way of a protrusion 38 formed on an outer peripheral surface of the runner 30 , for example. The tube shell fastener 590 may extend through the protrusion 38 and attach the runner 30 in place by aligning with the threaded openings 295 provided on the bosses 290 integral to the interior surface 250 of the base member 40 . The tube shell fastener 590 may screw into the threaded openings 295 , for example, to securely attach each runner 30 to the base member 40 in a designated location within the plenum chamber formed between the shell 20 and the base member 40 .
[0039] As shown in FIG. 7 , the shell 20 may be formed with contours 22 for further securing the runners 30 in position. Furthermore, the shell 20 may be formed to cover and clamp down on the top of the tube shell fastener 590 attaching the runners 30 to the base member 40 . Thus, by attaching the shell 20 to the base member 40 , the runners 30 may be secured in place and the tube shell fasteners 590 may be effectively trapped by the shell 20 , preventing the tube shell fasteners 590 from working out of the threaded openings 295 and becoming a hazard to the operation of the engine, for example. Similarly, in the event that one forgets to secure a runner 30 in place by using a tube shell fastener 590 , the runner 30 may be held in place by the contours 22 of upper surface 450 and the clamping effect of the shell 20 with the base member 40 .
[0040] FIG. 8 corresponds to view S-S of FIG. 3 and is another cross-sectional view of the intake manifold assembly 10 , in accordance with aspects of the present invention. The shell 20 may be attached to the base member 40 , which may enclose the runners 30 , for example. When properly oriented, the mating surface 530 of the shell 20 contacts the mating surface 50 of the base member 40 . A sealing ridge 560 may be provided on the mating surface 530 of the shell 20 , and a matching sealing groove 260 may be provided in the mating surface 50 of the base member 40 . A rope style o-ring type seal 261 , for example, may be provided in the sealing groove 260 . As such, when the shell 20 is aligned over the base member 40 , the sealing ridge 560 is forced into the sealing groove 260 , pinching the o-ring seal 261 and creating a seal when the shell 20 is attached to the base member 40 .
[0041] FIG. 8 also shows an exemplary bumper 55 applied to a lower surface of the base member 40 . One or more bumpers 55 may be applied along the lower surface of base member 40 . The bumpers 55 , which may be self-adhesive, for example, compress against and are supported by the top of a valley cover of the engine 100 . By using the valley cover as a stressed member, the plenum of the intake manifold assembly 10 may be enlarged by reducing the support structure necessary for the base member 40 . The valley cover of the engine 100 may therefore provide the necessary structural support to the bottom of the intake manifold assembly 40 .
[0042] As shown in FIGS. 2 and 9 , once the shell 20 is aligned with the base member 40 , openings 480 in the mating flange 440 may align with the through-holes 230 in the mating surface 50 , for example. Fasteners 600 , such as bolts, for example, may be inserted through the openings 480 and through-holes 230 from above, and secured from below by an appropriate securing device, such as through tightening a nut, for example. The fasteners 600 , for example, may thus extend through the mating flange 440 of the shell 20 and the base member 40 , creating a clamping force to hold the engine manifold assembly 10 together, with the runners 30 secured between the shell 20 and the base member 40 .
[0043] As shown in FIG. 10 , when assembled, the interior of the intake manifold assembly 10 may communicate with the exterior via the inlet 430 of the shell 20 and air outlets 110 in the base member 40 . In operation, the intake manifold assembly 10 accepts incoming air through inlet 430 . The air then travels into the plenum chamber between the shell 20 and the base member 40 and is drawn in through the plenum sections 37 of the individual runners 30 . The air travels the lengths of the respective runners 30 and through the air outlets 110 formed in the base member 40 , at which time the air flows into the inlet ports in the cylinder heads 80 and 90 of the engine 100 .
[0044] The volume and velocity of air traveling through an intake manifold is limited by the size and shape of the inlet of the intake manifold. Generally speaking, the larger the inlet 430 of the intake manifold 10 , the larger the volume of air that can be directed into the engine 100 . Traditionally, intake manifold modification has been limited to altering only certain easily accessible features, such as inlet size or air outlet size, because of the single component or permanently bonded types of construction. However, these features may be altered only to a degree, past which the part is no longer usable. Alternatively, intake manifold modification has constituted removing the installed intake manifold, obtaining an entirely new intake manifold with features of differing shapes or sizes, such as a smaller or larger inlet, and attaching the new intake manifold to the engine. This process can include a substantial financial cost for both purchase of a new part and labor for installation, not to mention the risk of damage being done to the engine during removal and exchange of entire manifold assemblies. However, an intake manifold assembly in accordance with aspects of the invention described above, provides significant benefits.
[0045] First, the intake manifold assembly 10 can be made to allow for a larger volume of air by simply removing the shell 20 having an inlet 430 of a given diameter, 92 mm for example, and replacing it with a shell 20 having an inlet 430 with a different diameter, 102 mm for example. Replacing only the shell 20 versus the entire intake manifold 10 results in a lower cost and less waste. Second, an added benefit of the present invention is the ability to simply unbolt the shell 20 and remove, replace and or exchange one or more of the individual runners 30 with runners 30 of different lengths or shapes, for example. The length and shape of the runners 30 directly affects how air flows within the intake manifold 10 , and hence, how the air is delivered to the engine 100 . Therefore, the interchangeability of the runners 30 is also advantageous from an engine tuning perspective. For example, different runners 30 may be designed to serve different target performance ranges. Thus, different runners 30 may be used with the same or different base members 40 , for example, to serve different engine displacements and revolution per minute (rpm) ranges. The ability to unbolt the shell 20 from the base member 40 to access and/or exchange the runners 30 , and then simply bolt the intake manifold assembly 10 back together, eliminates the welding, gluing, and other cumbersome requirements typical with most intake manifolds.
[0046] By modular construction of the intake manifold assembly 10 , the shell 20 and/or the runners 30 can be changed without having to disassemble the base member 40 from the engine 100 . Therefore the seals between the mating faces 40 and 50 , the gaskets 570 , and the mating surfaces of the cylinder heads 80 and 90 remain intact. Accordingly, there is less risk of debris entering into the engine 100 and, therefore, less risk of internal engine damage.
[0047] The ability to construct each and every component of the modular intake manifold assembly 10 from an advanced polymer material, for example, provides the added benefits of lighter weight, increased strength and improved heat dissipating characteristics. The injection molded design of the various components of the intake manifold assembly 10 allows perfect bolt-on fitment for the use of factory accessories without modification or clearance concerns, including integrated nitrous bungs and provisions for various Positive Crankcase Ventilation (PCV) features, vacuum nipples, fuel rails, and throttle body linkages, for example.
[0048] FIGS. 11A-11E , 12 A- 12 G, and 13 A- 13 K show various views and cross-sectional views of an exemplary intake manifold assembly 10 as described above and in accordance with aspects of the present invention.
[0049] While this invention has been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary aspects of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the invention is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents.
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An intake manifold assembly for an internal combustion engine that has a modular construction and includes a base member, a runner, and a shell, wherein the base member removably attaches to the engine, and the runner and the shell each separately and independently removably attach to the base member. In another aspect, the assembly further includes a fastener for attaching the runner to the base member, wherein the shell is formed so as to retain the fastener between the shell and the base member when the shell is attached to the base member. In another aspect, the assembly further includes a bumper affixed to a surface of the base member, wherein the bumper abuts a surface of the internal combustion engine. In another aspect, the base member includes a sealing ridge that mates with a sealing groove provided on the shell.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of US Provisional Application No. 62/023,805, filed Jul. 11, 2014, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to a holder of a speed loader for revolver-type firearm.
[0004] 2. Description of the Related Art
[0005] On the current market involving firearm reloading accessories, there are numerous types of revolver reloading devices, commonly called “speed loaders.” These devices hold cartridges in a circular arrangement so that the cartridges may be swiftly and concurrently loaded into the cylinder of a revolver-type firearm. Such a device will be referred to herein as a “speed loader” and a typical version is shown in FIGS. 1 and 2 . A speed loader 1 involves a metal or plastic body 10 incorporating tubular compartments arranged in a radial configuration to hold the required cartridges for reloading a revolver (not shown). Generally a revolver's cylinder holds six cartridges, but speed loaders are available for revolvers whose cylinder holds anywhere from five to ten cartridges. In FIG. 1 , six cartridges 11 sit within the tubular compartments of the body 10 with the bullet end 14 of each cartridge 11 projecting upward. Cartridges 11 are held in place by the action of an upper retainer 12 and a lower retainer 13 . When the speed loader 1 of FIG. 1 is used to reload a revolver, the user must align the bullet ends 14 of the cartridges with the tubular compartments of the revolver's cylinder. When the cartridges 11 are inserted deep enough into the revolver's cylinder, a central pin on the ejector star of the revolver's cylinder presses against a release mechanism 15 on the speed loader 1 , causing the upper and lower retainers 12 and 13 to release the cartridges 11 from the body 10 . Once released from the body 10 , the cartridges 11 drop freely from the speed loader 1 and fully seat themselves into the cylinder of the revolver. Different types of revolver speed loaders achieve the same result through different means.
[0006] The revolver has proven itself to be a functionally reliable and simple to use sidearm for both law enforcement and lawfully armed citizens with an appropriate concealed weapons permit. Although generally replaced by the semi-automatic pistol in the law enforcement community, the revolver is still a popular sidearm for many plainclothes and off-duty law enforcement personnel. The increase, country wide, over the last 20 years in concealed weapons permits has also allowed the revolver to remain popular with lawfully armed citizens, who turn to the revolver as a reliable tool for self-defense. The revolver's popularity in competition shooting has increased, as well, over the last decade, as an ever-increasing number of shooting organizations have created shooting divisions to accommodate it.
[0007] Those who carry a revolver for self-defense, uniformed or plainclothes duty, and competition tend to carry spare ammunition somewhere on their person—the most popular place being on the belt. A “speed loader” is the most popular device for reloading a revolver. Speed loaders hold cartridges in a circular arrangement so that said cartridges may be swiftly and concurrently loaded into the cylinder of a revolver-type firearm. Traditional methods for carrying a speed loader on one's belt include a speed loader holder (also referred to as a speed loader carrier or speed loader pouch). Such devices generally place the speed loader on the outside of the belt, causing a distinctive visual bulge on the beltline (otherwise known as “printing”). This is problematic, for the visual printing of a firearm and any accompanying reloading device(s) should be virtually non-existent.
[0008] Most speed loader holders secure the speed loader by using a flap which originates on the belt-side of the holding device and runs over the top of the speed loader, being secured on the outward side of the holder by a snap or Velcro. This method of retaining the speed loader adds not only more outward bulk, but it requires an extra step (i.e., using an index finger to unsnap the flap) when one needs to retrieve the speed loader from the holder. Eliminating the extra step of unsecuring the speed loader is beneficial in an emergency situation or in competition where time is of the essence.
[0009] Due to the above mentioned problems of bulk and retention involving traditional speed loader holders, the best place to position a speed loader is above one's belt. While this is not a new concept, speed loader holders (such as the one shown in U.S. Pat. No. 4,408,707) that hold the speed loader above the belt still utilize a retention flap secured by a snap or Velcro to secure the speed loader, thus requiring the extra time-consuming step of unsnapping the flap prior to speed loader removal. Another design flaw involving speed loader holders (such as that in U.S. Pat. No. 4,408,707) is that the holder positions the speed loader's release mechanism only a fraction of an inch above the user's belt. Any downward force upon the holding device will cause the speed loader's release mechanism to contact the top of the belt, resulting in a premature release of the cartridges from the speed loader itself.
SUMMARY OF THE INVENTION
[0010] Some aspects of the present invention are: to provide a holder for a revolver speed loader which produces minimal outward bulk while simultaneously protecting the speed loader's release mechanism from contacting the user's belt; and to eliminate any retention devices which require a step other than simply pulling the speed loader free from the holder.
[0011] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0013] FIG. 1 is a top plan view of a prior art revolver speed loader containing six cartridges.
[0014] FIG. 2 is a side elevation view of the prior art revolver speed loader and cartridges of FIG. 1 .
[0015] FIG. 3 is an illustration of a holder for a speed loader of a revolver-type firearm standing upright in ¾ view (perspective view) according to a first embodiment.
[0016] FIG. 4 is an illustration of the holder of FIG. 3 lying on its back in ¾ view (perspective view).
[0017] FIG. 5 a is an illustration of the holder of FIG. 3 as seen from front elevation view.
[0018] FIG. 5 b is an illustration of the holder of FIG. 3 as seen from rear elevation view.
[0019] FIG. 5 c is an illustration of the holder of FIG. 3 as seen from a right side elevation view.
[0020] FIG. 5 d is an illustration of the holder of FIG. 3 as seen from a left side elevation view.
[0021] FIG. 6 is an illustration of FIG. 3 as seen from a top plan view.
[0022] FIG. 7 is an illustration of the holder of FIG. 3 as seen from a bottom plan view (worm's-eye view).
[0023] FIG. 8 is an illustration of the holder of FIG. 3 standing upright in ¾ view (perspective view) as it would sit on a belt.
[0024] FIG. 9 is an illustration of the holder of FIG. 3 as seen from right side elevation view as it would sit on a belt. Belt is seen in elevation view as a cross-section.
[0025] FIG. 10 is an illustration of the holder of FIG. 3 as seen top plan view as it would sit on a belt.
[0026] FIG. 11 is an illustration of the holder of FIG. 3 standing upright in ¾ view (perspective view) in a typical location on a user's belt with rest of the waistline as context. FIG. 12 is a cross-section view of the holder of FIG. 3 as seen from right side elevation view as it would sit on a belt, with the speed loader situated therein. FIG. 13 is an illustration of the holder of FIG. 3 standing upright in ¾ view (perspective view), with the speed loader situated therein.
[0027] FIG. 14 is a cross-section view of the holder for the speed loader as seen from right side elevation view as it would sit on a belt, with the speed loader being situated therein and a hand grasping the speed loader. FIG. 15 is a cross-section view of the holder for the speed loader as seen from right side elevation view as it would sit on a belt, with the speed loader being situated therein and a hand grasping the speed loader, and leaning it out away from user's body, preparing for removal of said speed loader.
[0028] FIG. 16 is a cross-section view of the holder for the speed loader as seen from right side elevation view as it would sit on a belt, with the speed loader being situated therein and a hand grasping the speed loader, and pulling the speed loader out of the holder. FIG. 17 is a cross-section view of the holder for the speed loader as seen from right side elevation view as it would sit on a belt, with the speed loader being situated therein and a hand grasping the speed loader as the speed loader is completely removed from the holder for insertion into a cartridge cylinder of a revolver-type firearm.
[0029] FIG. 18 is an illustration of a holder of a speed loader for a revolver-type firearm standing upright in ¾ view (perspective view).
[0030] FIG. 19 is a cross-section view of the holder of FIG. 18 as seen from right side elevation view as it would sit on a belt, with the speed loader situated therein. FIG. 20 is an illustration of the holder of FIG. 18 with two slits as seen from a top plan view.
[0031] FIG. 21 is an illustration of the holder of FIG. 18 with two slits as seen from a bottom plan view (worm's-eye view).
[0032] FIG. 22 is a cross-section view of the holder of FIG. 18 as seen from a right side elevation view as it would sit on a belt, with the speed loader situated therein, with a hand grasping the speed loader.
[0033] FIG. 23 is a cross-section view of the holder of FIG. 18 as seen from a right side elevation view as it would sit on a belt, with the speed loader partially removed, with the hand pulling the speed loader upward.
[0034] FIG. 24 is a cross-section view of the holder of FIG. 18 seen from a right side elevation view as it would sit on a belt, with the hand grasping the speed loader, the speed loader being fully removed from the holder and ready for insertion into a cartridge cylinder of a revolver-type firearm.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0035] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0036] Aspects of the present invention utilize a device (herein referred to as “holder”) which is employed to house a speed loader and is shown in an embodiment in FIGS. 3-24 . A holder 17 comprises a cylindrical body 18 conforming to the general shape of a revolver reloading speed loader 1 (shown in FIGS. 12 and 13 ). The cylindrical body 18 may be designed to a height and diameter to accommodate a variety of speed loaders 1 . The dimensions are defined by the caliber, ammunition type, and size of the speed loaders 1 that the holder 17 is intended to hold.
[0037] The cylindrical body 18 has two concave curved walls 21 and 22 . The out-board wall 21 serves to retain the speed loader while the in-board wall 22 , which rests against the body of a user, secures the speed loader 1 with a half-moon retention lip 23 . The cylindrical body 18 has a narrow opening on each side 24 (see FIGS. 5 a - 5 d ) sufficiently wide enough to permit fingers 30 (such as a thumb on one side and index and middle fingers on the other side) of a hand 28 of a user to grip the speed loader 1 in order to remove it from the holder 17 (see FIGS. 14-17 ). The narrow openings 24 are above lower walls 32 , are between the outboard and inboard walls 21 and 22 , and the lower walls have heights lower than those of the outboard and inboard walls 21 and 22 .
[0038] The cylindrical body 18 contains a slit 25 (see FIGS. 3 , 4 , 5 a , 5 c , 6 , 7 , for example) on one side to allow the out-board retaining wall 21 to flex out enough to enable the user 28 to tilt the speed loader 1 away from the half-moon retention lip 23 on the in-board wall 22 when the user needs to remove the speed loader 1 from the holder 17 (see FIGS. 14-17 ).
[0039] On the bottom of the cylindrical body 18 is a flat floor 26 (see FIGS. 6 and 7 ) on which the speed loader 1 sits. Because the holder 17 positions the speed loader 1 above the user's belt 16 , the use of a floor prevents the speed loader's release mechanism 15 from coming in contact with the top of the belt 16 which would cause the speed loader 1 to inadvertently release its cartridges 11 . Although illustrations of the floor 26 conform to the description given above, the invention is not so limited. Variations on the amount to which the floor 26 is fully enclosed at the bottom of the cylindrical body 18 have been anticipated, contemplated and possible. For example, the floor 26 may be fully enclosed if so required, instead of only partially enclosed.
[0040] Formed as part of the cylindrical body 18 is a J-hook 19 (see FIGS. 5 a - 5 d , 9 and 12 ). The J-hook 19 a flat appendage 20 , extending vertically down from the cylindrical body 18 , and a hook 27 at the bottom of the appendage 20 which makes a 180 degree curve back up toward the cylindrical body 18 . The dimensions of the J-hook 19 are defined by the height and thickness of the belt 16 on which the speed loader holder 17 is designed to sit but can be sized to fit belts of different thicknesses and widths. Other known ways to attach holsters, accessory cases, and other similar articles such as, for example, snaps for directly snapping onto the user's belt 16 , are equally suitable for use with the holder 17 instead of the J-hook 19 .
[0041] The transition from the cylindrical body 18 into the flat appendage 20 of the J-hook 19 is such that it positions the J-hook 19 closer to the central axis of the cylindrical body 18 than the inside edge of the inboard wall 22 as seen best in FIGS. 9 , 10 , and 12 . This unique design significantly reduces the bulge on the outside of the belt 16 as a portion of the holder 17 sits both directly above the user's belt 16 and on the in-board side of the belt 16 against the user's body.
[0042] With reference to FIGS. 14-17 , in use, to remove the speed loader 1 from the holder 17 , the user's hand 28 grasps the opposite sides of the speed loader 1 with a thumb on one side in one opening 24 and index and/or middle finger on the other side in the other opening 24 ( FIG. 14 ), leans the speed loader 1 away from the half-moon retention lip 23 thus releasing the holder's retention on said speed loader 1 ( FIG. 15 ), and draws the speed loader 1 up at an angle from the user's 28 side and away cleanly from the holder 17 ( FIG. 17 ) for insertion into the cartridge cylinder of a revolver.
Description of New Embodiment (FIG. 18 )
[0043] FIGS. 18-24 show a holder 37 for a speed loader 1 according to a second embodiment. In this embodiment, the cylindrical body 18 possesses two concave curved walls 21 and 22 . The outboard wall 21 and the inboard wall 22 serve to hold the speed loader 1 within the cylindrical body 18 . Two retention lips 29 secure the speed loader 1 within the cylindrical body 18 , preventing the speed loader 1 from becoming loose from the holder 37 during physical activities such as running. Each retention lip 29 sits on top of the respective outboard wall 21 and the inboard wall 22 . The retention lips angle upward and project in toward the central axis of the cylindrical body 18 . The angle and length of each retention lip 29 depend on both the shape and diameter of the speed loader body 10 . Although FIG. 18 illustrates a holder 37 with two retention lips 29 , thus conforming to the description given above, the holder 37 is not so limited. Variations on the number of retention lips have been anticipated, contemplated and are possible. For example, a number other than two may be used, if so required, depending on the shape and diameter of the speed loader body 10 . This also means that, in regards to the retaining walls (such as inboard wall 22 and outboard wall 21 ), a number other than two may be used if so required, depending on the shape and diameter of the speed loader body 10 . Again, lower walls 32 are situated between the outboard and inboard walls 21 and 22 .
[0044] As the user applies an upward force essentially parallel to the axis of the cylindrical body 18 (or angled like before) to lift the speed loader 1 out of the holder 37 , the speed loader 1 rides up against the underside of the retention lips 29 , forcing them to spread apart (see FIG. 23 ). The spreading out of the retention lips 29 forces the out-board wall 21 to flex away from the central axis of the cylindrical body 18 , thus releasing the speed loader 1 from the holder 37 . The inboard wall 22 may also flex out and away from the central axis of the cylindrical body and relative to the floor 26 , but generally, if it does, the amount of flex is significantly less than that of the outboard wall 21 . The cylindrical body 18 contains a slit 25 (see FIG. 18 ) on one side of the outboard wall 21 which allows the outboard wall 21 to flex out and away from the central axis of the cylindrical body 18 (see FIG. 23 ). Variations on the number of slits 25 have been anticipated, contemplated and are possible. For example, two slits may be used (see FIGS. 20-21 ), if so required. Further, the number of slits 25 may more than 2 , in the embodiments shown in FIGS. 3 , 4 , 18 , 20 and 21 , such as additional slits being situated between the other sides of the lower walls 32 and the adjacent other sides of the outboard and inboard walls 21 and 22 .
[0045] The preferred material used to make the holder 17 or 37 is a glass-fiber reinforced plastic. Glass-fiber reinforced plastics are strong and rigid yet have a certain amount of natural flexibility. Other materials may be used in the manufacture of this invention so long as the material used exhibits excellent tensile strength and flexural strength. The holder 17 or 37 may be integrally formed and of a single material, for ease of manufacture and/or durability.
[0046] With reference to FIGS. 22-24 , in use, to remove the speed loader 1 from the holder 37 , the user's hand 28 grasps the opposite sides of the speed loader 1 with the thumb on one side in the one opening 24 and the index and/or middle finger on the other side in the other opening 24 ( FIG. 22 ) and pulls the speed loader 1 upward (or angled like in the first embodiment) and away cleanly from the holder 37 ( FIGS. 23-24 ) for insertion into the cartridge cylinder of a revolver.
[0047] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A holder for a revolver speed loader which produces minimal outward bulk while simultaneously protecting the speed loader's release mechanism from contacting the user's belt, and which eliminates any retention devices which require a step other than simply pulling the speed loader free from the holder.
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TECHNICAL FIELD
[0001] The technical field of this device is in electronics. The more specific areas of electrical expertise needed for this product is digital electronics for the control and timing circuitry, analog electronic knowledge for the alarm and device powering considerations (the whole design can be done in analog circuitry if preferred), and wireless RF electronic experience (although if a universal garage door design is purchased and interfaced no RF experience is necessary).
BACKGROUND
[0002] Most people who have a garage door have accidentally left it open. Leaving the garage door open can have consequences such as; having belongings stolen from the garage or even the house, animals such as snakes can enter the garage to live, and in colder climates pipes can freeze and break. Prior art has come up with devices to fix this issue but are too cumbersome to use. Wires need to be connected, sensors need to be mounted, usually expensive, complicated and time consuming. This led to the idea of creating a device that can be mounted on a garage door, powered off of a battery, work with existing garage door openers, provide a warning before closing the door, and be very simple to install.
SUMMARY OF INVENTION
[0003] The Background has led to two most probable and different devices, 1) the first and the simplest is a device that mounts to the inside of a garage door and detects the tilt of the garage door. When the garage door is not perpendicular to the ground for greater than a certain amount of time, the module sets off an alarm. A certain amount of time after that if the garage door is still not perpendicular to the ground and the device has not been turned off, a signal is sent to the garage door opener to close the garage door or to a wall mounted module that presses the garage door open/close button to close the garage. 2) The second device is almost the same as the first except that instead of setting off an alarm, it sends a phone call or text message to a specified phone number. Replying by pressing a touch-tone button on the phone or a text message with a specific message will tell the device to try and close the garage door.
DETAILED DESCRIPTION
[0004] Device 1 (see FIG. 3 ) consists of a sensor such as a tilt sensor, a universal garage door remote or wall-mounted device to press the garage door open close button (see FIG. 2 and FIG. 4 ), control inputs/switches, a system controller, and an alarm device(s).
[0005] Device 2 would be the same as Device 1 , as it would contain a sensor a universal garage door remote or wall mounted device to press the garage door open/close button, control inputs/switches, a system controller, and an alarm device; in addition however it would also contain a telephone module to make the module contain a cell phone, or it would talk to another module that is plugged into a phone line.
[0006] The sensor could be one or more of many different devices, such as measurement sensors to measure the distance the garage door is off the floor, or tilt sensors to measure the tilt of the garage door. Due to simplicity the tilt sensor would be preferable.
[0007] The universal garage door remote is what stores all the codes to all the different garage doors; this allows one product capable of working on thousands of different garage doors. When the universal garage door remote is signaled, the universal garage door remote transmitter sends an RF signal to the garage door opener to close the garage door. An alternative to using the universal garage door remote would be to send a wireless signal to a module that would press the garage door open/close button (see FIG. 2 ).
[0008] The alarm device(s) are audible and/or visual; the purpose is to warn anyone around the garage door that the door is going to soon close. Most probably a flashing light and a siren or beep would be the preferable alarm method. Another probable alarm device is a device that calls a phone number if the garage door is open too long. The additional device can be a module that plugs into a standard phone line, or a separate mobile phone built into the automatic garage door closing device.
[0009] The control inputs/switches control a) turning on and off the device, b) programming the universal remote for a specific garage door type, c) changing the values of how long the garage door can be open before the alarm goes off, d) change how long the alarm goes off before the signal is sent to close the garage door, and e) to change the phone number to send a text message to warning that the garage door is open. The device would also need to have a method to show the current settings so a simple to complex display can be used to show setting values.
[0010] The system controller regulates the operation of the device; the operation it performs is the following. If the door is sensed to be open, the controller waits a specified amount of time for the garage door to close. If after this variable time the garage door is still not closed and the phone module is not part of this system then the controller starts the alarm(s). The alarm will continue for another specified amount of time and if by the end of that time the garage door is still open, the controller then sends an appropriate signal to close the garage door. If the phone module is part of the system then a phone call or text message is sent to a specified phone number. The phone module then waits for a response such as the press of a specific touch-tone button, or to receive a text message. Pressing different options can do different things, returning/pressing 1 closes the garage door, 2 leaves the garage door open and doesn't warn you anymore, 3 leaves the garage door open and will warn you again after a specified amount of time if the garage door has still not been closed.
[0011] The controller also checks the status of the input switches/sensors to see if any of the system parameters such as delay time until sending off an alarm is to be changed. A potentiometer or switch that rotates adjusts the amount of time delay from when the door is opened until an alarm goes off, a toggle switch turns the system on and off. The phone module includes a display to show the phone number to call when the garage door is open. All systems have indicator lights to show if any of the batteries are going low, when the batteries are low alarms also go off but with different intensities to warn the user to change the system batteries.
[0012] All the sensors and features built into a garage door opener continue to work and are not inhibited with this device. Likewise if a car or a person blocks a door sensor, this device will try but will not be able to close the garage door.
DESCRIPTION OF DRAWINGS
[0013] FIG. 1 : An illustration of how one of the devices may look mounted to a garage door.
[0014] FIG. 2 . Illustration of a device that can press a garage door button and close a garage door.
[0015] FIG. 3 : High-level block diagram of an automatic garage door closer with an RF transmitter that sends the same signal as a garage door remote to close the garage door.
[0016] FIG. 4 : High-level block diagram of an automatic garage door closer that presses the garage door open/close button on the wall to close the garage door.
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A product that resides inside of a garage with a working wireless electric garage door opener, the product detects when the garage door is open for too long and when the garage door is open too long the product sends out warnings, then after the appropriate conditions occur the product can close the garage door. The product additionally requires no special installation of sensors or wires.
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RELATED APPLICATIONS
This application claims priority to U.S. patent application Ser. No. 60/047,214, filed on May 20, 1997.
FIELD OF THE INVENTION
This invention relates to a high temperature electrical heating method and apparatus.
BACKGROUND TO THE INVENTION
U.S. Pat. Nos. 4,640,352 and 4,886,118 disclose conductive heating of subterranean formations of low permeability that contain oil to recover oil therefrom. Low permeability formations include diatomites, lipid coals, and oil shales. Formations of low permeability are not amiable to secondary oil recovery methods such as steam, carbon dioxide, or fire flooding. Flooding materials tend to penetrate formations that have low permeabilities preferentially through fractures. The injected materials bypass most of the formation hydrocarbons. In contrast, conductive heating does not require fluid transport into the formation. Oil within the formation is therefore not bypassed as in a flooding process. Heat injection wells are utilized to provide the heat for such processes.
Heat injection wells can also be useful in decontamination of soils. U.S. Pat. Nos. 5,318,116 and 5,244,310, for example, disclose methods for decontamination of soils wherein heat is injected below the surface of the soil in order to vaporize the contaminates. The heaters of patent '310 utilize electrical resistance of spikes, with electricity passing through the spikes to the earth. Patent '116 discloses heater elements passing through the wellbore to the bottom of the formation to be heated. The wellbore surrounding the heater includes a catalyst bed, which is heated by the heater elements. Heat conductively passes through the catalyst bed to a casing surrounding the catalyst bed, and then radiantly from the casing to the soil surrounding the wellbore. Typical alumina based catalysts have very low thermal conductivities, and a significant temperature gradient will exist through the catalyst bed. This significant temperature gradient will result in decreased heat transfer to the earth being heated at a limited heater element temperature.
Patent '118 discloses a heater well with heater cables cemented directly into the wellbore. The heater well optionally includes a channel for lowering a thermocouple through the cemented wellbore for logging a temperature profile of the heater well. Being cemented directly into the wellbore, a need for a casing is eliminated, but the diameter of the cable is relatively small. The small diameter of the heater cable limits the amount of heat that can be transferred to the formation from the heater cable because the area through which heat must pass at the surface of the cable is limited. A cement will have a relatively low thermal conductivity, and therefore, a greater heat flux at the surface of the cable would result in an unacceptably high heater cable temperature. Multiple heater cables may be cemented into the weilbore to increase the heat transfer to the formation above that which would be possible with only one cable, but it would be desirable to further increase the heat that can be transferred into earth surrounding the heaters.
U.S. Pat. No. 2,732,195 discloses an electrical heater well wherein an "electrically resistant pulverulent" substance, preferably quartz sand or crushed quartz gravel, is placed both inside and outside of a casing of a weilbore heater. The quartz is placed there to reinforce the casing against external pressures, but materials that have significant translucency to radiant energy are not suggested.
It is therefore an object of the present invention to provide an electrical heater element wherein the electrical heater element has a significant surface area at a temperature that is closer the temperature of the electrical resistance element than those of the prior art. This heater element is useful as a well heater for such purposes as thermal recovery of hydrocarbons and soil remediation.
SUMMARY OF THE INVENTION
These and other objects are accomplished by an electrical heater comprising: a heating element effective to generate radiant energy; a casing surrounding the heating element separated from the heating element; and support material between the casing and the heating element wherein the support material comprises a granular solid material that is translucent to radiant energy in the peak wavelength of energy which is radiated by the heating element at operating temperatures. The translucency of the support material is such that at least 50% of the radiant energy emitted by the heating element is radiated to the casing. The support material not only provides support for the casing, but can be chosen to prevent shorting of electricity from the heating element to the casing. Support from the support material reduces the wall thickness required in the casing, and therefore lowers the cost of the heater. The translucence of the electrical insulation material enables radiant heat transfer directly from the heating element to the casing. The casing temperature is therefore significantly closer to the temperature of the heating element.
In an application such as a weilbore heater for thermal recovery of hydrocarbons and soil remediation, the casing can be of a significant diameter, such as three to twelve inches. The thickness of the casing at these diameters is not excessive because the granular electrical insulation provides support for the casing and prevents collapse of the casing due to external pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a heating element according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The heater of the present invention comprises a heating element, a casing surrounding the heating element, and support material separating the resistance heating element and the casing. The support material is translucent to radiant energy generated by the resistance heating element so that heat transfer from the electrical heating element to the casing is both radiant, and conductive. Adding radiant heat transfer to the conductive heat transfer mechanism significantly aids the transfer of heat, and thus the difference in temperature between the casing and the resistance element is reduced. Radiant heat transfer enables a casing of significant diameter, for example, 2 to about 12 inches. This greater diameter casing results in increased area for flux of heat from the heating element. The heat that can be transferred from the casing is therefore increased accordingly.
The support material can also be an electrical insulating material. The support material enables the casing to be fabricated thinner than what would be required to support an expected external pressure on the casing. In applications such as heat injectors for injection of heat to an oil shale or diatomite formations, significantly lower cost casing may be used due to the support from the support material.
When the present invention is applied in a well heater, the casing may either be cemented into the formation or not cemented into the formation. Leaving a larger diameter borehole surrounding the heater may result in greater heat transfer to the formation because of radiant heat transfer from the casing. Alternatively, any space between the casing and the borehole may be filled with cement to help support the casing, or may be filled with granular solids such as the electrical insulating material of the present invention to both provide support, and to provide radiant heat transfer through the material to the walls of the borehole.
As is well known in the art, for each temperature, a curve may be found for energy transferred from a black body as a function of wavelength. Chemical Engineering Handbook 5th ed., Perry and Chilton, p. 10-48, 10-52 (1973), describes these functions. These functions will peak, and from the peak will decrease and asymptotically approach zero at great wavelengths. These functions will peak at shorter wavelengths for higher temperatures, and greater wavelengths for lower temperatures.
The temperature from which energy is radiated from the electrical heating element is readily estimated or determined empirically.
The support material is selected so that the material has a translucency to radiated energy of the peak wavelength of the energy radiated from the resistance heating element. Materials that are translucent are generally translucent over a specific band of wave lengths. Quartz (crystalline silicon dioxide) has a band of translucency that extends to a wavelength of about three microns. This corresponds to the maximum on a curve of wavelength vs. energy for radiation at about 730° C. Thus, about half of the energy emitted from a black-body source would be absorbed by quartz for every centimeter of depth. At higher element temperatures, less heat would be absorbed by the quartz. But higher temperatures require extremely expensive materials. Glass (borosilicate) is translucent over the range of visible light, but has negligible transparency to infrared wavelength radiation. Crystals of calcium fluoride are translucent to energy of up to about 12 microns wavelength. Thus, about 95 percent of energy transmitted by a black body source at 730° C. would be transmitted through a one centimeter depth of crystalline calcium fluoride. Calcium fluoride also has a very high melting point (1418° C.) and a fairly high thermal conductivity (0.022 watt/cm/° K at 730° C.).
At a sufficiently high temperature, a high quality crystalline quartz may be an acceptable support material according the present invention, but relatively high heater temperatures would be required, and thicknesses of the support material, and therefore diameter of the casing, would be relatively limited.
The energy radiated from the heater element to the casing can be estimated based on the black body curve of energy radiated as a function of wavelength, multiplied by the total absorption of the electrical insulation over the distance between the casing and the electrical resistance element. Adding this radiantly transferred heat to heat transferred by thermal conduction significantly increases the amount of energy that can be transmitted away from the heating element. Further, the relatively large diameter of the casing provides a significantly greater surface area through which heat is then transferred to the surrounding volume. When the heater is in a borehole, this larger surface area is important because earth surrounding the heating element is generally not a good conductor of heat, so the greater surface area significantly increases the heat transferred to the earth formation.
Referring now to FIG. 1, a heater 16 of the present invention is shown cemented into a formation to be heated 15, the formation to be heated being below a strata that is not to be heated 17. A casing 11 separates the formation from the heater element 12. An upper section of the heater element 18 is of a thicker cross section so that significant heat is not generated in this section. The heater element is shown as a hollow tube, so that a thermocouple 19 may be lowered through the heater by a wireline 20 through a seal 21 at the surface. The wireline can be stored on a spool 22 that is turned by an electrical motor 23. An annulus between the heater element 12 and the casing 11, within the portion of the formation to be heated, is filled with the support material 13. Within the portion of the formation that is not to be heated, the support material may be granular solid that is not the granular solid that is translucent to radiant energy, which may be less expensive.
Cement 14 may be placed around the casing to secure the casing in place. Alternatively, the annular space could be filled with granular solids that are translucent to the wavelength energy transmitted from the casing. This material may be the same as the support material between the casing and the heater element, or it may be different. Because the casing 11 will be at a lower temperature than the electrical resistance element, a material translucent to longer wave length energy may be required. But the material outside of the casing does not have to be electrically insulating.
A centralizer 24 is shown separating the heater element from the casing. The support material may also be electrically insulating, and thereby permitting the surface of the heating element to be a resistance element without electrical insulation around the element. In this embodiment, a plurality of non-electrical conductive centralizers would preferably be utilized. An electrically conductive centralizer may be used near the bottom of the electrical resistive element to ground the electrical resistive element in order to provide a path for electrical energy. An electrical power supply is connected to the heater element at the surface at a terminal 25, and the heater element is electrically isolated from the casing at the wellhead by means such as ceramic insulator 26 at a top seal flange 27.
At the bottom of the casing, the casing may be sealed by a seal plate 28 welded to the casing, or alternatively, the bottom of the casing may be sealed by cement and/or a cement shoe as is typical practice in the art of oil and gas drilling. When the bottom of the casing is sealed by a welded plate, a bellows 29 could be provided to both seal the bottom of the heating element and to provide electrical continuity to ground.
Within the formation to be heated, the heating element may be designed to have a varying heat output. This may be accomplished by providing an electrical heating element with a varying cross section area in order to tailor the generation of heat to a desired profile.
In another embodiment, a retrievable electric heating element can be inserted inside the center tubular. The electrical heating element can consist of a mineral-insulated heating cable or a ceramic bead insulated heating cable.
Although the invention is described in greatest detail in a well heater application, the invention is broadly applicable to other applications. For example, when a heater is to be operated in a high pressure liquid or gas environment.
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A heater is disclosed, the heater comprising: a heating element effective to generate radiant energy; a casing surrounding the heating element separated from the heating element; and support material between the casing and the heating element wherein the support material comprises a granular solid material that is translucent to radiant energy in the peak wavelength of energy which is radiated by the heating element at operating temperatures. The translucency of the support material is such that at least 50% of the radiant energy emitted by the heating element is radiated to the casing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2006/067592, filed Oct. 19, 2006 and claims the benefit thereof. The International Application claims the benefits of German application No. 10 2006 051 291.7 DE filed Oct. 26, 2005, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to controlling base stations in wireless communication networks.
BACKGROUND OF INVENTION
[0003] Wireless communication networks such as WLANs (wireless local area networks) or mobile radio networks for example are formed by base stations, whereby the base stations each have a radio transmitter unit which in each case implement a radio area. The radio areas or radio cells of the base stations are designed to be predominantly overlapping in the area of the respective communication network in order to ensure a continuous overall radio area for the wireless communication network.
[0004] Mobile terminals of wireless communication networks are registered in the case of stationary operation in a radio area and a connection, or a communication relationship, from a mobile terminal to a further mobile terminal or also a cabled terminal is effected by way of the base station, in which the mobile terminal is currently registered. If the mobile terminal moves from one radio area or from one base station into a further adjacent radio area or to the base station implementing the further radio area, at the edge of the radio area in which the mobile terminal is registered the mobile terminal is redirected from the one to the other base station. To this end, in the mobile terminal the levels of the received radio signals from the adjacent radio areas are measured and if the level of the radio signal from the further radio area exceeds the level of the radio signal from the current radio area the terminal is redirected from the current to the further base station—also referred to in professional circles as a handover. This handover procedure is standardized in the GSM or WLAN or DECT wireless communication networks, whereby the communication relationship for the respective mobile terminal is also redirected precisely from a current to a further base station by the handover procedure.
[0005] In order to achieve such a handover of the terminal, the base stations or the radio stations of the radio areas must at least periodically emit a radio signal so that the respective radio area can be recognized or the level of the received radio signal can be measured by the mobile terminal. This periodic emission of the radio signal by a base station must occur even if no connection is switched or routed by way of the respective base station or if no mobile terminal is activated in the radio area of the respective base station.
SUMMARY OF INVENTION
[0006] The object of the invention is to configure the control of the base stations in wireless communication networks in a more efficient manner. The object is achieved by the features described in the independent claims.
[0007] The fundamental aspect of the invention consists in the fact that a base station is switched to inactive if no radio signal is received from one of the mobile terminals, whereby radio signals can continue to be received from mobile terminals. If a base station which has been switched to inactive receives a radio signal from at least one mobile terminal, this base station is switched to active.
[0008] One important advantage of the invention consists in the fact that the number of base stations which emit radio signals is reduced to a minimum because the radio area is deactivated in the case of inactive base stations, in other words no radio signal is emitted, whereby radio signals can be received by terminals. By this means, base stations can be employed more efficiently and cost-effectively. A further advantage consists in the fact that the impact on the environment caused by radio signals is reduced.
[0009] Further advantageous developments of the invention, in particular a base station configured according to the invention, are set down in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be described in detail in the following with reference to two drawings. In the drawings:
[0011] FIG. 1 shows a wireless communication network with two radio areas implementing the invention and
[0012] FIG. 2 shows a flowchart relating to the wireless communication network illustrated in FIG. 1 in explanation of the invention.
DETAILED DESCRIPTION OF INVENTION
[0013] FIG. 1 illustrates a wireless communication network KN which generally has a plurality of radio areas FB. By way of explanation of the invention, the wireless communication network KN is formed by way of example by two radio areas or radio cells FB 1 ,FB 2 . It is furthermore assumed for the embodiment that the wireless communication network KN is implemented by means of a WLAN (wireless local area network)—indicated in FIG. 1 by the designation KN(WLAN). The base stations BS 1 ,BS 2 are connected to one another by way of a local network LAN which is routed to further base stations that are not shown and to other network components such as facilities for accessing further wireless or cabled communication networks. Alternatively, the invention can be provided in different wireless communication networks KN such as DECT or GSM or GRPS networks for example.
[0014] The first and second radio areas FB 1 ,FB 2 are implemented by the first and second base stations BS 1 ,BS 2 . To this end, the base stations BS 1 ,BS 2 each have radio transmitter units—not shown—which emit a first and a second radio signal fs 1 ,fs 2 in an area defined as radio area FB—which is indicated in FIG. 1 by dashed circles. The radio area FB is for example defined by the fact that the level of the radio signal fs 1 ,fs 1 in this area is sufficient for it to still be capable of being received in mobile terminals MT which are located in this area. In order to form a continuous wireless communication network KN, the adjacent radio areas FB overlap, in other words the two radio areas FB 1 ,FB 2 illustrated also overlap in area B. In this area B the radio signals fs 1 ,fs 2 from a mobile terminal MT can be received by both base stations BS 1 ,BS 2 .
[0015] According to the invention, the two base stations BS 1 ,BS 2 are switched to inactive if no radio signal fsm is received from any mobile terminal MT—indicated in FIG. 1 by the designation MT(fsm). This means that the radio transmitter units of the two base stations BS 1 ,BS 2 are deactivated to the extent that no further radio signal fs 1 ,fs 2 is emitted. The receiver units of the two base stations BS 1 ,BS 2 remain active, however, in other words radio signals fsm from mobile terminals MT can be received and can initiate further actions.
[0016] Let it initially be assumed for the embodiment that a radio signal fsm from a mobile terminal MT is received in neither of the two base stations BS 1 ,BS 2 . According to the invention, this means that no radio signal fs 1 ,fs 2 is emitted from either of the two base stations BS 1 ,BS 2 .
[0017] Let it furthermore be assumed for the embodiment that a mobile terminal MT or mobile part is first situated and activated in the first radio area FB 1 . The activation is effected for example by supplying the mobile terminal MT with power, whereby a transmitter unit—not shown—in the mobile terminal MT periodically emits a radio signal fsm indicating its identity and a receiver unit—not shown—in the mobile terminal MT is switched to ready-to-receive. This and further steps according to the invention are illustrated in the flowchart in FIG. 2 . In the first base station BS 1 , the radio signal fsm emitted by the activated mobile terminal MT is received and the radio transmitter unit of the first base station BS 1 is activated as a result of this, in other words a first radio signal fs 1 identifying the first base station BS 1 is emitted periodically.
[0018] The emitted first radio signal fs 1 is received in the mobile terminal MT and as a result of this a registration process which is not shown is initiated, in which the mobile terminal MT is authenticated and registered both in the first base station BS 1 and also in the wireless communication network KN. Communication relationships can subsequently be established from or to this mobile terminal MT—not shown.
[0019] Let it be assumed as the next step for the embodiment that the mobile terminal MT is moved from the first radio area FB 1 across the area B into the second radio area FB 2 —indicated in FIG. 1 by an arrow and a dashed mobile terminal MT′. If the mobile terminal MT is situated in the area B in which the two radio areas FB 1 ,FB 2 overlap, then the radio signal fsm emitted by the mobile terminal MT is also received with sufficient level in the second base station BS 2 which has been switched to inactive.
[0020] According to the invention, as a result of receiving a radio signal fsm from a wireless terminal MT in the second base station BS 2 the latter's radio transmitter unit is activated, in other words a second radio signal fs 2 indicating its identity is emitted by the second base station BS 2 . In the mobile terminal MT, both the radio signal fs 1 from the first base station BS 1 and also the radio signal fs 2 from the second base station BS 2 are now received—indicated in FIG. 2 by two arrows designated as fs 1 ,fs 2 . As long as the level of the received first radio signal fs 1 is higher than the level of the second radio signal fs 2 , then the mobile terminal MT remains registered by way of the first base station BS 1 in the wireless communication network KN or an existing communication relationship or a connection will be routed by way of the first base station BS 1 .
[0021] If the mobile terminal MT moves further into the second radio area FB 2 in the area B, the level of the second radio signal fs 2 will exceed the level of the first radio signal fs 1 —indicated in FIG. 2 by means of a rectangle labeled with fs 2 <fs 1 . If it is definitely determined that the level of the second radio signal fs 2 in the mobile terminal MT has been exceeded, a registration process with the wireless communication network KN is performed by way of the second base station BS 2 , after which the mobile terminal MT is registered by way of the second base station and the registration by way of the first base station BS 1 is canceled. This process is also referred to as a handover, whereby an existing communication relationship between the mobile terminal MT and another terminal which is not shown is redirected, or switched, by the first base station BS 1 by way of the second base station BS 2 .
[0022] According to the invention, the first base station BS 1 is switched to inactive if no further radio signal fsm is received from the mobile terminal MT. A radio signal fsm is assessed in the first base station BS 1 as no longer having been received if a predefined level of the received radio signal fsm from the mobile terminal is not reached. This means that if the mobile terminal MT moves out of the first radio area FB 1 the first base station BS 1 is switched to inactive, whereby it is assumed that no further mobile terminal is emitting a radio signal in the first radio area FB 1 . In the case of deactivation of the first base station BS 1 the transmitter unit of the first base station BS 1 is deactivated to the extent that no first radio signal fs 1 is emitted. The deactivated, or switched to inactive, first base station BS 1 can however continue to receive radio signals fsm from terminals, in other words the receiver unit of the first base station BS 1 continues to remain active.
[0023] After the mobile terminal MT′ has entered the second radio area FB 2 , the second radio signal fs 2 from the second base station BS 2 is received in the mobile terminal MT′ and the radio signal fsm from the mobile terminal MT′ is received in the second base station BS 2 and accordingly processed further or forwarded.
[0024] If the mobile terminal MT′ situated in the second radio area FB 2 is deactivated, in other words if the power supply is switched off for example, then no further radio signal fsm is emitted by the mobile terminal MT′. If, according to the invention, no radio signal fsm from the mobile terminal MT′ and also no radio signal from a further terminal situated in the second radio area FB 2 is received in the second base station BS 2 , then the second base station BS 2 is switched to inactive. This means that the receiver unit of the second base station BS 2 is deactivated to the extent that it emits no further second radio signal fs 2 .
[0025] In the case of a plurality of overlapping radio areas—not shown—in the overlap areas the same steps are carried out in each case as described previously, in other words depending on the level of the received radio signals from the base stations a registration is performed by way of the base station in question and any possibly existing communication relationship is redirected or is switched by way of the base station via which the mobile terminal is registered in the wireless communication network. According to the invention, in this situation those base stations are switched to inactive for which no further radio signal is received from a mobile terminal situated in its radio area. Switching to inactive means at least a deactivation of the radio transmitter unit of the base stations concerned, in other words no radio signal is emitted.
[0026] According to the invention, in the context of switching a base station BS 1 ,BS 2 to active and of subsequently receiving a radio signal fs 1 ,fs 2 identifying the base station BS 1 ,BS 2 a radio signal fsm can be emitted temporarily or intermittently by a mobile terminal MT. This is advantageous in particular if a change in location of the terminal MT is detected—for example by means of a GPS system integrated in the terminal MT—or if the mobile terminal MT has emitted no further radio signal (fsm) over a period of time—in particular an extended period of time. By this means, the current radio area FB 1 ,FB 2 or the current base station BS 1 ,BS 2 or also in the case of paging operation the current call area can be conveyed to the terminal MT and an incoming call can be forwarded to the respective radio or call area.
[0027] The invention is not restricted to the embodiment, but can be used in all wireless communication networks in which radio areas or radio cells are formed with base stations, whereby the steps according to the invention can in each case be incorporated in protocols or radio signals of the respective wireless communication networks KN with little additional effort. Through the invention, it is possible to reduce both the power consumption of the base stations and also the environmental impact caused by the base stations through radio signals.
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A base station is controlled inactively provided that no radio signal is received from a mobile terminal in the radio range thereof while radio signals can still be receive from mobile terminals. An inactively controlled base station is once again controlled actively when a radio signal of at least one mobile terminal is received. The radio range, of the base station, is deactivated while radio signals can be received from the mobile terminal when the base station is controlled inactively. Thus, the number of actively controlled base station may be minimized and the environmental impact of radio signals caused by the base stations reduced.
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RELATIONSHIP TO OTHER APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 08/199,850, filed Feb. 22, 1994, and now abandoned.
FIELD OF INVENTION
This invention relates to the drawing of materials through reducing dies, and, more particularly, to the drawing of metallic wire.
BACKGROUND OF THE INVENTION
In general, metallic wire, such as copper wire, is produced from rod stock by passing, i.e. pulling or drawing, the rod through a series of reducing dies, wherein each die produces an output rod or wire of lesser diameter than the input until the output of the final stage is wire of the desired diameter. In order that the drawing process be facilitated, the material being drawn, and also the dies, are heavily lubricated with a suitable lubricant to reduce friction. With proper lubrication the amount of pulling power needed and the concomitant incidence of wire breakage are reduced, and, generally, the overall quality of the wire is improved. As a consequence, much attention has been directed to apparatus and methods of achieving proper lubrication. In U.S. Pat. No. 3,526,115 of Armstrong et al, for example, there is shown a wire drawing arrangement and a method for lubricating the wire and dies to produce good quality wire, in which the wire is passed through a lubricant filled tubular chamber before entering the die. According to the disclosure of that patent, it was found that lubricant under high pressure within the chamber was more effective than lubricant under low or zero pressure.
Most metallic materials, most particularly copper, tend to oxidize fairly rapidly under the heat and humidity conditions generally encountered in the pre-drawing stages and the drawing process itself. Thus the surface of copper rod develops a thin layer or film of copper oxide even before being introduced into a die drawing apparatus.
SUMMARY OF THE INVENTION
The present invention, which is applicable to the drawing of a number of different materials, but will be described in terms of drawing copper, is an apparatus and method of reducing the frictional effects due to an oxide film on the copper rod and wire, thereby resulting in a decrease in required drawing or pulling power, a decrease in the incidence of wire breakage, and an improvement in the surface quality of the wire produced.
The basic apparatus of the invention, in a preferred embodiment thereof comprises a drawing stage having a single drawing die configuration, through which the copper rod or wire is passed from an upstream direction to a downstream direction. The wire entering the apparatus from upstream thereof is passed over one or more capstans into an elongated hollow metal tube located between the capstans and the drawing die. After exiting the downstream end of the tube the wire passes through the die over another capstan and proceeds to the next station or stage of the wire drawing apparatus which may be substantially the same as that described except for the die diameter. A suitable lubricant contained in a storage reservoir is sprayed upon the wire at the upstream capstans and at the entrance of the die. In addition, the hollow tubular member has lubricant supplied thereto. As thus far described, the apparatus is representative of the usual prior art drawing stage except for the presence of the hollow tube apparently shown only in the Armstrong et al. patent.
In accordance with the principles of the invention, a voltage is applied to the wire from a source of D.C. voltage, and to the hollow metal tube, so that a voltage difference exists between the wire and the tube. The voltage is applied to the wire by the application of voltage to one of the upstream capstans which may be made of copper, steel, or other conductive material. Alternatively, the voltage may be applied to the wire by a brush or sliding contact. Within the tube itself, the wire represents one electrode, the tube a second electrode, and the lubricant emulsion an electrolyte.
It has been found that this application of a voltage to the wire and the tube has a pronounced effect on the oxide skin or film existing on the wire, materially changing the amount and/or nature thereof, so that the frictional forces usually present as the wire passes through the die are substantially reduced. This reduction in friction results in a reduction in wire pulling power needed, and hence in a marked reduction in the frequency of wire breakage. An additional benefit is a greatly improved surface quality of the wire which is believed to be the result of several factors. Thus, the application of a negative voltage to the wire and a positive voltage to the tubular electrode across the electrolyte causes the copper oxide film to be reduced to oxygen and copper, with the oxygen going into suspension within the electrolyte, i.e., the lubricant. The voltage causes the H+ ions which exist in the lubricant due to the disassociation of the H 2 O to produce H 2 molecules in the form of gas at the surface of the copper, which has the effect of breaking the copper oxide off of the wire, that is, it "bubbles" the copper oxide off. Because there is less copper oxide film on the wire, the drawing die does not force as much copper oxide into the wire as is normally the case, hence the surface of the wire is more nearly pure copper rather than a mixture of copper and copper oxide. In other cases, application of the voltage changes the nature of the film in such a way that the pulling force is reduced.
The various features and advantages of the present invention will be more readily understood from the following detailed description, read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of an illustrative embodiment of the invention;
FIG. 2 is a graph of results obtained with the apparatus of FIG. 1;
FIGS. 3A and 3B are electron microscope micrographs, of respectively, the surface of a wire drawn without utilizing the invention and a wire drawn using the invention; and,
FIGS. 4A and 4B are electron microscope micrographs of the wire surfaces of FIGS. 3A and 3B at a greater magnification.
DETAILED DESCRIPTION
FIG. 1 is a diagrammatic representation of a single wire drawing stage which incorporates the principles of the invention. It is to be understood that, in practice, a plurality of such stages, with successively smaller dies arranged in tandem or series will generally be used.
A wire or rod 12 enters stage 11 in the direction of the arrow and passes over revolving capstans 13, 14 and 16, arrayed as shown, at least one of which, e.g. capstan 14, is powered. From capstan 16 the wire 12 passes through an elongated metallic tube 17 which extends between capstan 16 and a diamond drawing die 18, mounted in die holders 19 and 21. After passing through die 18 the wire passes over a capstan 22 to the next stage, not shown.
A lubricant supply reservoir 23 contains a suitable lubricant such as, for example, an emulsion of mineral or compounded oil and water wherein the suspended oil droplets are dispersed by means of a suitable emulsifier. Lubricant may be supplied, by pumping or other means, not shown, from reservoir 23 to the wire 12 through a conduit 24 and nozzle 26, which sprays lubricant on the wire 12 at capstan 13, as shown. Lubricant is also supplied through a conduit 27 to the interior of metallic tube 17 where, as will be apparent hereinafter, it functions as an electrolyte as well as a lubricant. A conduit 28 supplies lubricant through a nozzle 29 to both the wire 12 and the opening 31 in die 18. Excess or waste lubricant is captured by suitable means such as a catch basin 32, shown in dashed lines, from where it can be filtered and returned to reservoir 23. For simplicity, the pumping means, conduits, and any filter means have not been shown and it is to be understood that such components are standard, commercially available items.
In accordance with the principles of the invention, a source 33 of D.C. voltage has its negative terminal 34 connected to, for example, capstan 14, for applying a negative voltage to wire 12. The positive terminal 36 of source 33, which is grounded, as shown, is connected to tube 17. Thus, within tube 17, the wire 12 corresponds to a cathode and tube 17 to an anode, with the lubricant constituting an electrolyte. Such an arrangement has, as is well known, a corrosive effect on the metals, hence, tube 17 is preferably made of a non-corrosive or corrosion resistant electrically conductive material. Hence tube 17 may be made of stainless steel or copper with a platinum foil or platinum plated interior surface. Graphite or a platinized titanium or platinized niobium or platinized tantalum material might also be used. Such materials lessen the frequency with which the tube 17 must be replaced during operation due to the corrosive effects. Under certain laboratory conditions, e.g., the use of different lubricants, it has been found that a positive voltage on the wire produces the desired result of reducing pulling force.
With a drawing stage configured substantially the same as stage 11 of FIG. 1, and with a load cell 37 for measuring the pulling force on wire 12 at the die 18, results have been achieved which show a marked reduction in the pulling force, and hence the tension on wire 12, upon the application of a voltage to wire 12, with the interior wall of tube 17 at ground potential. In FIG. 2, there is shown a graph of the results of such operation, with the abscissa representing time and the ordinate representing voltage output of the load cell 37. The voltage output of load cell 37 is directly proportional to the tension, hence, the pulling force, on wire 12 as it is pulled through die 18 and indirectly, a function of the amount of oxide film on the wire. Such pulling force is, of course, a direct function of the friction between wire 12 and die 18. The results shown in FIG. 2 are the result of the application of approximately seventeen (17) volts negative to wire 12 with tube 17 grounded and can be interpreted as follows. With the voltage applied at zero (0) to one (1) minute, the output of load cell 37 was approximately twelve and one-half ten-thousandths (0.00125) volts. When the voltage was removed at one (1) minute, the output of load cell 37 immediately rose to approximately twenty-one ten-thousandths (0.0021) volts, thus indicating an almost seventy percent (70%) increase in friction between wire 12 and die 18. When the voltage was again applied, at approximately two and one-half (21/2) minutes, the output of load cell 37 dropped substantially immediately to an average value of thirteen ten-thousandths (0.0013) volts where it remained until the voltage was again removed at approximately four and one-half (41/2) minutes. (The spikes and dips shown at 41/2 minutes are transients associated with the removal of the voltage). From 41/2 minutes to approximately 61/2 minutes the output of the load cell 37 was again high and, upon application of the voltage at approximately 61/2 minutes, the output again dropped to the low value of twelve to thirteen ten-thousandths volts.
As indicated hereinbefore, the high voltage output from the load cell 37 indicates an increased friction, and the lower voltage output indicates a decreased friction, even though the lubricant was continuously supplied. Thus, the voltage or potential application is, apparently, independent of the use of a lubricant. This has apparently been born out of experiments in which distilled water, a poor lubricant, was used instead of a true lubricant. Results similar to those shown in FIG. 2 were obtained. Similar results have also been obtained using different applied voltages, from, for example, one (1) volt to forty-five (45) or more volts. The optimum voltage is dependent upon several factors, such as, for example, the material being drawn, the particular lubricant used, and the material and dimensions of the tube 17. Also, the polarity of the voltage depends upon the lubricant used, thus, for some lubricants, the wire 12 might have to be at a positive potential relative to tube 17 for best results.
As was pointed out hereinbefore, the reduction in friction results from anode-cathode-electrolyte relationship within tube 17. This relationship functions to reduce or change the oxide film on the material being drawn, thereby reducing the pulling forces caused by friction and deformation within the die. Additionally, the surface quality of the drawn material, i.e., copper wire, is materially improved. In FIGS. 3A and 3B, which are scanning electron microscope micrographs, there are shown the results of wire drawing with and without an applied voltage. FIG. 3A shows the surface condition of a drawn wire using a drawing arrangement such as shown in FIG. 1 and without any applied voltage. It can be seen that the surface is extremely rough, primarily as a result of the oxide film both on and in the surface of the wire. FIG. 3B shows a similar view of the wire surface, where the wire was drawn with an applied potential. It can be seen that the surface is quite smooth and uniform as a result of the elimination of virtually all or at least a major portion of the oxide during the drawing operation. The improved surface shown in FIG. 3B is highly desirable in that there will be less friction in subsequent drawing stages, and that the oxide material is not incorporated into the wire which, consequently, is more nearly pure metal. When wire is used to transmit high frequency energy, the major portion of the energy is concentrated near the outer surface of the wire, a phenomenon known as skin effect. Thus, the wire of FIG. 3B has, for such transmission, less resistance and better overall transmission characteristics at high frequencies than the wire of FIG. 3A inasmuch as the resistivity at the surface is less, the oxide containing material having a higher resistivity than the pure metal. Similarly, FIGS. 4A and 4B show the drawn wire as viewed from the top, with greater magnification than for FIGS. 3A and 3B. The wire shown in FIG. 4A was drawn without potential control, and the wire of FIG. 4B was drawn with potential control. The improvement in the surface of the wire of FIG. 4B over that of the wire of FIG. 4A is readily apparent.
From the foregoing description of the preferred embodiment of the invention it can be seen that the invention produces drawn wire or the like that is materially improved over drawn wire produced by conventional drawing arrangements. This improvement is both manifest in the actual drawing operation wherein friction between the wire and the die and resistance to deformation are reduced, with a consequent reduction in required pulling power and wire breakage, and in the improved surface quality of the wire.
The principles of the invention have been disclosed in an illustrative embodiment thereof. Numerous variations or changes in the actual mechanism for realizing the advantages of the invention may occur to workers in the art without departure from these principles.
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A wire or rod drawing apparatus has a drawing die and a metallic tubular member through which the wire passes before entering the die. A D.C. voltage is applied between the rod and the tubular member for creating a voltage difference therebetween, and a lubricant is applied to the wire within the tubular member to function as an electrolyte.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a valve, particularly a mixing valve, with a valve casing, a water outlet and at least one water inlet.
2. Prior Art
It is known to connect a dental syringe to the outlet end of a mixing valve with the aid of an adapter. When the dental syringe is attached, the water tap can no longer be normally used.
It is also known (DOS No. 30 25 023) to connect a dental syringe to the shower tube of a bath or shower bath fixture. For this purpose, the normal shower must firstly be disconnected and then the dental syringe connected. Here again, it is no longer possible to use the shower tube normally, when the dental syringe is connected.
It is also known (DOS No. 29 47 720) to attach a three-way valve to the outlet end of a water tap. This three-way valve has two water outlets, it being possible to connect a feed tube for a dental syringe to one water outlet and a so-called bubbler to the other water outlet. Such an additional three-way valve naturally has a prejudicial effect and significantly impairs the appearance of a mixing valve.
In addition, dental syringes are known, which have their own water container, which is filled prior to operation and supply the liquid with the aid of a pump.
SUMMARY OF THE INVENTION
The object of the invention is to permit a very simple connection and operation of a dental syringe, a toothbrush, or similar supplementary apparatus, without the appearance and function of the valve fitting being impaired. Moreover, this must be accomplished with only the smallest possible change in the construction of the fitting.
According to the invention this object is achieved in that a valve of the aforementioned type has a connection for a supplementary apparatus, provided with a quick-action coupling device, leading in to the interior of the valve casing. This makes it possible to simply connect to the valve a supplementary apparatus, for example a dental syringe, without the valve, particularly a mixing valve having its normal use impaired. It is particularly favourable if the quick-action coupling device is a plug-in coupling.
No additional control element is required for operating the supplemental apparatus, because the passage of water through the apparatus can be controlled with the aid of the conventional control element of the valve. It is naturally also possible to use a dental syringe with a simple shutoff valve, for example in the tube connecting the dental syringe to the valve. In this case, the dental syringe can be continuously connected to the mixing valve.
However, it is particularly advantageous if, according to another feature of the invention, the connection has a check valve. In this case, after use, the supplemental apparatus can easily be detached.
According to a further development, in the case of a mixing valve, the connection leads into an area of the valve which carries mixed water. As a result, it is possible to set and select the water supply (both temperature and flow rate) with the aid of the normal mixing valve operatons.
In order to permit the connection of the supplemental apparatus in the case of already existing valves or mixing valves, the invention also proposes to lead the connection for the supplementary apparatus at least partly through the control element. In this case, it is merely necessary to replace one control element by another. The possibility of easy reequipment is also provided. For example, one hand-operated mixing valves are known, in which a control member is connected to a handle with the aid of a control element. The latter, which can be shaped like a rod or lever, is longitudinally bored according to the invention and the bore outlet on the valve inside issues into the valve mixing area. The connection for the supplementary apparatus is then arranged on the lever handle.
However, it is also possible for an optionally flexible line to lead from the mixing area to a connection for the supplementary apparatus.
In order that the visual appearance and function of the mixing fixture are minimally impaired, the invention also provides for the connection to issue on to the back of the valve and/or handle. In this case, the visual appearance is not impaired in the slightest. It is also advantageously possible for the connection to be constructed in recessed manner, so that no part thereof projects above the outer contour of the mixing fixture. This is particularly advantageous in permitting easier cleaning of the mixing valve.
It is particularly advantageous to use the invention in the case of a single lever-operated mixing valve with a spherical plug (as shown in Applicant's U.S. Pat. No. 4,449,551), in which case the connection leads into the spherical plug. This is a particularly favorable and simple embodiment of the connection and it is in particular possible to use a hollow connecting rod between the lever handle and the spherical plug and this serves as a line. A thermally insulating seal is then advantageously inserted between the connecting rod and the lever handle.
BRIEF DESCRIPTION OF THE DRAWING
Further features, details and advantages of the invention can be gathered from the following description of a preferred embodiment thereof, as well as from the drawing. This drawing shows a section through the connection of a spherical plug to a lever handle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawing shows a cap nut 11, which seals at the top the lower part of a valve and in whose interior is arranged a spherical plug 12. The spherical plug 12 cooperates with water inlet ports 42, 43 and outlet port 44. The handle 14 is pivotably mounted with respect to the cap nut 11 of the valve casing 40. The solid lines of the FIGURE show a first relative position between the cap nut 11 and the handle 14. The phantom line depiction of the top of the cap nut 11 illustrates a second relative position of the cap nut 11 and the handle 14, although as noted, the cap nut 11 is fixed in position and the handle 14 is pivoted relative to the fixed cap nut.
The spherical plug 12 is connected via a connecting rod 13 to the handle 14, on to which is shaped in one piece on the right-hand side of the drawing, an operating lever 15. Handle 14 is terminated upwards by a cover 16. The lower end of the connecting rod 13 engages into the interior of the spherical plug 12, while its upper end engages in a corresponding blind bore 17 in handle 14. Connecting rod 13 is fixed in blind bore 17 with the aid of a screw 18. Further details of such valves may be seen in Applicant's U.S. Pat. No. 4,449.551, which details do not form a part of this invention.
Within the handle 14 is provided a plug-in coupling 19 for the connection of a supplementat apparatus, which is not shown in the drawing. The drawing shows the plug-in coupling above its center line 20 in the open position and below the center line 20 in the closed position. The plug-in coupling 19 contains an outer part 21, into which is screwed a bush 22 from the left-hand side of the drawing. A packing ring 25 is placed between the inner end face 23 of bush 22 and a shoulder 24 of outer part 21. On the inside of bush 22 is provided an annular groove 26, in which is placed a second packing ring 27. In bush 22 is placed a guide member 28, whose front side can be moved to the right by a connecting member 29 insertable into the plug-in coupling 19. With its right-hand end, in the sense of the drawing, guide member 28 engages with a ball 30, which is under the bias of a spring 31. If the connecting member 29 is removed from the plug-in coupling 19, the ball 30 engages on packing ring 25, which represents the sealing of the plug-in coupling 19.
The connecting member 29, which is connected to the supplemental apparatus by a tube (not shown), has in its front end an annular notch 33, which brings about engagement together with the packing ring 27.
The interior of plug-in coupling 19 is connected by means of a through bore 34 with the blind bore 17. Connecting rod 13 has a longitudinally directed blind bore 35, which passes into a radially directed bore 36. Radial bore 36 is arranged in such a way that, when the connecting rod 13 is inserted, it coincides with the opening of the through-bore 34. A packing ring 37 is arranged over the opening of bore 36.
It would also be possible to thermally insulate by means of a seal 41 the complete space between the connecting rod 13 and the blind bore 17.
When the mixing valve shown in the drawing is operating, liquid passes out of the interior of spherical plug 12, through bores 35, 36, 34 into the interior of the plug-in coupling 19, from where it can pass through the interior of connecting member 29 to the supplemental apparatus, when ball 30 is displaced to the right. When the connecting member 29 is extended, the connection formed by the plug-in coupling 19 is sealed in a liquid-tight manner.
It is pointed out that the preferred embodiment of the invention shown in the drawing can be used in a known mixing valve, without any modification thereto. It is merely necessary to modify handle 14 by inserting plug-in coupling 19 and the connecting rod 13 through bores 35, 36, the rest of the mixing valve remaining unchanged. It can also be seen that the connection or plug-in coupling 19 is arranged on the side of handle 14 remote from the actual operating lever 15. As operating lever 15 is normally at the front, the connection for the dental syringe or other supplemental apparatus is located on the back of handle 14. Thus, the connection cannot be seen from the front, so that the visual impression of the mixing fitting is not impaired. It is also clear that if the connecting member 29 is removed from the plug-in coupling 19, the latter does not project over the outer contour of handle 14. This also ensures that the visual appearance is not impaired. In addition, the cleaning and care of the mixing fitting are in no way impaired.
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A valve contains a connection for connecting to a tube of a supplemental shower head or spray nozzle, the connection preferably containing a check valve. In the case of the preferred embodiment, the connection for the supplemental apparatus is arranged in the handle of the operating lever connected to a spherical plug valve. The water is supplied to the handle through the hollow connecting rod, from the interior of the spherical plug.
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BACKGROUND
[0001] The invention relates to tubes such as those used in conventional caulking guns. In particular, the invention relates to the applicator tips from which caulking (or another composition of similar viscosity) is dispensed from a caulk tube.
[0002] Conventional caulking tubes typically include a cone-shaped end portion that the user cuts to open the tube to release the caulk.
[0003] As an associated problem, once the applicator tip (which is typically made of a polymer) is cut, the size of the opening can no longer be reduced, but only increased by cutting the tip at a larger-diameter portion closer to the tube. Additionally, caulking tips are often cut at a slight angle because an angled tip provides for smoother release of the caulk and better adherence to the surface being caulked. Thus, if a user cuts the cone at an improper or less helpful angle, the only manner of correcting the angle is to cut the tip again and form a larger opening. In turn, if the user wants a smaller opening, or a different angle for the opening, the only realistic option is to start with a fresh tube of caulk.
SUMMARY
[0004] In one embodiment, the invention is an adaptor for conventional caulk tubes. In this embodiment, the invention is a snap on, cone-shaped threaded adaptor that fits over the applicator end of a conventional caulk tube. The several tips of different sizes are attached to the cone section of the snap on adapter.
[0005] In another embodiment the adaptor can include a replaceable closed-end tip, for resealing a partially-used tube of caulk for later reuse.
[0006] In another embodiment the invention is the combination of a tube of a highly viscous composition with a tube tip for dispensing a composition from said tube and a dispensing adapter mounted on the tube tip.
[0007] The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the followed detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of an embodiment of an adapter and tips according to the present invention.
[0009] FIG. 2 is a perspective view of a second embodiment of an adapter and tips according to the present invention.
[0010] FIG. 3 is a side elevational view of the embodiment illustrated in FIG. 2 .
[0011] FIG. 4 is a side elevational view of the embodiment illustrated in FIG. 1 .
DETAILED DESCRIPTION
[0012] In one embodiment, the invention is a caulk tube adapter that replaces—and in the illustrated embodiment overlies—the conventional dispenser tip of a caulking tube.
[0013] Caulk is a widely-available, common, well-understood, and highly viscous composition that is commercially sold in tubes and is appropriate for describing the features of the invention. The skilled person will understand, however, that the invention is not limited to caulk per se, but is useful for dispensing a variety of substances that have compositions and viscosities that make them convenient to be stored in and dispensed from tubes that are analogous to caulk tubes.
[0014] Additionally, because caulk is highly viscous, a caulk tube is often used as a cartridge in a caulking gun. Caulking guns are likewise well understood in the art and are common enough that no need exists to illustrate one separately. In general, a caulk gun is used to apply mechanical force to a caulk tube (usually in a piston-like manner) to in turn urge the caulk out of the relevant opening; i.e., the caulk tube tip 31 in the drawings.
[0015] The invention is, however, not limited to rigid cartridges or caulking guns, but instead can be used in conjunction with any type of commercial packaging that includes the caulk tube tip 31 or its equivalent.
[0016] FIG. 1 illustrates one embodiment of the adapter broadly designated at 10 . The adapter 10 includes an adapter body 11 and an adapter tip 12 , which is illustrated as threaded in FIG. 1 . The adapter tip 12 includes an adapter tip dispensing opening 13 . The adapter tip 12 includes a set of male threads 14 that will be best understood with respect to FIG. 4 . The adapter body 11 includes at least one set, and preferably several sets, of attachments illustrated as the clips 15 . The attachments (C-clips are exemplary) are positioned adjacent an indented saddle (or slot) 16 ( FIGS. 3 and 4 ) into which the respective custom tips 17 and 20 can nest and be engaged by the C-clips 15 . The C-clips are exemplary rather than limiting and other fasteners can be selected by those of skill in this art and without undue experimentation. Basically, the C-clips or their equivalents are sufficiently flexible to permit the custom tips to be attached or removed on a repeated basis without damaging either the clips of the custom tips.
[0017] In exemplary embodiments, the adapter and its various subparts can be formed of any material that is structurally sufficiently strong and that generally does not react unfavorably with caulk. Because of their well-understood properties, wide availability, ease of manufacture into shaped items, and relatively low-cost, polymers are generally appropriate for the adapter of the invention. Typical polymers for the adapter can include (but are not limited to) polyethylene, polypropylene, polyesters, polyurethanes, and polycarbonates. Depending upon the expected use environment, the polymer can be selected on the basis of cost, strength, resistance to chemical attack, or some other factor.
[0018] It will also be understood that although polymers are convenient materials for the adapter, the adapter material is not limited to polymers. Thus, when other materials would be superior or necessary for a particular application, no functional reason precludes the use of materials such as ceramics, metals, or composites.
[0019] FIG. 2 illustrates a second embodiment for which many of the features are either identical or similar to the first embodiment. The adapter is broadly designated at 21 and includes an adapter body 11 which is generally the same as the adapter body 11 illustrated in FIG. 1 . FIG. 2 , however, illustrates a snap type adapter tip 22 as will be described in more detail with respect to FIG. 3 . The adapter body 11 also includes the C-clips 15 and the indented saddles 16 for carrying the custom tips 23 and 24 .
[0020] Although FIGS. 1 and 2 illustrate that the respective adapters 10 , 21 carry two of the custom tips 17 , 20 , 23 , 24 it will be understood that this is exemplary rather than limiting. Thus, and depending upon the size of the adapter and tips, a larger number of custom tips can be mounted on the adapter body 11 .
[0021] The orientation of FIG. 2 also illustrates that in both embodiments the adapter body 11 forms a tube tip receiving opening 25 which has a size and shape that will snugly receive a caulk tube tip 31 in a manner that will be described in more detail in FIG. 3 . The tube tip receiving opening 25 extends entirely through the adapter body 11 (e.g., FIGS. 3 and 4 ) to form the adapter tip dispensing opening 13 . In some embodiments (not shown), the tip receiving opening can form an additional structure within, or in some cases extending from, the adapter body 11 .
[0022] It will be understood that the adapter is not limited to a single size tube tip receiving opening 25 , but that the adapter body 11 and the tube tip receiving opening 25 can be formed in different sizes to fit different caulk tube tips.
[0023] In a similar manner, the rear portions of the custom tips 17 , 20 , 23 , 24 also include respective adapter receiving openings 26 for receiving the adapter tip 22 .
[0024] In both embodiments ( FIG. 1 and FIG. 2 ), the forward portions of each custom tip 17 , 20 , 23 , 24 includes a custom tip dispensing opening 27 . In particular, the adapter receiving opening 26 extends entirely through the custom tip to form the custom tip dispensing opening 27 .
[0025] FIG. 3 is a side elevational view of the adapter 21 illustrated in FIG. 2 . FIG. 3 illustrates the adapter 21 in its environmental context; i.e., attached to the caulk tube 30 and specifically on the caulk tube tip 31 . FIG. 3 illustrates that the snap type adapter tip 22 includes an annular groove 32 and that each snap fit custom tip 23 , 24 includes an annular hook 33 . The snap fit custom tip 23 , 24 is sufficiently flexible for the hook 33 to expand over the larger portions of the adapter tip 22 and then snap into the annular groove 32 to secure the custom tip 23 , 24 on the adapter tip 22 .
[0026] Snap fittings are generally well understood in the art and will not be otherwise discussed in detail. A variety of snap type fittings can be employed, however, and thus the illustrated version is exemplary rather than limiting of these choices. In a snap fitting, the shape of the groove 32 , the shape of the hook 33 and other factors can be adjusted to require greater or lesser force to add or remove the custom tip 23 , 24 from the adapter tip 22 as may be desired or necessary.
[0027] In the embodiment illustrated in FIG. 3 , the adapter 10 , 21 fits on the caulk tube tip 31 with a friction fit. In other embodiments (not shown), the adapter 10 , 21 and the caulk tube tip 31 can snap together using appropriate fittings. In yet other embodiments (not shown) the adapter 10 , 21 can be held in place by the caulk gun rather than as a friction or snap fit onto the caulk tube tip 31 . In these embodiments, either the adapter 21 or the adapter opening 25 can terminate in a washer-like structure that drops into (and behind) the U-shaped tip opening of a typical caulk gun. When the caulk gun applies pressure against the caulk tube, the tube holds the washer (and thus the adapter) firmly in place.
[0028] FIG. 3 also illustrates a different shape custom tip 28 in which the face of the custom tip dispensing opening 27 is illustrated as oblique (rather than parallel) to the face of the adapter tip dispensing opening 13 , and in which the custom tip dispensing opening is somewhat smaller than the other illustrated embodiments.
[0029] FIG. 4 is a side elevational view of the adapter 10 illustrated in FIG. 1 . The elements of the adapter 10 of this embodiment are the same in most respects as the adapter 21 illustrated in FIG. 3 , with the exception that the threaded adapter tip 12 includes the male threads 14 and the custom tips 17 , 20 include female threads 34 that correspond to the male threads 14 .
[0030] FIG. 4 also illustrates a closed end custom tip 18 which can be positioned on the adapter 10 to close the caulk tube of 30 (and seal). It will be understood, of course, that the close tip can be combined with a snap on custom tip or that the angled tip 26 can be threaded for use with the threaded adapter 10 .
[0031] It will be further understood that for clarity purposes the illustrated custom tip dispensing openings 27 are not necessarily drawn to scale. In practice, the invention provides the advantages of custom tip dispensing openings 27 that are relatively small to thereby provide the user with an option to produce a smaller bead of caulk from the somewhat larger caulk tube tip 31 .
[0032] The user can position the adapter 10 , 21 on a caulk tube tip 31 . In exemplary embodiments the shape of the tube tip receiving opening 25 corresponds to the shape of the caulk tube tip 31 . Because of this, the caulk tube tip 31 can be trimmed prior to or during use. Indeed, one of the advantages of the adapter is that a caulk tube 30 and caulk tube tip 31 can be used without the adapter of the invention until the adapter is needed. In other words, when the user, having already cut the caulk tube tip 31 to a desired opening size, wants to change—and specifically reduce—the opening size, the user can add the adapter 10 , 21 to the caulk tube tip 31 .
[0033] Additionally, with the adapter 10 , 21 in position, the user can select and change the desired custom tip 17 , 20 , 23 , 24 conveniently on an as-needed or desired basis. As a further advantage, the closed end tip 18 can be used to close the caulk tube 30 to keep the caulk from drying in the tube and thus keep the caulk available for further use.
[0034] The removable nature of the adapter 10 , 21 and the convenient materials (e.g. polymers) from which it is formed make it easy to clean the adapter 10 , 21 during or between uses.
[0035] In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
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A dispensing adaptor is disclosed for tubes of high viscosity compositions. The adaptor includes an adaptor body, the interior of which defines a tube tip receiving opening having a size and shape corresponding to the tip of a tube of high viscosity composition, an adapter tip on the adaptor body through which the tip receiving opening continues, a custom tip for the adapter tip that fits on the adapter tip, and at least two sets of custom tip attachments on the adapter body.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/527,611 filed Mar. 11, 2005, which is a continuation of U.S. Provisional Patent Application Ser. No. 60/450,847 filed Feb. 28, 2003, to which priority is claimed under 35 U.S.C. §120 and which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to soil aerification (or “aeration”). More particularly, it relates to a method and apparatus for the aerification of turf grasses using a self-rotating turf drill.
2. Description of the Related Art
What is Aerification
Aerification is a mechanical process that creates more air space in the soil and promotes deeper rooting, thus helping plants stay healthy. In most cases, this is achieved by removing cores (often called plugs) and then filling the holes with topdressing. Topdressing is often a certain grade of sand which may have other amendments added to allow the soil to maintain air space, improve water penetration, and encourage healthy root growth. The sand is brushed or poured into the holes which are usually healed within several days.
The condition of turf largely depends on the events occurring below the surface. For grass to grow, deep healthy roots are needed, and roots require oxygen. In good soil, they receive oxygen from tiny pockets of air trapped between soil and sand particles. On a sports field, the everyday traffic from players combined with the weight of heavy mowing equipment causes the soil to become compacted and the air pockets on which the roots depend for oxygen are lost. Aerification is a mechanical process that creates more air space in the soil and promotes deeper rooting, water percolation and compaction relief.
The practice of aerating turf is becoming increasingly widespread. The benefits of aerification include:
Improved water infiltration and better drainage Deeper penetration of fertilizers Improved plant rooting Thatch control Increased stress tolerance Break up of sod layers that can restrict rooting and water movement Release of toxic gases from soils Increased drying and drainage of persistently wet soils Loosening of soil, allowing for increased air space Softening of sports fields to reduce risk of injury
In addition, putting green aerification can provide for additional surface smoothing.
Compaction Relief
Definition of Compaction
Compaction of sports playing fields and golf course tees, greens and fairways is an inevitable product of their use—golf carts, maintenance machinery and feet all contribute to the process that is defined as “the consolidation of soil particles.”
Compaction decreases water and oxygen movement in the soil, hinders root growth and lessens the ability of the soil to drain. Soil compaction causes these negative effects by turning macropores (larger voids in the soil largely responsible for drainage and air flow) into many micropores (smaller voids that hold water). As compaction increases, bulk density also usually increases, which means that more soil solids occupy a unit volume of soil, reducing the porosity.
With turfgrass, techniques used to relieve compaction must be effective without being highly visible. Aerification—either with solid tines that create a hole in the soil, or with hollow tines or drills that remove a core of soil—is one of the more common ways of improving compacted soils.
When a soil compaction condition is accompanied by excessive thatch buildup, as is almost always the case in poorly maintained turf, each condition contributes to the effect of the other. Thatch is a mat of undecomposed plant material (e.g., grass clippings) accumulated next to the soil in a grassy area (as a lawn, sports field or putting green). It is a tightly intermingled layer of living and dead stems, leaves and roots of grasses, which develops between the layer of green vegetation and the soil surface. When thatch exceeds about ½ inch of undecomposed material, it acts as a barrier to water and air infiltration into the soil below and will provide an environment encouraging turf diseases and harmful insects. Compacted soils, on the other hand, are subject to greater temperature extremes than loose soils, because of limited air movement; microbial activity necessary to thatch decomposition is reduced or halted.
Water that cannot penetrate the soil runs off or accumulates in low spots where it harbors fungus growth.
Alleviating either condition will help, but only when thatch is kept under control and the soil is properly aerified will turf have the best chance for healthy, vigorous growth and disease resistance.
The accumulation of organic matter (thatch) and fine particles (silt and/or clay) can, over time, produce a surface layer that reduces porosity. Aerification can modify the profile, improving oxygen, water, and root movement, especially when the use of hollow tines or turf drills is combined with core removal and backfilling channels with high-quality topdressing sand.
Prior Art Methods of Aerification
Turfgrass cultivation activities include hollow tine aerification, solid tine aerification, spiking, slicing, and water injection. These activities, to varying degrees, can reduce thatch, prepare turf for overseeding, and relieve soil compaction. Perhaps the best machine for working large areas is a piston driven aerator that thrusts the core cutters vertically. Direct up and down coring leaves a clearly defined hole. Drum-type roller aerators will work but may cause tearing damage to the remaining grass since this type of cutter enters the turf at one angle, moves in an arc with the drum movement, and is withdrawn at a different angle.
Solid Tine
Solid-tine aerification allows turf managers to aerate more frequently, since the procedure produces less surface disruption. Solid tines larger than ¼ inch in diameter open turf to allow water and air infiltration, but the process compresses displaced soil downward and to the sides. This actually increases soil compaction around newly created aerification holes. Repeated solid-tine aerification with larger-diameter tines can create a hardpan at the aerating depth.
Related to solid tine aerification are slicing and spiking aerifiers. Slicing, spiking, and solid tine aerification do not pull plugs of soil from the turf. Slicing aerifiers cut thin slits into the soil and spiking aerifiers cut thin, triangular-shaped holes in turf. While they do not relieve soil compaction as efficiently as hollow tine aerification, these practices cause less surface disruption and can be done anytime.
Hollow Tine
These devices pull out plugs of soil that are deposited on the surface. One of the most common operations that one can perform using a hollow tine aerator is conducting a soil exchange program, offering the professional an ideal opportunity to remove soil cores and replace them with a suitable top dressing, altering the soil profile.
Self-powered hollow tine aerifiers (core aerifiers) insert hollow tines into the soil, removing a soil plug ¼″ to ¾″ in diameter and 2″ to 12″ deep, depending on soil type, soil moisture, and type of machine. Core spacing varies depending upon the make and model of the machine. In general, the more cores removed per square foot, the more effective the cultivation will be; removing fifteen to thirty cores per square foot is recommended. Hollow tine aerification is considered the most efficient compaction reliever of the prior art methods. It is preferably done during active turf growth.
Slitting
Using triangular blades ranging in size 100-250 mm (4″ to 10″), these machines create lots of short, narrow, close slits; slitting is useful for getting air down into the soil; it's quick; it does a fair job in dethatching; however, this approach is not highly effective at reducing compaction. Slitting also has its benefits, particularly in autumn when it can be employed to help ‘connect’ the surface of the soil with the underlying drainage layers. In the spring and summer, slitting ensures that water from rain and irrigation soak through the turf rather than being shed in a sideways fashion by the thatch.
Water Injection
Water injection aerification is a recently-introduced method of turf aerification. Water, under high pressure, is injected into the turf surface to relieve soil compaction. In addition, it can be used to inject turf management chemicals into the soil. It causes little surface disruption and can be done anytime during the growing season. This new technology has not been commonly available for use outside of golf course applications.
Deep Drill Aerification
Drill-type aerifiers employ rotating turf drills. The drill bits eliminate compaction along the sides and bottom of the aerification hole, and allow for quick and effective penetration even in heavily compacted soils including hardpan, muck and roots. The “gentle footprint” of drill-type aerifiers, in conjunction with the absence of cyclic vibration and the “straight in, straight out” action of the drill bits, gives this type of machine the capability of aerating fields that are wet, dry or experiencing periods of high stress.
Deep drill aerifiers are also preferred for use in all problem areas because the rotating drill bits will penetrate subsoil areas, where other machines tend to walk or bounce, often causing trauma to the playing surface. Turf drill bits fracture the cylinder wall without glazing, thereby allowing lateral movement of air and water. “Drill & Fill” aerifiers are available which back-fill the drilled holes with a selected top dressing, usually sand, thereby modifying the soil profile.
Turf drill bits are commercially available in ⅝″×12″, ⅝″×16″, ¾″×12″, and 1″×12″ sizes. One particular deep drill aerifier currently on the market produces 5″ spacing of holes. Drill aerification is especially preferred when one must penetrate hard soils. However, drill aerification is a very slow process as compared to reciprocating type aerifiers.
As noted above, aerification has the added benefit of smoothing the surface of a putting green. The process of punching holes and either reincorporating the plugs brought up or removing the plugs and filling the channels can offer some surface smoothing. Surface topdressing alone will fill/smooth low spots. The combination of aerifying and the follow-up topdressing will, over time, both fill low spots and soften high spots, resulting in more efficient surface smoothing than topdressing alone.
SUMMARY OF THE INVENTION
The method and apparatus of the present invention combines the speed and mechanical simplicity of solid or hollow tine aerification with the penetration depth, clean cutting and cylinder wall fracturing of deep drill aerification. A turf drill is held in a chuck which permits free rotation of the drill bit when it is pushed into the ground (loaded in compression) but which restricts rotation of the bit when it is withdrawn from the ground (loaded in tension). When the chuck is locked and the drill bit is pulled from the soil, the flutes on the bit cut a clean, generally cylindrical hole in the soil with minimal compaction of the surrounding earth. In one embodiment, the drill bit comprises a non-fluted upper portion which helps prevent entanglement and lifting of the turf as the bit is withdrawn.
In some embodiments, the distal end of the drill bit is provided with opposing beveled surfaces which impart a rotational movement to the bit as it is pushed into the soil. Since the bit is self-rotating, there is no need for rotational means in the aerifier head, and therefore drills according to the present invention can be utilized in aerifiers previously equipped with solid or hollow-core tines. Since rotational means are not needed in the aerifier's heads, the tines may be placed in greater proximity to one another which permits greater density of aerification holes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cut-away view of a simplified, reciprocating-type aerifier equipped with a turf drill according to the present invention.
FIG. 2 is a partial cross-sectional view of the chuck of the present invention in its free rotation state.
FIG. 3 is a cross-sectional view taken along line 3 - 3 in FIG. 2 .
FIG. 4 is a side view of the lower portion of the central shaft of the chuck.
FIG. 5 is a partial cross-sectional view of the chuck of the present invention in its locked, rotation-inhibiting state.
FIG. 6 is a side view of a drill bit according to the present invention.
FIG. 7 is an end view of the tip of the drill bit illustrated in FIG. 6 taken along line 7 - 7 .
FIG. 8 is an enlarged, side view of the tip of the drill bit illustrated in FIG. 6 .
FIG. 9 is an enlarged, side view of the tip of the drill bit illustrated in FIG. 6 rotated 90°.
FIG. 10 is a partial cross-sectional view of another embodiment of the chuck of the present invention in its free rotation state.
FIG. 11 is a cross-sectional view taken along line 11 - 11 in FIG. 10 .
FIG. 12 is a cross section taken along line 12 - 12 in FIG. 10 .
FIG. 13 is a partial cross-sectional view an alternative embodiment of the chuck of the present invention in its locked, rotation-inhibiting state.
DETAILED DESCRIPTION
In the following description, “drill” should be understood to mean an apparatus comprising both a drill chuck and a drill bit held within the chuck.
Referring now to FIG. 1 , a portion of a reciprocating turf aerator is shown as a partial cut-away drawing. The aerator is shown in simplified form to illustrate how the turf drill of the present invention may be used in practice. Aerator 12 may be moved across an expanse of ground such as soil 22 on wheel(s) 14 . Reciprocating heads 20 are connected to crankshaft 16 by connecting rods 18 which cause heads 20 to move generally up and down as crankshaft 16 rotates. Drills 10 , attached to heads 20 , are thereby alternately thrust into and withdrawn from soil 22 . In some commercially-available aerators, crankshaft 16 is driven by the power take off (PTO) of a tractor used to pull aerator 12 across a putting green, for example.
As mentioned above, this is a simplified view of a reciprocating aerator. Commercial aerators are typically equipped with articulating heads that additionally move fore and aft relative to the track of the aerator across the ground such that during insertion, withdrawal and the interval there between during which the drill bits are in the soil, the heads and drills (or tines) do not move transversely with respect to the ground. In this way, cylindrical, vertical holes may be achieved while the aerator advances continuously across the ground. Apparatus which provide this type of motion are described in U.S. Pat. No. 6,041,869 entitled “Turf Aerator with Constantly Vertical Tines” and are available from manufacturers such as Redexim/Charterhouse, Jacobsen (under the Ryan brand name) and others.
The chuck 24 of one particular embodiment of the present invention is shown in partial cross section in FIG. 2 . Shaft 26 may be adapted at its upper or distal end to engage the head platforms 20 of a mechanical aerator. Reciprocating aerators are particularly preferred, but the drill embodiments illustrated in the drawing figures can be employed in a variety of aerators.
The proximal end (lower end in FIG. 2 ) of shaft 26 is contained within rotating body 28 of chuck 24 and is rotatably supported by bushing 30 and thrust bearing 32 . In the particular embodiment illustrated in FIG. 2 , the proximal end of shaft 26 has conical tip 48 (see FIG. 4 ) which fits within a corresponding conical portion of bearing 32 . Bushing 30 and thrust bearing 32 may be fabricated from a softer metal than that used for shaft 26 to reduce frictional wear. Additionally, chuck 24 may be provided with grease fitting 36 (also known as a Zerk fitting) through which a suitable lubricant may be introduced for lubricating shaft 26 within bushing 30 and bearing 32 . One preferred lubricant is lithium grease. In other embodiments of chuck 24 , self-lubricating bearings and bushings may be used, in which case it may not be necessary to provide means for introducing lubricant from an external supply.
Shaft 26 is free to both rotate within bushing 30 and thrust bearing 32 and to slide longitudinally (within limits, as described below) within bushing 30 and the upper, cylindrical portion of thrust bearing 32 . As indicated by the arrow in FIG. 2 , chuck 24 is shown loaded in compression such as would occur when the drill was being pushed into the ground. The conical tip at the proximal end of shaft 26 is shown fully engaged in thrust bearing 32 in FIG. 2 as it would be during insertion of the drill in the ground.
Chuck 24 comprises a lock which engages when a turf bit held in the chuck is loaded in tension and which disengages when the bit is loaded in compression. In the embodiment illustrated in FIG. 2 , rotating body 28 has an opposing pair of set screws 34 . The set screws 34 have a conventional threaded portion for engaging the threads of tapped holes within rotating body 28 and also a cylindrical tip 35 of reduced diameter which is sized to project into the upper central bore of rotating body 28 . Such set screws are sometimes referred to as “dog point” set screws. In the embodiment illustrated, the holes in rotating body 28 into which set screws 34 are screwed are not threaded the full thickness of the wall of rotating body 28 . Rather, the threads begin at the exterior surface of rotating body 28 and end prior to reaching the central bore of rotating body 28 . In this way, the insertion of projecting points 35 may be limited. It is preferred that projecting points 35 do not contact shaft 26 when set screws 34 are fully seated within rotating body 28 . The rotation and sliding of shaft 26 within rotating body 28 would be inhibited if projecting tips 35 were to contact shaft 26 . Alternatively, bushing 30 may be sized and positioned such that the shoulders of set screws 34 contact bushing 30 . In this way, over-insertion of set screws 34 may be prevented and bushing 30 may be secured within rotating body 28 .
As illustrated in the detail of FIG. 4 , shaft 26 includes stop collar 44 which prevents withdrawal of shaft 26 from rotating body 28 when a tensile force is applied to shaft 26 (such as occurs during withdrawal of the drill from the soil). Stop collar 44 may be provided on its upper surface with one or more indentions. In the embodiment illustrated, four such indentions are provided spaced 90° apart and each describes an arc of a circle in cross section. Indentations 46 and conical tips 35 of set screws 34 are preferably sized such that projections 35 will seat in indentations 46 when stop collar 44 is brought into contact with set screws 34 . This condition is illustrated in FIG. 5 .
FIG. 5 shows the same embodiment as that illustrated in FIG. 2 . In this case, however, the drill is loaded in tension, as indicated by the arrow in the drawing. This condition obtains when the drill is being withdrawn from the soil and frictional forces on the drill bit 50 are opposing the upward motion imparted by the aerator. It will be noted that the conical tip of shaft 26 is partly withdrawn from the conical portion of thrust bearing 32 and stop collar 44 is in contact with cylindrical projections 35 of set screws 34 . Further upward motion of shaft 26 relative to rotating body 28 is thereby prevented. Since stop collar 44 may be coated with lubricant, contact of the upper surface of stop collar 44 with cylindrical projections 35 may not inhibit the rotation of shaft 26 relative to rotating body 28 until an opposing pair of indentations 46 align with set screw projections 35 at which point shaft 26 may move slightly further upward, seating projections 35 within indentations 46 at which point further rotation of shaft 26 is significantly inhibited. It will be appreciated that the number and spacing of set screws 34 in rotating body 28 and the number and spacing of indentations 46 in stop collar 44 may vary from that of the embodiment shown in FIGS. 2 through 5 .
Also shown in FIGS. 2 and 5 is dirt shield 38 which may be used to help deflect dirt, sand and other soil components from the interface of bushing 30 and shaft 26 . Dirt shield 38 may be a stamped metal fitting which is concentric with shaft 26 . Rotating body 28 may also be provided with chamfer 42 to further aid in the shedding of dirt from the top of rotating body 28 . In operation in aerifiers having multiple drills in close proximity one to another, dirt particles are often thrown up by the drills as they are withdrawn from the ground which particles may land on nearby drill chucks. It is, of course, advantageous to shield bearings from the introduction of abrasive particles.
Also shown in FIG. 2 and FIG. 5 is the upper portion of the shank of turf drill bit 50 . Rotating body 28 is provided with a central bore on its lower surface for receiving drill bit 50 . Drill bit 50 may be provided with notch or flat 52 for engaging set screw 40 which both retains bit 50 within chuck 24 and prevents the rotation of bit 50 relative to rotating body 28 . In the illustrated embodiment, set screw 40 is shown as being a dog point set screw. Set screw 40 may be a conventional set screw, but it may be convenient to have set screw 40 be of the same type and size as set screws 34 so as to reduce inventory and replacement parts requirements and to reduce the chance that a conventional set screw would be inserted in place of set screw 34 thereby impairing the function of chuck 24 . Alternatively, set screw 40 may be a different diameter from that of set screws 34 .
As will be appreciated by those skilled in the art, there are many ways a drill bit may be secured in a chuck. The securing method using a set screw described above and illustrated in the drawing figures has been found to be particularly suited to the application of the invention, but other methods may be used. By way of example, a hole may be provided in the chuck with a corresponding hole in the bit shank. A pin (such as a roll pin) or a machine screw passing through the hole in the chuck and into the hole in the bit shank would secure the bit in the chuck.
One embodiment of a drill bit of the present invention is shown in FIG. 6 . Bit or drill tine 50 is comprised of an unfluted, generally cylindrical upper portion 54 and a lower, fluted section 56 . As noted above, the upper portion of the shank of bit 50 may be provided with flat or notch 52 which provides a planar contact area for set screw 40 of chuck 24 used to secure bit 50 in the lower central bore of rotating body 28 .
Flutes 58 , which may be generally rectangular in cross-section, are formed in a helical pattern around core or central shaft 62 . Smooth portion 54 is provided to lessen the chance of turf entanglement when the bit is withdrawn from the turf. In practice, the insertion depth may be adjusted such that fluted portion 56 penetrates to a soil depth just below the turf layer while portion 54 is within the turf layer.
Details of the tip of bit 50 are shown in FIGS. 7 , 8 and 9 . The tip may be formed by grinding generally planar, opposing flats 60 at the angle shown as α in FIG. 8 . The position of notch 52 is shown as a dashed line in FIG. 7 to illustrate the angular position of the dividing line or “chisel edge” between the opposing flats 60 . It will be noted that flats 60 are offset from each other with respect to the center line of the bit. Because of this offset, a torque is imparted to bit 50 (counterclockwise as viewed in FIG. 7 ) when it is inserted into the ground. Thus, when bit 50 is pushed into the ground by an aerator, it tends to rotate about its longitudinal axis and the flutes 58 create a pair of helical grooves in the soil around the central hole created by the displacement of the soil by central shaft 62 .
Conventional turf drills typically are carbide tipped to maintain sharpness for an adequate length of time. It has been surprisingly found that the drill bits of the present invention do not require carbide tips or inserts to provide adequate service life. The drill bits of the present invention rotate about 2½ revolutions per insertion. In contrast, bits used in conventional turf drilling machines rotate about 25 revolutions per insertion. It is contemplated that the reduction in friction engendered by the factor of 10 decrease in rotations per insertion is responsible for the longer-wearing nature of the bits of the present invention.
In one particularly preferred embodiment, L 1 is about 10½ inches, L 2 is about 7½ inches and D, the drill tine's diameter, is about ½ inch. The shank diameter may be chosen to fit the head of the particular aerator to be used and it may be greater than, less than, or the same as the tine diameter. In this embodiment, the diameter of central shaft or core 62 is about ¼ inch and the flutes 58 are about 0.1 inch wide (thick) and 0.125 inch high. The twist length, the linear distance over which a flute makes a complete revolution about central shaft 62 , is about 3 inches. The tip angle (α in FIG. 8 ) is about 45°. A particularly preferred drill tine is fabricated from American Iron and Steel Institute (AISI) Grade 4140 steel heat treated after fabrication to a value of at least about 50 on the Rockwell “C Scale” of hardness. Following heat treatment, drill tine 50 may be shot-peen finished.
It will be appreciated by those skilled in the art that there are many means for effecting the locking feature of the chuck of the present invention. By way of example, one such alternative is shown in FIGS. 10 through 13 , inclusive. In this embodiment, a spline 70 or splines 70 on shaft 26 is used in conjunction with keyway 69 or keyways 69 in locking member 68 held within rotating body 28 .
In the embodiment illustrated, bushing 30 is held within upper bore 72 of rotating body 28 by retaining ring 64 which fits within groove 65 in the wall of upper bore 72 . Locking member 68 which may include a plurality of keyways 69 rests on shoulder 73 at the lower boundary of upper bore 72 . Thrust washer 66 may be provided between locking member 68 and bushing 30 to protect the relatively softer material of bushing 30 from impact with splines 70 of shaft 26 when shaft 26 slides upward. Keyways 69 are sized and spaced such that splines 70 will fit within them when shaft 26 is urged upward (loaded in tension) and rotating body 28 rotates relative to shaft 26 until the splines 70 and keyways 69 align. FIG. 10 shows chuck 24 loaded in compression (as during insertion of the drill into the ground). In this condition, splines 70 are below locking member 68 and thus rotating body 28 can freely rotate relative to shaft 26 . FIG. 13 shows chuck 24 loaded in tension (as occurs during withdrawal of the drill from the ground). In this condition, splines 70 engage keyways 69 in locking member 68 and rotation of rotating body 28 (and bit 50 ) relative to shaft 26 is prevented.
Locking member 68 may be fabricated as an extrusion cross cut to the desired thickness. Rotating body 28 may be heated to expand the diameter of upper bore 72 and locking member 68 inserted while the bore is expanded. Upon cooling and contraction, locking member 68 (if appropriately sized) will be rotatably secured within upper bore 72 .
While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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A novel drill for the aerification of turf grasses is disclosed. The drill comprises a chuck and a fluted turf drill bit held by the chuck. The chuck includes a locking mechanism which permits the chuck to rotate freely about its longitudinal axis when loaded in compression (as when the drill is inserted into the ground) but which locks, preventing rotation, when the drill is loaded in tension (such as when the drill is withdrawn from the soil). The drill bit has a smooth upper section and a fluted lower section. The smooth section decreases the probability of entangling the turf in the drill bit with subsequent lifting of the turf when the drill is withdrawn. The tip of the drill bit is adapted to provide a torque to the drill bit during insertion into the ground. Thus, the bit spirals into the ground upon insertion, but locks upon removal, thereby permitting the flutes of the bit to cut a cylindrical hole in the ground while removing soil from the hole by retaining it in the space between the flutes. The drill of the present invention may be used in aerators previously limited to solid or hollow-core tines.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2016-085599, filed on Apr. 21, 2016, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The embodiments discussed herein are related to a computer-readable recording medium, a determination method, and an information processing device.
BACKGROUND
[0003] When a driver of a vehicle gets more and more tired, a series of driving behaviors of the driver such as recognition, determination, and operations becomes late, thereby becoming a cause of the occurrence of the accident. For example, in case of the transport industry, a load is transported in the distance in many cases, and thus a driving time may be prolonged. For this reason, any of driving control systems that use a digital tachograph sounds a warning when a continuous driving time elapses for a predetermined time, for example four hours.
[0004] Recently, there is known a method for detecting physical fatigue, mental fatigue, and sleepiness caused by a long drive to detect an alerting timing by using an index such as palpebration, a flicker, and a heart rate of a driver.
[0005] Patent Document 1: Japanese Laid-open Patent Publication No. 2009-009495
[0006] However, in the above technology, it is difficult to accurately detect the degradation of driving ability of a driver caused by fatigue, habituation, or the like.
[0007] In other words, the above technology employs a continuous driving time as a warning standard. However, even when a continuous driving time does not run beyond a predetermined time, a driver may be subject to detrimental influence with respect to a series of driving behaviors. The reason is because degrees at which fatigue is accumulated are different if drivers are different from each other, and degrees at which fatigue is accumulated are different depending on a physical condition or the like even in case of the same driver. As described above, in the above technology, even when fatigue of a driver is accumulated so as to be detrimental to a series of driving behaviors, a warning is not performed until a predetermined time elapses if a continuous driving time does not reach the predetermined time, and thus its warning can be delayed.
[0008] Because biological information such as palpebration, a flicker, and a heart rate is not easily measured during driving, has an individual difference, and includes noises, accuracy of measurement is not good. Moreover, because the burden of a driver increases by attaching a measuring device of a heart rate to the driver, it is not practical.
SUMMARY
[0009] According to an aspect of the embodiments, a non-transitory computer-readable recording medium stores a determination program that causes a computer to execute a process including: acquiring at every predetermined time position information and speed information from a vehicle that travels a road; computing, by using the position information and the speed information, a distance by which the vehicle travels from a passage of a first spot at which the road changes from a downward slope to an upward slope to a spot at which the vehicle accelerates over a first predetermined value or a distance by which the vehicle travels from a passage of a second spot at which the road changes from an upward slope to a downward slope to a spot at which the vehicle decelerates over a second predetermined value; and determining degradation of driving ability of a driver who drives the vehicle based on the distance.
[0010] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0011] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a diagram illustrating an entire configuration example of a system according to a first embodiment;
[0013] FIG. 2 is a diagram explaining a traveling behavior;
[0014] FIG. 3 is a functional block diagram illustrating the functional configuration of a driving control device according to the first embodiment;
[0015] FIG. 4 is a diagram illustrating an example of information stored in a sag standard database;
[0016] FIGS. 5A to 5C are diagrams illustrating examples of sags;
[0017] FIG. 6 is a diagram illustrating an example of information stored in a traveling information database;
[0018] FIG. 7 is a diagram explaining a degradation determination of performance;
[0019] FIG. 8 is a flowchart illustrating a flow of a process;
[0020] FIG. 9 is a functional block diagram illustrating the functional configuration of a driving control device according to a second embodiment;
[0021] FIG. 10 is a diagram illustrating an example of information stored in a statistical information database;
[0022] FIG. 11 is a diagram illustrating estimation results of parameters of a decelerating traveling distance and a continuous driving time;
[0023] FIG. 12 is a diagram illustrating a relationship between a decelerating traveling distance and a continuous driving time;
[0024] FIGS. 13A to 13C are diagrams illustrating examples of crests; and
[0025] FIG. 14 is a diagram illustrating a hardware configuration example.
DESCRIPTION OF EMBODIMENTS
[0026] Preferred embodiments will be explained with reference to accompanying drawings. Moreover, the disclosed technology is not limited to the embodiments explained below. The embodiments explained below may be appropriately combined within a scope in which the combined embodiments do not contradict each other.
[a] First Embodiment
[0027] Entire Configuration
[0028] FIG. 1 is a diagram illustrating an entire configuration example of a system according to the first embodiment. A driving control system illustrated in FIG. 1 includes a driving control device 10 and digital tachographs 1 a , 2 a , and 3 a . As an example of an on-vehicle device that sounds a warning against fatigue, a digital tachograph is illustrated in FIG. 1 . However, a digital tachograph is only one example as described later, and thus the on-vehicle device may be another on-vehicle device. Moreover, the on-vehicle device may be provided outside the driving control system.
[0029] The digital tachographs 1 a , 2 a , and 3 a are respectively mounted on a vehicle A, a vehicle B, and a vehicle C. The digital tachographs 1 a , 2 a , and 3 a and the driving control device 10 are connected to one another via a network N to be communicable mutually. The network N can include, regardless of wired or wireless, a communication network of any type such as Internet, LAN (Local Area Network), and VPN (Virtual Private Network).
[0030] Each of the digital tachographs is a kind of an on-vehicle device mounted on a vehicle, and also is referred to as a tachograph. Hereinafter, when the digital tachographs 1 a , 2 a , and 3 a are collectively referred, they may be simply referred to as “digital tachograph”.
[0031] As one embodiment, each digital tachograph can be connected via a connector and an electronic control unit (ECU) dedicated to a digital tachograph of a vehicle, which are not illustrated, in order to acquire a traveling record such as a speed and a distance. For example, each digital tachograph can acquire, as traveling data, a time-series change of a statutory traveling parameter such as a speed and a distance and also time-series data of position information including latitude and longitude via a global positioning system (GPS) receiver etc. that is not illustrated. Moreover, as an example, each digital tachograph can acquire traveling data in a predetermined sampling period, for example, at intervals of 0.5 seconds or less.
[0032] More specifically, each digital tachograph regularly transmits various types of traveling data on each vehicle that is a probe car to the driving control device 10 . For example, the digital tachograph 1 a transmits an identifier (ID), a position coordinate, a speed, an acceleration, an engine speed, an inter-vehicle distance, etc. of the vehicle A to the driving control device 10 every second. Moreover, a position coordinate is data per 0.1 seconds acquired from the GPS receiver including an external antenna of the vehicle A. A speed is data obtained by acquiring an instantaneous value in units of 0.1 km/h from a pulse signal of the vehicle.
[0033] In addition to the information, each digital tachograph can transmit a use history etc. of a service area and a parking area in one trip from start to stop of an engine, for example. For an acceleration, each digital tachograph can calculate it like acceleration (a i )=(V i −V i −1)/t (i) and notify it of the acceleration. Herein, “a i ” indicates an acceleration [m/s 2 ] at a section “i”, “V i ” indicates a speed [m/s] at the section “i”, and “t i ” indicates a time [s] from the inflow into a section “i−1” to the inflow into the section “i”.
[0034] The driving control device 10 is a computer that provides a driving management support service supporting driving management such as self-diagnosis of safe driving or guidance of safe driving by a driving manager etc., promotion of eco-drive and labor management by using traveling data acquired by the digital tachographs 1 a , 2 a , and 3 a.
[0035] As one embodiment, the driving control device 10 can be implemented by installing in a desired computer a driving management support program for realizing the driving management support service as package software and online software. For example, the driving control device 10 may be implemented as a Web server for providing the driving management support service, or may be implemented by outsourcing as a cloud service for providing the driving management support service.
[0036] In the driving control device 10 , because a function for sounding a warning against fatigue is the same as providing an existing similar driving management support service, a part on a warning against fatigue etc. will be mainly explained below. The present embodiment can be applied to any of a sag part and a crest part. Herein, as an example, a sag part will be mainly explained. In the present embodiment, a sag part may be referred to as a sag, and a crest part may be referred to as a crest.
[0037] For example, the driving control device 10 performs an analysis in consideration of the change of a traveling behavior during the passing of a sag section for each driver. Herein, as an index indicating a traveling behavior, we focus attention on a decelerating traveling distance. FIG. 2 is a diagram explaining a traveling behavior. As illustrated in FIG. 2 , the driving control device 10 specifies a spot (kp 2 ) at which acceleration is first started after the passing of a sag base (kp 1 ), and sets a distance between both spots as an index indicating a traveling behavior. A decelerating traveling distance is a traveling distance from a sag base to a spot at which acceleration is first performed when each vehicle travels a rising slope after the passing of the sag base while each vehicle is traveling a sag part on an express highway, and is defined with a decelerating traveling distance (L)=kp 2 −kp 1 . In FIG. 2 , a time from a service area (SA) to the sag base can be defined as a continuous driving time, and a difference (dv=v 1 −v 2 ) between a speed v 1 at the sag base (kp 1 ) and a speed v 2 at the acceleration spot (kp 2 ) can be defined as a speed decrease amount.
[0038] For each sag on an express highway in which a vehicle can travel freely with a speed not less than a constant value for example, the driving control device 10 computes and holds a decelerating traveling distance of the vehicle that has passed through this sag, and standardizes the decelerating traveling distance to generate a criterion. For example, the driving control device 10 can set, as a criterion, an average value of decelerating traveling distances of a vehicle that has passed through sags. Moreover, the driving control device 10 can generate a probability distribution such as a normal distribution by using the plurality of decelerating traveling distances acquired for the sags, and perform determination based on the probability distribution.
[0039] In this way, the driving control device 10 generates a criterion from the plurality of decelerating traveling distances measured for the sags in real time, compares the decelerating traveling distances of the vehicle measured in real time with the criterion, and specifies the change in the traveling behavior of the driver. Then, when the change in the traveling behavior of the driver is caused, the driving control device 10 determines the degradation of performance by fatigue and transmits a warning to the vehicle.
[0040] Functional Configuration
[0041] FIG. 3 is a functional block diagram illustrating the functional configuration of the driving control device according to the first embodiment. As illustrated in FIG. 3 , the driving control device 10 includes a communication unit 11 , a storage 12 , and a controller 20 .
[0042] The communication unit 11 is an example of a wireless communication interface that controls communication with each digital tachograph. For example, the communication unit 11 receives various types of traveling data from each digital tachograph, and transmits a message such as a warning and a display instruction for the message to each digital tachograph.
[0043] The storage 12 is an example of a storage device such as a memory and a hard disk, and stores therein a sag standard database 13 , a traveling information database 14 , and a past information database 15 .
[0044] The sag standard database 13 is a database that stores a criterion of a decelerating traveling distance for each sag. FIG. 4 is a diagram illustrating an example of information stored in the sag standard database 13 . As illustrated in FIG. 4 , the sag standard database 13 stores “sag information, position information (sag base), criterion” in association with one another. The “sag information” to be stored herein is an identifier etc. specifying a sag. The “position information (sag base)” is the position of a sag, namely, the position coordinate of a sag base in FIG. 2 .
[0045] The “criterion” is a criterion generated by using decelerating traveling distances of a plurality of vehicles that have previously traveled a corresponding sag. For example, the setting of a criterion can be performed, after computing an average and a standard deviation by using the decelerating traveling distances of the plurality of vehicles, based on a specified probability distribution indicated by the average and standard deviation. The probability distribution to be stored herein can be generated from a past traveling history, or a probability distribution to be assumed can previously set.
[0046] As another example, an average value etc. of the decelerating traveling distances of the plurality of vehicles can be employed. An average value is illustrated in FIG. 4 . In case of an example of FIG. 4 , it is illustrated that the position coordinate of a sag base of “sag 1 ” is (x1, y1) and an average value of decelerating traveling distances after passing through “sag 1 ” is “200 m”.
[0047] A decelerating traveling distance that is used for the generation of a criterion can be selected in accordance with a vehicle that is a target for driving management. For example, original data for generating a criterion can be narrowed down as follows: a decelerating traveling distance of the same-level vehicle as the weight of a vehicle of a management target; a decelerating traveling distance of a vehicle that is driven by the same-year driver as a driver of a vehicle of a management target; a decelerating traveling distance of a vehicle that is driven by the same-level driver as a driving record of a vehicle of a management target; and a decelerating traveling distance of a vehicle measured day and night when a vehicle of a management target travels. Herein, the same-level and same-year do not mean completely-identical. In other words, for example, like ±10 kg and ±5 years old, the same-level and same-year can have a certain level of width.
[0048] Herein, an example of a sag in the present embodiment will be explained. FIGS. 5A to 5C are diagrams illustrating examples of sags. A sag illustrated in FIG. 5A is a downward slope toward a sag base S 1 , and becomes an upward slope after passing through the sag base S 1 . A sag illustrated in FIG. 5B is flat toward a sag base S 2 , and becomes an upward slope after passing through the sag base S 2 . A sag illustrated in FIG. 5C is a gentle upward slope having small inclination toward a sag base S 3 , and becomes a steep upward slope having large inclination after passing through the sag base S 3 . Any sag illustrated in the drawings can be processed as a sag in the present embodiment.
[0049] The traveling information database 14 is a database that stores driving data when each vehicle passes through each sag. FIG. 6 is a diagram illustrating an example of information stored in the traveling information database 14 . As illustrated in FIG. 6 , the traveling information database 14 stores therein “sag information, acceleration spot, decelerating traveling distance (measured value), evaluated value (z value)” in association with one another.
[0050] The “sag information” to be stored herein is an identifier etc. specifying a sag. The “acceleration spot” is a spot first accelerated after passing through a sag, namely the position coordinate of the acceleration spot (kp 2 ) in FIG. 2 . The “decelerating traveling distance (measured value)” is, when a vehicle travels a rising slope after passing through a sag base during traveling a sag part on an express highway, a measured value of a traveling distance from the sag base to a spot at which acceleration is first performed. The “evaluated value” indicates a comparison result with a criterion corresponding to this sag. For example, when a criterion is an average value, a difference between an average value and a measured value is stored as an “evaluated value”.
[0051] As another example, when a criterion is a probability distribution such as a normal distribution, a “z” value is stored as an “evaluated value”. FIG. 6 is an example of driving information of the vehicle A and illustrates an example of a “z” value that is used as an evaluated value.
[0052] In the example of FIG. 6 , it is illustrated that an acceleration spot after passing through a “sag 1 ” is (x2, y3), a measured value of a decelerating traveling distance from the sag base of the sag 1 to the acceleration spot is “180 m”, and the measured value corresponds to the z value “55” in the normal distribution for the sag 1 .
[0053] The past information database 15 is a database that stores passage information when passing through a sag every vehicle, every driver, or every road. In other words, the past information database 15 stores a passage history of a sag. Similarly to FIG. 6 , information to be stored is “sag information, acceleration spot, decelerating traveling distance (measured value), evaluated value”, etc.
[0054] The controller 20 is a processing unit that manages the whole process of the driving control device 10 , and includes an acquiring unit 21 , an evaluated value computing unit 22 , a tendency estimating unit 23 , a determining unit 24 , and a warning unit 25 . The controller 20 can be realized by a central processing unit (CPU), a micro processing unit (MPU), etc. Moreover, the controller 20 can be realized by hard-wired logic such as ASIC (Application Specific Integrated Circuit) and FPGA (Field Programmable Gate Array). For example, the acquiring unit 21 , the evaluated value computing unit 22 , the tendency estimating unit 23 , the determining unit 24 , and the warning unit 25 are an example of an electronic circuit of a processor or an example of a process that is executed by a processor.
[0055] The acquiring unit 21 is a processing unit that acquires probe data from each vehicle. Specifically, the acquiring unit 21 receives probe data from each vehicle every second, for example, and extracts traveling data such as an identifier (ID), a position coordinate, a speed, an acceleration, an engine speed, and an inter-vehicle distance of the vehicle from the received probe data. Then, the acquiring unit 21 notifies the evaluated value computing unit 22 of the acquired traveling data.
[0056] When the travel of the sag is detected, the evaluated value computing unit 22 is a processing unit that computes a measured value and an evaluated value and stores them in the traveling information database 14 . Specifically, the evaluated value computing unit 22 generates the traveling information database 14 in accordance with the information stored in the sag standard database 13 and the acquired traveling data.
[0057] For example, when acquiring a position coordinate identical with the position information of the sag 1 from the probe data of the vehicle A, the evaluated value computing unit 22 determines that the vehicle A is traveling the sag 1 and saves each traveling data acquired from the probe data as a start spot. After that, the evaluated value computing unit 22 acquires and monitors an acceleration and a position coordinate from the probe data transmitted from the vehicle A at any time, and saves a position coordinate of probe data including an acceleration not less than a predetermined value as an end spot.
[0058] Then, the evaluated value computing unit 22 computes a distance from the position coordinate of the start spot to the position coordinate of the end spot as a decelerating traveling distance (measured value). After that, the evaluated value computing unit 22 stores the computed decelerating traveling distance (measured value) in the traveling information database 14 as the measured value of the sag 1 of the vehicle A. In this way, the acquiring unit 21 computes and stores a measured value of each sag for each vehicle. Moreover, a decelerating traveling distance (measured value) can be computed by using well-known various techniques. For example, a decelerating traveling distance (measured value) can be computed by using a coordinate of a start spot and a coordinate of an end spot, or can be computed by using a time from a start spot to an end spot, a speed, an acceleration, etc.
[0059] The detection of an end spot can be performed by using various techniques. For example, the evaluated value computing unit 22 can specify, as an end spot, a spot at which an absolute value of an acceleration included in probe data becomes more than a predetermined value, a spot at which an absolute value of a change from the previous acceleration to the present acceleration becomes more than a predetermined value, a spot at which a sign of an acceleration is changed from the previous acceleration, a spot at which a change is performed from deceleration to acceleration, and the like.
[0060] Next, upon storing the decelerating traveling distance (measured value), the evaluated value computing unit 22 computes an evaluated value by using the measured value and the criterion, and stores the evaluated value in the traveling information database 14 . For example, when a probability distribution such as a normal distribution is stored in the sag standard database 13 as the criterion of the sag 1 , the evaluated value computing unit 22 computes the z value of the decelerating traveling distance (measured value) for the sag 1 by using the probability distribution. The evaluated value computing unit 22 then stores the z value in the traveling information database 14 as the evaluated value of the sag 1 .
[0061] As another example, when an average value is stored in the sag standard database 13 as the criterion of the sag 1 , the evaluated value computing unit 22 computes a difference between the average value and the decelerating traveling distance (measured value) for the sag 1 . The evaluated value computing unit 22 then stores the computed difference in the traveling information database 14 as the evaluated value of the sag 1 .
[0062] In this way, the evaluated value computing unit 22 computes, for each sag, an evaluated value obtained by comparing a criterion and a measured value and stores the evaluated value in the traveling information database 14 whenever the decelerating traveling distance (measured value) is stored.
[0063] The tendency estimating unit 23 is a processing unit that estimates a tendency of a decelerating traveling distance of a driver for each vehicle. Specifically, the tendency estimating unit 23 estimates a tendency of a decelerating traveling distance of that day for each vehicle when evaluated values for a predetermined number of times are stored for the sag of the traveling information database 14 . In other words, the tendency estimating unit 23 estimates, for each vehicle, a tendency of a decelerating traveling distance of that day from real-time measured values after the vehicle starts.
[0064] For example, when the z values are computed for the sags 1 to 30 for the vehicle A, the tendency estimating unit 23 acquires 30 z values from the traveling information database 14 . The tendency estimating unit 23 then computes an average and a standard deviation by using the acquired 30 z values, and generates a probability distribution such as a normal distribution indicated by the average and standard deviation. After that, the tendency estimating unit 23 notifies the determining unit 24 of the generated probability distribution as the tendency of the decelerating traveling distance for the vehicle A.
[0065] As another example, when average values are computed for the sags 1 to 30 for the vehicle A, the tendency estimating unit 23 acquires 30 average values from the traveling information database 14 . The tendency estimating unit 23 further computes an average value of the acquired 30 average values. After that, the tendency estimating unit 23 can notify the determining unit 24 of the computed average value as the tendency of the decelerating traveling distance for the vehicle A.
[0066] The determining unit 24 is a processing unit that determines the degradation of driving ability (hereinafter, may be referred to as “performance”) by using the tendency specified by the tendency estimating unit 23 and a measured value measured in real time. Because a tendency has been specified by using decelerating traveling distances (measured values) of the sags 1 to 30 for the vehicle A when being explained by using the example, the determining unit 24 determines the degradation of driving ability by using decelerating traveling distances (measured values) from a sag 31 .
[0067] FIG. 7 is a diagram explaining a degradation determination of performance. For example, it is assumed that a normal distribution of an average (φ and a standard deviation (σ) is supposed by the tendency estimating unit 23 as a tendency as illustrated in (a) of FIG. 7 . At this time, the determining unit 24 computes a probability with which a z value for the sag 31 is generated, and determines the degradation of driving ability assuming that the shift is performed to a distribution different from the normal distribution of (a) of FIG. 7 when the probability is not more than a threshold.
[0068] For example, the determining unit 24 computes an area φ(z), when an evaluated value for the sag 31 is a Z value, in accordance with a probability density function f(x). Then, the determining unit 24 determines that a possibility with which driving ability is decreasing is low when the area φ(z) is larger than a threshold, determines that a possibility with which driving ability is decreasing is high when the area φ(z) is not more than the threshold, and notifies the warning unit 25 of the result.
[0069] Specifically, it is assumed that an evaluated value (Z) for the sag 31 is Z=1.0*z value. In this case, as illustrated in (b) of FIG. 7 , the determining unit 24 computes an area φ(z) in case of Z=1.0 in accordance with the probability density function f(x). In this case, because the area φ(z) becomes larger than a threshold (0.025), the determining unit 24 determines that a possibility with which driving ability is decreasing is low.
[0070] On the other hand, it is assumed that an evaluated value (Z) for the sag 31 is Z=2.5*z value. In this case, as illustrated in (c) of FIG. 7 , the determining unit 24 computes an area φ(z) in case of Z=2.5 in accordance with the probability density function f(x). In this case, the determining unit 24 determines that a possibility with which driving ability is decreasing is high because the area φ(z) becomes smaller than the threshold (0.025).
[0071] As described above, when detecting traveling data for which an occurrence probability in a normal distribution generated from real-time traveling data becomes low, the determining unit 24 determines that a possibility with which driving ability is decreasing is high. In other words, when an excessively long decelerating traveling distance (measured value) is detected or when an excessively short decelerating traveling distance (measured value) is detected, the determining unit 24 determines that a possibility with which driving ability is decreasing is high.
[0072] As another example, when a difference between a measured value measured in real time and an average value estimated as a tendency is not less than a threshold, the determining unit 24 can determine that driving ability is decreasing.
[0073] When once detecting the degradation of driving ability, the determining unit 24 can instruct the warning unit 25 to alarm a warning. Alternatively, when continuously detecting the degradation of driving ability multiple times, the determining unit 24 can instruct the warning unit 25 to alarm a warning. In other words, the timing of a warning can be optionally set and changed.
[0074] The warning unit 25 is a processing unit that outputs an alert on fatigue when the degradation or decrease of driving ability is detected by the determining unit 24 . As an example of the alert, the warning unit may output a beep sound, or may output the following message by using voice or display. For example, the warning unit can output a message such as “Is it tired?” and “Please take a break because there is a possibility with which fatigue affects ability to drive safely”. Moreover, as an example of the output destination of the alert, an on-vehicle display device, an on-vehicle speaker, etc. can be selected as an output destination, and also an information processing device to be used by a driving manager can be selected as an output destination.
[0075] It is possible to promote a break at an appropriate timing by outputting an alert on fatigue as described above. Furthermore, because each driver brings into a drive in the sufficient state of the rest when each driver takes a break at an appropriate timing, a probability of the occurrence of the accident is reduced, and further a time for a series of driving behaviors of recognition, determination, and operations is shortened. As a result, we can expect the relaxation of a traffic jam in a sag and a crest.
[0076] Flow of Process
[0077] FIG. 8 is a flowchart illustrating a flow of a process. Herein, a use example of a normal distribution will be explained instead of the average value. A process executed herein is performed for each vehicle, namely, for each driver.
[0078] As illustrated in FIG. 8 , when computing a decelerating traveling distance at a sag position in accordance with probe data acquired by the acquiring unit 21 (S 101 : Yes), the evaluated value computing unit 22 of the driving control device 10 computes a z value by using a distribution of values of a corresponding sag stored in the sag standard database 13 and stores the z value in the traveling information database 14 (S 102 ).
[0079] Then, the evaluated value computing unit 22 repeats Step S 101 and the next steps until z values for a predetermined number of times are computed (S 103 : No).
[0080] After that, when z values for the predetermined number of times are computed (S 103 : Yes), the tendency estimating unit 23 generates a probability distribution (normal distribution) of the z values by using the z values for the predetermined number of times (S 104 ). Next, the tendency estimating unit 23 saves the generated probability distribution as an evaluation criterion of the driver (S 105 ).
[0081] After that, when computing a decelerating traveling distance at a sag position in accordance with the probe data acquired by the acquiring unit 21 (S 106 : Yes), the evaluated value computing unit 22 computes a z value by using a reference value of the corresponding sag stored in the sag standard database 13 and stores the z value in the traveling information database 14 (S 107 ).
[0082] Next, the determining unit 24 computes, by using the saved probability distribution and the z value computed in Step S 107 , an occurrence probability of the z value (S 108 ). Then, when the computed occurrence probability is larger than a threshold (S 109 : No), the process returns to Step S 106 and the next steps are performed.
[0083] On the other hand, when the computed occurrence probability is not more than the threshold (S 109 : Yes), the determining unit 24 determines whether the subthreshold occurrence probabilities are continuously detected for a predetermined number of times (S 110 ).
[0084] Herein, when the subthreshold occurrence probability is less than the predetermined number of times (S 110 : No), the process returns to Step S 106 and the next steps are performed. On the other hand, when the subthreshold occurrence probabilities are detected continuously for the predetermined number of times (S 110 : Yes), the warning unit 25 notifies the vehicle of an alert (S 111 ).
[0085] One Aspect of Effect
[0086] As described above, the driving control device 10 can generate a criterion in accordance with a decelerating traveling distance at a sag position acquired in real time, and detect the degradation of driving ability by using this criterion. Therefore, because a criterion in which the situation of a driver of that day is reflected can be generated for each trip, the driving control device 10 can detect the degradation of driving ability according to a health condition and a fatigue condition of the driver. As a result, the driving control device 10 can improve a detection accuracy of the degradation of driving ability.
[0087] Because the degradation of driving ability can be detected without using biological information such as palpebration, a flicker, and a heart rate, the driving control device 10 can suppress a burden other than a drive. Moreover, because new hardware such as a sensor is not used, reduction in cost can be expected.
[0088] Herein, in the first embodiment, it has been explained that a criterion is generated by using a decelerating traveling distance at a sag position measured in real time. However, the present embodiment is not limited to this. For example, when a driver is scheduled to travel an express highway X and a traveling record of each sag on the highway X at the time of previously passing through the highway X is stored, it is possible to previously generate a criterion by using the past traveling record.
[0089] For example, the tendency estimating unit 23 generates a normal distribution and saves it as a criterion by using z values of sags X 1 to X 90 located in the highway X. After that, when a decelerating traveling distance at a sag position is computed after starting the travel on the highway X, the determining unit 24 computes an occurrence probability of the decelerating traveling distance with the same method as that of the embodiment. In this way, the driving control device 10 can determine the degradation of driving ability from the driving at the first sag position on the highway X. As a result, because the degradation of driving ability can be determined from immediately after a startup, the driving control device 10 can early detect physical deconditioning etc. of the driver.
[0090] In this example, when a criterion is previously generated, it has been explained that the criterion is generated by using a traveling history of the exact same highway as the highway X to be scheduled to travel. However, the present embodiment is not limited to this. For example, a criterion can be generated by using a traveling history of a highway having a shape similar to the highway X, a traveling history of a highway to which the occurrence tendency of sags included in the highway X is similar, a traveling history of a highway having sags of the same as the number of sags included in the highway X, and the like. Moreover, a past traveling history to be employed can be narrowed down depending on a time zone to be traveled, the type of a vehicle to be traveled, and the like. Even in this case, it is possible to determine the degradation of driving ability from immediately after a startup and to early detect physical deconditioning of the driver.
[b] Second Embodiment
[0091] In the first embodiment, it has been explained that a driver can be appropriately notified of the timing of a break by detecting the degradation of driving ability in real time. On the contrary, the driving control device 10 may compute the timing of a break from a past driving history, for example, and notify a driver of it.
[0092] Therefore, in the second embodiment, an example in which the timing of a break is computed from a past driving history and a driver is notified of it will be explained. Because the entire configuration is similar to that of FIG. 1 , detailed descriptions are omitted.
[0093] Functional Configuration
[0094] FIG. 9 is a functional block diagram illustrating the functional configuration of the driving control device 10 according to the second embodiment. As illustrated in FIG. 9 , the driving control device 10 includes the communication unit 11 , the storage 12 , and the controller 20 .
[0095] Unlike the first embodiment, the driving control device 10 illustrated in FIG. 9 further includes a statistical information database 16 and a driving scheduling unit 26 . Because the other processing units are similar to those of the first embodiment, detailed descriptions are omitted.
[0096] The statistical information database 16 is a database that collectively stores a traveling history for each sag on each highway irrespective of a driver and a vehicle, and stores a relationship between a continuous driving time and a decelerating traveling distance for each sag. For example, the statistical information database 16 stores a relationship between a continuous driving time and a decelerating traveling distance for a vehicle that travels each sag from Iyo-Saijo Interchange to Sendai Interchange of the downline of Matsuyama Expressway crossing the East and West of Ehime-ken using Takamatsunishi Interchange of Kagawa-ken as a starting point.
[0097] FIG. 10 is a diagram illustrating an example of information stored in the statistical information database 16 . As illustrated in FIG. 10 , the statistical information database 16 stores a relationship between a continuous driving time and a decelerating traveling distance for each sag such as a sag A and a sag B. More specifically, the statistical information database 16 registers, for the sag A, 50 m, 120 m, etc. as a history as a decelerating traveling distance when a vehicle of which a continuous driving time is zero to 100 seconds travels the sag A, and further registers 150 m, 190 m, etc. as a history as a decelerating traveling distance when a vehicle of which a continuous driving time is 101 to 500 seconds travels the sag A.
[0098] The driving scheduling unit 26 is a processing unit that estimates a continuous driving time recommended as a break timing in accordance with the statistical information stored in the statistical information database 16 to generate a driving plan. Herein, the driving scheduling unit 26 checks a relationship between a continuous driving time and an index indicating a traveling behavior of a driver, and performs an analysis with a goal of grasp of an impact that a continuous driving time has on a traveling behavior by modelization.
[0099] Herein, we consider a time-series change for a relationship between a continuous driving time and each traveling behavior index. In the early driving stage in which a driver does not get tired, it is expected that an index indicating a traveling behavior keeps a constant value. It is considered that it arrives at a stage at which an index value is suddenly changed by the gradual appearance of driver fatigue. In other words, the change of behavior becomes larger as a continuous driving time becomes longer. However, supposing that the increase is not a monotonic increase, it is considered that the reaction of the behavior of a vehicle is not largely changed up to an inflection point, and thus it is expected that a change is largely made after a certain inflection point.
[0100] Therefore, the driving scheduling unit 26 performs an analysis by using a polygonal line regression model. The model is an especially effective technique when explanatory variables are distributed over some different groups and indicate different relationships between the divided sections. Herein, a boundary (threshold) of a line segment is referred to as an inflection point. In the estimation of parameters, by using a least squares method, three regression lines are applied to sections made and divided to adapt to a data set as much as possible while minimizing a square-sum of a difference (residual) between an observed value and a calculated value of a dependent variable. Therefore, it becomes Equation (1) when it is formulated.
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[0101] Herein, y is a dependent variable (decelerating traveling distance (m)), x is a continuous driving time (s), k is an inflection point (s), and α and β are parameters. They are calculated based on the acquired data. Moreover, in the selection of an optimum model, a continuous driving time is divided every 500(s), estimation is performed for each combination, and a model in which a value of the least square error is the minimum among them is selected as an optimum model.
[0102] FIG. 11 is a diagram illustrating an estimation result of parameters of a decelerating traveling distance and a continuous driving time. FIG. 12 is a diagram illustrating a relationship between a decelerating traveling distance and a continuous driving time, and is a graph made by the obtained regression formula.
[0103] As illustrated in FIGS. 11 and 12 , as the results of the analysis, when there is a combination of a first inflection point k 1 =5000 seconds of a continuous driving time and a second inflection point k 2 =5500 seconds thereof, the driving scheduling unit 26 obtains the highest determination coefficient value (R2=0.080). As indicated by the result, when the continuous driving time becomes 5000 seconds, an increased amount of the decelerating traveling distance, namely, the inclination of a regression line gives rise to a change. Specifically, in the section of 5000-5500 seconds, a coefficient value β 2 significantly indicates a positive value. Moreover, in the section over 5500 seconds, a result indicating a negative coefficient value is obtained.
[0104] From these estimation results, when a continuous driving time exceeds a predetermined time, the driving scheduling unit 26 specifies that a decelerating traveling distance tends to increase along with the increase of a driving time. In other words, when a continuous driving time exceeds a predetermined time, the driving scheduling unit can specify that a change is provoked in a traveling behavior. Therefore, when the continuous driving time exceeds 5000 seconds, the driving scheduling unit 26 instructs the warning unit 25 to alarm a warning. As a result, the warning unit 25 outputs a message promoting a break etc. when the continuous driving time exceeds 5000 seconds without stopping at a service area etc.
[0105] One Aspect of Effect
[0106] As described above, the driving control device 10 can promote a break at an appropriate timing. Because each driver brings into a drive in the sufficient state of the rest when a break is taken by each driver at an appropriate timing, a probability of the occurrence of the accident is reduced, and further a time for a series of driving behaviors of recognition, determination, and operations is shortened. As a result, we can expect the relaxation of a traffic jam in a sag and a crest.
[0107] In the second embodiment, it has been explained that the statistical information database 16 stores a relationship between a continuous driving time and a decelerating traveling distance for a vehicle that travels each sag in a corresponding section. However, it is possible to improve the calculation precision of a threshold of a continuous driving time by segmentalization and storing. For example, the statistical information database 16 can store the weight of a vehicle that travels each sag in a corresponding section, a driving record of a driver, the night and day, and the like in association with one another, and select traveling data in accordance with the situation of a driving plan.
[c] Third Embodiment
[0108] It has been explained about the embodiments of the present invention till now. The present invention may be practiced by various different configurations in addition to the embodiments described above.
[0109] Digital Tachograph
[0110] In the above embodiments, it has been explained that the driving control device 10 determines the degradation of performance related to fatigue etc. However, the present embodiments are not limited to this. A digital tachograph of each vehicle illustrated in FIG. 1 or another on-vehicle device can also perform the determination. In other words, it is sufficient that an on-vehicle device can acquire position information and speed information. Each the process may performed by mounting each function part illustrated in FIGS. 3 and 9 on a drive recorder. Moreover, an on-vehicle device is not necessarily a device for a business vehicle. Therefore, each the process may be also performed by mounting each function part illustrated in FIGS. 3 and 9 on a navigation device etc.
[0111] Crest
[0112] In the embodiments, a sag has been explained as an example. However, the embodiments are not limited to this. The same process can be also performed at a crest etc. In case of a crest, the embodiments are different from a point that does not employ a distance from the passage of a crest to its acceleration, but employs a distance from the passage of a crest to its deceleration. However, the same process may be employed.
[0113] FIGS. 13A to 13C are diagrams illustrating examples of crests. A crest illustrated in FIG. 13A is an upward slope toward a crest top C 1 and becomes a downward slope after passing through the crest top C 1 . A crest illustrated in FIG. 13B is flat toward a crest top C 2 and becomes a downward slope after passing through the crest top C 2 . A crest illustrated in FIG. 13C is a gentle downward slope having small inclination toward a crest top C 3 and becomes a steep downward slope having large inclination after passing through the crest top C 3 . In the present embodiment, any crest illustrated in the drawings can be processed as a crest.
[0114] Target History
[0115] In the embodiments, it has been explained that a tendency is specified when the z values of 30 decelerating traveling distances (measured values) are computed. However, the embodiments are not limited to this. For example, a tendency can be specified by using the z value of the computed decelerating traveling distance (measured value) when a predetermined time has elapsed from the start of a travel. Moreover, the driving control device 10 can also perform a process by using a deviation value instead of a z value.
[0116] Standardization
[0117] In the embodiments, it has been explained that a decelerating traveling distance (actual value) of a corresponding vehicle is evaluated by using a criterion of each sag and then a criterion is generated by using this evaluated value. However, the embodiments are not limited to this. For example, a criterion can be generated by using only a decelerating traveling distance (actual value) of a corresponding vehicle without using a criterion of each sag.
[0118] The driving control device 10 computes, at any time during the travel of a vehicle, a decelerating traveling distance (actual value) when the vehicle travels a sag and an accelerating traveling distance (actual value) from the travel of a crest of the vehicle to its acceleration. Then, when computing a decelerating traveling distance (actual value) and an accelerating traveling distance (actual value) exceeding a threshold, the driving control device 10 can transmit an alert.
[0119] The driving control device 10 generates a probability distribution such as a normal distribution from a past history for each sag, and computes, in accordance with the probability distribution, computes a probability with which a distance computed at the time of passage of a sag is generated. Then, when the probability is not more than a threshold, the driving control device 10 can determine that driving ability is decreasing. Moreover, in addition to a measured value, when a z value computed each time a vehicle travels a sag is not more than a first threshold or is not less than a second threshold, the driving control device 10 can determine that driving ability is decreasing.
[0120] Dispersion and Integration
[0121] Each component of each device illustrated in the drawings is not necessarily constituted physically as illustrated in the drawings. In other words, the specific configuration of dispersion/integration of each device is not limited to the illustrated configuration. Therefore, all or a part of each device can be dispersed or integrated functionally or physically in an optional unit in accordance with various types of loads or operating conditions. For example, the acquiring unit 21 , the evaluated value computing unit 22 , the tendency estimating unit 23 , the determining unit 24 , the warning unit 25 , or the driving scheduling unit 26 may be connected to the driving control device 10 via the network as an external device of the driving control device 10 . Moreover, other devices may respectively include the acquiring unit 21 , the evaluated value computing unit 22 , the tendency estimating unit 23 , the determining unit 24 , the warning unit 25 , and the driving scheduling unit 26 , and be connected to the network and cooperate with one another so as to realize the functions of the driving control device 10 .
[0122] Determination Program
[0123] Various types of processes explained in the above embodiments can be realized by executing a previously-prepared program by using a computer such as a personal computer and a workstation. Therefore, an example of a computer performing a determination program having the same functions as those of the above embodiments will be explained below with reference to FIG. 14 .
[0124] FIG. 14 is a diagram illustrating a hardware configuration example. As illustrated in FIG. 14 , a computer 100 includes an operating unit 110 a , a speaker 110 b , a camera 110 c , a display 120 , and a communication unit 130 . Furthermore, the computer 100 includes a CPU 150 , a ROM 160 , an HDD 170 , and a RAM 180 . These components 110 - 180 are connected to one another via a bus 140 .
[0125] As illustrated in FIG. 14 , the determination program realizing the same functions as those of the acquiring unit 21 , the evaluated value computing unit 22 , the tendency estimating unit 23 , the determining unit 24 , the warning unit 25 , and the driving scheduling unit 26 illustrated in the first embodiment is stored in the HDD 170 . The determination program may be integrated or dispersed similarly to the components of the acquiring unit 21 , the evaluated value computing unit 22 , the tendency estimating unit 23 , the determining unit 24 , the warning unit 25 , and the driving scheduling unit 26 illustrated in FIGS. 3, 9 , etc. In other words, all data illustrated in the first and second embodiments are not necessarily stored in the HDD 170 , and thus it is only sufficient that data used for the process is stored in the HDD 170 .
[0126] Under the circumstances, the CPU 150 reads out the determination program from the HDD 170 and then loads it into the RAM 180 . As a result, the determination program functions as a determination process as illustrated in FIG. 14 . The determination process loads various data read from the HDD 170 into an area assigned to the determination process among storage areas of the RAM 180 , and performs various types of processes by using the loaded various data. For example, as an example, a process that is executed by the determination process includes the process etc. explained in each embodiment. All processing units illustrated in the first embodiment are not necessarily operated by the CPU 150 , and it is only sufficient that a processing unit corresponding to a process as a target for execution is realized virtually.
[0127] The determination program is not necessarily stored in the HDD 170 or the ROM 160 from the start. For example, the determination program is stored in a “transportable physical medium” such as a flexible disk, so-called FD, CD-ROM, DVD disc, magneto-optical disk, and IC card, which is inserted into the computer 100 . Then, the computer 100 may acquire and perform the determination program from these transportable physical media. Moreover, the determination program is previously stored in an another computer, a server apparatus, etc. connected to the computer 100 via a public line, the Internet, LAN, WAN, etc., and the computer 100 may acquire and perform the determination program from these apparatuses.
[0128] According to one embodiment, it is possible to improve a detection accuracy of the degradation of driving ability.
[0129] All examples and conditional language recited herein are intended for pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventors to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A non-transitory computer-readable recording medium stores a determination program that causes a computer to execute a process including: acquiring at every predetermined time position information and speed information from a vehicle that travels a road; computing, by using the position information and the speed information, a distance by which the vehicle travels from a passage of a first spot at which the road changes from a downward slope to an upward slope to a spot at which the vehicle accelerates over a first predetermined value or a distance by which the vehicle travels from a passage of a second spot at which the road changes from an upward slope to a downward slope to a spot at which the vehicle decelerates over a second predetermined value; and determining degradation of driving ability of a driver who drives the vehicle based on the distance.
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RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. patent application Ser. No. 07/244,318 filed Sept. 15, 1988, now U.S. Pat. No. 4,896,614 issued on Jan. 30, 1990.
BACKGROUND OF THE DISCLOSURE
This invention relates to the destruction of hazardous waste materials, particularly, to a method and apparatus for conversion of hazardous waste material into useful by-products.
The safe disposal of hazardous waste materials is a high priority for both private industry and governmental agencies. A superfund has been established by the government to clean up areas of hazardous waste which present eminent danger to the public health and welfare. Thousands of regulations have been promulgated by the government to insure the safe use and disposal of hazardous materials. Use of some hazardous materials has been banned or extremely restricted. Due to the severity of the problem, various methods have been utilized for disposing of hazardous materials. Research continues in an effort to develop a method for the destruction of hazardous material which is also environmentally safe.
Various methods have been attempted for the disposal of hazardous material, including the use of electric plasma arcs to destroy toxic waste. Plasma generators are known in the prior art. A plasma arc generated by a plasma gun develops an extremely hot temperature zone having temperatures in the range of 10,000° F. to 30,000° F., or above. At such high temperatures, almost all organic and inorganic compounds may be converted into useful by-products.
U.S. Pat. No. 4,644,877 discloses a method and apparatus for the pyroelectric destruction of toxic or hazardous waste materials. The waste materials are fed into a plasma arc burner where they are atomized and ionized, and then discharged into a reaction chamber to be cooled and recombined into product gas and particulate matter. The recombined products are quenched using a spray ring attached to the reaction vessel. An alkaline atomized spray produced by the spray ring neutralizes the recombined products and wets the particulate matter. The product gases are then extracted from the recombining of products using a scrubber, and the product gases are then burned or used for fuel.
U.S. Pat. No. 4,479,443 discloses a method and apparatus for thermal decomposition of stable compounds. High temperatures necessary for decomposition are generated by a plasma generator. U.S. Pat. Nos. 4,438,706 and 4,509,434 disclose a procedure and equipment for destroying waste material. The material is decomposed in a plasma state in the presence of an oxidizing agent so that the waste material is converted into stable combustion products.
U.S. Pat. No. 4,615,285 discloses a method of destroying hazardous waste by means of under-stoichiometric incineration at a temperature of at least 1,200° C. The ratio between injected waste material and oxidant is regulated to give a quotient CO 2 /(CO×CO 2 ) of less than 0.1.
U.S. Pat. Nos. 4,602,991 and 4,729,891, by the Applicant herein disclose a coal liquefaction process and hydrogen generating method, respectively, wherein the feed stock is heated in an inductive furnace under vacuum conditions.
As is noted above, various methods have been tried for disposing of hazardous waste material. Until the present invention, however, a commercially viable process which combines vacuum, induction and plasma technology for conversion of hazardous materials into useful by-products has not been available.
SUMMARY OF THE INVENTION
The present invention is directed to a method of destroying hazardous waste material, both liquid and solid waste material. The method comprises the steps of converting the hazardous material by exposing it to at least one high temperature plasma arc in the absence of oxygen. The converted gases and any non-gaseous constituents are collected in a depressurized reactor chamber which is devoid of oxygen. Solid waste material is directed through two reaction chambers. The collected gases are then directed through a series of chillers, compressors and molecular sieves for separation of the gases into individual components. The separated components are collected in storage vessels. None of the by-products of the process of the invention are released into the atmosphere.
DETAILED DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a schematic flow diagram of a method of treating hazardous waste material in the absence of oxygen;
FIG. 2 is a partial sectional view of the plasma generator of the invention; and
FIG. 3 is a schematic flow diagram of a method of treating solid hazardous waste material in the absence of oxygen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, the system of the invention for treatment of hazardous waste material is generally identified by the reference numeral 10. The system 10 includes a plasma generator 11 and plasma gun 12 connected to a reactor chamber 14. The plasma gun 12 is of a type commercially available. The plasma gun 12 is connected to a power supply which delivers power to operate the plasma gun 12. The plasma arc generated by the plasma gun 12 is sustained by nitrogen or argon gas which is supplied to the plasma gun 12 from a gas supply 16. Hydrogen may also be supplied to aid the conversion of waste material containing oxygen. The hydrogen will combine with the oxygen to form water. The plasma arc generated by the plasma gun 12 is a high temperature plasma sustaining plasma temperatures in the range of 10,000° F. to 30,000° F., or higher. At such high temperatures, almost all organic and inorganic compounds are split into individual components. While in the preferred embodiment, a plasma gun 12 generates the required temperatures for converting the waste material, it is understood that sufficiently high temperatures for accomplishing the conversion may be developed by other means, such as lasers or induction heating. The conversion of hazardous material may be accomplished at a temperature of 1,200° F. or above.
A source or feedstock of hazardous material 18 is connected to the plasma gun 12 via a feed line 20. The hazardous material is transported to the plasma gun 12 in a flowing slurry of liquid material through the feed line 20. Alternatively, a screw conveyer may be used to transport solid material to the inlet of the plasma gun 12. In the preferred embodiment, the hazardous material is fed to the plasma gun 12 through the feed line 20 at a predetermined rate of approximately three to six gallons per minute. If desired, the hazardous material may be fed to the plasma gun 12 at higher rates. For example, solid waste may be fed at a rate of up to two tons per hour or more. A valve 22 connects the feed line 20 to the hazardous material 18. The valve 22 may be opened or closed to increase or decrease the flow rate of hazardous material transported through the feed line 20.
A partial sectional view of the plasma gun 12 is shown in FIG. 2. Due to the extremely high temperatures generated by the plasma gun 12, a water bath is used to cool the plasma gun 12. The barrel of the plasma gun 12 comprises an inner tube 13 concentrically positioned within an outer tube 15. The inner tube 13 is approximately seven feet eight inches in length and projects outwardly from the end of the outer tube 15 which is approximately six feet in length. Flange support members 17 are mounted about the inner tube 13 and secured to the ends of the outer tube 15. The support members 17 position the inner tube 13 concentrically within the outer tube 15 and close off the annular space 19 defined therebetween. Water is circulated in the annular space 19 for forming a cooling bath about the inner tube 13. Water is directed into the annular space 19 though a water inlet 21 and exits through a water outlet 23. Water is pumped to the plasma gun 12 from a water source 25 though a water line 27 and returned to the water source 25 through a return line 29 so that continuous water circulation is provided to maintain the plasma gun 12 at a relatively cool temperature.
The forward end of the inner tube 13 is provided with an opening 31. The plasma generator control head 33 is connected to the forward end of the inner tube 13. The electrodes of the plasma generator extend through the opening 31 so that the plasma arc is generated within the inner tube 13. The rear end of the inner tube 13 is closed by a removable plug 35. The plug 35 may be removed permitting inspection of the inner tube 13 for pitting or damage from heat or chemical reaction.
The hazardous waste material is incinerated within the inner tube 13. The waste material is delivered to the inner tube 13 via the line 20 which is connected to the plasma generator control head. The plasma gun 12 is connected to the reactor chamber 14 in a suitable manner. The reactor chamber 14 is maintained under vacuum conditions in the range of 10 -1 to 10 -3 torr or any lower attainable vacuum, thereby substantially removing all air from the reactor chamber 14. The reactor chamber 14 is evacuated by vacuum pumps 24 connected thereto. A sample container 26 is connected to the reactor chamber 14 for collecting a sample of the gases collected in the reactor chamber 14. The sample of gases is analyzed to insure that the hazardous material has been completely converted to harmless by-products.
From the reactor chamber 14, the collected gases are directed through a chiller 28 for rapidly cooling the gases and then through a NaOH solution tower 37 for converting any hydrochloric acid gases into sodium chloride (NaCl). A compressor 30 is connected to the outlet end of the NaOH tower 37 for pressurizing and directing the collected gases through a series of molecular sieves to remove undesirable impurities in the constituents forming the gas flow from the reactor chamber 14. The gas flow is separated into its individual constituents which are stored in storage vessels 34. Compressors 38 are connected between the molecular sieves 32 and storage vessels 34 for pressurizing the constituents of the gas flow into the storage vessels 34.
As an example, but in no way limiting the scope of the present disclosure, the individual constituents or by-products of the conversion of hazardous materials include nitrogen, hydrogen, carbon dioxide, methane and any silicate, metallic or any other solid constituents that are not converted into a gaseous by-products. The gaseous constituents are separated by passing the gases through the molecular sieves 32 and collecting the individual constituents in the storage vessels 34. The non-gaseous constituents are collected in the reactor 14 and removed upon completion of the conversion process. The reactor 14 includes an internal screw conveyor or the like for expelling any non-gaseous constituents collected in the reactor 14. The hazardous material is thereby converted into harmless by-products which are captured in the storage vessels 34. The process of the present invention is totally environmentally safe as no emissions are released into the atmosphere.
Referring again to FIG. 1, in operation the system 10 is initially pressurized and visually inspected for leaks and pressure drops. Pressures of 50 psi to 80 psi are maintained for a period of time to insure that the system does not leak. After checking that the vacuum pumps 24 are operating properly, the vacuum valves are opened and a vacuum is pulled throughout the system and isolated between closed valves 22 and 40 insuring that all oxygen in the system between the closed valves 22 and 40 is removed. Upon obtaining a vacuum of a minimum of 10 -1 torr, the plasma gun 12 is activated. The valve 22 is then opened permitting the hazardous material to be delivered to the plasma gun 12. Initially, the pressure in the hazardous material tank is approximately 50 psi. When the pressure has dropped to 5 psi or less, the hazardous material tank 18 is empty and the valve 22 is shut off. The hazardous material is converted in the plasma arc formed by the plasma generator within the inner tube 13 of the plasma gun 12. The converted gases are collected in the reactor chamber 14. During the conversion of the hazardous material, the pressure in the system 10 increases. The valve 40 however is maintained in the closed position until the system pressure reaches the level of approximately 15 psi. Prior to opening the valve 40, a sample of the converted gases is collected in the sample container 26. The sample container 26 is double valved to separate it from the system 10. The sample of gases is then analyzed to determine whether the hazardous materials have been destroyed. If any traces of hazardous material remains in the sample, the gases are collected and passed through the plasma generator a second time.
Referring now to FIG. 3, a configuration of the system 10 is shown for treatment of solid hazardous material. The system is substantially the same as shown in FIG. 1 and therefore like reference numerals have been used to identify like components. As shown in FIG. 3, the solid waste material is collected in a collection vessel 50. The solid waste material, for example, tires or the like, is fed to the plasma guns 12 through a feedline or conduit 52 at a predetermined rate of up to two tons per hour or more upon opening a valve 53. A screw conveyor or the like transports the solid hazardous waste material from the collection vessel 50 to the plasma guns 12 via the conduit 52. The plasma guns 12 may be connected in series or may be spaced around a plenum which, when energized, will form a concentrated hot zone through which the solid waste material will flow and be collected in the reactor 54. As was discussed above in relation to the system shown in FIG. 1, a vacuum is pulled by the vacuum pumps 24 insuring that all oxygen in the system shown in FIG. 3 is removed. Once the proper vacuum is achieved, the plasma guns 12 are activated and solid waste material is flowed through the hot zone created by the plasma guns.
As the solid waste material passes through the hot zone, it is converted into non-hazardous components and collected in the reactor 54. At this stage of the process, the collection vessel 54 includes carbon black and disassociated gaseous components of the solid waste material in a non-hazardous states. Also, depending on the composition of the solid waste material passed through the hot zone created by the plasma guns 12, some solids such as metals, cans, or the like may be collected in the reactor 54. While the plasma guns 12 create an extremely hot zone, not all components of the solid waste material stream will be converted into a gaseous effluent. Complete conversion of the solid waste material into a gaseous state is dependent upon the volume and flow rate of solid waste material passing through the temperature zone created by the plasma guns 12.
The carbon black and nonconverted solid components of the hazardous material are collected in the bottom of the reactor 14 and transported via a screw conveyor or the like through line 56 to a magnetic separator 58. In the magnetic separator 58 the carbon black is separated from the metal solids and transported to the reactor 60 via a line 62. The solid metal material such as cans, are released from the magnetic separator through a discharge line 64 to a storage vessel for subsequent recycling or other use.
The disassociated non-hazardous gaseous components of the solid waste material are removed from the reactor 54 via a line 66. A volatile organic compound analyzer 68 is incorporated in the line 66 for analyzing the gas stream discharge from the reactor 54. The gas stream may be discharged directly to the chillers 28 via the line 70 or directed to the reactor 60 via the line 72. Valves 74 and 76 are incorporated in the lines 70 and 72, respectively, for directing the gas stream along the selected path.
Lines 62 and 72 join at the inlet of the vessel 60. The carbon black and gas stream from lines 62 and 72 pass through a second hot zone formed by a plasma gun 12 mounted at the inlet of the reactor 60. The gases and carbon black collected in the reactor 54 are passed through a second high temperature zone to insure that hazardous components in the solid waste material are completely converted into individual non-hazardous by products such as nitrogen, hydrogen, and carbon dioxide which are directed to the chillers 28 via line 71 and subsequently collected in the storage vessels 34 in the manner described above in relation to FIG. 1. The reactor 60 includes an internal screw conveyor or the like for expelling the carbon black collected at the bottom thereof via outlet conduit 61 into storage tanks for subsequent use.
When handling hazardous materials, certain steps must be taken to prevent hazards or mishaps from occurring. In the system 10, all components are fabricated of stainless steel material. The system is completely vacuumed as discussed above and all valves used are vacuum valves. In the event of a malfunction, solenoid valves are connected to an emergency shut off on the plasma generator and are utilized to stop the flow of hazardous material. Two manual valves are also incorporated in the system to shut off the flow of hazardous material in case of electrical failure or the like. Pressure gauges 36 monitor the pressure in the system and high temperature gaskets are used at the connections of various components forming the system. A thermal couple 38 is also incorporated in the system for reading or monitoring temperatures of the gases in the system. All exposed pipe of the system is sprayed with water for maintaining it a relatively low temperature.
While the foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims which follow.
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Hazardous waste treatment method and apparatus are disclosed in the preferred and illustrated embodiment. A feedstock of solid or liquid hazardous waste material is combusted in a plasma generator in the absence of oxygen and converted into non-hazardous components which are collected in a reactor chamber. The non-hazardous components are further converted into a gaseous outflow which is cooled and separated into selected constituents which are collected in storage vessels.
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BACKGROUND OF THE INVENTION
This invention relates to a handle structure for a mattress.
A conventional mattress, whether of twin, double, queen or king size, is generally parallelepipedal in form and has top and bottom surfaces and a peripheral wall. The top and bottom and the peripheral wall of the mattress are made of fabric known as tick. A decorative tape is used to bind the seams joining the wall to the top and bottom of the mattress.
It is conventional to attach handles to the wall of the mattress to facilitate lifting and turning of the mattress. A common form of handle is illustrated in U.S. Pat. No. 2,248,328 and comprises a flexible cord having a tubular ferrule at each end, each ferrule being provided with a projecting finger or barb. Two grommets are fitted in the mattress wall, about five inches apart and are linked by a backing bar of steel or tough synthetic polymer material. The tubular ferrules are inserted through the grommets respectively and are held in position by the barbs, which hook behind the grommets. The backing bar serves to protect the mattress wall from damage by the barb.
For many years, inner spring and foam mattresses were manufactured with a standard thickness of approximately seven inches. Recently, however, mattresses that are substantially thicker than seven inches, even up to about sixteen inches in thickness, have been manufactured in order to capture the luxury market, which is driven by demand for greater comfort and superior back support. Since the structure of the newer thicker mattress is the same as that of the older standard mattresses, the newer mattress contains much more material and accordingly the newer mattress is much heavier than the older standard mattress. Further, some mattresses are now made of a latex material and a mattress made of latex material can be substantially heavier than an innerspring or foam mattress of the same size and thickness.
The conventional type of handle, as described in U.S. Pat. 2,248,328 functions well with a mattress of the standard thickness and of conventional (innerspring or foam) construction but it may become detached from the wall of a heavier mattress when the mattress is lifted or turned. Further, the cord of the conventional handle tends to dig into the hand of the person lifting or turning the mattress, and in the case of a heavier mattress, this may cause discomfort and even injury.
In order to alleviate the problems of the conventional handle, it has been proposed that a mattress handle should be made from a strip of fabric having two end regions by which the strap is sewn securely to the mattress wall. In a particular instance of this type of handle, the end regions of the strap are square in configuration and each end region is sewn to the mattress wall along all four sides of the square, along the two diagonals and along a line midway between the upper and lower sides of the square. This type of handle, and its manner of attachment, overcome the disadvantages of the conventional handle. However, it has proven impractical to automate the operation by which the handle is placed on the mattress wall and the end regions of the handle are sewn to the mattress wall and therefore it is necessary for an operator to position the strap and guide the sewing machine head along the desired path. Consequently, it is expensive and time consuming to attach the handle to the mattress wall by sewing in accordance with the pattern described above.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the invention there is provided a mattress border structure comprising a mattress border having first and second transverse stitched seams spaced apart lengthwise thereof, and a strap having first and second opposite end regions held in the first and second seams respectively.
In accordance with a second aspect of the invention there is provided a mattress structure comprising a mattress top, a mattress bottom, a border joining the mattress top and mattress bottom and having first and second stitched transverse seams spaced apart lengthwise thereof, and a strap having first and second opposite end regions held in the first and second transverse seams respectively.
In accordance with a third aspect of the invention there is provided a mattress border structure comprising a mattress border having first and second folds spaced apart lengthwise thereof, a strap having first and second opposite end regions received in the first and second folds respectively, and first and second transverse lines of stitching closing the first and second folds respectively and traversing said first and second end regions respectively, whereby the first and second end regions are held in the first and second folds respectively.
In accordance with a fourth aspect of the invention there is provided a mattress structure comprising a mattress top, a mattress bottom, a border joining the mattress top and mattress bottom and having first and second folds spaced apart lengthwise thereof, a strap having first and second opposite end regions received in the first and second folds respectively, and first and second transverse lines of stitching closing the first and second folds respectively and traversing said first and second end regions respectively, whereby the end regions are held in the folds respectively.
In accordance with a fifth aspect of the invention there is provided a method of making a border for a mattress, comprising receiving a length of border material, and forming first and second transverse stitched seams in the length of border material with first and second end regions of a strap in the first and second seams respectively.
In accordance with a sixth aspect of the invention there is provided a method of making a mattress having top and bottom surfaces and a peripheral border which connects the top and bottom surfaces, comprising the steps of providing a length of border material, forming first and second stitched seams in the length of border material with first and second end regions of a strap in the first and second seams respectively, providing an assembly composed of a mattress top and a mattress bottom, and fitting the length of border material to the assembly.
In accordance with a seventh aspect of the invention there is provided a method of making a border for a mattress, comprising receiving a length of border material, forming first and second folds in the length of border material with first and second end regions of a strap in the first and second folds respectively, closing the folds with first and second transverse lines of stitching which traverse the first and second end regions respectively, whereby the end regions are held in the folds respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which
FIG. 1 is a partial schematic illustration of a first part of a production line for manufacture of mattresses,
FIG. 2 is a partial schematic illustration of a second part of a production line for manufacture of mattresses,
FIGS. 3A, 3B and 3C illustrate respective steps of a technique for attaching a strap to a mattress border to form a handle,
FIG. 4 is an enlarged view of a preferred form of strap, and
FIG. 5 illustrates a step in assembly of a mattress.
DETAILED DESCRIPTION
Referring to FIG. 1, a broad web 2 of border material wound on a roll 4 is unwound and the web is slit longitudinally into several strips 6A, 6B, etc. and the edges of each strip are serged to limit fraying of the strips and the possibility of a loose thread being caught in the machinery used for subsequent processing of border material. The strips of serged border material are wound onto rolls 8A, 8B, etc. Each roll 8 is delivered to an unwinding station (FIG. 2), at which the strip 6 of border material is unwound and cut into several segments 10A, 10B, etc. The length of each segment 10 is suitable for forming the border of one mattress and depends on the size of mattress that is to be made (twin, full, king or queen). Each segment 10 is passed to a stitching station at which a fold is formed in the segment. A strap 12 (FIG. 3A) is positioned with one end region in the fold and the fold is closed a short distance from the deepest point of the fold, by a single line of stitching 14 extending across the strip 10 and capturing the end region of the strap in the fold. A similar fold is formed at the opposite end of the strap and is closed in similar fashion by a line of stitching 16 (FIG. 3B). In this manner, the strap is secured firmly to the segment 10 of border material and forms a handle (FIG. 3C).
The strap may be made of tick, in which case it may be of uniform width and is preferably of the same pattern as the border material. However, it is preferred that the strap be made of synthetic polymer material, such as polypropylene, polyethylene or PVC, in which case the strap has a medial portion or bar 24 of generally uniform width and two parallel flanges 20A and 20B at opposite respective ends of the bar 24 and is therefore generally H shaped in plan, as shown in FIG. 4. Each flange 20 has a peripheral rim of relatively thick material, e.g. at least about one-eighth inch, surrounding a membrane 26 of substantially thinner material, e.g. one-sixteenth inch or less. The upper end surface and lower end surface of each flange 20 are rounded, and there are rounded transitions between the peripheral rim and the membrane 26. The bar 24 between the parallel flanges 20 is rather thicker than the flanges and is shaped to receive the fingers of a person gripping the handle.
In fitting the strap shown in FIG. 4 to a length segment 10 of the border material, the segment of border material is folded, as described above, and the flange 20A is placed in the fold. The line of stitching 14 is then made across the segment, the membrane 26A being aligned with the path of the needle so that the stitching penetrates the membrane and the border material is stitched into the recess surrounded by the peripheral rim of the flange. The sewing machine is controlled so that the stitching jumps the two ends of the flange. The opposite end of the strap is fitted to the length segment 10 in similar fashion, by stitching through the membrane 26B of the flange 20B. By stitching through the membrane, which although thin is nevertheless tough, the flanges are held securely to the length segment of border material. Three more straps 12 are attached to the length segment 10 of border material and the two ends of the segment are stitched together to form an endless band 30 (FIG. 5). The band 30 is delivered to a station at which it is fitted to a subassembly 34 comprising a mattress top and bottom and a mattress interior, such as metal springs or a suitable springy block of polymer material. The band is sewn along its edges to the peripheries of the mattress top and bottom and strips of decorative tape are sewn along the seams at which the band meets the mattress top and bottom, thus completing a mattress.
When the mattress is lifted using handles formed from straps of the type shown in FIG. 4, there may be a slight tendency for the flanges 20 to move upward relative to the border material in the respective folds. The flanges may contact the thread by which the strap is attached to the border material, but because the peripheral rims of the flanges are rounded, there is very little possibility of damage to the threads.
In a modification of the strap shown in FIG. 4, the membranes 26 are omitted, so that the rims of the flanges surround respective slots. The stitching passes through each slot and the border material is stitched into the slot.
The decorative tape that is used to bind the seams between the border material and the top and bottom of the mattress is generally uniform in color, i.e. unpatterned, and relatively few colors are commercially used. In the event that the strap 12 is made of synthetic polymer material, for as described with reference to FIG. 4, it is preferred that the strap 12 be uniform in color and that the color of the strap be coordinated with the tape. For example, the strap may be substantially the same color as the tape or it may be a complementary color.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims and equivalents thereof.
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A mattress border has two transverse stitched seams spaced apart lengthwise thereof. A strap has its two opposite end regions held in the two seams respectively.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of Internet searching. In particular, the present invention discloses a method and related system for deciding which external corpora to integrate into primary search engine results.
BACKGROUND
[0002] Traditional web search engines retrieve a ranked list of URL's in response to a query from a user. Increasingly, search results include content from specialized sub-collections or corpora known as “verticals”, which may include non-text media collections such as images and videos, as well as genre-specific subsets of the web such as news and blogs. When a general web search engine has access to or maintains vertical search engines, one important task becomes the detection and presentation of relevant vertical results, known as “vertical selection”. An objective is to maximize the user satisfaction by presenting the appropriate vertical display or displays: this includes the presentation of no display when the user is best satisfied by general web results.
[0003] One important aspect of the task of generating a single ranked list from multiple sub-collections (“distributed information retrieval”) is deciding which sub-collections to search given a user's query. This may be approached using query classification techniques that automatically match queries to a predefined set of categories. This predefined set may be topical categories such as games, business, or health. However, this methodology is incomplete and does not take other factors into account.
SUMMARY
[0004] Disclosed is a computer-implemented method and system for deciding which external corpora, such as verticals, to integrate into primary Internet search engine results in response to a query. In some embodiments, the method includes:
a. determining a first probabilistic estimate of the relevance of the external corpora (verticals) to the query from offline query-related data; b. combining the offline query-related data with user feedback data to determine a second probabilistic estimate of the relevance of the external corpora (verticals) to the query; and c. based on the second probabilistic estimate of relevance of the verticals to the query, determining which external corpora (vertical(s)) to integrate into the search engine results.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a system that permits a user at a personal computer system to access an Internet search engine server on the Internet, submit a query, and obtain search results.
[0009] FIG. 2 illustrates a diagram of exemplary search results, including web results and vertical results.
[0010] FIG. 3 illustrates a high level flow diagram of the external corpora (vertical) selection process using the query processing system in accordance with one embodiment.
[0011] FIG. 4 illustrates a flow diagram of the gathering of offline data.
[0012] FIG. 5 illustrates a flow diagram of the formation of an offline probability estimate.
[0013] FIG. 6 illustrates a flow diagram of the formation of a multiple Beta type prior probability distribution.
[0014] FIG. 7 illustrates a flow diagram of the formation of a logistic normal type prior probability distribution.
[0015] FIG. 8 illustrates a flow diagram of the incorporation of similar query feedback.
[0016] FIG. 9 illustrates one embodiment of a network environment for operation of the query processing system of the present invention.
[0017] FIG. 10 illustrates a high-level block diagram of a computer system for implementing the
DETAILED DESCRIPTION
[0018] FIG. 1 illustrates a system that permits a user at a personal computer system to access an Internet search engine server on the Internet, submit a query, and obtain search results. In one embodiment, a user sends query 105 to web search engine server 110 . Web search engine server 110 has access to web site database 115 , web site selector 120 , and vertical database 125 . Vertical module 130 , which may include one or more servers, such as a vertical search engine server 132 , includes vertical database 125 and vertical selector 135 . Vertical module interacts with Web site selector 120 to respond to query 105 with search results 140 , which may include both Web sites and one or more vertical displays. The results 140 are sent to user(s) 100 . In some embodiments, the methods and algorithms described herein are implemented by the vertical selector.
[0019] FIG. 2 illustrates a diagram of exemplary search results, including Web results 200 and vertical results 205 . The search results page presents results from documents available on the World Wide Web. In addition to a Web index, the system also has access to “verticals.” The result of issuing a query to verticals can be imbedded in the search results, where up to one vertical display 205 can be integrated above Web results 200 .
[0020] FIG. 3 illustrates a high level flow diagram of the external corpora selection process. In one embodiment, the external corpora comprise verticals. Although the invention is described in conjunction with selecting verticals as external corpora, any type of external corpora may be used without deviating from he spirit of scope of the invention. In 300 , evidence is derived from offline query data, which includes: a) query content, b) query log features, and c) query string features. Each of these features will be described in more detail hereinafter.
[0021] In 310 , a first estimate of the probability of each vertical being relevant to the query is computed using the offline evidence from step 100 . These estimates (which encompass k+1 situations for k possible verticals, one for each vertical, and one for no relevant verticals) are incorporated into a statistical quantity known as the “prior” probability distribution.
[0022] In step 320 , if user feedback results for the vertical relevance to the query are available, those results are used to modify the prior distribution obtained from the offline results. This may be accomplished in different ways, depending on the functional form assumed for the prior distribution. Two prior distributions include: 1) Beta (or multiple Beta) prior distribution, and 2) logistic normal prior distribution. The prior distribution modified by the user feedback data is called the posterior probability distribution. This posterior distribution incorporates the offline evidence or data, and also incorporates the user feedback data. It provides an improved estimate of the probabilities of relevance of the possible verticals to the query.
[0023] In optional step 325 , user feedback data from similar queries is incorporated into the user feedback for the current query. This step is positioned differently depending on the functional form of the prior distribution used. For a multiple Beta prior, similar query user feedback is incorporated just following step 310 . For a logistic normal prior, similar query user feedback is incorporated into the current query user feedback during step 320 .
[0024] In step 330 , display decisions are made, based on the results from steps 320 and 325 . Among the possible display decisions are: 1) pick one or no vertical with the highest probability of relevance, and 2) randomly choose a vertical, with probability of selection being set as proportional to the probability of relevance for each vertical.
[0025] Step 300 , the gathering of the offline data, is in itself a complex task. A more detailed flow description of step 300 is illustrated in FIG. 4 . The data is gathered from: a) query and vertical content, also termed “corpus features” in generality; b) query log features; and c) query string features.
[0026] In step 400 , for this embodiment, corpus features are incorporated from two distinct sets of corpora: collections of vertical-sampled documents, obtained using a variation of query-based sampling, and collections of Wikipedia-sampled articles, each mapped to a vertical heuristically using the Wikipedia article's categories. In one embodiment, four types of corpus features are used: retrieval effectiveness features; ReDDE features; soft ReDDE features; and categorical features. Retrieval effectiveness features may use Clarity, a cross-language information retrieval system, to quantify the predicted effectiveness of the query's retrieval on a vertical-representative corpus. ReDDE (Relevant Document Distribution Effectiveness, a resource-ranking algorithm that explicitly tries to estimate the distribution of relevant documents across the set of available databases) features are derived from a retrieval on an index that combines vertical-representative documents (either vertical- or Wikipedia-sampled). Soft ReDDE features generalize the ReDDE features. Instead of having documents map to a single vertical, a soft document-to-vertical membership has been derived using the similarity between the document and the vertical. Finally, categorical features are derived from the labels of automatically classified documents (e.g., sports, health, science). A query's membership to a class is proportional to the number of top-ranked documents assigned to the category. The data gathered from the corpus features, in other words, takes a query and correlates it with the verticals generated according to several query content and vertical content mappings. Note that although ReDDE and Clarity are two examples of corpus-based features, other corpus-based features may be used without deviating from the spirit or scope of the invention.
[0027] In step 405 , data is gathered from query log features. The use of query log features is motivated by the assumption that a vertical's relevance may correlate with the likelihood of the vertical being issued by the query. In one embodiment, vertical-specific unigram language models were built using one year of queries issued directly by users to the vertical in question. Query log features used the query generation probability given by the vertical's query-log language model. Note that other non-language model query log features may be used, in isolation or in combination. The data gathered from the query log, in other words, takes a specific vertical and models which queries were directed to that vertical over the past year.
[0028] In step 410 , data is gathered from query string features. The use of query string features derives from the query string itself, independent of external resources. For example, if the query contains the word “news”, we may assume news vertical intent. The rule-based vertical trigger features, used in one embodiment, are based on 45 classes that characterize vertical intent, (e.g., weather, zip code, music artist, movie). Each trigger class is associated with manual classification rules using regular expressions and dictionary lookups. In addition, a rule-based geographic entity tagger is used to assign probabilities to the set of geographic entities appearing in the query, (e.g., city, country, landmark). Each of these geography types is considered a separate feature. Note that the query string features described herein are exemplary and other query string features may be used without deviating from he spirit or scope of the invention.
[0029] Referring back to FIG. 3 , In step 310 , a model is used in which the three classes of features described above, (i.e., data pertaining to query content features, query log features, and query string features), are incorporated to form an initial offline estimate of the probability of relevance of each possible vertical display to the query. A more detailed flow description of step 310 is illustrated in FIG. 5 . Given a set of queries manually labeled with vertical intents, it is possible to train a statistical model to predict the relevant verticals for new queries, (i.e., to compute the probability that a vertical is relevant given a query). The correlation training process is based on a manually determined set of correlations for past queries. This set, however, is much smaller than the set expected to be seen in the production system. In one embodiment, in step 500 , each of the k possible verticals, as well as the case where no verticals are relevant, is modeled, for example, using a logistic regression of a Bernoulli random variable (which takes on a value of either 0 or 1). Thus, in step 505 , k+1 logistic regression models are trained, using the set of manually labeled queries as the training set, to predict the probability of success of each of the k+1 trials. It should be noted that, although a logistic regression classifier is used as an example, any binary classifier may be used. In step 510 , the output of the training process is converted to a probability of relevance for each vertical to the query. This probability, termed the offline model probability, is called π q v for query q and vertical v. π q v is used as an input for following steps.
[0030] Referring now to FIG. 3 , step 320 involves forming a prior probability distribution from the offline model probability obtained from the offline results of step 310 , then adding the user input data to the prior probability distribution, to obtain a posterior distribution. The user feedback in this case is constrained to be binary, (i.e., positive feedback or click, negative feedback or skip). Two forms of prior distributions will be set forth in some detail; other forms may be used.
[0031] The first exemplary form of prior distribution is a multiple beta prior. Beta distributions are generally described in Wikipedia at http://en.wikipedia.org/wiki/Beta_distribution. FIG. 6 illustrates the process flow using the multiple beta prior. In step 600 , the relevance of each vertical v to a query q is represented as a Bernoulli random variable, (i.e., with value 0 or 1). In step 605 , the probability of relevance of vertical v to query q, p q v , is modeled as being sampled from a Beta distribution. In step 610 , the probability distribution of p q v is therefore expressed as prior distribution
[0000] p q v ˜Beta(a q v , b q v ) (1)
[0000] with the a and b parameters, which control the shape of the prior distribution, being derived from the offline model probability π q v as follows:
[0000] a q v =μπ q v b q v =μ(1−π q v ) (2)
[0032] The inputs for the prior distribution, therefore, are π q v (the offline probability model), and μ, which is a hyper-parameter set by the system designer, which may be any positive number. A large value of μ will concentrate the distribution around π q v , whereas a small value of μ will spread out the distribution.
[0033] In step 615 , using the prior distribution of equations (1) and (2), and assuming that positive and negative feedback information input is available for the query-vertical pairs, (R q v is defined as the number of clicks 7 (e.g., positive feedback), and R q v is defined as the number of skips, (e.g., negative feedback) a posterior distribution of the relevance of the verticals to the queries is calculated which incorporates the offline data and the user feedback data. This posterior distribution is also a Beta distribution; its mean can be calculated to be
[0000]
p
~
q
v
=
R
q
v
+
μ
π
q
v
V
q
v
+
μ
3
)
[0000] where V q v =R q v + R q v represents the number of times vertical display v was presented for query q. The form of this equation provides additional interpretation of the designer-set hyper-parameter μ: for small values of μ the user feedback plays a more significant role, whereas for large values of μ the offline data plays a more significant role.
[0034] The second exemplary form of prior distribution is the logistic normal prior. Logistic normal distributions are described in I Aitchison and S. M. Shen, Logistic - normal distributions: Some properties and uses, Biometrika, 67(2): 261272, August 1980. The flow of this method is illustrated in FIG. 7 . In step 700 , this method incorporates cross-terms from different verticals, in the form of a covariance matrix Σ of dimension 2 tk×2 tk. k is the number of possible vertical choices, and t−1 is the number of queries that have been issued to the system. In step 705 , a prior distribution is derived of the form
[0000]
p
q
v
=
exp
(
W
tv
)
exp
(
W
tv
)
+
exp
(
W
_
tv
)
4
)
[0000] where: W and W are two t×k random matrices, with their elements sampled from a single multivariate normal, i.e., W, W ˜N(η,Σ); η is a 2 tk×1 vector of means.
[0035] In step 710 , as can be derived using this type of prior distribution, the posterior mean is expressed as:
[0000]
p
~
q
v
=
π
q
v
exp
(
a
q
v
)
π
q
n
exp
(
a
q
v
)
+
(
1
-
π
q
v
)
exp
(
b
q
n
)
,
where
5
)
a
q
v
=
R
q
v
+
∑
v
′
≠
v
σ
V
q
′
v
′
R
_
q
v
′
,
b
q
v
=
R
q
v
_
+
∑
v
′
≠
v
σ
v
q
′
v
′
R
q
v
′
6
)
[0000] R q v and R q v are Boolean variables indicating whether a vertical v received positive or negative feedback from query q. Note that the required inputs to yield the posterior mean output are: 1) the user click and skip data, and 2) parameter σ, a designer-specified parameter which controls the positive contribution of negative feedback on competing verticals to a vertical's probability of relevance. σ can take any positive value. A large value of σ would indicate only one relevant vertical, whereas a small value of σ would indicate multiple relevant verticals.
[0036] It has been found that the logistic normal prior method is best suited to cases where there is a clear preferred vertical, whereas the multiple beta method is more effective in cases of similar rated, or ambiguous, verticals.
[0037] Referring now to FIG. 3 , in optional step 325 , user feedback data from similar queries is incorporated into the user feedback for the current query. This step is positioned differently depending on the functional form of the prior distribution used. For a multiple Beta prior, similar query user feedback is incorporated just following step 310 . For a logistic normal prior, similar query user feedback is incorporated into the current query user feedback during step 320 . A flow diagram of incorporation of similar query feedback is illustrated in FIG. 8 .
[0038] A corpus-based similarity measure using language models of retrieved results is used to detect similarity between queries. In an embodiment, in step 800 , given two query language models, they are compared by comparing their associated language using the Bhattacharyya correlation. This is described in Wikipedia at the World Wide Web address of http://en.wikipedia.org/wiki/Bhattacharyya_distance. The Bhattacharyya correlation ranges between 0 and 1 and is defined as
[0000]
B
(
q
i
,
q
j
)
=
∑
w
∈
v
P
(
w
|
θ
q
i
)
P
(
w
|
θ
q
j
)
7
)
[0000] where P(w|θ qi ) is the probability of w given document q i .
[0039] The information from similar queries is incorporated as follows for the two types of priors discussed. First, in step 805 a , for the multiple beta model, the prior of the candidate query is modified to become {circumflex over (p)} q v known as the nearest neighbor estimate of p q v , given by:
[0000]
p
^
q
v
=
1
Z
q
∑
q
′
B
(
q
,
q
′
)
p
~
q
′
v
,
8
)
[0000] where Z q is a normalization factor equal to Σ q′ B(q, q′). In step 810 a , the offline model estimate π q v is then modified and computed to equal
[0000] {circumflex over (π)} q v =(1−λ q )π q v +λ q {circumflex over (p)} q v , 9)
[0000] where λ is a designer-set parameter that can range from 0 to 1, which controls the importance of the nearest-neighbor estimate relative to the offline model estimate. λ q equals λ multiplied by the maximum similarity value of the set of q's.
[0040] Second, in step 805 b , for the logistic normal prior model, similar query data is incorporated by adding elements to covariance matrix Σ. Using this method, it can be derived that the similar query data modifies the exponents a q v and b q v in equation (6) to become
[0000]
a
^
q
v
=
a
q
v
+
λ
∑
q
′
≠
q
B
(
q
1
q
′
)
(
R
q
′
v
V
q
′
v
+
∑
v
′
≠
v
σ
V
q
′
v
′
R
_
q
′
v
′
)
b
^
q
v
=
b
q
v
+
λ
∑
q
′
≠
q
B
(
q
1
q
′
)
(
R
_
q
′
v
V
q
′
v
+
∑
v
′
≠
v
σ
V
q
′
v
′
R
q
′
v
′
)
10
)
[0000] Thus, the similar query feedback data modifies the current query user feedback equations. Note that use of the Bhattacharyya similarity measure is exemplary: other types of similarity measures, such as cosine similarity, may be used without deviating from the spirit or scope of the invention.
[0041] Referring to FIG. 3 , in step 330 , display decisions are made, based on the results from steps 320 and 325 . Among the possible display decisions are: 1) pick one or no vertical with the highest probability of relevance, as predicted from the posterior distribution which may have additional factors such as similar query data included and 2) randomly choose a vertical, with probability of selection being set as proportional to the probability of relevance for each vertical.
[0042] The addition of a random aspect (known as the ε-greedy method) presents random displays for queries with some probability c. Another randomization method, referred to herein the Boltzmann method, exploits the posterior means across verticals. This method can be broadly described as follows: randomly choose a vertical with a probability proportional to the probability of relevance of that vertical. A visual representation of the randomness injected into the selection would be throwing darts at a board with regions corresponding to the various verticals, but the area of each region would be proportional to the corresponding vertical's probability of relevance. Thus verticals with a higher likelihood of relevance would be included in the random component more often than verticals with lower likelihood of relevance.
[0043] Specifically, using the Boltzmann method, in order to incorporate a random element, the decision about which vertical to present is sampled from a multinomial over verticals, this multinomial being derived from the estimated vertical relevance probabilities {tilde over (p)} q v . An exemplary form of the multinomial is a Boltzmann distribution of the form
[0000] P ( v )=1 /Z exp( {tilde over (p)} q v /τ),
[0000] where Z=Σ v exp({tilde over (p)} q v /τ), and τ, a positive quantity, is a designer-set parameter which controls the uniformity of the random vertical selection. As τ approaches ∞, the vertical selection becomes more random, and as τ approaches zero, it becomes less random.
Evaluation
[0044] An important aspect of the decisions is the evaluation of the effectiveness of the decisions. Table 1 summarizes the results for the best performing runs of the algorithms described herein, for all queries.
[0000]
TABLE 1
δ = 0.95
δ = 0.90
δ = 0.75
π
0.618 ± 0.001
0.618 ± 0.001
0.618 ± 0.001
MB U
0.745 ± 0.001
0.732 ± 0.001
0.669 ± 0.001
MB π
0.878 ± 0.002
0.836 ± 0.001
0.733 ± 0.001
MB S π
0.885 ± 0.002
0.843 ± 0.002
0.730 ± 0.003
ε − MB π
0.870 ± 0.001
0.835 ± 0.002
0.752 ± 0.001
B − MB π
0.896 ± 0.001
0.881 ± 0.001
0.816 ± 0.001
LN U
0.722 ± 0.001
0.709 ± 0.001
0.650 ± 0.001
LN π
0.891 ± 0.002
0.883 ± 0.001
0.851 ± 0.001
LN S π
0.894 ± 0.001
0.887 ± 0.002
0.853 ± 0.002
ε − LN π
0.891 ± 0.001
0.883 ± 0.001
0.851 ± 0.001
B − LN π
0.887 ± 0.001
0.880 ± 0.001
0.847 ± 0.001
[0045] Table 1 lists a quantity called the normalized U macro , the normalized macro-averaged utility, for the various algorithms. The average utility for an individual query is computed by summing the comparison between the user intent and the prediction, over the set of times the query was issued. This individual query average utility is then summed and averaged over the set of queries to obtain the macro-averaged utility. A normalization factor equal to the best expected value for macro-averaged utility is incorporated to obtain the normalized U macro . The upper bound on normalized U macro is 1, (i.e., a perfect system has a performance equal to 1). A designer-set parameter, δ, which ranges between 0 and 1, is defined as the probability of correctly detecting user feedback, (i.e., it introduces noise into the feedback). The higher the value of δ, the more accurate and less noisy is the feedback. Note that preferred adaptation algorithms are robust to noisy feedback.
[0046] Row 1 in Table 1 represents the offline estimate, without user feedback. Row 2 is the Multiple Beta model with a uniform prior (i.e., this is a feedback-only model); Row 3 is Multiple Beta with the offline π prior; row 4 incorporates similar query intent; Row 5 adds ε-greedy randomization; Row 6 utilizes the Boltzmann form for the randomization. Rows 6-10 follow the same pattern, but using the Logistic Normal prior model.
[0047] The results summarized in Table 1 demonstrate that, although feedback-only models can outperform offline-only models, combining the two results in significant improvements. It is seen that using a logistic normal prior outperforms multiple beta priors across all queries. However, it can also be seen that multiple beta priors with randomized decision making provides stable performance for both single and multiple intent queries, i.e., queries for which multiple verticals are relevant. Multiple Beta priors outperform logistic normal priors for multiple intent queries.
System Considerations
[0048] FIG. 9 illustrates one embodiment of a network environment 900 for operation of the query processing system of the present invention. The network environment 900 includes a client system 910 coupled to a network 920 (such as the Internet, an intranet, an extranet, a virtual private network, a non-TCP/IP based network, any LAN or WAN, or the like) and server systems 930 1 to 930 N . The client system 910 is configured to communicate with any of server systems 930 1 to 930 N , for example, to request and receive base content and additional content (e.g., in the form of a web page).
[0049] A server system, as defined herein, may include a single server computer or a plurality of server computers. The servers may be located at a single facility or the servers may be located at multiple facilities. In some embodiments, the vertical module may comprise a plurality of servers, such as server systems 930 1 to 930 N . The vertical selector may comprise one or more additional servers, coupled to and accessible by the server systems for the vertical module, such as server systems 930 1 to 930 N . In addition, the third parties to the query processing system, such as integrator networks, third party agents and third party recipients, comprises one ore more severs, such as servers 930 1 to 930 N . As such, servers 930 1 to 930 N are intended to represent a broad class of server farm architectures and the servers 930 1 to 930 N may be configured in any manner without deviating from the spirit or scope of the invention.
[0050] The client system 910 may include a desktop personal computer, workstation, laptop, PDA, cell phone, any wireless application protocol (WAP) enabled device, or any other device capable of communicating directly or indirectly to a network. The client system 910 typically runs a web-browsing program that allows a user of the client system 910 to request and receive content from server systems 930 1 to 930 N over network 920 . The client system 910 typically includes one or more user interface devices 940 (such as a keyboard, a mouse, a roller ball, a touch screen, a pen or the like) for interacting with a graphical user interface (GUI) of the web browser on a display (e.g., monitor screen, LCD display, etc.).
[0051] In some embodiments, the client system 910 and/or system servers 930 1 to 930 N are configured to perform the methods described herein. The methods of some embodiments may be implemented in software or hardware configured to optimize the selection of additional content to be displayed to a user.
[0052] FIG. 10 illustrates a high-level block diagram of a general-purpose computer system. The general-purpose computer system may be a user computer or a server computer. A computer system 1000 contains a processor unit 1005 , main memory 1010 , and an interconnect bus 1015 . The processor unit 1005 may contain a single microprocessor, or may contain a plurality of microprocessors for configuring the computer system 1000 as a multi-processor system. The main memory 1010 stores, in part, instructions and data for execution by the processor unit 1005 . If the query processing system of the present invention is partially implemented in software, the main memory 1010 stores the executable code when in operation. The main memory 1010 may include banks of dynamic random access memory (DRAM) as well as high-speed cache memory.
[0053] The computer system 1000 may further include a mass storage device 1020 , peripheral device(s) 1030 , portable storage medium drive(s) 1040 , input control device(s) 1070 , a graphics subsystem 1050 , and an output display 1060 . For purposes of simplicity, all components in the computer system 1000 are shown in FIG. 10 as being connected via the bus 1015 . However, the computer system 1000 may be connected through one or more data transport means. For example, the processor unit 1005 and the main memory 1010 may be connected via a local microprocessor bus, and the mass storage device 1020 , peripheral device(s) 1030 , portable storage medium drive(s) 1040 , graphics subsystem 1050 may be connected via one or more input/output (I/O) busses. The mass storage device 1020 , which may be implemented with a magnetic disk drive or an optical disk drive, is a non-volatile storage device for storing data and instructions for use by the processor unit 1005 . In the software embodiment, the mass storage device 1020 stores the query processing system software for loading to the main memory 1010 .
[0054] The portable storage medium drive 1040 may operate in conjunction with a portable non-volatile storage medium, such as a compact disc read only memory (CD-ROM), to input and output data and code to and from the computer system 1000 . In one embodiment, the query processing system software is stored on such a portable medium, and is input to the computer system 1000 via the portable storage medium drive 1040 . The peripheral device(s) 1030 may include any type of computer support device, such as an input/output (I/O) interface, to add additional functionality to the computer system 1000 . For example, the peripheral device(s) 1030 may include a network interface card for interfacing the computer system 1000 to a network.
[0055] The input control device(s) 1070 provide a portion of the user interface for a user of the computer system 1000 . The input control device(s) 1070 may include an alphanumeric keypad for inputting alphanumeric and other key information, a cursor control device, such as a mouse, a trackball, stylus, or cursor direction keys. In order to display textual and graphical information, the computer system 1000 may contain the graphics subsystem 1050 and the output display 1060 . The output display 1060 may include a cathode ray tube (CRT) display or liquid crystal display (LCD). The graphics subsystem 1050 receives textual and graphical information, and processes the information for output to the output display 1060 . The components contained in the computer system 1000 are those typically found in general purpose computer systems, and in fact, these components are intended to represent a broad category of such computer components that are well known in the art.
[0056] In some embodiments, the query processing system is software that includes a plurality of computer executable instructions for implementation on a general-purpose computer system. Prior to loading into a general-purpose purpose computer system, the query processing system software may reside as encoded information on a computer readable medium, such as a hard disk drive, non-volatile memory (e.g., flash), compact disc read only memory (CD-ROM) or DVD.
[0057] Some embodiments may include a computer program product which is a storage medium (media) having instructions stored thereon/in that may be used to control, or cause, a computer to perform any of the processes of the invention. The storage medium may include, without limitation, any type of disk including floppy disks, mini disks (MD's), optical disks, DVDs, CD-ROMs, micro-drives, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, VRAMs, flash memory devices (including flash cards), magnetic or optical cards, nanosystems (including molecular memory ICs), RAID devices, remote data storage/archive/warehousing, or any type of media or device suitable for storing instructions and/or data.
[0058] Stored on any one of the computer readable medium (media), some implementations include software for controlling both the hardware of the general purpose/specialized computer or microprocessor, and for enabling the computer or microprocessor to interact with a human user or other mechanism utilizing the results of the invention. Such software may include without limitation device drivers, operating systems, and user applications. Ultimately, such computer readable media further includes software for performing aspects of the invention, as described above.
[0059] Included in the programming (software) of the general/specialized computer or microprocessor are software modules for implementing the teachings of the invention, including without limitation encoding an archive from a library to generate an encoded archive that is compatible with a virtual library device, and uploading the encoded archive, according to the processes described above.
[0060] In one hardware implementation, the query processing system may comprise a dedicated processor including processor instructions for performing the functions described herein. Circuits may also be developed to perform the functions described herein.
[0061] It is not expected that the invention should be limited to the exact embodiments described herein. It should be apparent to those skilled in the art that changes and modifications can be made without departing from the inventive concept. By way of example, other types of query string, log, corpus, and feedback features can be combined. These include classifiers using user feedback information as features directly combined with non-feedback features.
[0062] The techniques described herein have application for use in cases where the vertical is owned by the search engine, (e.g., the corpora are properties of the general search engine). It may also be used when the corpora are not owned by the search engine, (e.g., a digital library interface which only provides a limited interface to the general search engine). Furthermore, it can also be used for non-vertical content such as “calculators” or other automatic processes which impact web search results. The scope of the invention should be construed in view of the claims.
|
A computer implemented method, computer-readable medium and system for deciding which external corpora, such as verticals, to integrate into primary Internet search engine results in response to a query is disclosed. Offline query-related data and user feedback data is incorporated. A probabilistic estimate is formed of the relevance of the verticals to the query.
| 6
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The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
CROSS REFERENCE TO RELATED APPLICATION
The copending, commonly assigned patent application entitled "Separation Of Toxic Metal Ions, Hydrophilic Hydrocarbons, Hydrophobic Fuel And Halogenated Hydrocarbons And Recovery Of Ethanol From A Process Stream", filed on the same date as the instant application Ser. No. 08/495,293, is fully incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATION
The copending, commonly assigned patent application entitled "Separation Of Toxic Metal Ions, Hydrophilic Hydrocarbons, Hydrophobic Fuel And Halogenated Hydrocarbons And Recovery Of Ethanol From A Process Stream", filed on the same date as the instant application Ser. No. 08/495,293, is fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to subsurface decontamination or remediation, and more particularly, to the remediation of contaminated fine-grained sediments.
2. Description of Related Art
The National Research Council (NRC) (1994) published a book entitled, "Alternatives to Groundwater Cleanup", (National Research Council, National Academy Press, Washington, DC. (1994)) that summarizes the current state of the art in removing subsurface contaminants. In this book, the NRC arrived at the following conclusions. Current and developing technologies are cost-effective in remediating coarse-grained sediments (CGS) such as sands and gravels, but ineffective in removing contaminants from fine-grained sediments (FGS). The reason for the inability of present and developing technologies to remediate the FGS is primarily the very low hydraulic conductivity of FGS that effectively stops the flow of flushing fluids such as water, air, and steam from penetrating the FGS and flushing contaminants away. In contrast, the CGS possess hydraulic conductivities that are many orders of magnitude greater than FGS; consequently, they are readily flushed. Further, this book concludes that "while current technology can restore portions of the nation's contaminated ground-water sites to meet drinking water standards, total clean up at many sites is not feasible, even though such decontamination is required by federal and state laws."
Most contaminated subsurfaces are heterogeneous composed of bodies of CGS and FGS due to prior geological deposition mechanisms. CGS are contaminated by either capillary inhibition or advective groundwater transport. These mechanisms are effective in only bringing contaminants to the exterior surfaces of the FGS. The primary processes of contaminating the interior of the FGS is molecular diffusion, and sorption is the primary mechanism by which contaminants attach themselves to the hydrophobic organic components of the FGS. In addition, the inorganic clay components of the FGS are intrinsically negatively charged, and attract the positively charged toxic metal ions (TMI) onto the FGS surfaces. Random fluctuations in pH, temperature, redox potential, or other particle collisions in the groundwater can dislodge the TMI, polluting the groundwater.
Since current and developing subsurface technologies rely upon a flushing fluid to remove these hydrophobic contaminants, the advective removal of such contaminants is realized only in the CGS, leaving the contaminated FGS largely unaffected. As a consequence, the contaminants that have either adsorbed onto the organic matter onto the surface of the FGS or that have entered the interior by molecular diffusion, act as sources of contamination that slowly bleed contaminants back into the cleaned CGS. The NRC reported several case studies in heterogeneous sediments that were remediated by current technologies, only to be recontaminated in a few years to comparable or higher levels by the mechanisms of back-diffusion and desorption of contaminants from the fine-grained sediments.
It is the recontamination mechanisms of desorption and back-diffusion that renders subsurface remediation so time-consuming (many decades and centuries) and so expensive (many millions of dollars). The NRC concluded that the remediation of heterogeneous subsurfaces in both the unsaturated (vadose) zone and the saturated (groundwater) zone of contaminants to the stringent drinking water standards is not currently achievable by current and developing remediation technologies.
Existing subsurface remediation process technologies have a number of deficiencies. Typically, fuel hydrocarbons (FH) and halogenated hydrocarbons (HH) enter the subsurface as non-aqueous phase liquids (NAPL). Processes such as gravity flow and capillary forces transport NAPL through the vadose zone to encounter the saturated zone. A fraction of the contaminants will dissolve in the ground water to an extent governed by their intrinsic water solubility. Groundwater advective transport may carry them down-stream of the spill site, and advectively-based hydrodynamic dispersion will dissipate these contaminants over a larger volume in the CGS permeable zones. At a FGS interface, molecular diffusion and adsorption, not advection, are the mechanisms by which pollutants contaminate FGS. Similarly, the pollutants exit FGS by back-diffusion and desorption, not advection. Hence, if the FGS are contaminated, it is the very slow processes of molecular diffusion and desorption that make remediation of contaminated heterogeneous subsurfaces so expensive and time consuming, because the fast mechanism of advection does not play the dominant role of remediating FGS as in the case of the CGS.
The NRC book states "Underground environments vary widely, and many common contaminants have characteristics that make decontamination difficult. Because fluids move through irregular spaces between grains of sand and gravel, or through fractures in solid rock, contaminants often seep away from their sources in unpredictable ways. In some cases, contaminants are trapped in clay or microscopic pores in rocks too small for water to flush them out. These trapped contaminants can become long-term sources of pollution as they slowly diffuse into nearby groundwater."
FIG. 1, taken from FIG. 3--3, page 110, in Alternatives in Ground Water Cleanup, illustrates the time required for trichloroethene (TCE) to diffuse out of clay lenses at various penetration depths. The deeper the contaminants have penetrated, the longer will contaminants continue to diffuse out of clay lenses. In FIG. 1, TCE has penetrated to three example depths: 0.3 m, 0.6 m, and 1.2 m, and will persist in back-diffusing, for 20 years, 66 years, and well over a century, respectively.
The NRC has analyzed standard technologies and concluded that conventional pump-and-treat (P&T) could take a few years to tens, hundreds, or even thousands of years to effect remediation, depending upon the site. The committee concluded that P&T systems are beneficial because they can partially remove underground contaminants, keep them from migrating away from their sources, and contain and limit the size of the contaminated region. However, P&T technology is ineffective for cleaning up locations with significant amounts of solvents, precipitated metals, contaminants that have diffused into small pore spaces of the FGS or that adhere strongly to soils or other sediments. The committee found that increasing the pumping rate to remove mass from source areas is not efficient.
While enhanced P&T systems such as air sparging and in-situ bio-remediation can increase significantly the removal of contaminants and reduce treatment costs, such systems have the same limitations as conventional P&T in FGS and will not be able to fully restore sites with severe contamination.
The book points out that the site hydrogeology is a very important factor in determining the relative ease in remediating a contaminated aquifer. Homogeneous high permeability regions of sites are the easiest to mobilize and flush contaminants, whereas the tight zones in heterogeneous regions and fractured rock are most difficult. Strongly sorbed contaminants and those that have diffused into the clays are difficult to extract and continue to dissolve and/or diffuse into the groundwater.
The NRC investigated many enhanced pump and treat systems and alternative technologies that have been proven capable of shortening remediation time in permeable regions and reducing cost and concluded that these methods are greatly limited by the presence of low permeability zones and sites of strong sorption. These technologies include soil vapor extraction, in-situ bio-remediation, bio-venting, pulsed pumping, air sparging, steam-enhanced extraction, in-situ thermal desorption, flushing with surfactants or cosolvents, and injection of chemicals to transform contaminants in place. Physical containment of contaminants can prevent contaminant migration, but is not considered a permanent solution.
FIG. 2 illustrates the various mechanisms of clay contamination such as sorption of FH and HH contaminants onto the hydrophobic component of organic material at the surface of the FGS, the molecular diffusion of HH and/or hydrophilic contaminants into clays to the present penetration depth, and toxic metal cations attached to the negatively charged inorganic components of the FGS. The model shows a line 2 separating the uncontaminated FGS region 4 from the contaminated FGS region 6, which is separated from the CGS region 8 by line 10. When the permeable zones are cleaned, mechanisms of desorption, back-diffusion, and slow bleed of TMI act as source terms recontaminating the groundwater again, sometimes even to higher levels than previously encountered.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a nontoxic chemical permeability in situ enhancement process for accelerating decontamination of subsurface fine-grain sediments.
It is another object of the invention to provide a method for the removal of certain classes of liquid and/or solid phase contaminants from fine-grained sediments, provided these contaminants are miscible or appropriately soluble in at least one of the treatment chemicals. Examples of such contaminant classes for which this treatment is applicable are hydrophilic hydrocarbons, and hydrophobic fuel hydrocarbons and halogenated hydrocarbons. Examples of hydrophilic hydrocarbons are acetone, ketones, methanol and propanol. Examples of fuel hydrocarbons are octane and heptane. Examples of halogenated hydrocarbons are chloroform, carbon tetrachloride and TCE.
Another object of the invention is to provide a process that is usable as part of a hybrid process that remediates heterogeneous contaminated subsurfaces and/or homogeneous subsurface containing contaminants trapped in fine-grained sediments.
The novel aspect of this invention is the application of permeability enhancing chemicals and organic solvents to the subsurface to accelerate the remediation of contaminated fine-grained sediments (FGS). Accelerated remediation of contaminated FGS is achieved by the application of clay hydraulic conductivity enhancement mechanisms, e.g., the collapse of the negative double layer surrounding the water-clay particle interface, by the introduction of either cationic flocculents (CF) or organic solvents (OS).
This invention exploits the same phenomena observed (dramatic increases in the hydraulic conductivity of clayey bodies) with the displacement of indigenous porewater with water containing cationic flocculents, (CF), or with organic solvents, (OS). Previous applications of this phenomenon were in the agricultural use of CF to alter clayey soils, and in the failure of clay-lined waste retention ponds containing OS. Specifically, clays have a very low hydraulic conductivity when they are water saturated. Water is a very polarizable molecule having a large dielectric constant of 78.5. As water surrounds the microscopic clay platelets, they acquire an electrostatic negative double layer that arises at the water/clay interface. The electrostatic repulsive forces surrounding each clay particle repel. The repulsive forces and the tortuous arrangement of these charged platelets effectively blocks the flow of water through such clays. If contaminants were to penetrate clays, they are unable to be flushed out of the clays since the hydraulic conductivity is so low.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows changes in average relative trichloroethene concentration in clay lenses of varying thicknesses as a function of time.
FIG. 2 is a conceptual model of FGS contamination near the CGS and FGS interface.
FIG. 3 shows a conceptual model of clay clusters.
FIG. 4 shows horizontal flooding and remediation of a contaminated saturation zone.
FIG. 5 shows vertical flooding and remediation of a contaminated vadose zone.
FIG. 6 is an ex-situ effluent separation facility.
FIG. 7 shows multiple treatment fronts in massive contaminated FGS.
FIG. 8 shows a process flow diagram of the present invention for contaminated fine-grained sediments.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 illustrates the currently accepted model describing the clay fabric. Individual clay platelets or particles 30 are represented by randomly oriented line segments. A clay cluster 32, represented by a polygon, is an ensemble of randomly oriented clay platelets that are in the swollen state surrounded by micropore water 34. Because of the high degree of tortuosity within a cluster, the water permeability is quite small. Groups of clusters form a mini-structure in which a mini-pore 46 is filled with a fluid, water or air, that communicates to the individual clusters. Finally, a macroscopic feature such as a crack 38 can serve as a conduit for clay hydration or dehydration.
The packing of lamellar clay crystals is driven by large capillary pressure changes producing clusters that are naturally anisotropic and that swell along a preferred axis normal to the plane of the predominant particle orientation. It is postulated that a network of cracks persists in clays even after they become water saturated and plastic even if they are not subject to large compressive stresses. If the lateral extent of the regions between cracks were greater than the majority of their component particles, cracks must occur at intervals about the average cluster size throughout the clay body. The distance over which an unbroken order persists in a clay matrix is limited by the stresses generated by either the swelling or shrinking of the neighboring cluster. During displacement of the indigenous porewater, particles bounding the coarser mini-pore voids are brought under the influence of short range attractive capillary pressures. Whether a particular flaw becomes a member of a network of cracks depends on factors such as a large stress gradient, the local water potential, inherent strength of the flaws, the presence of colloidal debris, and the orientation of clusters.
Thus once the hydraulic conductivity is viewed from the perspective of the soil fabric being permeated (see FIG. 3), then the multitude of factors that influence this fabric can be understood. The important factors include: water content, density, method of compaction and their relation to layering, break down of clods and uniform dispersion of soil particles, the hydraulic gradient and influence of seepage forces, the anisotropy and flow direction, the physical and chemical properties of the permeant, the thixotropic and other time effects, the degree of saturation that controls the space available for fluid flow, and pore clogging of mini-and macro-pores as a result of the growth of microorganisms.
Referring again to FIG. 3, the clay cluster fabric model can explain the observed increase in hydraulic conductivity of clays. Hydraulic conductivity increasing materials, such as cationic flocculents (CF) or organic solvents (OS), first enter the material through the macro and mini-pore structure. Communication is slowly established within a clay cluster, and the CF or OS displaces the indigenous micropore water and begins to collapse the double negative layers with a subsequent reduction in the clay cluster volume. Since volume is conserved, the volume of the minipores and macropores increase accordingly. The clay fabric losses its plasticity, and the shrinkage of clay cluster volumes produces internal tensile stresses exceeding the tensile strength of the altered clays, producing crack failures.
If a nearly incompressible fluid remains in the mini-and macro-pores, compaction will not occur. However, if such a fluid were to drain, or be replaced by a compressible fluid such as air, compaction may occur, such as in the case of air-dried clays that have lost a sizable amount of water through evaporation.
The invention utilizes the introduction of cationic flocculents (CF) or organic solvents (OS), having a dielectric constant considerably lower than water to alter the structure of the clays by collapsing the negative double layer in clays. These materials, (CF) or (OS), alter the clay fabric producing an altered material that can have a flocculated structure, a cracked structure, or both a cracked and a flocculated structure. Such structural alterations have the net effect of increasing the hydraulic conductivity of clays up to four orders of magnitude. Contaminants still exit the clays by molecular diffusion, but the length scales are reduced by several orders of magnitude. Since the time scale for molecular diffusion is proportional to the square of the length scale, estimated speedups, up to a million-fold reduction in the time for contaminants to diffuse out of FGS may be possible, as compared to unaltered clays. The use of an organic solvent to increase the hydraulic conductivity of clays has the additional benefit that the sorbed contaminants readily partition into organic solvents rather than water, and that either the hydrophilic or the hydrophobic contaminants that have entered the clays are either totally miscible in such solvents, or are highly soluble.
A cationic flocculent should be chosen so it is nontoxic, inexpensive, have a high charge density, yet be small enough to readily fit within the micropore spaces of the clayey fabric. Some examples are aluminum polyhydroxide; Al(OH) n ; ferric hydroxide, Fe(OH) 3 or gypsum and hydrated calcium sulfate.
The OS that should be considered for this process must possess the following properties: not prohibited by the United States Environmental Protection Agency (EPA) from being introduced into the subsurface, must be relatively inexpensive, must have a viscosity similar to water, must have a relatively high boiling temperature, must be soluble in water, hydrophobic fuel hydrocarbons and halogenated hydrocarbons must be miscible or highly soluble in it, hydrophilic contaminants must be miscible or highly soluble in it, and it must have a dielectric constant considerably lower than that of water. A candidate OS that fulfills these requirements is ethanol, (C 2 H 5 OH). The process in this invention is not limited to an OS such as ethanol, provided that the replacement OS meets regulatory approval and has most of the desired properties listed above.
Presently, ethanol is an organic solvent that is not prohibited by the United States Environmental Protection Agency (EPA) from being introduced into the subsurface, and possesses most of the desired characteristics of a remediating organic solvent. Ethanol has a dielectric constant near 24, is relatively inexpensive ($1.25/gal.), and most lower molecular weight hydrophobic fuel hydrocarbons and halogenated hydrocarbons are completely miscible in ethanol. In addition, hydrophilic hydrocarbons such as acetone, ketone, methanol, propanol, etc., are miscible or highly soluble in ethanol. For the higher molecular weight hydrocarbons, the solubility of such hydrocarbons in ethanol decreases approximately linearly with increasing molecular weight. In addition, ethanol is completely miscible in water. Ethanol is only effective in increasing the hydraulic conductivity of clays in concentrations above 80%, with the maximum effectiveness at 100%. In concentrations below 12%, bacteria metabolize ethanol in the presence of oxygen to eventually form water and carbon dioxide.
The cycling of slugs of cationic flocculents and organic solvents as ethanol through clays has the advantage that the hydraulic conductivity increases with each cycle since the clay fabric is altered toward increasing hydraulic conductivity. The micropore spaces that surround each clay particle are reduced and the mini and-macro pore space that surrounds clusters of clay particles increases.
Because fine-grained sediments are mixtures of the primary clays such as kaolinite, illite, and smectite, and additional components of organic material, silt, etc., the crack lengths, widths, and spacings will vary widely from location to location, and even within a given location. These constitutive compositions and crack information must be determined before remediation to optimize the field remediation work.
The field implementation of this invention is valid for both thin clayey lenses as well as for massive FGS bodies that are contaminated. The following procedure is valid for either type of contaminated FGS. However, the massively thick contaminated FGS bodies will require an additional preparatory phase that will be described later. The steps that are required are:
1. Characterization of the subsurface soils and assay of contaminant inventory.
2. Optional, but highly recommended, construction of an in-situ containment vessel containing the soils to be treated.
3. Placement of injection and extraction wells within treatment region.
4. Cationic flocculents and ethanol will be injected into the treatment region at appropriate wells. This injection will be applicable for both the saturated and unsaturated zones using horizontal and/or vertical flooding. FIG. 4. is an illustration for applying this process to the contaminated FGS in the saturation zone. A pre-determined volume of cationic flocculents 40 is first injected through injection well 41 to precondition the FGS, and is extracted from the subsurface with extraction well 42. Next, a pre-determined volume of pre-slug stabilizing buffer 43 is injected through injection well 41. After the volume of pre-slug stabilizing buffer has been delivered, a pre-determined volume of an ethanol slug 44 is injected through injection well 41, and this ethanol slug 44 is then followed by a pre-determined volume of a post-slug stabilizing buffer 45 that is injected through injection well 41. Extraction well 42 extracts the configuration consisting of: the pre-slug stabilizing buffer 43, the ethanol slug 44 that has altered the contaminated FGS body removing a fraction of the contaminants, and post-slug stabilizing buffer 45. The above process is repeated until the contaminants in the FGS has met or exceeded regulatory remediation requirements. FIG. 5. is an illustration of the vertical flooding to be performed on contaminated FGS in the vadose zone. The figure shows grout walls 50, grout floor 51, perforated wells 52, sand/gravel region 53, water table 54, vadose zone 55, clean clay lens 56 and contaminated clay lens 57.
5. Extraction wells remove the effluent from the containment vessel. The contaminants may be separated from the water-ethanol mixture, and further separation and recovery of the ethanol will occur. FIG. 6 is an abbreviated illustration of the ex-situ separation facility. It shows the injection of clean ethanol (ETOH) into well 60, located in containment vessel 61. Contaminated effluent 62 exits well 63 and undergoes soil and liquid separation processes. Soil is separated from liquid by process 64. The liquid and vapor are then separated by process 65. Vapor separation process 66 produces collected contaminants 67. Vapor separation process 66 also provides liquid feed for separation process 68, which cycles vapor back to vapor separation process 66, produces collected contaminants 67, clean water and clean ETOH to be reinjected into well 60 to repeat the entire effluent separation process.
6. The ethanol and cationic flocculents will be recycled by reinjecting into the containment vessel until no further contaminants are recovered and the concentrations of contaminants are at or below drinking water standards.
There are three primary reasons for constructing such an in-situ containment vessel:
1. Ethanol readily mobilizes hydrophilic and hydrophobic contaminants that might escape the capture zone of the extraction wells further contaminating a site.
2. Since the unsaturated or vadose zone is most likely to be contaminated, the vadose zone can be treated by this invention using vertical flooding by injecting cationic flocculents and ethanol in one or two wells and extracting the contaminants from other wells that are completed appropriately.
3. To alleviate the possibility of the overburden closing the opened cracks, the containment vessel prevents drainage of the permeability altering fluid from the clay pores in the FGS.
The first stage in the field implementation is characterization of the soil types, and an assay of the chemical contaminants. Attention must be given to the depth of penetration of the contaminants within each contaminated FGS body, the nature of the contaminants, the extent to which the organic matter in the FGS has sorbed contaminants, and the type and concentrations of toxic metal ions adhering to the FGS bodies. This database will be used in determining the remediation process design, especially for the removal of toxic metal ions.
The next step in the field implementation is the construction of an in-situ flow containment vessel. There are several technologies available to construct such a vessel; an effective, economical approach will be described. The vessel can be constructed by using very high pressure water jets to create a cavity in which a temporary or permanent grout is injected. A floor and sidewalls are recommended to enclose a FGS or a heterogeneous section to a depth below the detected contamination zone that may be above or below the water table. Depending upon the size of the containment vessel, one or more injection wells that are completed in the CGS will deliver cationic flocculents and pre-and post stabilizing buffered slugs of ethanol into the subsurface. One or more extraction wells will remove an effluent composed of groundwater, cationic flocculents, organic solvent such as ethanol, and contaminants.
The effluent will be treated at the surface to separate the water, any toxic metal ions, ethanol and hydrocarbon contaminants. The purpose of this separation is to reduce the bulk of contaminated material that will require disposal and to reclaim the organic solvent in appropriately pure form so it can be recycled in the remediation process.
Both the cationic flocculents and ethanol enter the clays by diffusion and displacement of water. As soon as these chemicals have penetrated a certain "skin depth", cracking and/or flocculation will occur. This cracking and/or flocculation accelerates, exposing continuously more surface area to the altering permeating fluids. However, a contaminated massive clay body has a relatively small surface to volume ratio. Hence the alteration of the clayey fabric to increase its hydraulic conductivity may be slow without intervention.
To accomplish the intervention, core samples are obtained at various locations within the massive clay body to determine the depth of penetration of the contaminants. As an example, within the same core holes, hydraulic fracturing is simulated using available high pressure water jets to cut a disk-shaped cavity within the clay, and pack the cavity with sand. The purpose of forming these sand-filled cavities within the clay is to produce multiple fronts to greatly reduce the time to produce a cracked, flocculated structure. FIG. 7. is an illustration of the creation of multiple treatment fronts in contaminated massive FGS bodies using the method described above. The decision to use alternative technologies to enlarge the available surface area for treatment needs to determined on a case by case basis.
Referring to FIG. 8, Block 80, a detailed site characterization is first performed to (1) determine the composition of the soils at the contaminated site, and (2) to perform chemical analyses of the soils to determine the composition and concentrations of the inventory. If the soils are contaminated and are composed of fine-grained sediments of low hydraulic conductivity, then this invention is applicable.
In constructing an in situ flow containment vessel (Block 82), the side-walls are drilled to a depth below the contamination layer as determined by the site characterization. High pressure water/sand jet drilling is an inexpensive method to create a vertical cavity. This cavity is filled with grout from the depth to the surface. (Alternately, oblique wells may be drilled and injected with grout.) Next, the floor of the in situ containment vessel is also constructed by high-pressure jet drilling by forming a cavity that is also filled with grout to the side walls. The assemblage of the four side walls and floor should be tested for leaks by a combination of lithium bromide (LiBr) and helium tracer tests. The leaks should be sealed, and retested for leaks.
Depending on whether the low hydraulic conductivity sediments are large massive structures in the subsurface, or thin lenses, different actions are taken. If the clay body is massive (Block 84), then there are available several technologies that can precondition the massive clay body to increase the treatment surface area. This is readily accomplished by the following example technologies. Create a series of disk shaped cavities by hydraulic jet drilling, fill them with sand or gravel, and emplace injection wells that are completed at these cavity locations (Block 86). FIG. 7 illustrates this method of creating multiple fronts. It shows injection well 70 and extraction well 71. Sand filled cavities 72 separate contaminated clayey body 73, uncontaminated clayey body 74, contaminated clayey bodies 75 and 75' and sand regions 76 and 77. Other methods of creating multiple fronts include hydraulic fracturing, thermal fracturing and accoustical fracturing.
A set of injection and extraction wells should be located on either side of the contaminated clay bodies; these wells should be completed in the permeable course grained sediments if possible.
If the saturated zone containing ground-water contains contamination, then the saturated zone should be horizontally flooded (FIG. 8, Block 88). Here, the injection and extraction wells are completed below the water table to the depth of the containment vessel floor, and are located in soils with much larger hydraulic conductivity than the contaminated FGS.
If non-aqueous phase liquids (NAPLs) have been detected, inject a dilute (50%) ethanol into the subsurface. The very high solubility NAPLs in ethanol will mobilize these contaminants and permit them to be removed from the subsurface. Continue injecting dilute ethanol until no more NAPLs are detected. Block 90 represents the testing process. Once the NAPLs are removed, remediation of the contaminated fine-grained sediments is begun.
In remediating the fine-grained sediments below the water table, cationic flocculents are first injected and allowed to alter the structure of the contaminated FGS. The coupled injection-extraction process should be undertaken at a very low hydraulic gradient to allow sufficient time for the cationic flocculents to permeate and alter the FGS structure. Then, nearly 100% ethanol is injected into the pretreated FGS; the ethanol is driven very slowly through the clay bodies by the injection-extraction process in order to give ample residence time to form an altered structure within the FGS. The ethanol, as it is altering the interior of the contaminated FGS, also decontaminates the surface. The sorbed contaminants on the organic material in the FGS preferentially move into the ethanol phase. The contaminants that have diffused into the interior of the FGS, now rapidly egress because: the network of cracks has tremendously reduced the diffusion time out of the altered FGS; the contaminants are now in a fluid in which they are miscible or highly soluble; and the ethanol and contaminants can be readily mobilized and extracted to the surface. Hydrocarbon contaminants are separated from the groundwater-cationic flocculent effluent stream at a surface chemical separation facility (Block 92). Next, the hydrocarbons are separated from the groundwater-effluent stream. A separate commonly assigned, copending patent application, Ser. No. 08/495,293, titled "Separation Of Toxic Metal Ions, Hydrophilic Hydrocarbons, Hydrophobic Fuel And Halogenated Hydrocarbons And Recovery Of Ethanol From A Process Stream", fully incorporated herein by reference, presents the details regarding the separation process. From the surface separation facility, cationic flocculents will be separated, decontaminated and held in a separate feed tank (Block 94). The hydrocarbon contaminants will be separated or destroyed (Block 96). The decontaminated ethanol-groundwater mixture will be treated to separate the groundwater (Block 98), leaving behind 100% pure ethanol that will be stored in a feed tank Block 100). The decontaminated groundwater and clay pore water will be held in temporary storage tanks until the conclusion of the remediation process. At the end of the remediation process, the ethanol will be extracted, and the water will be reinjected into the subsurface.
The first pass of the cationic flocculents and ethanol is expected to be inadequate in removing most of the hydrocarbon contaminants from the contaminated clay because of the dilution of the ethanol by the groundwater and the water contained within the pore spaces of the contaminated clays. The philosophy of this invention is to replace as much of the water in the subsurface by ethanol. When the concentration of ethanol in the subsurface approaches 100%, the maximum benefit of clay cracking and flocculation will occur, as well as the miscibility of hydrocarbon contaminants in the ethanol. At this stage, the optimal hydraulic conductivity increases and decontamination rate occurs.
In order to determine when the saturated zone is acceptably remediated to stringent drinking water standards, core samples of treated clays are taken, as well as any water. Chemical analyses will determine whether the concentrations are above standards, if so, the cycling of ethanol through the FGS continues until the hydrocarbon contamination levels are below acceptable standards. If the concentrations are acceptably low, the remediation phase of the saturated zone is complete.
In many instances, the unsaturated zone or vadose zone contains large amounts of contaminants in the FGS bodies. If this is not the case, the remediation is finished. The ethanol will be extracted from the saturated zone, and the groundwater held in storage tank will be injected into the ground. The in situ containment vessel will be rubblized, and surface equipment be removed.
However, if the vadose zone is indeed contaminated (FIG. 8, Block 102), then a vertical flooding process, from the saturated zone up to the surface within the confines of the in situ containment vessel will take place (Block 104). First, water containing cationic flocculents is injected into the containment vessel to vertically flood the contaminated FGS. Next, vertical pre-and post buffered slugs of ethanol are injected into the vadose zone to treat the contaminated vadose zone FGS bodies. The slugs of cationic flocculents and contaminants as well as water-ethanol and contaminants are extracted slowly, and decontaminated by process.
Similar to the process in the saturated zone, cationic flocculents are separated and stored in a tank. The hydrocarbon contaminants are separated from the effluent stream, and are either destroyed or disposed of. The ethanol-water mixture is separated and stored in a water storage tank and into an ethanol storage tank.
The soils in the vadose zone are sampled for chemical analysis. If the soils have contaminant concentrations above the stringent drinking water standards (Block 102), ethanol is reinjected into the vadose zone (Block 104), and cycled through the injection-extraction process until the soil contaminant concentrations are below drinking water standards. If this is the case, then the process is allowed to stop (Block 106).
When the stop decision is reached, the extractable cationic flocculents and ethanol are removed from the subsurface. The stored water is aerated, and seeded with the indigenous biota, and the water is then injected into the containment vessel. Depending upon the decision of the regulators, the in situ containment vessel can be destroyed so the remediated treatment cell is now allowed to communicate with the rest of the subsurface environment. The surface drilling and chemical separation facilities will be dismantled, and the injection and extraction wells will be capped. The remediated fine-grained sediments, after the removal of the cationic flocculents and ethanol, and the injection of decontaminated groundwater will nearly resemble the conditions of the soils before contamination. The remediated FGS; however, may have hydraulic conductivities that are larger than that of the pristine condition state. The main benefit will be that toxic contaminants will have been removed from the environment.
Changes and modifications in he specifically described embodiments can be carried out without departing from the scope of the invention, which is intended o be limited by the scope of the appended claims.
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The remediation of heterogeneous subsurfaces is extremely time consuming and expensive with current and developing technologies. Although such technologies can adequately remove contaminants in the high hydraulic conductivity, coarse-grained sediments, they cannot access the contaminated low hydraulic conductivity fine-grained sediments. The slow bleed of contaminants from the fine-grained sediments is the primary reason why subsurface remediation is so time-consuming and expensive. This invention addresses the problem of remediating contaminated fine-grained sediments. It is intended that, in the future, a heterogeneous site be treated by a hybrid process that first remediates the high hydraulic conductivity, coarse-grained sediments, to be followed by the process, described in this invention, to treat the contaminated low hydraulic conductivity fine-grained sediments. The invention uses cationic flocculents and organic solvents to collapse the swelling negative double layer surrounding water saturated clay particles, causing a flocculated, cracked clay structure. The modification of the clay fabric in fine-grained sediments dramatically increases the hydraulic conductivity of previously very tight clays many orders of magnitude.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for producing embossed thermoplastic sheet material utilizing a vacuum embossing method and apparatus with an endless, seamless screen as the embossing surface, the screen being supported by a support roll, a drive roll, and two seal rolls.
Embossed plastic film or sheet material has come into widespread use in many fields. One particularly large scale use of embossed thermoplastic sheet material is that of disposable articles such as hospital pads and drapes, wearing apparel and disposable diapers. Embossed film is also finding increased use in the packaging field, for example, as bags or overwraps for articles such as clothing and for shopping bags. In order to fulfill the requirements established by the end use of embossed film, is is desirable that the film have suitable properties for handling by fabricating machines, particularly those used for the manufacture of disposable articles, e.g., disposable diapers, sheets, pillow cases, drapes, raincoats, etc. In many cases it is important that the embossed thermoplastic film be soft and flexible and have the proper pattern and embossed depth in order to provide the desired "hand" or clothlike feel for the thermoplastic embossed material. Additionally, for many uses it is desired that the embossed thermoplastic material have as low a surface gloss as possible in order to simulate woven clothlike fabrics. Further, embossed thermoplastic materials must meet minimum physical specifications which are necessary in order that the films be handled in high speed, automatic fabricating machines, i.e., they should have suitable modulus, tensile strength, and impact strength.
Heretofore, embossed thermoplastic films such as polyethylene, polypropylene, polybutene-1, polyvinyl chloride and other flexible thermoplastic thin films have been made by various methods. One method is to extrude the thermoplastic film from a conventional slot die onto a continuously moving, smooth, cool, casting surface, e.g., a chill roll. The engraved pattern may be applied to the chill roll and the film pressed to the roll while in the amorphous or molten stage by press rolls. Alternatively, the chill roll may be smooth and the desired pattern in the film may be pressed into the film on the chill roll by means of an engraved and machined embossing roll which is pressed against the film and the chill roll to impress the pattern into the film as it is cooled on the chill roll.
Another technique used is to produce engraved rollers and to provide a heated, moving strip of film for engagement by the nip of the rollers, one of which carries the embossing pattern.
Embossed film has been prepared to a very limited extent by the use of vacuum embossing processes. Heretofore, it has been difficult to economically produce vacuum embossed film which has the characteristics and properties of film produced by the more conventional high pressure embossing processes. In one process for producing vacuum embossed film an endless belt made of a wire mesh which is butt welded to produce the endless belt is utilized. One embodiment is carried over a vacuum box, and heated film is applied thereto to impress the pattern of the screen on the heated film. In another embodiment the endless, butt welded screen is mounted on a cylindrical drum having a foraminous surface, and vacuum is applied to the hollow drum to pull the heated film into contact with the wire screen. However, the belts have a welded joint mark which marks the embossed film once during each revolution of the belt. Thus, the film is suitable only for use in limited applications wherein the pattern can be cut into sections and used to avoid the joint mark produced by brazing or welding the ends of the metal screen together.
Other processes used in vacuum embossing film utilize perforated vacuum embossing cylinders which carry an outer layer of a porous substance, such as metallic mesh, fiberglass, embossed paper or woven fabric materials as the outer embossing surface thereon. The perforated cylinders carry on their outer surface the sized sleeve which is either butt jointed and/or lap jointed and thus produces a transverse mark on the thermoplastic embossed film as it is carried over the joint in the sleeve covering. It has been suggested to reweave the fabric together; however, it has been found that this is an extremely tedious and expensive operation and cannot be commercially accomplished to produce a wide variety of rolls from fabric materials.
From the foregoing it can be seen that the previously utilized processes and apparatuses for vacuum embossing film suffer from numerous disadvantages which either increase the cost of vacuum embossed film and/or produce vacuum embossed film which does not have properties equivalent to that of film embossed by the pressure embossing method. Previously used processes and apparatuses for vacuum embossing film have suffered from the inability to produce long, continuous lengths of vacuum embossed film without having transverse marks across the film at periodic intervals equal to the length of the emobssing belt and/or the circumference of the screens which are used to cover the embossing cylinder.
Additionally, many of the processes and apparatuses used heretofore for vacuum embossing film do not produce clear, distinct, sharp patterns having the desired "hand" or feel which is comparable to pressure embossed film. Further, many of the films produced by vacuum embossing have been found to be very deficient in physical properties to equivalent embossed films, i.e., they have a low modulus, low tear strength, poor impact strength and nonuniform roll contours when rolled into large size rolls for shipment.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus for producing vacuum embossed thermoplastic film.
It is a further object of the present invention to provide apparatus for producing vacuum embossed thermoplastic film having enhanced physical properties.
It is a still further object of the present invention to provide an economical and efficient apparatus for producing vacuum embossed film.
The process of the present invention for vacuum embossing thermoplastic film may be carried out by continuously advancing a length of the film that is heated at least to its softening temperature and applying the heated film to a portion of the surface of an endless, seamless, perforated screen or belt supported on a plurality of rotatable rolls. The perforated screen or belt is advanced at the same rate as the heated film. A vacuum is applied to at least a part of the undersurface of the perforated screen or belt to pull the heated film into contact with the top surface of the screen or belt to cause the film to assume the shape of the pattern provided on the top surface of the screen or belt. Heat is removed from the embossed film at a rate sufficient to maintain the embossed film at a temperature sufficiently low enough to cause the embossed film to substantially retain the pattern when removed from the belt or screen. The film is continuously removed from the screen or belt.
The apparatus of the present invention for vacuum embossing sheet material includes a support roll, a drive roll, a support structure for mounting the support roll and the drive roll for rotation, an endless, seamless, flexible, porous screen mounted on the support roll and the drive roll for rotation therewith, and a vacuum assembly positioned between the pair of support rolls and engaging a portion of the underside of the screen that extends between the pair of support rolls.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, schematic view of one embodiment of an apparatus of the present invention suitable for carrying out the process of the present invention;
FIG. 2 is a top plan view of a portion of a preferred embodiment of the apparatus of the present invention with a portion of the endless, seamless screen being cut away;
FIG. 3 is an elevational sectional view taken along lines 3--3 of FIG. 2;
FIG. 4 is an end view of a portion of the apparatus of FIG. 3;
FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 2;
FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 2; and
FIG. 7 is a partial cross-sectional view taken along lines 7--7 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a schematic view of an apparatus of the present invention suitable for carryiing out the process of the present invention which includes a conventional slot die 10. It will be understood that slot die 10 is fed a plasticized melt of a suitable polymer for forming a film (e.g., polyethylene, polypropylene, polyvinyl chloride) and extrudes a sheet of film 11 in a horizontal direction. The sheet of film 11, while still hot from extrusion, is applied to the top surface of an endless, seamless, flexible, porous screen 22. Screen 22 is mounted on drive roller 14 and on support roller 15, rollers 14 and 15 being identical in construction. Spaced-apart cylindrical seal rolls 17--17 make rolling contact with the underside of screen 22. A vacuum is applied by manifold 25 to the area lying between seal rolls 17--17 and deckles 30--30 to pull the film 11 down onto screen 22 to emboss the film. After the film leaves screen 22 it next passes over chill roller 13 which is temperature-controlled to cool the film, and from there it passes on to any suitable wind-up roller 56, or the like for storing the film. Rollers 13, 14 and 15 are hollow inside and have hollow shafts 13a, 14a and 15a, respectively, at each end thereof for circulating heating or cooling fluid therethrough. It is understood that any suitable means may be used for heating the film prior to the heated film being received in the apparatus described hereinbefore in FIG. 1, e.g., infrared lamps, hot air, passing the film over heated rollers, or in contact with other suitable heated surfaces.
FIGS. 2-7 depict in greater detail a preferred embodiment of an apparatus of the present invention for vacuum embossing film. Referring now to FIGS. 2-6, the apparatus includes a generally hollow, cylindrical drive roller 14 which drives screen 22 about support rollers 15 and over seal rolls 17--17. Rollers 14 and 15 can be made from any suitable metal, e.g., steel, aluminum, bronze, etc. Drive roller 14 is preferably covered with a suitable elastomeric covering (not shown) such as, for example, a neoprene or silicone rubber. As seen in FIGS. 2 and 4, drive roller 14 is rotatably supported by hollow shaft members 14c and 14b received in bearings 52 and 52a, which are attached to end plates 34 and 34a. Shaft member 14c is connected by hollow nipple 29 to rotating union 36. Union 36 is connected by a supply conduit (not shown) to a suitable supply of a heating or cooling fluid, e.g., water or oil, and the shaft member 14b is connected to a discharge conduit and union (not shown) for returning the fluid to the supply source. Thus a heating or cooling fluid may flow through the hollow interior 14f (see FIGS. 3 and 5) of drive roller 14, as indicated by the arrows in FIG. 2.
Also located on shaft 14c is pulley 55. Pulley 55 is driven by any suitable drive means such as a flexible V-belt, for example. Pulley 55 could also be replaced by a sprocket or any other conventional drive means.
As can be seen in FIGS. 3 and 5, inner cylinders 14d and 15d are contained with rollers 14 and 15, respectively. The inner cylinders 14d and 15d are sealed at each end by end plates 53--53 and are connected to rollers 14 and 15 by supports 54, as shown in FIG. 3. The inner cylinders 14d and 15d form a fluid space 14f and 15f through which heating or cooling fluids flow as indicated by the arrows in FIG. 5. More rapid and efficient heat transfer is effected by this preferred design. However, inner cylinders 14d and 15d and end plates 53--53 could be eliminated if desired.
Support roller 15 is identical in construction, as previously mentioned, to drive roller 14 and is supported by hollow shaft members 15b-15c, respectively, which are received in bearings 19a and 19 attached to end plates 34a and 34. Also, support roller 15 is hollow inside and is constructed in such a manner that heating or coolant fluids such as oil or water may be forced therethrough in the manner previously explained. As can be seen in FIGS. 2, 3 and 5, support roller 15 may be heated or cooled by supplying a fluid through hollow shaft members 15c at one end and discharging the fluid through hollow shaft members 15b at the other end.
Drive roller 14 is biased away from support roller 15 by tensioning set screw 51, as can be seen in FIG. 4. An identical screw is located at the opposite end of roller 14. The screws 51--51 urge bearing assembly 52 and 52a outwardly to cause drive roller 14 to place tension upon screen 22, thereby forcing screen 22 snugly against the support roller 15, and seal rolls 17--17.
A vacuum assembly, designated generally by the numeral 23 is positioned between support roller 15 and drive roller 14 to supply vacuum to a portion of the underside of the top of screen 22. The assembly includes a generally cylindrical manifold pipe 25, which extends between end plates 34 and 34a and is attached thereto by welding or other suitable means. Seal retainer strips 24 are attached by bolts or other suitable means to each side edge of manifold pipe 25 and project outwardly therefrom. A pair of spaced apart seal rolls 17--17 are slidingly supported by manifold pipe 25 and strips 24--24. Rolls 17--17 make a sliding seal with retainer strips 24--24 and manifold pipe 25. Seal rolls 17--17 are preferably made from Teflon or other suitable plastic materials having a low coefficient of friction.
Located between seal rolls 17--17 are deckles 30--30 which in turn are threadably connected to deckle screws 31--31. Deckle screws 31--31 are connected by collars 21--21 to end plates 34 and 34a. By turning deckle screws ends 31a--31a held in mounting bracket 35 and end plate 34a, deckles 30--30 can be made to move inwardly and outwardly along the shaft of the screw to adjust for various widths or screen 22 or film 11. Each deckle 30, as can be seen in FIG. 3, has a straight top edge and a curved bottom edge which make sliding contact with the underside of screen 22 and manifold pipe 25, respectively. The side edges of each deckle are generally semi-circular in shape and fit flush against seal rolls 17--17 to provide a sliding vacuum seal therebetween.
As can be seen in FIGS. 2 and 6, manifold pipe 25 has openings 27 therein through which air flows in the direction indicated by the arrows when a vacuum is applied to manifold pipe 25. Vacuum is thus applied to the underside of screen 22 which overlies the vacuum chamber 50 defined by seal rolls 17--17. deckles 30--30 and manifold pipe 25. When heated film 11 is carried by screen 22 over seal rolls 17--17, the vacuum or low pressure existing in chamber 50 pulls the heated film 11 tightly against screen 22 to emboss the film.
In one preferred embodiment of the present invention, a hydraulic cylinder 63 is mounted on end plate 34a, as shown in FIGS. 2-5. The purpose of hydraulic cylinder 63 is to prevent screen 22 from sliding or walking off the end of drive roll 14 or support roll 15. Hydraulic cylinder 63 accomplishes this purpose by moving the end 15b of drive roll 15 upward or downward, thereby "steering" or causing screen 22 to move toward one end or the other of rolls 14 and 15.
As can be seen in FIG. 2, the hydraulic cylinder 63 is controlled by an electric eye (photoelectric cell) 60 which is adapted to read or "see" the edge 22a of screen 22. When electric eye 60 does not "see" the edge 22a of screen 22, a signal is sent through line 62 to cylinder control 65, which in turn varies the hydraulic pressure in hydraulic line 66 connected to hydraulic cylinder 63 to actuate hydraulic cylinder 63. Hydraulic cylinder 63 causes steering unit 64 to move bearing 19a upward or downward. Preferably there are two hydraulic cylinders 63--63, although only one is shown in the drawings. The other hydraulic cylinder would be located on end plate 34 at the opposite end 15c of roll 15 in the same manner in which hydraulic cylinder 63 is connected to end plate 34a. The other cylinder would move the end 15c of roller 15 in a direction equal to and opposite to the direction in which cylinder 63 moves end 15b, thus causing roll 15 to pivot about its center.
To carry out the process of the present invention a sheet of heated thermoplastic film 11 is applied to the top surface of screen 22 lying between drive roller 14 and support roller 15. Screen 22 is rotated by drive roller 14 thereby pulling film 11 over vacuum chamber 50. Vacuum is applied to each end of the vacuum manifold pipe 25, and a vacuum is created within the chamber 50 pulling the heated film into firm embossing contact with the upper surface of the embossing screen 22 to thereby transfer the pattern of the embossing screen to the heated film 11. The heated film 11, after passing over the vacuum space 50 is carried by screen 22 over drive roll 14 and around chill roll 13 where the embossed film is rapidly cooled to set the pattern of the film. Then, the cooled film is removed and wound on a storage roll 56, or other suitable storage means. The heated film 11 may be supplied by any of the means described hereinbefore, i.e., by extrusion from a slot die mounted directly above the embossing apparatus or by passing the film through a heated air oven, or by heating the film by noncontacting or contacting means, i.e., infrared heaters or heated rollers. The film, after passing over vacuum chamber 50 may also be cooled by circulating a cooling medium, e.g., refrigerated water, through hollow drive roll 14. Optionally, the embossed film may also be cooled by applying cold air to the top surface of the film after it passes over the vacuum chamber. Screen 22 may be preheated to enhance embossing of heated film 11 by circulating a heating medium through hollow support roll 15.
Suitable thermoplastic materials may be embossed by the process of the present invention, i.e., thin webs of from 0.25 mils up to as thick as 10 mils. Exemplary thermoplastic materials suitable for vacuum forming according to the present invention are polyethylene and polyethylene copolymers, e.g., polyethylene-polypropylene copolymers; polyvinyl chloride polymers and copolymers, e.g., polyvinyl chloride-polyvinyl acetate copolymers; polypropylene homopolymers and copolymers; Saran films; Mylar films; polystyrene films, and others.
While the use of refrigerated air and water contact have been described as one form of cooling the embossing roll or screen, it is understood that other forms may be used, i.e., internal fluid cooling may be utilized by providing suitable conduits and passages on the inside of the embossing roll. Also, conduits and passages can be provided in both the drive roll 14, support rolls 15, and chill roll 13 to remove heat from the embossing screen 22.
The foregoing embodiments are exemplary of the process and apparatus for carrying out the present invention; however, many variations of the invention may be made without departing from the spirit and scope of the invention.
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An apparatus for vacuum embossing sheet thermoplastic material which utilizes an endless, seamless structure as the embossing surface. A sheet of heat-softened thermoplastic film is passed over an embossing screen, the embossing screen being supported by a support roll, a drive roll and two seal rolls. A vacuum is applied to the screen between the seal rolls to pull the film into contact with the screen thereby producing an embossed pattern on the film corresponding to the outer surface of the screen. After the film is removed from the endless, seamless screen the film is cooled to set the pattern in the film. The process produces an embossed film which has high strength, low surface gloss or light reflectance, and a deep embossed pattern.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a pigment composition and to a process for its manufacture. More particularly the invention relates to an improved Alkali Blue pigment composition characterized by a soft texture and high strength and to a process for its manufacture.
2. Description of the Prior Art
"Alkali Blue" is generally known in the art as, and is used herein to define, an arylpararosaniline sulfonic acid of the general formula ##STR1## wherein R may be hydrogen, chlorine, bromine, alkyl containing from 1 to 4 carbon atoms, alkoxy containing from 1 to 4 carbon atoms, nitro-, amino-, sulfonamide- alkylamino containing from 1 to 4 carbon atoms, R 1 and R 2 may be hydrogen, or alkyl containing from 1 to 4 carbon atoms, R 3 may be hydrogen or phenyl with or without a grouping such as R and X may be hydrogen, chlorine, bromine, SO 3 H or COOH.
Due to the strongly polar hydrophilic property of the pigments represented by the above general formula, moist press cakes of these pigments, upon drying, tend to form hard agglomerates and aggregates. Additionally, the extremely fine particle size of the pigment with the resulting hydrogen bonding at the surface makes it extremely difficult to produce ink paste suitable for use in printing by employing the three-roll mill dispersion of the dry pigment into vehicles imparted for that purpose. The difficulties which are associated with the dispersion of thermally dried Alkali Blue press cakes are well known to those skilled in the art and have also been disclosed in various publications, e.g., E. K. Fischer, Am. Inkmaker 23 (1945) No. 12 and T. C. Patton, Editor, Pigment Handbook, Vol. 1, page 620.
As a result of the difficulties associated with the dispersion of the dry Alkali Blues for technical use, other methods have been developed suitable for use in, e.g., the printing ink industry. One of these is called the "flush process." In this process the water wet pigment in the press cake is transformed to an oil wet product by kneading in a double arm mixer with the desired vehicle. The water which separates out is drained off and the "flush" is subjected to vacuum treatment or transferred to a roll mill and milled until the remaining residual water has been evaporated. The flush paste is then ready for use directly in ink formulations. The product thus produced usually contains from 35 to 40 percent by weight of the pigment.
In order to prepare large quantities of pigment by the flushing procedure, large size kneading machines working discontinuously are necessary which results in high manufacturing costs. The high vehicle content (60 to 65 percent by weight) in the pigment paste made by the flushing procedure leads to other difficulties associated with compatibility with other ink vehicles for various end uses and in the balancing of properties such as color strength, viscosity, tack, etc. at the required concentration levels in the formulated inks.
As a result, numerous attempts have been made to manufacture more concentrated pigment compositions which can be used in a wide variety of applications. Pigment preparations (containing 10 to 70 percent by weight of natural synthetic acidic resins) which can be dried and converted into readily dispersible pigment powders with high tinctorial strength and grain softness have been reported.
U.S. Pat. No. 4,032,357 teaches the preparation of an Alkali Blue powder and a process for manufacture of same by treatment of an aqueous alkaline solution of a pigment with an organic acid dispersant followed by the addition of a hydrophobic oil phase. U.S. Pat. No. 3,925,094 teaches the preparation of dyestuffs by employing resin acids in order to obtain pigments with good dispersion and high strength. U.S. Pat. No. 3,635,745 teaches the preparation of dyestuffs by treating alkaline solutions of the pigment with an aqueous alkaline solution of resinic acids or the acid modified products thereof. U.S. Pat. No. 4,189,328 teaches the preparation of Alkali Blue pigment compositions by treatment of the Alkali Blue pigments with phenols, cresols and naphthols. None of the prior art teaches the use of amines by themselves or in combination with other surfactants to produce soft textured high strength Alkali Blue pigment compositions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A soft textured high strength Alkali Blue pigment is produced by adding to a caustic solution of the Alkali Blue, produced by phenylation with aniline of parafuchsin, sulfonation (primarily to mono) with sulfuric acid and subsequent drowning in water, a suitable quantity of an alkyl aryl sulfonic acid, the resulting solution of which is subsequently mixed with an acid solution of an amine. The pH of the slurry is adjusted to below 1.0 and after heating, the slurry is cooled, the pigment is filtered, washed and dried at suitable temperatures.
More specifically, a crude Alkali Blue, produced by phenylation with aniline of parafuchsin, sulfonation (primarily to mono) with sulfuric acid and subsequent drowning in water, is dissolved in aqueous sodium hydroxide to obtain a solution at a pH of from 12.6 to 13.0 and which contains from 4 to 10 percent by weight, of the Alkali Blue on a dry basis. To this solution is added from 2 to 20 percent, and preferably from 5 to 12 percent, based on the weight of pigment, of an alkyl aryl sulfonic acid or sulfonate. Following this addition, the solution is well stirred and heated in the range from 50° C. to 95° C., preferably from 55° C. to 65° C. This solution is next mixed with an amine or mixture of amines, equivalent in weight to the alkyl aryl sulfonic acid/sulfonate previously added. The amine is used as a solution in an aqueous mineral acid, preferably dilute hydrochloric acid containing from 4 to 10 percent by weight HCl in an amount sufficient to fully neutralize the caustic and precipitate out the Alkali Blue pigment. The pH of the resultant pigment slurry upon admixture with the hydrochloric acid solution is adjusted to a pH of less than 1.0, preferably from 0.8 to 0.85, by using additional HCl acid if necessary. The pigment slurry is slowly heated and held at a temperature in the range of 80° C. to 100° C., from 0 to 60 minutes, depending on the amount and nature of additives used, after which the slurry is flooded with cold water bringing the temperature down to 60° C. It is then filtered, washed free of salt and dried at a temperature in the range of 40° to 80° C., preferably between 50° and 60° C.
Alternatively, Alkali Blue pigment in the form of a regular, untreated presscake made from reprecipitating crude Alkali Blue from a caustic solution using a mineral acid, to obtain pigmentary properties, filtered and washed, is stirred into water by suitable means to obtain a lumpfree smooth slurry. An amine or a mixture of amines dissolved in an aqueous acid solution is mixed with the slurry. The resulting mixture is treated with an aqueous solution of an alkyl aryl sulfonic acid or sulfonate, filtered, washed and dried to obtain a high strength and soft textured Alkali Blue pigment.
More specifically, in the above process, a known amount of Alkali Blue pigment in the form of a presscake is stirred into water using a Premier Disperator at 3000 to 6000 rpm for 10 to 30 minutes to obtain a smooth slurry containing from 5 to 10 percent by weight pigment. A solution of an amine or mixture of amines in aqueous 2 to 10 percent by weight mineral or water soluble carboxylic acid (e.g., acetic acid), where the total amine content is 2 to 20 percent and preferably 5 to 12 percent by weight of the dry pigment is then mixed with the pigment slurry. The resulting mixture is treated with a predetermined amount of alkyl aryl sulfonic acid or sulfonate equivalent to the amine(s) used. The sulfonic acid or sulfonate used is in the form of an aqueous solution preferably in the range 5 to 15 percent by weight. Finally, the slurry is stirred at high speed for 10 to 30 minutes or given several passes through a colloid mill before it is filtered, washed and dried in the range 40° to 80° C., preferably between 50° and 60° C.
The alkyl aryl sulfonic acid compounds which may be employed in the invention can contain from 1 to 14 carbon atoms in the alkyl portion of the molecule.
The amines which may be employed in the practice of the invention have the following formula: ##STR2## wherein R 1 is an alkyl radical containing from 3 to 36 carbon atoms or a phenyl radical or benzyl radical, R 2 and R 3 may be hydrogen or identical with R 1 . Among those amines contemplated are diethylamine, triethylamine, n-propylamine, dipropylamine, tripropylamine, allylamine, diallylamine, triallylamine, butylamine, dibutylamine, tributylamine, amylamine, diamylamine, triamylamine, cyclohexylamine, hexylamine, dicyclohexylamine, 1,3-dimethylbutylamine, 2-aminoheptane, 2-amino-4-methylhexane, 1,4-dimethylpentylamine, 2-ethylhexylamine, bis(2-ethylhexylamine), 1-cyclopentyl-2-aminopropane, bis(1-ethyl-3-methylpentyl)-amine, 1,1,3,3-tetramethylbutylamine, octylamine, aniline, benzylamine, methylbenzylamine, phenylethylamine, diphenylamine, methyldiphenylamine, tribenzylamine, triphenylamine, dodecylamine, tetradecylamine, cocoamine, n-hexyldecylamine, dimethyloctadecylamine, octadecylamine, tallow amine, hydrogenated tallow amine, soyamine, dicocoamine and mixtures thereof.
The following Examples exemplify the invention. All parts are by weight unless otherwise designated.
EXAMPLE 1
Into a one liter beaker was added 522.5 grams of an aqueous NaOH solution (pH=12.6) containing 50 grams of red shade Alkali Blue, produced by phenylation with aniline of parafuchsin, sulfonation (primarily to mono) with sulfuric acid and subsequent drowning in water. To this was added 50 grams of a 2 percent by weight aqueous NaOH solution containing 8.3 grams of dodecyl benzene sulfonic acid. The mixture was stirred and maintained at a temperature of 60° C. In a separate large beaker, 7.5 grams of dimethyloctadecylamine was dissolved in 730 grams of a 2 percent by weight aqueous HCl solution. The acid solution of the amine was slowly added to the HCl solution. The slurry mixture was maintained at 60° C. Sufficient 10 percent by weight HCl was added to the slurry to adjust the pH to about 0.8. The slurry was then heated to 95° C. and maintained at the temperature for 5 minutes. The slurry was then flooded with cold water, cooling the temperature to 60° C. The mixture was filtered, washed with water and the resulting press cake dried at 50° C. The pigment obtained was strong in tint and dispersed easily in oleoresinous vehicles.
EXAMPLE 2
Into a one liter beaker was added 467.3 grams of a 2 percent by weight aqueous NaOH solution containing 50 grams of Alkali Blue, produced by phenylation with aniline of parafuchsin, sulfonation (primarily to mono) with sulfuric acid and subsequent drowning in water. To this was added 50 grams of 2 percent by weight aqueous NaOH solution containing 3.58 grams of dodecylbenzene sulfonic acid. The mixture was stirred and maintained at 60° C. In a separate beaker 3.24 grams of dimethyloctadecylamine was dissolved in 800 grams of 1.5 percent by weight aqueous HCl. This solution was heated to 60° C. and the alkaline solution of pigment was slowly added to it. The pH of the resulting slurry was adjusted to 0.85 and heated to boiling. After 10 minutes the slurry was flooded with cold water to a temperature of 60° C., the pigment filtered, washed and dried at 55° C. The resulting blue pigment was very strong in tint and soft in texture.
EXAMPLE 3
An experiment such as described in Example 2 was repeated, except that Armeen-C, made by Armak Company, (coco-amine; 95% primary, 5% secondary and tertiary) was used in place of dimethyloctadecylamine. The resulting pigment was again strong in tint and soft in texture.
EXAMPLE 4
Example 2 was repeated, except that Duomeen-C, made by Armak Company, (N-coco-1, 3-diaminopropane; primary amine content-43%, secondary amine content-43%) was employed in place of dimethyloctodecylamine. The pigment recovered was strong in tint and soft in texture similar to that obtained in Example 2.
EXAMPLE 5
4116 g of a blend of regular, untreated Alkali Blue presscakes, made from reprecipitating crude Alkali Blue from a caustic solution using a mineral acid, to obtain pigmentary properties, filtered and washed, containing 1000 g of dry pigment was placed in a 5 gallon can and blended with 9 liters of water using a Premier Disperator at 5000 rpm for 15 minutes to obtain a smooth slurry. 46 g of Armeen DM-18-D, made by Armak Company, (dimethyloctadecylamine) dissolved in 250 g of water containing 10 g of hydrochloric acid was slowly added to the pigment slurry followed by 15 minutes of high speed stirring. 50 g of dodecylbenzene sulfonic acid in the form of a 10 percent solution in water was next slowly added to the pigment slurry which was subsequently mixed thoroughly for another 15 minutes at ca. 6000 rpm. The slurry was filtered by suction, washed and dried at 50° C. to obtain about 1070 g of an intense blue pigment which was very strong in tint and very easy to disperse in oleoresinuous vehicles.
EXAMPLE 6
Example 3 was repeated except that Colloid Mill, Colby Disperser/Homogenizer made by Colby Associates, was used for dispersion in place of the Premier Dispersator. The slurry was given three passes through the Colloid Mill before addition of the amine solution, three passes after the addition of the amine solution and finally, three more passes after the addition of dodecylbenzene sulfonic acid solution. The strong and soft textured product recovered following filtration, washing and drying was similar to that obtained in Example 3.
EXAMPLE 7
This experiment was similar to Example 3 except that (a) acetic acid was used in place of HCl to dissolve the amine before its addition to the pigment slurry; and (b) following the incorporation of dodecylbenzene sulfonic acid, the pigment slurry was directly dried without any intermediate filtration and washing.
The pigment recovered had excellent strength and very good texture.
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Alkali blue pigment composition characterized by a soft texture and high strength. Pretreated aqueous solutions of the alkali blue pigments are treated with an alkaline solution of an alkyarylsulfonic solution of an amine to recover the desired pigment composition.
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This invention relates to an antenna for the ultra high frequency band which is compact, inconspicuous and resistant to vandalism.
BACKGROUND OF THE INVENTION
In many radio transmitting or receiving applications, as for instance on exposed controller boxes or in mobile communications or paging systems, the mounting location of the antenna must be near ground level. Almost inevitably the mounting arrangement leaves open the possibility of antenna theft or vandalism. Slender dipole or whip-like antennas are particularly vulnerable. To substantially reduce such threat, the antenna must be of rugged construction and preferably inconspicuous. In the ultra-high-frequency (UHF) band where wavelengths are measured in inches or centimeters, certain antenna designs make dimensional accuracy very critical and add thereby to the cost of manufacturing the antenna. To date a low cost antenna possessing the desired vandalism-resistant character while achieving good performance has not been available.
SUMMARY OF THE INVENTION
The object of the invention is to provide for the UHF band an antenna having good performance and which, by virtue of its compactness, ruggedness and inconspicuousness, is particularly suited to neighborhoods where vandalism or theft is a constant threat.
A vandalism-resistant antenna embodying my invention comprises a ring-shaped radiator in the form of a printed circuit on a dielectric board or disc, mounted within a shallow enclosure of insulating material having high impact strength. The radiator is preferably approximately 1/4 wavelength long at the operating frequency and is located at a constant spacing above a ground plane. A coaxial type radio frequency (RF) connector is incorporated as part of the antenna structure and serves both as a means for fastening the radiator-board assembly to a mounting surface serving as the ground plane, and for coupling the antenna to the appropriate transmitter or receiver.
DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a pictorial view of a vandal-resistant antenna embodying the invention and contained within a shallow enclosure mounted on top of a lighting controller box.
FIG. 2 is a top plan view of one antenna structure embodying the invention, shown with the cover of the enclosure removed.
FIG. 3 is a cross-sectional view of the antenna structure of FIG. 2.
FIG. 4 is a top plan view of another antenna structure embodying the invention, shown with the cover of the enclosure removed.
FIG. 5 is a cross-sectional view of the antenna structure of FIG. 4.
DETAILED DESCRIPTION
The antenna structure mounted within the enclosure 1 pictured in FIG. 1 is shown in FIGS. 2 and 3. It comprises a ring radiator 2 about 1/4 wavelength long formed by a thin layer of metal such as copper printed on a circular dielectric board or plate 3 of insulating material such as fiber glass-reinforced polyester plastic. As shown, it is sized for approximately 450 MHz, at which frequency a 1/4 wavelength is 16.7 cm or approximately 61/2 inches. It may be made by conventional printed circuit photographic processes which assure dimensional accuracy.
The printed board is mounted within the shallow enclosure formed by a cover member 4 and a bottom plate 5, both consisting of high impact plastics such as acrylonitrile-butadiene-styrene (ABS) polymer or polycarbonate (Lexan}polymer. The plastic material of the enclosure is preferably pigmented or painted to the same color as the mounting surface. A ridge 6 on the inside wall of the cover serves to locate the bottom plate which is dimensioned to snap into place by stretching the cylindrical side wall 7 slightly. The bottom plate is preferably also cemented in place to seal the enclosure and to increase its strength and resistance to blows. As can be seen from FIG. 1, the enclosure has a very low profile, somewhat like a hockey puck or like a miniature pie plate inverted, and presents an inconspicuous exterior which blends into the mounting surface. Its rugged construction enables it to withstand severe blows from vandals without damage to the internal components.
The printed board 3 is supported within the enclosure by a conventional female type coaxial RF connector comprising an externally threaded lower portion 8 and a rectangular four corner post upper portion 9 made of metal which is wetted by solder or alternatively plated with such metal wherever soldering is required. The four posts have reduced top portions extending through holes in board 2 which are encircled by copper rings printed on the plastic material. The board is permanently fastened to the connector by soldering the top portions of the posts to the copper rings at 9a to 9d. The base of the rectangular portion 9 of the connector is seated on bottom plate 5. The spacing and the dielectrics between the metal layer forming the ring radiator 3 and the ground plane on which the antenna is mounted are important factors in determining the antenna characteristic impedance. The spacing is determined by the thickness of board 3, the height of connector portion 9, the thickness of bottom plate 5 and the thickness of spacer 10.
The antenna 1 is mounted on a street lighting controller box 11 as shown in FIG. 1 by first drilling a hole in the top of the box. A spacer washer placed around the lower portion 8 of the connector which is then extended through the hole. A nut 13 under a lockwasher 14 within the controller box is tightened to lock the antenna in place. A compressible gasket 15 under the bottom plate seals the box and prevents entry of water.
The printed ring radiator 2 forms a grounded dipole which is capacitively loaded throughout its length. It is grounded at its base through the printed radial arm 16 which passes between the post ends 9a and 9b, continues between the post ends 9c and 9d, and then doubles back at 17 toward post end 9d to which it is soldered. Post 9d extends the exterior conductor or sheath of the coaxial connector which is part of the ground plane. At the central point between the post ends, the center conductor 18 of the coaxial connector 8 is extended up through an aperture in board 3 and through a hole at 18a in printed arm 16 at which point it is soldered to the printed arm. The distance from ground point 9d around loop 17 to tap point 18a determines the ohmic antenna value seen by the coaxial line. The preferred value is 50 ohms, and the dimensions of the printed arm 16 and of the loop 17 can be varied to achieve such value or some other desired value.
FIGS. 4 and 5 show another antenna structure embodying the invention and which may be contained within enclosure 1 or some other low profile insulating housing. In this variant the same reference numerals are used to denote corresponding parts which have already been described with reference to FIGS. 2 and 3. The printed board 3 is supported by a conventional chassis-mount coaxial RF connector comprising an externally threaded tubular portion 21 terminating in an expanded ring or collar 22. The connector extends down through a central hole in board 3, the collar 22 engaging the top of the board and a nut 23 being tightened under the board to effect a secure attachment. The height or spacing of the board above bottom plate 5 is determined by four posts 24 molded integrally with the bottom plate from which they rise to engage the underside of board 2. The connector extends through bottom plate 5, spacer 10 and top wall 11 of the controller box. Printed board 3 is fixed in enclosure 1 by tightening nut 13 under the top of a controller box in the same way as in the assembly of FIGS. 2 and 3.
The coupling of ring radiator 2 to the coaxial connector in FIGS. 4 and 5 is as follows. The ring radiator is grounded at its base through the printed radial arm 24 which extends into an printed ring 25 encircling the central hole in the board. The collar 22 of the RF connector is seated on ring 25 and thus the ground plane is extended to it and to the base of the antenna. The center conductor 18 of the coaxial line is extended, or alternatively connected by means of a soldered jumper 18b if preferred, to the end 26 of an inductive branch 27 which makes a right angle turn before joining arm 24. The dimensions of the inductive branch and the point of connection to arm 24 may be varied to achieve a 50 ohm tap or other desired value of input resistance. A coaxial cable (not shown) conventionally connects connector 21 within the controller box to the radio receiver housed in the box.
The electrical design of the present antenna for the UHF band is in many respects akin to that of the directional discontinuity ring radiator (DDRR) antenna occasionally used in the VHF band. Its electrical performance is similar to that of an ordinary 1/4 wavelength vertical whip antenna subject to a 1 to 2 decibels reduction in gain. Its mechanical features including the use of a printed circuit board and the fewness of the soldered joints make for low manufacturing cost together with dimensional accuracy assuring constant electrical performance.
The specific antenna designs which have been illustrated and described are intended by way of example of the invention only, and its scope is to be determined by the appended claims which are intended to cover any modifications coming within its spirit.
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A vandalism-resistant antenna for the UHF band comprises a ring-shaped radiator printed on a dielectric board or disc mounted within a shallow enclosure of insulating material having high impact strength. The radiator is approximately 1/4 wavelength long at the operating frequency and is located at a constant spacing above a ground plane. A coaxial RF connector fastens the radiator-board assembly to a mounting surface serving as the ground plane, and couples the antenna to a transmitter or receiver.
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CLAIM OF PRIORITY
Applicant claims priority based on provisional patent Ser. No. 60/679,828 filed May 11, 2005, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
This invention relates generally to chair rail moldings and indirect lighting, and more particularly to a lighted chair air rail for use in home and office lighting and decor.
BACKGROUND AND SUMMARY OF THE INVENTION
Chair rail moldings have traditionally been used to protect walls from being damaged by the backs of chairs, and more recently have been used as casings, bases, wallpaper borders, panel moldings, etc. Indirect lighting systems are used for various purposes such as providing lighting in addition to overhead and other traditional lighting systems, providing an alternative to traditional lighting systems, and various decorative purpose. Indirect lighting systems are useful in rooms where dim lighting levels are preferred at various times such as hallways during the night, a baby's nursery, and other areas where a low level of light is preferred over bright levels of traditional lighting. For example, indirect lighting is preferable in a baby's nursery during nighttime hours for periodically tending to the baby without disturbing the baby with bright lighting.
Heretofore indirect lighting has been available in various configurations and several alternatives exist for concealing indirect lighting at or near the top of walls, e.g., behind crown molding. However there is currently no chair rail molding configuration which provides means for mounting and concealing indirect lighting at or near the height of a chair rail.
The present invention comprises a chair rail design which overcomes foregoing and other difficulties which have long since characterized the prior art. In accordance with the broader aspects of the invention, there is provided means for supporting an indirect lighting system behind a decorative chair rail.
In accordance with more specific aspects of the invention, a horizontal facia mounts on a frame secured to a wall. The frame also comprises means for supporting an indirect lighting source. The horizontal facia may further comprise means for mounting decorative trim thereon. The resulting lighted chair rail provides an additional alternative light source which provides a low level light source when brighter lighting is undesirable.
The lighted chair rail of the present invention may also be configured to accommodate interchangeable decorate plates. Alternatively, the lighted chair rail may be configured to provide a lighted facing for an alternative decorative appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein:
FIG. 1 is an environmental view illustrating a chair rail apparatus comprising a first embodiment of the present invention;
FIG. 2 is a sectional view of the chair rail apparatus of FIG. 1 ;
FIG. 3 is a sectional view of the chair rail apparatus of FIG. 1 comprising an additional component for mounting decorative trim thereon;
FIG. 4 is a sectional view similar to FIG. 2 illustrating a second embodiment of the invention;
FIG. 5 is a sectional view similar to FIG. 3 further illustrating the second embodiment of the invention;
FIG. 6 is a sectional view illustrating a third embodiment of the invention;
FIG. 7 is a sectional view similar to FIG. 6 illustrating an additional component for mounting decorative trim thereon;
FIG. 8 is a perspective view illustrating a fourth embodiment of the invention in which certain components parts have been broken away more clearly to illustrate certain features of the invention; and
FIG. 9 is a sectional view illustrating a fifth embodiment of the invention.
DETAILED DESCRIPTION
Referring now to the Drawings, and particularly to FIG. 1 , there is shown a room 10 which may comprise an integral part of a home, an office, etc. The room 10 comprises a plurality of walls 12 and a floor 14 , it being understood that the room 10 would typically also include a ceiling situated at the upper ends of the walls 12 and extending above the floor 14 . In accordance with the present invention the walls 12 of the room 10 are provided with a lighted chair rail assembly 16 . As will become more apparent hereinafter, the lighted chair rail assembly 16 may comprise any of the various embodiments of the invention illustrated in FIGS. 2-8 , inclusive, and described hereinafter in conjunction herewith as well as variations thereof.
Referring to FIG. 2 , there is shown a lighted chair rail 20 comprising the first embodiment of the present invention. The lighted chair rail 20 comprises a frame 22 which is secured to an interior wall within a home, an office, etc. by means of suitable fasteners and/or suitable adhesives. A facia 24 is detachably secured to the frame 22 by suitable fasteners 26 which are preferably integrally formed with the remaining components of the facia 24 . The facia 22 may be provided with a decorative component 28 at the lower end thereof in the manner of typical chair rail constructions.
In addition to supporting the facia 24 , the frame 22 supports a plurality of upright lighting assemblies 30 . The lighting assemblies 30 are conventional in design and construction and are adapted for operation by typical household electrical current. Alternatively, the lighting assemblies 30 may be battery operated. A lens 32 is provided at the intersection between the frame 22 and the facia 24 whereby light generated by the lighting assemblies 30 is directed upwardly from the interior of the chair rail 20 in the manner illustrated in FIG. 1 .
FIG. 3 illustrates a chair rail 34 comprising a variation of the chair rail 20 shown in FIG. 2 and described herein above in conjunction therewith. The chair rail 34 is substantially identical to the chair rail 20 but differs therefrom in that the facia 24 of the chair rail 34 is provided with an elongate groove 36 which detachably receives and supports a decorative accessory 38 .
FIG. 4 illustrates a chair rail 40 comprising a second embodiment of the invention. Many of the component parts of the chair rail 40 are substantially identical in construction and function to the component parts of the chair rail 20 as illustrated in FIG. 2 and described herein above in conjunction therewith. Such identical component parts are designated in FIG. 4 with the same reference numerals utilized in the foregoing description of the chair rail 20 but are differentially thereof by means of a prime (′) designation. The chair rail 40 differs from the chair rail 20 in that rather than being provided with a plurality of upright lighting assemblies 30 , the chair rail 40 is provided with a horizontally disposed lighting apparatus 42 which extends the entire length of the chair rail 40 .
FIG. 5 illustrates a chair rail 44 comprising a variation of the chair rail 40 illustrated in FIG. 4 and described herein above in conjunction therewith. The chair rail 44 is identical to the chair rail 40 except that the facia 24 ′ thereof is provided with a longitudinally extending groove 46 which supports a decorative assembly 48 .
Referring to FIG. 6 , there is shown a chair rail component 50 comprising a third embodiment of the invention. The chair rail component 50 comprising a facia 52 which may be utilized in conjunction with the embodiments of the invention illustrated in FIGS. 2 and 3 in lieu of the facia 24 thereof, or in conjunction with the embodiments of the invention illustrated in FIGS. 4 and 5 in lieu of the facia 24 ′ thereof. The facia 52 includes various components which are substantially identical to components of the facia 24 as shown in FIG. 2 and described herein above in conjunction therewith. Such identical components are designated in FIG. 6 with the same reference numerals utilized above in the description of the facia 24 but are differentiate therefrom by a double prime (″) designation.
The facia 52 differs from the facia 24 of FIG. 2 in that the facia 52 is provided with opposed longitudinally extending flanges 54 and 56 . The flanges 54 and 56 are utilized to receive and retain a decorative item which extends continuously along the entire length of the chair rail comprising the facia 52 . Alternatively, the flanges 54 and 56 may support a plurality of decorative items located at spaced apart locations along the length of the chair rail comprising the facia 52 .
FIG. 7 illustrates a chair rail 58 which is substantially identical in construction and function to the chair rail 50 illustrated in FIG. 6 and described herein above in conjunction therewith. The chair rail 58 differs from the chair rail 50 in that the chair rail 58 is provided with a longitudinally extending groove 60 which receives and supports a decorative accessory 62 extending longitudinally along the entire length of the chair rail comprising the facia 58 .
Referring to FIG. 8 , there is shown a lighted chair rail 64 comprising a fourth embodiment of the invention. The lighted chair rail 64 comprises a unitary frame 66 which extends the entire length of the chair rail 64 . The frame 66 is supported on a wall and in turn supports one or more lighting assemblies 68 which may comprise either the vertically disposed lighting assemblies 30 shown in FIG. 2 and described herein above in conjunction therewith or the horizontally disposed lighting assemblies 42 shown in FIG. 4 and described herein above in conjunction therewith. The frame 66 is further characterized by a pair of opposed grooves 70 and 72 .
The grooves 70 and 72 receive a facia 74 . The facia 74 comprises a lens which allows light to pass outwardly from the lighting assemblies 68 into the room in which the chair rail 64 is deployed. The facia 74 is preferably translucent in nature such that light from the light assemblies 68 passes through the facia 74 but the lighting assemblies 68 are not directly observable therethrough.
Referring to FIG. 9 , there is shown a lighted chair rail 80 comprising a fifth embodiment of the invention. The lighted chair rail 80 comprises a unitary frame 82 which extends the entire length of the chair rail 80 and which is normally supported on a wall. The frame 82 supports a plurality of light sources 84 preferably comprising silicon encased LED (light emitting diode) units. The lighted chair rail 80 further comprises a facia 86 which is secured on the frame 82 by a pair or tongue-and-groove connections 88 . A white PLEXIGLAS® light diffuser lens 90 is supported on the facia 86 and on the upper end of the frame 82 . The function of the lens 90 is to direct light from the light source 84 onto a wall having the frame 82 supported thereon.
Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.
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A lighted chair rail comprises a frame secured to a wall and a horizontal facia mounted on the frame and positioned in a spaced apart relationship to the wall. Light bulbs supported on the frame direct light through a lens mounted on the horizontal facia onto the wall. The horizontal facia may also include decorative items.
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CROSS REFERENCE TO RELATED APPLICATIONS
The invention is related to the following copending U.S. patent applications assigned to the assignee of the present invention:
DATA RECORDING APPARATUS FOR AN ULTRASONIC INSPECTION SYSTEM, Ser. No. 06/815,050, filed on Dec. 31, 1985 by D. P. Sarr;
ULTRASONIC INSPECTION SYSTEM WITH LINEAR TRANSDUCER ARRAY, Ser. No. 06/815,047, filed on Dec. 31, 1985 by D. P. Sarr and F. D. Young;
ULTRASONIC INSPECTION SYSTEM APPARATUS AND METHOD, Ser. No. 06/815,048, filed on Dec. 31, 1985 by D. P. Sarr;
AN IMPROVED ULTRASONIC TESTING APPARATUS, Ser. No. 06/815,163, filed Dec. 31, 1985 by G. A. Geithman and D. P. Sarr;
ULTRASONIC TRANSDUCER WITH SHAPED BEAM INTENSITY PROFILE, Ser. No. 06/815,162, filed Dec. 31, 1985 by G. A. Geithman and D. H. Gilbert, now U.S. Pat. No. 4,700,575; and
ULTRASONIC 64 CHANNEL INSPECTION SYSTEM WITH MULTIGATE/MULTI MODE SELECTION SOFTWARE CONFIGURABILITY, Ser. No. 06/815,044, filed Dec. 31, 1985 by D. P. Sarr.
BACKGROUND OF THE INVENTION
The present invention relates to the field of ultrasonic defect detecting systems, and especially to such systems which are used for nondestructive inspection (NDI) of elements having varying thicknesses. This invention has particular application in the testing of aircraft structures made from graphite/epoxy materials.
There are three major types of NDI systems which are used for testing elements, for example, aircraft parts: loss-of-back (LOB), pulse echo (PE) and through transmission ultrasonic (TTU). The LOB technique compares a predetermined threshold value with the peak amplitude of the ultrasonic reflections from an element's rear surface, i.e., the surface most distant from the ultrasonic transducers. If the element has no defects in the volume between the front and back surfaces proximate the transducers, then the peak amplitude of the reflections from the back surface should exceed the threshold. If a defect is present in that volume, the peak amplitude of the signal reflected by the rear surface decreases significantly, in fact below the threshold, because the defect reflects much of the ultrasonic energy before it ever reaches the rear surface.
FIGS. 1A and 1B, which show voltage signals corresponding to ultrasonic reflections from an element having no defects and having a defect, respectively, illustrate this phenomenon. There are three major reflection portions in FIG. 1A. The portion that occurs first, which is the leftmost in FIG. 1A, is an artifact from the ultrasonic pulse transmitted toward the element (sometimes called the "Main Bang"). The next major portion is a reflection from the front surface of the element. The third major portion (the rightmost) is a reflection from the rear surface. Since FIG. 1A corresponds to the reflections received from an element with no defects, the peak amplitude of the reflections from the rear surface is above the predetermined threshold V N , thereby indicating the absence of any defects.
In FIG. 1B, there are four major signal portions proceeding in order from left to right corresponding in time to their receipt by an ultrasonic transducer. The first, and largest, is the artifact from the Main Bang, the second represents a reflection from the front surface of a part, the third represents a reflection from a defect in the interior of the part, and the fourth represents a reflection from the rear surface of the part. Because the defect reflects some of the ultrasonic energy that penetrates the front surface, a smaller amount of energy is available to be reflected from the rear surface. As FIG. 1B shows, that rear surface reflection is below the predetermined threshold V N , so the presence of a defect is noted.
FIGS. 1A and 1B also show the concept of a time window which is used for finding the proper signals for testing. The time period denoted T R indicates a time window during which reflections or transmitted signals from the rear surface are expected to be received. It is important in the LOB technique to know when that window should begin and end to ensure that the reflections being examined are those from the rear surface, and not those from a defect or the front surface.
The PE technique bears some similarity to the LOB technique. However, instead of examining the peak amplitude of the rear surface reflection as the LOB technique requires, the PE techniques tests the peak amplitudes of the reflections from the element's interior, i.e., from between the front and rear surfaces. If any reflections from the interior above a certain threshold level are received, those reflections are evidence of a defect. If no sufficiently large reflections are received from the element interior, then the element portion under investigation is deemed defect-free.
The TTU technique differs from the above techniques in that it requires two transducers for each transducer channel, the transducers being located on opposite sides of the element to be examined. Instead of examining ultrasonic reflections, however, the TTU technique involves determining the amount of ultrasonic energy that was able to pass entirely through the part.
As the above methods indicate, it is extremely important to control the time window in which the examination takes place. For example, in the LOB method, the time window must be such as to capture only reflections from the rear surface (see T R in FIGS. 1A and 1B). In the PE method, it is extremely important to obtain a time window that captures reflections between the front and rear surfaces, and which does not include reflections from either of those surfaces (see time window T I in FIGS. 1A and 1B).
It is not difficult to identify the reflection from the front surface because that is the first reflection that occurs after the Main Bang artifact. If the element being examined has a varying thickness, however, it becomes very difficult to determine where the rear surface is because the location of that surface changes in relation to the front surface, and hence the corresponding time windows related to the rear surface must also change. Furthermore, the only ultrasonic information which is available to find the rear surface are the reflections from the part under test. However, as FIGS. 1A and 1B show, the reflections from a defect and from a rear surface appear very similar. Furthermore, by the time a reflection is properly identified, the ultrasonic detector is usually making another measurement.
One solution to this problem has been to determine thickness mechanically with a calibrated roller, for example. Rollers, however, react slowly and are inaccurate not only because they may lose contact with the surface, but also because the rollers experience wear which gradually makes their measurements imprecise. In addition, rollers cannot be used in many instances. For example, an element may be mounted or configured in a manner to preclude the use of a roller, or the temperature of the elements, for example molten steel sheets, may be too extreme for rollers.
Another way of solving the problem was discussed in U.S. Pat. No. 3,942,358 to Pies. The device in this patent includes an array of transducers which both transmit and receive ultrasonic pulses in the PE mode. The transducers are coupled to electric circuitry which measures the time difference between receipt of the surface reflection and the next major reflection, and then finds the maximum time difference. That maximum time difference is stored and compared to the maximum speed elapsed times determined from succeeding scans. Whenever a maximum time measurement from a succeeding scan exceeds the stored amount, the new maximum time is stored in place of the old value. The result of the entire operation is that the maximum time difference for the entire element, and hence the maximum thickness, is stored and used to set a time window corresponding to the rear surface.
In this system, however, two ultrasonic scans need to be made for each element. The first scan determines the maximum thickness, and the second scan then looks for defects. In addition, since each transducer channel is used for determining thickness during one scan and defects during the next scan, the electronics of this system can become rather complex.
Pies does recognize that for elements of varying thickness, the transmit times could be updated during the scans. This still results in complicated circuitry, however, to perform the thickness measurement task. The system in Pies also cannot detect extensive defects.
It is therefore an object of this invention to provide fast and accurate NDI ultrasonic testing of parts.
Another object of this invention is accurate NDI testing without the use of complicated circuitry.
SUMMARY OF THE INVENTION
The present invention overcomes the problems of the prior art and achieves the objects of this invention with NDI testing apparatus and methods employing a plurality of transducer channels for examining the signals reflected from or transmitted through a part under test. At least one of those channels is dedicated to making thickness measurements by examining reflections from the front and rear surfaces. If the dedicated thickness channel(s) makes a thickness measurement which differs from a current thickness value by less than some predetermined amount, then that new measurement replaces the old thickness value, since it is assumed that the new measurement reflects a thickness change which is relatively slow. If the thickness channel measurement differs from the current thickness value by greater than the predetermined amount, then it is assumed that the second reflection received was not from the rear surface, but rather from a defect in the interior of the element, and the current thickness value remains unchanged.
To achieve the objects and in accordance with the purposes of this invention, as embodied and as broadly described herein, the apparatus of this invention for ultrasonic inspection of a part comprises means for generating a transmission signal; a plurality of transducer channels, coupled to the transmission signal generating means, for generating ultrasonic pulses for transmission into said part, for receiving portions of said ultrasonic pulses, and for creating electrical reflection signals representing said portions, one of the transducer channels being a thickness transducer channel and including means for determining a value representing the thickness of a portion of the part adjacent to the thickness transducer channel; means, coupled to each of the transducer channels, for measuring the amplitude of the electrical reflection signals only during a time window corresponding to the part thickness value; and thickness gating means, coupled to the measuring means, for automatically adjusting the thickness value, and thereby the time window, according to the electrical reflection signals received by the thickness transducer channel.
A method of ultrasonic inspection of a part according to this invention comprises the steps of generating a transmission signal; transmitting ultrasonic pulses into the part using a plurality of transducer channels; receiving and transducing portions of that transmitted ultrasonic pulse and creating electrical reflection signals representing those portions; measuring the amplitude of the electrical reflection channels only during a time window corresponding to a part thickness value; and determining a part thickness value by examining the electrical reflection signals from one channel of the apparatus.
The accompanying drawings, which are incorporated in and which constitute a part of the specification, illustrate one embodiment of the invention and, together with the description, explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are representations of voltages corresponding to ultrasonic reflections received from a part under inspection;
FIGS. 2 and 2A are a block diagram and a detailed circuit diagram, respectively, of a System Pulse Controller of an embodiment of the present invention;
FIGS. 3 and 3A are a block diagram and a detailed circuit diagram, respectively, of a Transducer Array Electronics unit of the embodiment of the present invention;
FIGS. 4 and 4A are a block diagram and a detailed circuit diagram, respectively, of a Three-position Gate of the embodiment of the present invention;
FIGS. 5 and 5A are a block diagram and a detailed circuit diagram, respectively, of a Thickness Gate Controller of the present invention;
FIGS. 6 and 6A are a block diagram and a detailed circuit diagram, respectively, of a Log Amplifier and Peak Detector circuit of the embodiment of the present invention;
FIG. 7 is a system diagram of the present invention;
FIG. 8 is a flow chart for an initialization routine of the embodiment of the present invention; and
FIG. 9 is a timing diagram for explanation of the operation of the embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made in detail to a presently preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. The embodiment shown relates to an LOB apparatus. Pesrons of ordinary skill in the art will recognize the applicability of the invention to the PE and TTU systems for nondestructive inspection.
FIGS. 2-7 relate to a preferred embodiment of the ultrasonic testing apparatus of the present invention. FIG. 7 is a system diagram which shows system elements and their interrelationship, and FIGS. 2-6 show each element of the system in detail. The block elements in each of the block diagrams (FIGS. 2-6) correspond to the simiarly numbered components shown by the dotted lines around certain circuit elements in the corresponding circuit diagrams (FIGS. 2A-6A).
FIGS. 2-7 show that there are five major components of the system. The System Pulse Controller (FIGS. 2 and 2A) generates the initial timing for the system and there is one of these components per system. In response to controls set on a panel, the System Pulse Controller generates an MB (Main Bang) Clock and PULSER COMMAND (hereafter referred to without the inverting bar) signals. The MB Clock signal period is the same as the time between transmissions of ultrasonic pulses into the element or part under test. The PULSER COMMAND signals each correspond to a different transducer channel and are used both to activate the transmitted ultrasonic pulse for that channel, and to synchronize the operation of the channel electronics with remainder of the system.
The second major system component is the Transducer Array Electronics (FIGS. 3 and 3A) which provides the electrical interfacing of the system with the transducer. In the present embodiment, there is one of these components as shown in FIGS. 3 and 3A for each channel used. The Transducer Array Electronics responds to the corresponding PULSER COMMAND signal to generate a high voltage pulse that drives an ultrasonic transducer to transmit an ultrasonic pulse toward the part or element. The electronics also receives the transduced ultrasonic reflections (or transmissions in the TTU mode) of that pulse and creates the Ultrasonic Input Signal which is then analyzed for defect testing.
The third major system component is the Three-position Gate (FIGS. 4 and 4A) which generates timing signals for a corresponding transducer channel. Each of these Gates corresponds to a different transducer channel. The Three-position Gate receives the PULSER COMMAND and Ultrasonic Input Signal corresponding to the same transducer channel. The Gates for all the transducer channels generate a Blanking signal (shown in its inverted form in the figures) which is used primarily for eliminating unwanted signals from the corresponding oscilloscope trace, and for ensuring that the peak detection circuitry, described below, tests the correct portion of the Ultrasonic Input Signal. The Three-position Gate also receives two other signals: a 15 MHz System clock and an Old Part Thickness Analog signal. The second of those signals is an analog voltage whose level corresponds to the determined part thickness. From the System clock and the Old Part Thickness Analog signal, the Three-position Gate generates two signals which are the inverse of each other. The GATE signal is used for the oscilloscope display and the SAMPLE signal is used to control the time window during which the Ultrasonic Input is measured. The Three-position Gate corresponding to the thickness transducer signal also generates the System Material Enable signal, which is a pulse whose duration corresponds with the current estimate for the thickness of the part under investigation.
The fourth system component, called the Thickness Gate Controller (FIGS. 5A and 5B), generates the 15 MHz System Clock and the Old Part Thickness Analog signal used by the Three-position Gates. There is only one Thickness Controller in the preferred embodiment. This element compares the current Old Part Thickness Analog signal with voltages representing new thickness estimates which are derived from the System Material Enable signal. If the new estimate differs from the Old Part Thickness Analog signal by less than a predetermined amount, for example, 5%, the Thickness Controller updates the Old Part Thickness Analog voltage signal by replacing that signal with the new estimate.
The fifth component is called the Log Amplifier and Peak Detection circuit (FIGS. 6A and 6B), and there is one of these for each channel. This element processes the Ultrasonic Input signal for display on a visual display device, such as an oscilloscope, and also for detection of defects. The Log Amplifier and Peak Detection circuit also examines the peaks of that signal within a time window depending upon the SAMPLE pulse. The measured peaks during the time window are then sent to a microcomputer in a preferred embodiment for further evaluation.
With this overall system viewpoint, the specific operations of each one of these elements will be easier to understand. The detailed circuit diagrams for each element are shown, but not described in detail because persons of ordinary skill in the art will, from the diagrams, know the details of such circuit operation. In addition, the system shown has eleven (11) transducer channels, but it should be understood that either a fewer or a greater number of transducer channels could also be used consistent with the present invention.
In accordance with the present invention, the apparatus for ultrasonic inspection of a part of this invention includes means for generating a transmission signal. In the preferred embodiment of the invention shown in the figures, the System Pulse Controller shown in FIGS. 2 and 2A includes circuitry for generating a main transmission signal, called the MB clock, and transmission signals for each channel, called PULSER COMMAND signals. Repetition rate controller 100 determines the rate of the MB Clock signal, which is the rate at which ultrasonic transmission pulses are generated. In FIG. 2A, which is the detailed circuit representation of the system pulse control in FIG. 2, IC1 outputs a pulse at a rate which depends upon the value of potentiometer VR1. Potentiometer VR1 is panel-mounted and set by the operator of the system.
Coupled to the output of the repetition rate controller 100 is pulse width generation and width control circuitry 110 which controls the duration of the transmission pulses. The duration of the transmission pulses is related to the amount of ultrasonic energy that is transmitted into the part. FIG. 2A shows that the specific circuitry for control circuitry 110 includes two "one-shots" (also called monostable multivibrators) IC4 and IC5. When triggered by the output of IC1, IC4 generates a one microsecond pulse which is used to trigger IC5. IC5 generates two pulses having opposite polarities. The duration of those pulses is between 50 nanoseconds and 1.7 microseconds. The specific width of the pulse depends upon the setting of potentiometer VR2. The positive-going one of the two pulses is the MB Clock signal.
The remaining two elements shown in the System Pulser Controller of FIGS. 2 and 2A are four bit counter 120 and channel select circuitry 130. Counter 120 receives the output of the repetition rate controller and generates a four-bit binary count that repeats cyclically. Channel select circuitry 130 includes a demultiplexer IC3 which receives the count output from IC2 and sequentially generates single pulses, in order, from each of the output. Each of those pulses serves as one input to a different NOR gate 135 in circuitry 130, each such NOR gate 135 corresponding to one of the channels. The other input to each of gates 135 is the inverse of the MB Clock signal. The output of each NOR gate 135 is a PULSER COMMAND signal for a different one of the transducer channels. The PULSER COMMAND signal is a pulse with a width equal to that of the MB Clock signal.
Corresponding to each transducer channel is a Transducer Array Electronics system as shown in FIGS. 3 and 3A. The systems are used to generate a high voltage signal to drive an ultrasonic transducer in response to the corresponding PULSER COMMAND signal, and also to generate an Ultrasonic Input signal from the reflections received by the transducer.
The transmission electronics includes TTL buffer 200 to isolate the PULSER COMMAND signal from the remainder of the circuitry, and a MOS/FET Driver 210 to interface the PULSER COMMAND signal with a MOS/FET High Voltage Transistor Switch 220. Transistor Switch 220 generates a high voltage pulse to drive the ultrasonic transducer with a pulse whose duration is equal to the duration of the PULSER COMMAND signal.
Ultrasonic receive electronics 230 are coupled to the output of the transducer and change the voltage signals from that transducer into signals of the proper level for further signal processing. If this invention is used in the LOB or PE mode, then only one transducer per channel is used, and the jumper, denoted by the dotted line, is put in place to couple that transducer to the ultrasonic receiver electronics 230. If the system is in the TTU mode, then the jumper is not used, but instead the receiver input comes from the second transducer, located on the opposite side of the part from the transmission transducer, and which is connected to amplifier 230 via the dotted line.
Once the ultrasonic signals have been received and properly amplified, then they must be examined to sense the presence of defects. Accordingly, the present invention includes means for measuring the amplitude of the electrical reflection signals from the transducer channels only during a determined time window. That time window corresponds to a part thickness value that represents the thickness of the part at a portion adjacent to the thickness channel transducer. In the preferred embodiment, the Log Amplifier and Peak Detection circuitry shown in FIGS. 6 and 6A provide for the measurement of the peaks of the corresponding Ultrasonic Input Signal during a time window determined from the Blanking and SAMPLE signals.
In the system and circuitry shown in FIGS. 6 and 6A, Peak Detector 540 receives the corresponding Ultrasonic Input signal from amplifier 230 shown in FIGS. 3 and 3A. The Ultrasonic Input signal is conditioned by a 50 ohm termination analog buffer 500, a log amplifier 510, and an analog buffer 530 before being analyzed by peak detector 540. The purpose of log amplifier 510 is to compress the Ultrasonic Input signal into a signal range of 0-10 volts. Typically, log amplifier 510 provides an 80 dB dynamic range, but persons of ordinary skill in the art will recognize that the dynamic range of such an amplifier is adjustable. The output of log amplifier 510 is also fed via analog buffer 520 to an oscilloscope display for viewing.
As shown in greater detail in FIGS. 6A, peak detector 540 includes capacitor C1 with diode D1 to ensure that C1 charges up to the highest (i.e., peak) input value when a transistor T1 is off. When transistor T1 is on, it shorts C1 to ground and prevents it from charging up. Transistor T1 is controlled by the Blanking signal.
The output of peak detector 540 feeds sample and hold circuit 550. The purpose of sample and hold circuit 550 is to hold the voltage of capacitor C1 at the time period when the SAMPLE signal is active. The end of the active period of the Sample signal corresponds to the end of the time window described above. In this manner, peak detector circuit 540 and sample and hold circuit 550 ensure that the peak of the Ultrasonic Input signal is measured only during a certain time window corresponding to the local thickness of the part under investigation.
The log amplifier and peak detector circuitry in FIGS. 6 and 6A also includes an amplifier 560 to adjust the output of sample and hold circuit 550 to the proper voltage range and current drive for input to a microcomputer unit having an analog/digital converter input (see FIG. 7). The purpose of the microcomputer, which could instead be any type of appropriate analysis equipment depending upon the system's requirements, is for acquiring and displaying data for defect analysis. Of course, the microcomputer may also perform whatever signal analysis is desired.
In accordance with the present invention, the apparatus for ultrasonic inspection of a part also includes thickness gating means for automatically adjusting the thickness value, and thereby the time window, for the measuring means according to electrical reflection signals received by the thickness transducer channel. In the embodiment shown in FIGS. 2-7, the Three-position Gate in FIGS. 4 and 4A and the Thickness Gate Controller in FIGS. 5 and 5A adjust a thickness value, which is called the Old Part Thickness Analog value and is an analog voltage representation of the local part thickness. The adjustment of that level involves the use of a System Material Enable signal, which is a pulse whose duration relates to the part thickness.
According to one variant of this invention, the thickness gating means includes adjustable means for presetting the part thickness value. A setup procedure is shown in FIG. 8, and will be explained along with certain specific circuit elements of the Three-position Gate and Thickness Gate Controller.
In the initialization step, the Ultrasonic Signal is adjusted by placing switch 360 in the IF SYNC mode (step 605). As soon as the signal strength is sufficient (steps 610 and 620), switch 360 is changed to the GATE or thickness sync modes (Step 630).
Next, the IP sync adjustment potentiometer, which is VR-3 in FIG. 4A, is set so that the oscilloscope display of the GATE signal (which, according to the switch setting, is the IP Sync Signal) shows a high-to-low transition before the display reflection from the front surface (step 640). The purpose of the IP sync signal is to eliminate interference either from the Main Bang transmission pulse, from reflector plates, or from any other source of interference that would cause receipt of reflection prior to the receipt of the front surface reflection.
Next, the IF blanking adjustment is set by aligning the transducer with a thinner section of the part to be inspected and then using the IF sync adjustment potentiometer VR4 in FIG. 4A to move a low-to-high transition just after the display of the front surface reflection (steps 650 and 660). Finally, the Initialize button is pressed (step 670) which causes an initial thickness value to be entered into old part thickness value D/A circuit 460, shown in FIGS. 5 and 5A, in a manner to be described below. After this procedure, the ultrasonic apparatus of this invention is now ready for operation.
As shown in FIGS. 4 and 4A, the System Clock, which is a 15 MHz clock generated in the Thickness Gate Controller, passes through a TTL receiver 300 and a causes high speed counter 310 to begin counting. Counter circuit 310 had previously been cleared by the appropriate PULSER COMMAND. The output of counter circuit 310 then feeds a digital/analog converter 320 which generates a ramp voltage that tracks the count and has a level corresponding to the period of time elapsed since the PULSER COMMAND.
The Old Part Thickness Analog Voltage signal, which, as indicated above, is a voltage signal whose level represents the currently-determined thickness of the part, is fed through a thickness adjustment circuit 330. Circuit 330 allows an operator to adjust the Old Part Thickness Analog Input to a comparator 340. The ramp voltage and the adjusted Old Part Thickness Analog signal both feed part thickness limiter comparator circuitry 340 shown in FIGS. 4 and 4A.
In the preferred embodiment and as shown in FIG. 4A, comparator 340 includes a monolithic chip comparator IC6 whose output changes state when the ramp voltage exceeds the adjusted Old Part Thickness Analog voltage. The system, and the thickness adjustment circuit 330, are set so that IC6's state change occurs just prior to the anticipated receipt of a rear surface reflection, that anticipated time being based on the believed thickness of the material as reflected in the Old Part Thickness Analog signal.
The output of comparator 340 then feeds ultrasonic gate generator 370, assuming that switch 360 is properly set to the thickness sync mode, to cause the generation of the GATE and SAMPLE signals. Both signals have a predetermined duration determined by "one-shot" IC9. The SAMPLE signal corresponds to the time window for measuring the peak amplitude, since it is a pulse which last from a time just prior to the anticipated receipt of a rear surface reflection, and which remains high for a predetermined period of time sufficient to allow capture of the entire anticipated rear surface reflection. Each channel generates a GATE and SAMPLE signal.
In the preferred embodiment, the Three-Position Gate also generates for each channel a Blanking signal used with the oscilloscope display of the corresponding Ultrasonic Input signal. Only the thickness transducer channel, however, generates a System Material Enable signal and a Blanking signal for use in subsequent timing. The Blanking signal for use in subsequent timing is shown in FIG. 4A as being generated by the flip-flop labelled IC7.
In accordance with the present invention, the thickness gating means of this invention includes means for evaluating the electrical reflection signals received by the thickness transducer channel to determine a part thickness estimate. The System Material Enable signal in the preferred embodiment of this invention may be thought of as a part thickness estimate. That signal is generated by signals received from interface timing generator 380 shown in FIGS. 4 and 4A. Interface timing generator 380 includes IC8 which is a monolithic chip comparator that compares the Ultrasonic Input signal with a threshold value set using potentiometer VR-5. A high output from IC8 means that the Ultrasonic Input signal has exceeded the threshold. The first time that this occurs after the PULSER COMMAND signal corresponds to the received reflection from the front surface and causes the System Material Enable signal goes from a low to a high level. The next time that IC8 generates a pulse, which would correspond to receipt of reflections either from the rear surface or from a defect, the System Material Enable signal drops from a high to a low level. The "thickness estimate" represented by the pulse duration of the System Material Enable signal, will either represent a new thickness measurement or the distance between the front surface and a defect. To determine which value the System Material Enable signals represents, it is compared to the current thickness value represented by the Old Part Thickness Analog signal.
According to the present invention, there is means for replacing the part thickness value with the part thickness estimate when the part thickness value and estimate bear a predetermined relationship with each offer. In the preferred embodiment, the testing of the thickness part estimate and Old Part Thickness Analog signal is performed by the Thickness Gate Controller shown in FIGS. 5 and 5A. As seen in those figures, the System Material Enable signal causes the counter enable 410 to gate the 15 MHz System Clock signals to binary counter 420. The final count of counter 420 represents the number of System Clock pulses which are gated through to the counter during the System Material Enable signal. That final binary count is the input to Part Thickness Estimate D/A circuit 440, whose analog voltage output reflects that final count.
A digital value corresponding to the Old Part Thickness Analog signal has previously been stored in a register internal to the old part thickness value D/A circuit 460. That value was initially input when the Initialize button 430 was pushed, which activated the load input to circuit 460 and caused it to store the binary count generated during the initialization. Thereafter, the digital value in the old part thickness value D/A circuit 460 is periodically updated as described below.
The output of the old part thickness value D/A circuit 460 represents the Old Part Thickness Analog level, which is also made available to the Three-position Gate via Analog Voltage Buffer 480. The Old Part Thickness Analog signal and the part thickness estimate are input to the part thickness comparator circuitry 470 which is shown in greater detail in FIG. 5A. In the embodiment shown in FIG. 5A, the part thickness estimate is fed through amplifiers A1 and A2, which multiply the part thickness estimate by values greater and less than unity, respectively. Preferably those values are 1.05 and 0.95, which represent a ±5% deviation, but the potentiometers in the feedback circuit for amplifiers A1 and A2 may be adjusted for different values. These multiple values are inputs to part thickness comparator circuitry 470 along with the Old Part Thickness Analog signal. If the part thickness estimate is greater than 0.95 and less than 1.05 the Old Part Thickness Analog level (or within other limits if the ±5% deviation are not used), then the output of part thickness comparator circuitry 470 changes state and cause new part thickness "valid" pulse generator 450 to load the digital output of counter 420, which corresponds to the part thickness estimate, into old part thickness value D/A circuit 460. This causes an updating of the Old Part Thickness Analog value. If, however, the part thickness estimate is outside of the predetermined range, then the Old Part Thickness Value stored in circuit 460 remains the same.
FIG. 9 shows the timing relationship of the signals just discussed. FIG. 9A is the System Clock, FIG. 9B is the Ultrasonic Input Signal, FIG. 9C is the PULSER COMMAND, FIG. 9D is the output of D/A converter 320, FIG. 9F is the Old Part Thickness Analog signal, and FIG. 9F is the output of the comparator 340, which switches state when the signals 9D and 9E (as adjusted) are equal, i.e. at voltage V t . As described above, this equality causes the generation of the GATE (and SAMPLE) signal as shown in FIG. 9G. FIG. 9H is the System Material Enable signal.
It will be apparent to those skilled in the art that modifications and variations can be made in the ultrasonic inspection apparatus and methods of this invention. The invention in its broader aspects is not limited to the specific details, representative methods and apparatus, and illustrative examples shown and described. Departure may be made from such details without departing from the spirit or scope of the general inventive concept.
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Ultrasonic apparatus and methods for detecting defects in a part include a plurality of transducer channels, at least one of which is dedicated to determining the thickness of the part. An initial thickness value is determined and stored, and then subsequent thickness estimates are compared to the original thickness value and, if the estimates bear a predetermined relationship with the stored thickness value, then the thickness estimates become the new thickness values.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a switched-capacitor-type stabilized power supply device.
[0003] 2. Description of the Prior Art
[0004] A conventional switched-capacitor-type stabilized power supply device will be described with reference to FIG. 7. An input terminal IN is connected to the positive side of a capacitor C 2 and to the input side of a voltage step-up circuit 12 . The negative side of the capacitor C 2 is grounded.
[0005] The voltage step-up circuit 12 is provided with a capacitor C 1 and switching devices SW 11 to SW 14 . The node between one end of the switching device SW 12 and one end of the switching device SW 13 is connected to the input side of the voltage step-up circuit 12 . The other end of the switching device SW 12 is connected to one end of the switching device SW 11 , and the other end of the switching device SW 11 is connected to the output side of the voltage step-up circuit 12 . The other end of the switching device SW 13 is connected to one end of the switching device SW 14 , and the other end of the switching device SW 14 is grounded. One end of the capacitor C 1 is connected to the node between the switching devices SW 11 and SW 12 , and the other end of the capacitor C 1 is connected to the node between the switching devices SW 13 and SW 14 .
[0006] The output side of the voltage step-up circuit 12 is connected to one end of a resistor R 1 , to one end of a capacitor C 3 , and to an output terminal OUT. The other end of the capacitor C 3 is grounded. The other end of the resistor R 1 is grounded through a resistor R 2 .
[0007] The node between the resistors R 1 and R 2 is connected to the non-inverting input terminal of a comparator 3 . Connected to the inverting input terminal of the comparator 3 is the positive side of a constant voltage source 4 that output a reference voltage V ref1 . The negative side of the constant voltage source 4 is grounded. The output terminal of the comparator 3 is connected to a control circuit 5 , which is connected to the control terminals of the switching devices SW 11 to SW 14 . The comparator 3 is of the type that exhibits hysteresis.
[0008] Now, the operation of the conventional switched-capacitor-type stabilized power supply device configured as described above will be described. A direct-current power source (not shown) is connected to the input terminal IN so that an input voltage V in is applied to the input terminal IN. The control circuit 5 turns on and off the switching devices SW 11 to SW 14 according to the level of the output signal S 1 of the comparator 3 , which will be described later. The control circuit 5 incorporates an oscillator, and evaluates the level of the output signal S 1 of the comparator 3 every period T.
[0009] When the output signal S 1 of the comparator 3 is at a low level, the control circuit 5 performs alternately, by switching every period T, charge control operation in which it keeps the switching devices SW 12 and SW 14 on and the switching devices SW 11 and SW 13 off and discharge control operation in which it keeps the switching devices SW 12 and SW 14 off and the switching devices SW 11 and SW 13 on.
[0010] On the other hand, when the output signal S 1 of the comparator 3 is at a high level, the control circuit 5 , rather than switching between the two types of control operation every period T, performs only charge control operation in which it keeps the switching devices SW 12 and SW 14 on and the switching devices SW 11 and SW 13 off.
[0011] As a result of the control circuit 5 performing charge control operation, the capacitor C 1 of the voltage step-up circuit 12 is charged, and its charge voltage reaches V in . During this charge period, an output current flows from the output terminal OUT to a load (not shown) connected to the output terminal OUT, and therefore the capacitor C 3 discharges, and the output voltage V o lowers.
[0012] On the other hand, as a result of the control circuit 5 performing discharge control operation, the negative side of the capacitor C 1 is connected to the input terminal IN, and thus the potential at the negative side of the capacitor C 1 , which was equal to zero when the control circuit 5 was performing charge control operation, becomes equal to V in . Accordingly, the potential at the positive side of the capacitor C 1 , which was equal to V in when the control circuit 5 was performing charge control operation, becomes equal to 2×V in . In this way, during the discharge period, a voltage stepped up by a factor of 2 is fed to the capacitor C 3 , and thus the output voltage V o increases.
[0013] The resistors R 1 and R 2 serve as a voltage detecting means for detecting the output voltage V o , outputting a division voltage V a of the output voltage V o to the comparator 3 . The comparator 3 compares the division voltage V a of the output voltage V o with the reference voltage V ref1 and, when the division voltage V a of the output voltage V o is higher than or equal to the reference voltage V ref1 , turns the output signal S 1 to a high level.
[0014] Since the comparator 3 is of the type that exhibits hysteresis, once it turns the output signal S 1 to a high level, it keeps the output signal S 1 at a high level even when the division voltage V a of the output voltage V o becomes lower than the reference voltage V ref1 . When the output voltage V o becomes so low that the division voltage V a of the output voltage V o is lower than V ref1′ (<V ref1 ), the comparator 3 turns the output signal S 1 from a high level to a low level.
[0015] As a result of the operation described above, the division voltage V a of the output voltage V o is kept in the range from V ref1′ to V ref1 and the output voltage V o is thereby stabilized within a predetermined range, so that the output voltage V o is kept substantially equal to the set output voltage V o *.
[0016] In the conventional switched-capacitor-type stabilized power supply device shown in FIG. 7, the voltage step-up circuit 12 employs a 2× voltage step-up circuit that steps up the input voltage by a factor of 2. It is possible, however, to realize voltage step-up circuits of various voltage step-up factors, such as 1.5× and 3×, by varying the combination of switching devices and capacitors used in them.
[0017] A battery is generally used as a direct-current power source for supplying electric power to a switched-capacitor-type stabilized power supply device. To extend the life of the battery, it is essential that the switched-capacitor-type stabilized power supply device operate stably until the battery voltage falls considerably low, and that it operate with as high power conversion efficiency as possible. In recent years, in particular, switched-capacitor-type stabilized power supply devices have been increasingly used as power sources for driving blue or white LEDs used as backlights for liquid crystal displays incorporated in cellular phones. This trend has been increasing the demand for switched-capacitor-type stabilized power supply devices that permit extended battery lives.
[0018] To permit a switched-capacitor-type stabilized power supply device to operate stably until the battery power falls considerably low, it needs to be provided with a voltage step-up circuit with a high voltage step-up factor.
[0019] However, inconveniently, increasing the voltage step-up factor of the voltage step-up circuit increases the difference between the voltage stepped-up by the voltage step-up circuit when the battery voltage is still high and the set output voltage Vo*, and thus lowers power conversion efficiency. For example, in the case of the conventional switched-capacitor-type stabilized power supply device having a 2× voltage step-up circuit shown in FIG. 7, its power conversion efficiency η[%] is approximated as (100×V o )/(2×V in ), and thus, when, for example, V o =V in , the power conversion efficiency η is 50%. Moreover, where the voltage step-up circuit has a fixed voltage step-up factor n, as in the conventional switched-capacitor-type stabilized power supply device, the switched-capacitor-type stabilized power supply device needs to withstand V in ×n. Thus, inconveniently, increasing the voltage step-up factor n of the voltage step-up circuit requires designing the switched-capacitor-type stabilized power supply device to withstand an accordingly high voltage.
SUMMARY OF THE INVENTION
[0020] An object of the present invention is to provide a switched-capacitor-type stabilized power supply device that offers high power conversion efficiency even when the input level to it and/or the output level from it varies greatly.
[0021] To achieve the above object, according to the present invention, a switched-capacitor-type stabilized power supply device is provided with: an input terminal to which a direct-current voltage is applied; a plurality of voltage step-up circuits each having a different voltage step-up factor; an output-side capacitor that is charged with the output voltage from the voltage step-up circuits; a voltage detecting circuit for detecting the voltage across the output-side capacitor; a control circuit for turning switching devices on and off according to the voltage detected by the voltage detecting circuit; a switching circuit for connecting and disconnecting the input terminal to and from the voltage step-up circuits; and a switching control circuit for controlling the switching circuit according to the input level to and/or the output level from the switched-capacitor-type stabilized power supply device. Here, the voltage step-up circuits each have a capacitor and a switching device, which is turned on and off by the control circuit, and operate by charging and discharging the capacitor through the switching operation of the switching device so as to step-up the direct-current voltage and output a stepped-up voltage while the capacitor is discharging.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] This and other objects and features of the present invention will become clear from the following description, taken in conjunction with the preferred embodiments with reference to the accompanying drawings in which:
[0023] [0023]FIG. 1 is a diagram showing the configuration of the switched-capacitor-type stabilized power supply device of a first embodiment of the invention;
[0024] [0024]FIG. 2 is a diagram showing the configuration of the switched-capacitor-type stabilized power supply device of a second embodiment of the invention;
[0025] [0025]FIG. 3 is a diagram showing the configuration of the switched-capacitor-type stabilized power supply device of a third embodiment of the invention;
[0026] [0026]FIG. 4 is a diagram showing the configuration of the switched-capacitor-type stabilized power supply device of a fourth embodiment of the invention;
[0027] [0027]FIG. 5 is a diagram showing the configuration of the switched-capacitor-type stabilized power supply device of a fifth embodiment of the invention;
[0028] [0028]FIG. 6 is a flow chart showing the operation performed by the judging circuit included in the switched-capacitor-type stabilized power supply device of FIG. 3; and
[0029] [0029]FIG. 7 is a diagram showing the configuration of a conventional switched-capacitor-type stabilized power supply device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] [0030]FIG. 1 shows the configuration of the switched-capacitor-type stabilized power supply device of a first embodiment of the invention. It is to be noted that such circuit elements and signals as are found also in the conventional switched-capacitor-type stabilized power supply device shown in FIG. 7 are identified with the same reference numerals, and their explanations will be omitted.
[0031] An input terminal IN is connected to the positive side of a capacitor C 2 , to a switching control circuit 6 , to one end of a switching device SW 1 , and to one end of a switching device SW 2 . The negative side of the capacitor C 2 is grounded. Also connected to the switching control circuit 6 is the positive side of a constant voltage source 7 that outputs a reference voltage V ref2 . The negative side of the constant voltage source 7 is grounded. Moreover, the switching control circuit 6 is connected to the control electrodes of the switching devices SW 1 and SW 2 .
[0032] The other end of the switching device SW 1 is connected to the input side of an n 1 × voltage step-up circuit 1 , and the other end of the switching device SW 2 is connected to the input side of an n 2 × voltage step-up circuit 2 . The output sides of the n 1 × and n 2 × voltage step-up circuits 1 and 2 are connected together, with the node between them connected to one end of a resistor R 1 , to one end of a capacitor C 3 , and to an output terminal OUT. The other end of the capacitor C 3 is grounded. The other end of the resistor R 1 is grounded through a resistor R 2 . Here, the n 1 × voltage step-up circuit 1 has a lower voltage step-up factor than the n 2 × voltage step-up circuit 2 . That is, n 1 <n 2 .
[0033] The node between the resistors R 1 and R 2 is connected to the non-inverting input terminal of a comparator 3 . Connected to the inverting input terminal of the comparator 3 is the positive side of a constant voltage source 4 that outputs a reference voltage V ref1 . The negative side of the constant voltage source 4 is grounded. The output terminal of the comparator 3 is connected to a control circuit 5 , which is connected to a switching device (not shown) included in the n 1 × voltage step-up circuit 1 and to a switching device (not shown) included in the n 2 × voltage step-up circuit 2 .
[0034] The switched-capacitor-type stabilized power supply device configured as described above operates in the following manner. The switching control circuit 6 compares an input voltage V in with the reference voltage V ref2 output from the constant voltage source 7 , and, if the input voltage V in is equal to or higher than the reference voltage V ref2 , it turns the switching device SW 1 on and the switching device SW 2 off so as to select the n 1 × voltage step-up circuit 1 . By contrast, if the V in is lower than the reference voltage V ref2 , the switching control circuit 6 turns the switching device SW 1 off and the switching device SW 2 on so as to select the n 2 × voltage step-up circuit 2 .
[0035] It is advisable to set the reference voltage V ref2 equal to the minimum level of the input voltage V in that the n 1 × voltage step-up circuit 1 can step up to the set output voltage Vo*.
[0036] In this way, when the input voltage V in is high, the n 1 × voltage step-up circuit 1 , which has the lower voltage step-up factor, is selected in order to reduce the difference between the voltage stepped-up by the voltage step-up circuit and the set output voltage Vo* and thereby increase power conversion efficiency; when the input voltage V in is low, the n 2 × voltage step-up circuit 2 , which has the higher voltage step-up factor, is selected so that the input voltage V in can be stepped up to the set output voltage Vo*. This makes it possible to realize a switched-capacitor-type stabilized power supply device that operates stably with a low input voltage and that offers high power conversion efficiency even when the input voltage varies greatly. Thus, where a battery is used as the direct-current power source connected to the input terminal IN, it is possible to extend the life of the battery.
[0037] [0037]FIG. 2 shows the configuration of the switched-capacitor-type stabilized power supply device of a second embodiment of the invention. It is to be noted that such circuit elements and signals as are found also in the switched-capacitor-type stabilized power supply device of the first embodiment shown in FIG. 1 are identified with the same reference numerals, and their explanations will be omitted.
[0038] The switched-capacitor-type stabilized power supply device of the second embodiment shown in FIG. 2 differs from the switched-capacitor-type stabilized power supply device of the first embodiment shown in FIG. 1 in that the constant voltage source 7 is not provided and that the output terminal OUT is connected to the switching control circuit 6 .
[0039] The level of the set output voltage Vo* can be varied by varying the resistances of the resistors R 1 and R 2 and the level of the reference voltage V ref1 output from the constant voltage source 4 . When the level of the set output voltage Vo* is varied, the minimum level of the input voltage V in that the n 1 × voltage step-up circuit 1 can step up to the set output voltage Vo* varies accordingly.
[0040] Therefore, in the switched-capacitor-type stabilized power supply device of the second embodiment, the switching control circuit 6 receives the input voltage V in and the output voltage V o , and calculates the value (V o /V in ) by dividing the output voltage V o by the input voltage V in . When V o /V in is smaller than the voltage step-up factor n, of the n 1 × voltage step-up circuit 1 , the switching control circuit 6 turns the switching device SW 1 on and the switching device SW 2 off so as to select the n 1 × voltage step-up circuit 1 ; when V o /V in is equal to or greater than the voltage step-up factor n 1 of the n 1 × voltage step-up circuit 1 , the switching control circuit 6 turns the switching device SW 1 off and the switching device SW 2 on so as to select the n 2 × voltage step-up circuit 2 .
[0041] In this way, even in a configuration that permits the set output voltage Vo* to be varied, when the input voltage V in is high, the n 1 × voltage step-up circuit 1 , which has the lower voltage step-up factor, is selected in order to reduce the difference between the voltage stepped-up by the voltage step-up circuit and the set output voltage Vo* and thereby increase power conversion efficiency; when the input voltage V in is low, the n 2 × voltage step-up circuit 2 , which has the higher voltage step-up factor, is selected so that the input voltage V in can be stepped up to the set output voltage Vo*. This makes it possible to realize a switched-capacitor-type stabilized power supply device that permits the set output voltage Vo* to be varied but nevertheless operates stably with a low input voltage and offers high power conversion efficiency even when the input voltage varies greatly. Thus, where a battery is used as the direct-current power source connected to the input terminal IN, it is possible to extend the life of the battery.
[0042] [0042]FIG. 3 shows the configuration of the switched-capacitor-type stabilized power supply device of a third embodiment of the invention. It is to be noted that such circuit elements and signals as are found also in the switched-capacitor-type stabilized power supply device of the first embodiment shown in FIG. 1 are identified with the same reference numerals, and their explanations will be omitted.
[0043] The switched-capacitor-type stabilized power supply device of the third embodiment shown in FIG. 3 differs from the switched-capacitor-type stabilized power supply device of the first embodiment shown in FIG. 1 in that the switching control circuit 6 is connected to the control terminals of the switching devices SW 1 and SW 2 not directly but through a judging circuit 8 that is connected to the positive side of a constant voltage source 9 that outputs a reference voltage V ref3 . The negative side of the constant voltage source 9 is grounded. The reference voltage V ref3 is equal to the voltage that the switched-capacitor-type stabilized power supply device is designed to withstand.
[0044] The switched-capacitor-type stabilized power supply device configured as described above operates in the following manner. The switching control circuit 6 feeds a signal S 2 to the judging circuit 8 . When the input voltage V in is equal to or higher than the reference voltage V ref2 , the switching control circuit 6 outputs, as the signal S 2 , a signal that requests the switching device SW 1 to be turned on and the switching device SW 2 to be turned off By contrast, when the input voltage V in is lower than the reference voltage V ref2 , the switching control circuit 6 outputs, as the signal S 2 , a signal that requests the switching device SW 1 to be turned off and the switching device SW 2 to be turned on.
[0045] In the judging circuit 8 , the voltage step-up factor n 2 of the n 2 × voltage step-up circuit 2 is stored beforehand. The judging circuit 8 judges whether to make the output signal S 2 of the switching control circuit 6 valid or not. Now, how this judgment is made will be described with reference to a flow chart in FIG. 6.
[0046] First, the judging circuit 8 checks whether or not the signal S 2 is a signal requesting the switching device SW 1 to be turned off and the switching device SW 2 to be turned on (step # 10 ).
[0047] If the signal S 2 is not a signal requesting the switching device SW 1 to be turned off and the switching device SW 2 to be turned on (“No” in step # 10 ), the n 2 × voltage step-up circuit 2 is not selected, and therefore there is no risk of a voltage being generated that is higher than the voltage that the switched-capacitor-type stabilized power supply device can withstand. Thus, the flow proceeds to step # 40 , where the signal S 2 is made valid and is fed, as it is, to the switching devices SW 1 and SW 2 . The flow then comes to an end.
[0048] On the other hand, if the signal S 2 is a signal requesting the switching device SW 1 to be turned off and the switching device SW 2 to be turned on (“Yes” in step # 10 ), when the signal S 2 is made valid, the n 2 × voltage step-up circuit 2 will be selected. Therefore, it is checked whether or not, when the signal S 2 is made valid, there is a risk of a voltage being generated that is higher than the voltage that the switched-capacitor-type stabilized power supply device can withstand (step # 20 ).
[0049] In step # 20 , whether the value calculated by multiplying the voltage step-up factor n 2 by the input voltage V in is equal to or higher than the reference voltage V ref3 or not is checked. If the value calculated by multiplying the voltage step-up factor n 2 by the input voltage V in is lower than the reference voltage V ref3 (“No” in step # 20 ), even when the n 2 × voltage step-up circuit 2 , which has the higher voltage step-up factor, is selected, there is no risk of a voltage being generated that is higher than the voltage that the switched-capacitor-type stabilized power supply device can withstand. Thus, the flow proceeds to step # 40 , where the signal S 2 is made valid and is fed, as it is, to the switching devices SW 1 and SW 2 . The flow then comes to an end.
[0050] On the other hand, if the value calculated by multiplying the voltage step-up factor n 2 by the input voltage V in is equal to or higher than the reference voltage V ref3 (“Yes” in step # 20 ), when the n 2 × voltage step-up circuit 2 , which has the higher voltage step-up factor, is selected, a voltage will be generated that is higher than the voltage that the switched-capacitor-type stabilized power supply device can withstand. Thus, the flow proceeds to step # 30 , where the signal S 2 is made invalid and a signal requesting the switching device SW 1 to be turned on and the switching device SW 2 to be turned off is fed to the switching devices SW 1 and SW 2 . The flow then comes to an end.
[0051] Operating in this way, the judging circuit 8 makes it possible to limit the maximum level of the voltage generated in the switched-capacitor-type stabilized power supply device and thereby prevent destruction of its constituent circuit elements resulting from generation of a voltage higher than the voltage that the switched-capacitor-type stabilized power supply device can withstand.
[0052] [0052]FIG. 4 shows the configuration of the switched-capacitor-type stabilized power supply device of a fourth embodiment of the invention. It is to be noted that such circuit elements and signals as are found also in the switched-capacitor-type stabilized power supply device of the second embodiment shown in FIG. 2 are identified with the same reference numerals, and their explanations will be omitted.
[0053] The switched-capacitor-type stabilized power supply device of the fourth embodiment shown in FIG. 4 differs from the switched-capacitor-type stabilized power supply device of the second embodiment shown in FIG. 2 in that a switching device SW 3 and a voltage step-down regulator 10 are additionally provided, with one end of the switching device SW 3 connected to the node between the switching devices SW 1 and SW 2 , the other end of the switching device SW 3 connected to the input side of the voltage step-down regulator 10 , and the output side of the voltage step-down regulator 10 connected to the output terminal OUT.
[0054] In the switched-capacitor-type stabilized power supply device of the fourth embodiment, the switching control circuit 6 receives the input voltage V in and the output voltage V o , and calculates the value (V o /V in ) by dividing the output voltage V o by the input voltage V in . When V o /V in is smaller than 1, the switching control circuit 6 turns the switching device SW 1 off, the switching device SW 2 off, and the switching device SW 3 on so as to select the voltage step-down regulator 10 . When V o /V in is equal to or greater than 1 and smaller than the voltage step-up factor of the n 1 × voltage step-up circuit 1 , the switching control circuit 6 turns the switching device SW 1 on, the switching device SW 2 off, and the switching device SW 3 off so as to select the n 1 × voltage step-up circuit 1 . When V o /V in is equal to or greater than the voltage step-up factor of the n 1 × voltage step-up circuit 1 , the switching control circuit 6 turns the switching device SW 1 off, the switching device SW 2 on, and the switching device SW 3 off so as to select the n 2 × voltage step-up circuit 2 .
[0055] In this way, even when the input voltage V in is higher than the set output voltage Vo*, the switched-capacitor-type stabilized power supply device can output the set output voltage Vo*. In addition, when the input voltage V in is high, the n 1 × voltage step-up circuit 1 , which has the lower voltage step-up factor, is selected in order to reduce the difference between the voltage stepped-up from the input voltage V in and the set output voltage Vo* and thereby increase power conversion efficiency; when the input voltage V in is low, the n 2 × voltage step-up circuit 2 , which has the higher voltage step-up factor, is selected so that the input voltage V in can be stepped up to the set output voltage Vo*.
[0056] [0056]FIG. 5 shows the configuration of the switched-capacitor-type stabilized power supply device of a fifth embodiment of the invention. It is to be noted that such circuit elements and signals as are found also in the switched-capacitor-type stabilized power supply device of the fourth embodiment shown in FIG. 4 are identified with the same reference numerals, and their explanations will be omitted.
[0057] The switched-capacitor-type stabilized power supply device of the fifth embodiment shown in FIG. 5 differs from the switched-capacitor-type stabilized power supply device of the fourth embodiment shown in FIG. 4 in that a drive control circuit 11 is additionally provided that is connected to the control circuit 5 , to the switching control circuit 6 , to the voltage step-down regulator 10 , to the n 1 × voltage step-up circuit 1 , and to the n 2 × voltage step-up circuit 2 .
[0058] The n 1 × and n 2 × voltage step-up circuits 1 and 2 are each provided with, in addition to a capacitor and a switching device, a circuit that is fed with a constant voltage. The voltage step-down regulator 10 , too, is provided with a circuit that is fed with a constant voltage. In the switched-capacitor-type stabilized power supply device of this embodiment, the n 1 × and n 2 × voltage step-up circuits 1 and 2 and the voltage step-down regulator 10 are each provided with a switching device that connects and disconnects a constant voltage source to and from their respective circuit fed with the constant voltage, and the drive control circuit 11 feeds a control signal to the control terminals of those switching devices.
[0059] The drive control circuit 11 receives from the switching control circuit 6 a signal S 3 that indicates which of the n 1 × and n 2 × voltage step-up circuits 1 and 2 and the voltage step-down regulator 10 has been selected. According to the signal S 3 , the drive control circuit 11 turns off the switching devices that connect and disconnect the constant voltage sources to and from the circuits fed with the constant voltages in two of the n 1 × and n 2 × voltage step-up circuits 1 and 2 and the voltage step-down regulator 10 which are not being selected.
[0060] The control circuit 5 is composed of a portion that is needed exclusively to control the operation of the voltage step-down regulator 10 , a portion that is needed exclusively to control the operation of the n 1 × voltage step-up circuit 1 , a portion that is needed exclusively to control the operation of the n 2 × voltage step-up circuit 2 , and a portion needed to control the operation of more than one of those circuits. According to the signal S 3 , the drive control circuit 11 stops the supply of electric power to part of the control circuit 5 . Specifically, according to the signal S 3 , the drive control circuit 11 stops the supply of electric power to those portions of the control circuit 5 which are needed exclusively to control the operation of two of the n 1 × and n 2 × voltage step-up circuits 1 and 2 and the voltage step-down regulator 10 which are not being selected.
[0061] This helps reduce the unwanted consumption of electric power (stand-by electric power consumption) by those of the n 1 × and n 2 × voltage step-up circuits 1 and 2 and the voltage step-down regulator 10 which are not being selected and by the portions needed exclusively to control the operation of those circuits. This makes it possible to achieve even higher power conversion efficiency.
[0062] Although the first to fifth embodiments described above all deal with cases in which two voltage step-up circuits are provided, three or more voltage step-up circuits may be provided. The switching control circuit may be so configured as to detect only the output voltage as long as the input voltage is constant, or may be so configured as to detect the output current and control the switching according to the lowering of power conversion efficiency or the like that results when the output current is large.
[0063] Moreover, for miniaturization and cost reduction, circuit integration is recommended. For example, in the switched-capacitor-type stabilized power supply device of the first embodiment shown in FIG. 1, it is advisable to form on a single-chip semiconductor integrated circuit device all the circuit elements other than the input terminal IN, the capacitor C 2 , the resistors R 1 and R 2 , the capacitor C 2 , the output terminal OUT, and the capacitors (not shown) included in the the n 1 × and n 2 × voltage step-up circuits 1 and 2 .
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To permit a switched-capacitor-type stabilized power supply device to operate stably until the battery power falls considerably low, it needs to be provided with a voltage step-up circuit with a high voltage step-up factor. However, inconveniently, in a conventional switched-capacitor-type stabilized power supply device, increasing the voltage step-up factor of the voltage step-up circuit increases the difference between the voltage stepped-up by the voltage step-up circuit when the battery voltage is still high and the set output voltage, and thus lowers power conversion efficiency. By contrast, a switched-capacitor-type stabilized power supply device of the invention has a plurality of voltage step-up circuits each having a different voltage step-up factor, a switching circuit for connecting and disconnecting an input terminal, to which a direct-current voltage is applied, to and from the voltage step-up circuits, and a switching control circuit for controlling the switching circuit according to the input level to and/or the output level from the switched-capacitor-type stabilized power supply device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a transparent optical element comprising a plurality of layers that consist of respective cellular tilings.
2. Description of the Related Art
In the context of the present description, the expression “transparent optical element” is understood to mean a component that is intended to form an image of a scene from light that originates from this scene and that passes through the element. For example, it could be an optical lens, an ophthalmic lens such as a spectacle glass or a contact lens, or an ocular implant, etc. Optionally, such an element may possess a Fresnel structure in order to increase the optical power obtainable with regard to constraints related to the production process of the element, to its thickness, to the material used, etc.
Although such a transparent optical element may possess various additional optical functions such as providing an absorbing power, a polarizing power, or increasing contrast, etc., its image-forming function may be characterized by a distribution of an optical phase shift that the element produces, in a defined area, for a given monochromatic light wave that passes through the element. Generally, the transparent optical element possesses a useful area that extends transversely relative to an optical axis. An average direction of propagation of the light wave may then be chosen to be superposed on this axis, and the distribution of the optical phase shift may be determined inside the useful area of the element.
It is known that such transparent optical elements may be digital in nature, or pixelated. In this case, the optical phase shift possesses discrete values that are produced at points representing a sampling of the useful area of the transparent optical element. Simplistically, the optical phase shift could be constant in a limited zone, commonly called a cell, around each sampling point. The value of the optical phase shift of the element at every point in any given cell would therefore be equal to that of the sampling point located in this cell. More realistically, the phase shift is not constant inside each cell, but is intermediate between minimum and maximum values that are fixed by a target phase shift function for this cell. The cells are contiguous in the useful area of the optical element, and form a tiling in this area. The actual refractive function of the digital transparent optical element then results from the combination of this tiling with the optical phase shift values that are obtained in all the cells.
It is also known that the optical phase shift Δφ, for a monochromatic light wave is equal to the product of two times the number pi, and of the distance H traveled through each cell, and of the difference between the value n of the refractive index of the transparent material that fills this cell and the value of the index of air. In other words: Δφ=2π·H·(n−1)/λ, where λ represents the wavelength of the light. A first possible way of producing the transparent optical element thus consists in varying the value of the refractive index of the material filling the cells, between the different cells of the element. In this case, all the cells may have the same depth, which is measured along the optical axis of the element. Another possible way of producing the transparent optical element consists in producing cells of variable depth, using the same transparent homogenous material to fill all the cells. For example, the optical element may consist of a transparent, optionally curved, homogenous sheet that has a variable stepped thickness. For this reason, at least one of the faces of the sheet may possess sagittal height values that vary between different cells of the tiling of this face.
However, a digital transparent optical element generally has the following drawbacks:
the individual cells in which the optical phase shift is capable of taking different values have a minimum size, which is in general set by the technology used to manufacture the element. This minimum size spatially limits the sampling of a distribution function of the optical phase shift, which function is used as a target to produce a desired refractive function. In other words, the actual distribution function of the optical phase shift for the digital element only approximately reproduces the target distribution function. The difference between these two distribution functions is a shortcoming in the refractive function that is actually produced by the optical element. Such is especially the case when the target distribution function is continuous, or continuous inside portions of the useful area of the element; the number of different discrete values that are obtainable for the optical phase shift in each cell is also limited. For example, only 16 to 128 different values are obtainable. Because of this limited number of possible values, a difference may exist between the value of the optical phase shift produced for each of the sampling points of the digital optical element and the value of the target distribution function for the same point. This limitation in the number of different values that may be obtained for the optical phase shift inside each cell is different from the limitation that results from the minimum size of the cells. However, it also contributes to the difference between the actual distribution function of the optical phase shift of the digital element and the target distribution function; the range of values that are possible for the optical phase shift in each cell of the element is itself limited. In other words, the optical phase shifts that can be produced in the cells of the element are bounded by a minimum value and a maximum value. These minimum and maximum values are also a result of the technology used to manufacture the element. However, the apparent range of values for the optical phase shift is commonly increased by employing phase jumps that are multiples of two times pi for a given wavelength called the nominal wavelength. This nominal wavelength may, for example, be about 550 nm (nanometers). However, a chromatic aberration results therefrom for the refractive function that is actually produced by the element, above all when the amplitude of each phase jump is equal to a small even integer number times pi. Such a chromatic aberration is then disadvantageous in many applications; and discontinuities in the optical phase shift at the boundaries separating contiguous cells of the tiling on the surface of the digital optical element scatter part of the incident light wave. In other words, a fraction of the energy of this light wave is not simply transmitted by the element in accordance with its optical phase shift distribution function, but the propagation direction is in addition deviated laterally. This scattered part of the wave then forms a luminous background that decreases the contrast of the image that is formed by the optical element. This decrease in contrast may be considered as a decrease in the transparency of the element. When the network of the boundaries separating cells of the tiling is periodic, the scattered part of the incident wave may form parasitic images or be concentrated in privileged diffraction directions, which are also liable to disadvantage use of the optical element.
SUMMARY OF THE INVENTION
Under these conditions, the present invention aims to ameliorate or obviate at least certain of the above drawbacks.
More particularly, a first aim of the invention consists in providing a cellular transparent optical element that enables the difference between its optical phase shift distribution function and a target distribution function to be decreased, the latter distribution possibly being continuous or continuous in portions.
A second aim of the invention consists in providing a cellular transparent optical element that has a smaller chromatic aberration, especially a smaller axial chromatic aberration.
To achieve these and other aims the invention provides a transparent optical element that comprises a plurality of layers superposed along an optical axis of the element. Each layer extends perpendicularly to the optical axis and consists of a tiling of contiguous cells. For each layer, a distribution function of an optical phase shift possesses a constant value inside each cell of this layer. The refractive function of the element thus results from a combination of the respective optical phase shift distribution functions of the layers.
Thus, the transparent optical element of the invention may be a digital element.
The element is characterized in that the tilings of at least two of the layers do not coincide in a projection of these layers onto a surface perpendicular to the optical axis, so that the boundaries between some of the contiguous cells of one of the two layers cut some cells of the other of the two layers in said projection.
Thus, on the projection surface, the cells of one of the layers are themselves divided by the intercellular boundaries of the other layer. The superposition of the two layers then appears to be divided into useful cells that have dimensions that are smaller than or equal to those of the cells of each layer. In other words, the superposition of layers according to the invention makes it possible to decrease an apparent useful cell size in order to produce a given refractive function. For this reason, the difference between the distribution function of the optical phase shift of the element of the invention and a target distribution function, especially a target distribution function that is continuous or continuous in portions, may be decreased. This has the effect of decreasing the intensity of the parasitic light that is diffracted and of better distributing it angularly. This parasitic light is then less perceptible.
Furthermore, the number of possible values for the total optical phase shift of the element results from a combination of the values that can be produced for each of the layers. It is therefore higher than the number of values possible for each layer. Therefore, for this reason also, it is possible to reproduce more precisely a target optical phase shift distribution function with a transparent optical element according to the invention.
Simultaneously, the range of total optical phase shift values that are possible for the transparent optical element of the invention results from a juxtaposition of the corresponding ranges for all the layers. It is therefore wider than the latter, and makes it possible to avoid having to use phase jumps having amplitudes of small integer numbers of two times pi, for a nominal wavelength. The chromatic aberration of the refractive function of the transparent optical element of the invention may thus be decreased.
In various embodiments of the invention, one or more of the following improvements may be applied, whether alone or in combination:
the respective tilings of the layers, which do not coincide on the projection surface, may be identical but offset one relative to the other by a translation, by a rotation, or by a combination of a translation and a rotation; at least one of the respective tilings of the layers, which do not coincide on the projection surface, may be random or pseudo-random. Optionally, one of the tilings of the element may be random or pseudo-random while another tiling of the same element may be periodic or regular; when the tilings, which do not coincide on the projection surface, are offset one relative to the other by a translation or by a combination of a translation and a rotation, and when these tilings are each periodic with a common period in at least one period direction associated with each layer, a length of the translation in the period direction of one of these layers may lie between 25% and 75% of the common period, in addition to an integer number of times the common period. Preferably, the translation length may lie between 25% and 75% of the common period; more generally, the transparent optical element may comprise N layers the tilings of which are identical, but each of which tilings is offset by a translation or by a combination of a translation and a rotation relative to one of these N tilings, which is taken as a reference, N being an integer number greater than or equal to two. The N tilings may each be periodic with a common period a in at least one period direction that is associated with each layer. In this case, a length of the translation of the tiling of each of the N layers relative to the reference tiling, in the period direction of the reference tiling, may lie between 25% and 75% of i·a/N in addition to an integer number of times the common period, where i is a natural integer numbering the N layers having identical tilings, with i ranging from 0 to N−1 and i being zero for the layer of the reference tiling; the tiling period that is common to the layers having identical tilings may lie between 3 μm (microns) and 1 mm (millimeter); the respective optical phase shift distribution functions of the layers having identical tilings may themselves be identical except for the respective translations, rotations or combinations of translations and rotations of these layers; and the refractive function of the element may be invariant in rotation about its optical axis, except for residual variations due to a discretization of the values of the distribution functions of the optical phase shift.
The transparent optical element of the invention may form an optical lens, in particular an ophthalmic lens, and especially a spectacle glass.
Moreover, the optical phase shift values that are produced by each layer may result from variations in a refractive index of a transparent material from which this layer is formed, between different cells. Alternatively, the optical phase shift values that are produced by each layer may be the result of variations in depth or height between different cells of this layer. They may also result from combined variations in both refractive index and depth between different cells inside a given layer.
Optionally, contiguous cells in a given layer may be separated from one another by intercellular walls. Such walls may prevent compounds that are initially contained in the different cells from mixing. In addition, the intercellular walls may act as a spacer between a base film and a film closing the layer in question, which films are located on either side of the cells.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Other features and advantages of the present invention will become apparent from the following description of nonlimiting example embodiments, given with reference to the appended drawings, in which:
FIG. 1 is a cross-sectional view of an optical element according to the invention;
FIGS. 2 a and 2 b are cross-sectional views of layers that may be used in the optical element in FIG. 1 ;
FIGS. 3 a and 3 b are cross-sectional views of other layers that may be used in the optical element in FIG. 1 ;
FIGS. 4 a and 4 b show possible tilings for the layers used in the optical element in FIG. 1 ;
FIG. 5 a illustrates a first embodiment of the invention, and FIGS. 5 b and 5 c illustrate two transparent optical elements known from the prior art, mentioned by way of comparison; and
FIGS. 6 and 7 illustrate two other embodiments of the invention.
For the sake of clarity, the dimensions of the elements that are shown in these figures do not correspond to their actual dimensions and the ratios of these dimensions are not the actual ratios. Furthermore, identical references that feature in different figures denote identical elements or elements that have identical functions.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a transparent optical element 100 , which may be a spectacle glass, comprises a substrate 10 and at least two layers 1 and 2 that are superposed on one face of the substrate 10 . The substrate 10 may itself be a spectacle glass, the layers 1 and 2 being applied and permanently fastened to the substrate 10 in a way that is known in the art and not described here. For example, intermediate films of adhesive material may be used to fasten the layer 1 to the layer 2 , on the one hand, and the array of layers 1 and 2 to the substrate 10 , on the other hand.
The substrate 10 has a refractive function, which may be characterized by a distribution of the optical power and astigmatism values that are produced at various points in its useful optical area. Each of the layers 1 and 2 may then be intended to modify these values by producing locally an additional optical phase shift for a light wave that passes through the element 100 . This optical phase shift, which is produced by each layer 1 , 2 , varies depending on the point at which each light ray passes through the useful area of the element 100 .
It is also possible for the substrate 10 to have no refractive function itself, but only the function of supporting the layers 1 and 2 . In this case, the latter alone provide the element 100 with its final refractive function.
Lastly, the substrate 10 is optional when the layers 1 and 2 are sufficiently stiff or indeed are adequately held, for example by being fixed into a frame via their peripheral edge.
The layers 1 and 2 are superposed in a stacking direction that is denoted D. They are parallel to each other, and may optionally have a common curved shape.
In any case, the stack of layers 1 and 2 , or optionally of a number of layers greater than two, is designed to produce a refractive function for a monochromatic wave that passes through the layers in the direction D. D may then correspond to an optical axis of the element 100 .
Each layer of an element according to the invention may have a structure that is identical or different to that of another layer in the same element.
FIGS. 2 a and 2 b show first possible layer structures, for which the variable optical phase shift is obtained by varying a local thickness of the layer. For example, in FIG. 2 a , the layer 1 or 2 consists of a transparent film 11 the thickness e of which varies between different zones that are defined on one of the faces of the film. Such thickness variations may be obtained by laser ablation, i.e. by locally ablating a given part of the material of the film by means of a laser beam. Alternatively, these thickness variations may also be obtained by photolithography. For a layer such as the one considered in the present invention, the optical phase shift produced by said layer is constant inside juxtaposed zones, these zones being called cells, and denoted by the letter C in the figures. The cells C together cover the layer, or a useful part of the latter, and form a tiling. The value of the optical phase shift in a given cell C is then fixed by the residual thickness of the layer 11 in this cell. Most often, this value is selected from a finite number of possible values, which are set by the process used to produce the local variation in the thickness of the film 11 . For example, the laser beam which is used to ablate the surface of the film may be pulsed, each pulse having the same energy, the thickness of the film then being controlled by tailoring the number of laser pulses that are directed toward a cell location.
FIG. 2 b shows a layer structure equivalent to that in FIG. 2 a , in which neighboring cells C are separated by a wall 12 that extends perpendicularly to the layer. The variable thickness e of the film 11 is obtained by varying a depth of the cells C, which depth is measured in the direction D. The thickness of the separating walls 12 , measured parallel to the layer, may be neglected in a first approach to the invention. Preferably, the tops of the walls 12 are located at the same common level in the direction D. They can then support a closing film 13 , thereby preventing dirt from filling the cells C and modifying the depth distribution relative to the layer as initially manufactured.
FIGS. 3 a and 3 b show other possible layer structures in which the variable optical phase shift is obtained by locally modifying a value of the light refractive index of a constituent material of the layer. All the cells C may then have an identical depth. For example, in FIG. 3 a , the layer 1 , 2 is made from a film 14 having a thickness e 0 , that is constant between any locations on this film. This film 14 contains a photoactive material that is such that the value of its light refractive index can be modified via local irradiation, for example by means of a laser beam. Sweeping the surface of the film 14 with a laser spot while simultaneously varying the intensity or the number of laser pulses delivered between different points allows the value of the refractive index in the cells C to be adjusted. Typically, the maximum difference in the refractive index values that can be obtained in this way is about 0.1 or 0.15.
Lastly, FIG. 3 b shows a layer structure that is equivalent to that in FIG. 3 a , but in which neighboring cells are separated by walls 12 . Thus, separate portions of the photoactive material are respectively contained in partitioned cells C, and each of the cells may be irradiated separately in order to adjust its light refractive index value. To do this, the cells C may initially be formed on the surface of a base film 15 , then filled with the photoactive material, irradiated one by one, then collectively closed by a film 13 on a side opposite the base film 15 . When the cells C are thus isolated from one another by the walls 12 , an alternative method for varying the refractive index value of the material that is contained in each cell consists in using, for this material, a mixture of a plurality of compounds. These various compounds have respective index values that are different, and intermediate values are obtained by varying the proportions of the mixture. In this case, the number of obtainable values is limited by the minimum amount of each compound that can be controllably introduced into each cell. Typically, sixteen to one hundred and twenty eight different values can be obtained in this way for the refractive index in the cells C.
Alternatively, layer structures other than those described above may be used. In particular, mixed structures may be implemented, in which the variations in optical phase shift are obtained both by variations in thickness and by variations in the refractive index of portions of transparent materials contained in the cells.
Furthermore, within a given optical element according to the invention, the layers may have respective structures that are different.
FIGS. 4 a and 4 b show two different tilings that may be used to form the cells C inside each layer. Such tilings may be regular and especially periodic in at least one direction parallel to the layer. For example, the tiling may have a square pattern of side length a ( FIG. 4 a ), a triangular pattern, a hexagonal pattern, etc. Alternatively, the tiling may be random or pseudo-random ( FIG. 4 b ). In the context of the present description, the expression “pseudo-random tiling” is understood to mean a cellular distribution that is defined using a construction algorithm designed to produce an apparently random tiling. In particular, such a pseudo-random tiling may be obtained by fixing an initial distribution of cell centers in a layer, then by constructing the boundaries between neighboring cells using what is called the Voronoï method. Optionally, such a construction may be restarted by moving at least certain of the cell centers, in order to increase the disorder in the cellular tiling finally obtained. Within a given optical element according to the invention, the layers may have different respective tilings.
By way of illustration, the cells C may have dimensions that are about a few microns to several hundreds of microns in size, parallel to the layer in question. Their depth, parallel to the direction D, may be between 1 and 50 μm, and for example equal to about 20 μm.
Each layer is said to be digital when the optical phase shift that is produced by said layer has values respectively dedicated to the cells of the tiling, these values possibly changing from one cell to the next, and when these values are restricted to a set of discrete values that are determined beforehand. Such is especially the case when the optical phase shift is adjusted using a process that is itself digital. Such a digital layer is only able to approximate the target continuous distribution function of the optical phase shift. The use, according to the invention, of at least two layers having tilings that do not coincide allows the difference between the actual distribution of the optical phase shift that is produced by the superposition of the layers, and the target distribution, to be decreased. Such a target continuous distribution may correspond to the refractive function of a unifocal spectacle glass, for example, or to the refractive function of a progressive spectacle glass. Optionally, the target distribution function of the optical phase shift may be continuous inside separate portions of the useful area of the element 100 , and discontinuous at the boundary between two areal portions. Such is especially the case when the target distribution function corresponds to the refractive effect of a Fresnel lens. Generally, the target distribution function may be any function. In particular, it may have no symmetry of revolution about the optical axis of the element.
The difference between the actual distribution function of the optical phase shift for an element produced according to the invention and its target distribution function may be estimated in various ways.
A first method is suitable for demonstrating luminous interference effects that the optical element could produce, and that would be liable to decrease image contrast. This first method consists in comparing, in a selected plane downstream of the optical element, the illumination produced, for an incident monochromatic wave, by the optical element of the invention and by a reference optical element, respectively. The integration plane will sensibly be chosen to be a focal plane of the emergent wave. Directions in which the optical element may diffract light with significant intensities may be established with this first method. Depending on the circumstances, it may be advantageous to deflect the diffraction directions, and a scattering halo, relative to the image direction, and thus decrease the diffraction and scattering intensities.
A second method of estimating the difference, which is commonly called Maréchal's criterion, consists in integrating, in a reference plane that is located downstream of the optical element, for an incident monochromatic wave that passes through said element, the square of the difference between the phases of the emergent wave for the actual distribution function and for the target distribution function of the optical phase shift, respectively. In particular, the integration plane may be located on the exit face of the optical element. Such a second method is particularly suitable for demonstrating the amount of error associated with an actual phase shift, during design of a digital glass.
A first example embodiment of the invention, in which the optical element 100 comprises two layers 1 and 2 having identical square tilings of pitch denoted a and equal to 200 μm, is now described with reference to FIG. 5 a . The respective tilings of the layers 1 and 2 are offset by translating one relative to the other along half the length of the diagonal of the square cells. In other words, the tiling of the layer 2 is simultaneously translated by a/ 2 along the two directions of the sides of the square cells C, relative to the tiling of the layer 1 .
The two layers 1 and 2 are digital layers that are produced using the same digital technology to adjust the optical phase shift in each cell C. The optical phase shift distribution of each of the layers 1 , 2 is optimized to reproduce the target continuous distribution of a convergent unifocal lens having a focal length of 2 m (meters). Under these conditions, the transparent optical element 100 is a digital version of a convergent unifocal lens with a focal length equal to 1 m.
By way of comparison, in order to illustrate the benefits of the invention, FIGS. 5 b and 5 c show two reference optical elements 101 and 102 , respectively, each comprising a single layer of square tilings reproducing the optical phase shift distribution of the convergent unifocal lens with a 1 m focal length. Production of these two reference optical elements 101 and 102 , which do not employ the invention, also uses the same digital technology as was used for the element 100 in FIG. 5 a to adjust the optical phase shift in each cell C.
The pitch of the square tiling of element 101 in FIG. 5 b is equal to a, i.e. identical to that of each of the layers 1 , 2 of the element 100 in FIG. 5 a . The pitch of the square tiling of element 102 in FIG. 5 c is equal to a/2. The diameters of the three elements 100 , 101 and 102 are identical.
Under these conditions, the optical phase shift produced by each cell C of the reference element 101 may be double that produced by the same cell for a single of the layers of the element 100 according to the invention. Furthermore, the discrete optical phase shift values that are produced by the cells C of the reference element 102 reproduce, with less discretization error than the reference element 101 , the continuous optical phase shift distribution of the convergent lens of 1 m focal length used as a target for these three elements.
The three elements 100 , 101 and 102 may then be compared in an equivalent manner either by implementing actual optical experiments, or via numerical simulations of such experiments. Such simulations, which were carried out in the present case, are based on optical Fourier calculations. It is assumed that the principle behind such calculations is known to those skilled in the art and that hence there is no need to describe it here.
First, the optical functions of the three elements 100 , 101 and 102 were compared, using the first method presented above, by illuminating each of them with a beam of parallel monochromatic light with a wavelength of 633 nm (nanometers) parallel to their respective optical axes. The luminous illumination produced in the image focal plane of each of them, located 1 m downstream of each element, was then recorded. The maximum intensities of the secondary diffraction peaks were −24.3 dB (decibels) for the elements 100 and 102 , and −18.1 dB for the element 101 , these intensities being measured relative to that of the geometric image point, which is located where the optical axis intersects the image focal plane. Thus, although the pitch of each of the layers of the element 100 according to the invention is double that of the reference element 102 , the parasitic diffractions that were produced by these two optical elements have comparable intensities that are lower than that of the reference element 101 . Furthermore, the angle between the first order diffraction direction and the optical axis is two times larger for the elements 100 and 102 than for the element 101 .
The optical functions of the two elements 100 ( FIGS. 5 a ) and 101 ( FIG. 5 b ) were also compared by adhesively bonding each of them to a divergent unifocal lens having a focal length equal to −1 m. This divergent lens was produced in the conventional way by continuously varying its thickness, in order to observe effects associated with the digital elements 100 and 101 . Refractive effects observed for the doublets obtained in this way correspond to defects in the digital elements 100 and 101 . Thus, a luminous pattern located at infinity, for example a Landolt C of outside angular diameter equal to 2.96° (degrees) and of angular stroke thickness equal to 0.74°, is observed through each of the doublets. Observing the pattern through the doublet containing the element 100 caused parasitic images to appear that were aligned parallel to the directions of the tilings, but the space between these parasitic images is two times larger for the element 100 according to the invention than for the reference element 101 .
The pattern was observed in the same way with a second element according to the invention, which element consisted of four layers again comprising square tilings, of pitch equal to a, these tilings however being progressively offset by multiples of a quarter of the length of the diagonal of the cells. The optical phase shift distribution in each layer of this second element reproduced that of a convergent lens with a focal length equal to 4 m. This second element according to the invention therefore also formed a digital version of a convergent lens with a focal length equal to 1 m. Observing the Landolt C through the new doublet formed by adhesively bonding the second four-layer element to the divergent lens of −1 m focal length showed that the space between the parasitic images was also twice as large as for the element 100 . Therefore, increasing the number of layers in a transparent optical element according to the invention makes it possible to improve the optical function thereof.
Furthermore, if the two layers 1 and 2 were offset within the element 100 by a length a/ 4 in the two directions of the sides of the square cells C, instead of by a/ 2 , the maximum intensity of the secondary diffraction peaks became −23.1 dB. Therefore, although the benefit of the invention is maximized for the element 100 when the translation length is equal to half the pitch a, a significant improvement is also obtained for other values of the translation length lying between 25% and 75% of the pitch a.
As shown in FIG. 6 , a third transparent optical element 103 , according to the invention, comprises two layers 3 and 4 again comprising square tilings of pitch a for example equal to 200 μm. The two layers 3 and 4 are identical to the layer 1 of the element 100 . They therefore each possess an optical phase shift distribution that corresponds to a convergent lens with a focal length equal to 2 m. The two layers 3 and 4 are superposed in the element 103 but rotated by 30° one relative to the other about their common optical axis D. The element 103 therefore also has a convergent lens function with a focal length of 1 m.
The illumination obtained in the image focal plane of the element 103 1 m downstream of this element, when it was illuminated by a beam of parallel monochromatic light of 633 nm wavelength, contained secondary diffraction peaks that had maximum amplitudes equal to −24.2 dB. The advantage conferred to the element 103 by the invention is therefore analogous to that conferred to the element 100 . In other words, the element 100 would be little degraded by an error in the angular alignment of the two layers 1 and 2 .
Observing the Landolt C through the element 103 adhesively bonded to the divergent lens of −1 m focal length caused parasitic images to appear that were much less bright than those visible with the element 102 , under the same illumination and observation conditions.
As shown in FIG. 7 , a fourth transparent optical element 104 according to the invention consists of two layers 5 and 6 comprising identical tilings that are rotated, one relative to the other, by 90° about the optical axis of the element D. The common tiling of the two layers 5 and 6 is pseudo-random. It was obtained from the tiling in the layer 1 described above by randomly shifting the centers of the cells C, then by constructing the intercellular boundaries using the Voronoï method. The optical phase shifts obtained in the cells C thus defined were again selected to reproduce a convergent lens with a focal length equal to 2 m.
A reference optical element, which did not employ the invention, was formed from a single layer having the same pseudo-random tiling as each of the layers 5 and 6 , but with an optical phase shift value in each cell C that was doubled relative to the value in the equivalent cell in one of these layers.
The optical element 104 and the latter reference element therefore again both have refractive functions that are similar to that of a convergent lens with a focal length equal to 1 m. When these two elements are illuminated by a beam of parallel light, the element 104 produces, in the image focal plane, a halo of scattered light that is more attenuated than is the case for the reference element. Thus, even in the case of random tilings, the invention allows drawbacks due to the digital nature of the element to be reduced.
Moreover, in an optical element according to the invention, the optical phase shift values of superposed cells belonging to the different layers add to one another. As a result, the width of the range of values accessible for the total phase shift is equal to the sum of the respective widths of the ranges of phase shift values accessible for each layer. Thus, an optical element according to the invention may possess apparent variations in optical phase shift that are greater than those of a single-layer element such as known from the prior art. Refractive functions that were not previously possible can thus be produced using the invention.
In particular, the greater variations in optical phase shift that are obtainable in an optical element according to the invention make it possible to avoid the need to implement small (despite the fact that they are multiples of two times pi) amplitude phase jumps. It is thus possible to use only phase jumps the amplitudes of which are greater than ten times pi, for example. Such large-amplitude phase jumps generate only a restricted chromatic aberration in the refractive function of the element, which chromatic aberration is compatible with many applications, especially ophthalmic applications.
It will be understood that the invention may be reproduced while modifying certain of its secondary aspects relative to the embodiments that were described in detail above. In particular, the following modifications may be applied, either separately or by combining a number of them together:
the superposed layers may be any number greater than or equal to two in number; the various layers in a given optical element may have different tilings. For example, certain layers may have periodic tilings and others may have random or pseudo-random tilings; the layers that are superposed in an optical element according to the invention may be adhesively bonded to one another or separated by intermediate spaces or intermediate films arranged between two successive layers; and the target values for the phase shifts that are produced by two layers of a given optical element may be different. Therefore, the respective phase shift distribution functions of the layers may also be different.
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A transparent optical element ( 100 ), includes a plurality of stacked layers ( 1, 2 ), each of which consist of cells in which optical phase-shift values are provided. The layers are arranged such that boundaries between certain contiguous cells of one of the layers cut into cells of another layer. In this way, a useful apparent cell size can be reduced so as to reproduce a target optical phase-shift distribution with greater precision. Additionally, the maximum amplitude of optical phase shift variations that are produced by the element increases with the number of stacked layers. The chromatism of the diopter function of the element can also be reduced.
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BACKGROUND OF THE INVENTION
The invention is directed to an apparatus for feeding powder coating apparatus with a powder-air mixture.
In electrostatic powder coating apparatus, the applicators, i.e. the powder spray guns, must be supplied with the powder in a form of a powder-air mixture, whereby an optimally uniform distribution and an exact and constant dosing of the powder particles in the powder-air stream are of special significance for a uniform coating.
Usually, the coating powder is prepared in special reservoirs for this purpose. These reservoirs comprise fluidization and conveying means. German Patent 36 11 039 discloses such a reservoir. Given the type of fluidization and conveyor means disclosed therein, it is difficult to undertake an exact conveying and dosing. This disadvantage is aggravated by what are usually long conveyor lines from the generally extremely large powder reservoirs to the remote powder coating apparatus. Further, it is not possible given this and similar, known apparatus to undertake a separate matching for every powder coating apparatus given the connection of a plurality of coating apparatus to a single reservoir, i.e. to match quantity and composition of the powder-air mixture to the respective demands.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to create a means for supplying powder coating apparatus with whose assistance one succeeds in significantly improving conveying uniformity and metering precision and in supplying a plurality of powder coating apparatus independently from one another with respect to throughput quantity and air proportion of the powder-air mixture proceeding from a single reservoir.
This object is achieved in an apparatus for feeding powder coating apparatus with a powder-air mixture, whereby the powder is fluidized in a powder reservoir and the powder-air mixture thereby arising is conveyed to the powder coating apparatus via an intermediate container that is likewise equipped with a fluidization means, the intermediate container comprising a dosing container closely proximate to the coating apparatus and having a cyclone-like air separator, a fluidization means and a dosing means for producing a dosed powder air mixture, and a convey or means for conveying the dosed powder-air mixture to the powder coating apparatus.
For maintaining a rated moisture value of enamel powder that is conditioned with respect to its temperature and moisture, German Published Application 37 29 705 in fact discloses that additional, moistening fluidization air be added to the conditioned powder-air mixture in a coating container coming from the preparation container when this moisture content drops. The system disclosed therein, however, serves only the purpose of setting the moisture content and the temperature of enamel powder. No separation of the air from the supplied, conditioned powder-air mixture thus ensues in the coating container.
One advantage of the solutions of the invention is that composition and volume of the powder-air stream can be matched to the respectively desired coating quality by separating the air from the incoming powder-air mixture, fluidization and dosing of the remaining powder in a dosing container allocated to a single powder coating apparatus, despite the fact that only a single reservoir is provided for a plurality of powder coating apparatus. It is thereby critical for the dosing precision that the fluidization air is first separated from the powder-air mixture incoming to the reservoir and that the remaining powder is then re-fluidized and re-dosed in defined fashion. A further advantage of the invention derives from the relatively short conveying distance from the dosing container--that can be accommodated in spatial proximity to the coating apparatus given a small structure--to the allocated powder coating apparatus, as a result whereof the conveying uniformity is substantially less deteriorated than given traditional, long conveying lines. Last but not least, the employment of a dosing container enables a powder coating apparatus allocated thereto to be operated even when the reservoir is not conveying, at least for a certain time span dependent on the volume of the dosing container.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be set forth in greater detail below with reference to a preferred exemplary embodiment shown in the drawings. Shown are:
FIG. 1 is a schematic illustration of an apparatus for feeding powder coating apparatus with a powder-air mixture;
FIG. 2 is a vertical section through the dosing container of FIG. 1;
FIG. 3 is a vertical section through the dosing container of FIG. 2 turned by 90°; and
FIG. 4 is a horizontal section through the dosing container of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic illustration of the apparatus comprising a reservoir 1, conveyor lines 2 and 4, a dosing container 3 and a powder coating apparatus 5. Only one dosing container 3 and one powder coating apparatus 5 are shown in the illustration of FIG. 1. Of course, a plurality of such dosing containers/coating apparatus pairs can also be connected to the reservoir 1. The conveyor line 4 from the dosing container to the powder coating apparatus 5 is usually short compared to the conveyor line 2 from the reservoir 1 to the dosing container 3.
The crux of the apparatus for feeding powder coating apparatus with a powder-air mixture is the dosing container 3 shown in greater detail in FIGS. 2 through 4. FIGS. 2 through 4 show various views of the dosing container comprising apparatus 3:
means for separating the air from the incoming powder-air mixture 10;
means for fluidizing the remaining powder 11;
means for dosing the newly produced powder-air mixture 12; and
means for continued conveying of the dosed powder-air mixture 13.
In the exemplary embodiment, a cyclone 15 is accommodated in a container cover 14, having a horizontal delivery passage 16 for the powder-air mixture coming from the reservoir and having an upper opening 17 forming a communication path to the atmosphere for eliminating the air constituents of the powder-air mixture. The dosing container 3 also comprises a powder chamber 20 having a lower powder discharge 28 that is covered by a cover bell 29. The floor of the powder chamber 20 is formed by the fluidization means 1 1 that comprises a fluidization floor 31 having fluidization air input 32 at the under side thereof. A dosing chamber 34 having a lateral dosing air input 35 is provided under this fluidization means, a fine-pore, gas-permeable dosing cartridge 36 being accommodated in the chamber 34. The dosing chamber 34 is followed by the conveyor means 13 that comprises an injector 38 having an injector air input 39 and exit 40 for the dosed powder-air mixture to the allocated powder coating apparatus. A powder level display 21 is provided in the powder chamber 20, this being accomplished in the exemplary embodiment as a pneumatic level monitoring having a pressure pipe 22 and a diaphragm 23 in the cross section of this pipe at the lower, free end thereof. In addition, the dosing container 3 is provided with mounts 25, 26 in order to be able to fasten it in the proximity of the work station, for example to a compartment wall.
The described apparatus works in the following way: the powder-air mixture coming from the reservoir 1 flows tangentially into the cyclone 15. A primary eddy thereby arises at the inside cyclone wall with which the heavy powder particles are separated in downward direction under the influence of the centrifugal acceleration, whereas the lightweight air particles are carried upward in a narrow, ascending secondary eddy and are eliminated through the opening 17. The powder is subsequently collected in the powder chamber 20 and is fluidized by the fluidization air flowing through the fluidization floor 31. The powder-air mixture produced is downwardly withdrawn through the powder discharge 28 by the suction effect of the injector 38. The powder-air mixture thereby flows through the dosing chamber 34 along the dosing cartridge 36 through whose fine-pore, gas-permeable wall further air can be added to the powder-air mixture via the dosing air input 35; i.e. the powder-air mixture can be "diluted" further. The conveying air entering through the injector air input 39 defines the quantity of powder-air mixture that is conveyed to the allocated powder coating apparatus and the powder-air stream is conveyed in a known way to the closely proximate coating apparatus.
During operation, the powder level in the powder chamber 20 is indicated by the powder level display 21. In case of a pneumatic level monitoring, the diaphragm 23 in the end of the pressure pipe 22 thereby acquires the level height in accord with the weight of the powder acting on it. With prescribed values for minimum and maximum filling level and on the basis of the measured powder level, the conveying of the powder-air mixture from the reservoir 1 to the dosing container 3 can be regulated by means of a minimum/maximum control means 24 (FIG. 1) in accord with the calculated differences between measured height and height limit values.
A preferred embodiment of the invention is set forth by way of example in the above description. However, other embodiments of the invention are also conceivable.
The sequence--of first fluidizing the powder that remains after the air has been eliminated and subsequently dosing the produced powder-air mixture can also be reversed on the basis of a corresponding arrangement of the dosing means 12 following the separation means 10 and preceding the fluidization means 11. This arrangement yields an especially exact dosing for specific applications.
Further, the powder level display 21 in the powder chamber 20 can also ensue capacitatively, inductively, mechanically or optoelectrically on the basis of a transparent container cylinder. Further, the dosed powder-air mixture can be conveyed to the allocated powder-coating apparatus with a worm, a star feeder or the like instead of being conveyed thereto with an injector.
In an alternative embodiment of the invention, the dosing container 3 is directly connected to the powder coating apparatus without an intervening conveyor line 4. This is particularly called for given permanently installed coating apparatus. In this case, it is also possible to accommodate the high-voltage generator of the electrostatic powder coating apparatus in or at the dosing container 3.
Over and above this, all component parts of the dosing container can be pluggably or screwably connected to one another.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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An apparatus for feeding powder coating apparatus with a powder-air mixture, whereby the powder is fluidized in a reservoir, the powder-air mixture that has thereby arisen is conveyed to a dosing container via conveyor lines and is prepared in this dosing container. The fluidization air is eliminated from the powder-air mixture coming from the reservoir, the remaining powder is re-fluidized and re-dosed in defined fashion, and the powder-air mixture produced is conveyed to the allocated powder coating apparatus.
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REFERENCE TO PENDING PRIOR PATENT APPLICATION
This is a continuation of prior U.S. patent application Ser. No. 08/815,491, filed Mar. 11, 1997 abandoned, by John A. Belli for BRACKETS FOR RETAINING POST AND BOARD ENDS, which in turn claimed benefit of prior U.S. Provisional Patent Application Serial No. 60/013,123, filed Mar. 11, 1996 by John A. Belli for SURFACE MOUNT FLANGES, and prior U.S. Provisional Patent Application Serial No. 60/039,642, filed Feb. 24, 1997 by John A. Belli for FLANGES. The specification and drawings of which are hereby also incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to bracket devices for mounting objects, such as posts or boards, to surfaces of support members for such objects.
BACKGROUND OF THE INVENTION
It often is desirable to mount a rail or board to a post, or to mount a post or board to a flat surface. Unfortunately, in many situations, this can be inconvenient or difficult to accomplish. For example, in post and rail fences, holes in the posts are adapted to receive the ends of the rails. The holes are spaced a standard distance apart on the posts. However, sometimes it is desirable to vary the distance between the rails. Further, replacement of broken rails can be difficult, particularly where the pair of supporting posts are securely mounted in the ground and where other good rails are still retained by the posts. In this situation it can be difficult to remove the bad rail and even more difficult to position a replacement rail.
Further, it often is desired to mount a post on a horizontal surface, such as, for example, a railing post on a wooden deck, the legs of equipment such as swings and other children's play devices on a concrete surface, the posts of swimming ladders on concrete decks, and fence posts on rock ledge, to mention only a few of the many possible post-to-surface mounting situations.
OBJECTS OF THE INVENTION
Accordingly, an object of the present invention is to provide devices by which a post or board or rail may be mounted on a surface which is horizontal, vertical, or inclined.
A further object of the present invention is to provide an improved method for quickly and easily mounting a post, board, or rail on a surface.
SUMMARY OF THE INVENTION
These and other objects of the present invention are addressed by the provision and use of a novel bracket for mounting on a surface and for retaining an end of an elongated object, the bracket comprising a flange portion for connection to the surface, and a tubular wall portion extending from the flange portion and having an open end for receiving the end of the elongated object, the tubular wall portion being continuous and endless circumferentially of the tubular wall portion for completely surrounding the end of the elongated object.
The objects of the present invention are further addressed by the provision and use of a method for mounting an elongated object on a surface, the method comprising the steps of: providing a bracket comprising a flange portion, and a tubular wall portion extending from the flange portion, the tubular wall portion having an open end for receiving an end of the elongated object and being continuous and endless circumferentially of the tubular wall portion for completely surrounding the end of the elongated object; and fixing the flange portion of the bracket to the surface and inserting the end of the elongated object through the open end of the tubular wall portion into a space defined by the tubular wall portion, whereby to mount the elongated object on the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:
FIG. 1 is a perspective view showing an illustrative embodiment of bracket for mounting a post to a substantially flat surface;
FIG. 2 is a top plan view of the bracket shown in FIG. 1;
FIG. 3 is a side elevational view of the bracket shown in FIGS. 1 and 2;
FIG. 4 is a bottom plan view of the bracket shown in FIGS. 1-3;
FIG. 5 is a perspective view of an alternative embodiment of bracket for mounting a post to a substantially flat surface;
FIG. 6 is a bottom view of the bracket shown in FIG. 5 .
FIG. 7 is a perspective view of another alternative embodiment of bracket for mounting a post to a substantially flat surface;
FIG. 8 is a sectional view taken along line 8 — 8 of FIG. 7;
FIG. 8A is a view like that of FIG. 8, but showing another alternative form of bracket for mounting a post to a flat surface;
FIG. 9 is a perspective view of still another alternative embodiment of bracket for mounting a post to a substantially flat surface;
FIG. 10 is a top plan view of the bracket shown in FIG. 9;
FIG. 11 is a perspective view of a post cap for capping the end of a post;
FIG. 12 is a front elevational view of another alternative embodiment of bracket, shown for mounting fence rails on posts;
FIG. 13 is an end view of a bracket shown in FIG. 12;
FIG. 14 is an enlarged side elevational view of the bracket of FIG. 13, with the bracket being modified slightly from the form shown in FIG. 13;
FIG. 15 is a perspective view of an alternative embodiment of bracket, somewhat similar to the bracket of FIG. 14 but showing a plurality of discrete flange members;
FIG. 15A illustrates how the bracket of FIG. 15 may be formed out of tubular stock;
FIGS. 15B-15D illustrate how the bracket of FIG. may be formed out of stamped sheet stock;
FIG. 16 is an end view of still another alternative embodiment of bracket for mounting fence rails on posts;
FIG. 17 is a side elevational view of the bracket of FIG. 16;
FIG. 18 is an exploded view of a fence post and rail arrangement, showing an alternative embodiment of bracket in centerline section and the post and rail in side elevation;
FIG. 18A is a sectional view taken along line 18 A— 18 A of FIG. 18 .
FIG. 19 is a side elevational view of a stair rail assembly including an alternative embodiment of bracket;
FIG. 20 is an enlarged side elevational view of a bracket of FIG. 19;
FIG. 21 is a front elevational view of the bracket shown in FIG. 20;
FIG. 22 is a side elevational view of a portion of a stair tread assembly including brackets similar to the bracket of FIG. 1, but somewhat modified;
FIG. 23 is a front elevational view of a mounted stair tread and brackets as shown in FIG. 22; and
FIG. 24 is a partial schematic view of a portion of the stair tread assembly of FIGS. 22 and 23, but showing a modified form of bracket.
DETAILED DESCRIPTION OF THE INVENTION
This patent application claims benefit of pending prior U.S. Provisional Patent Application Serial No. 60/013,123, filed Mar. 11, 1996 by John A. Belli for SURFACE MOUNT FLANGES, the specification and drawings of which are hereby incorporated herein by reference; and pending prior U.S. Provisional Patent Application Serial No. 60/013,123, filed Feb. 24, 1997 by John A. Belli for FLANGES, the specification and drawings of which are hereby also incorporated herein by reference.
Looking first at FIGS. 1-4, there is shown a first type of bracket 5 for mounting a post 10 to a substantially flat surface 15 . Bracket 5 generally comprises a tubular wall portion 20 for receiving and surrounding the distal end 21 of post 10 , and a flange portion 25 for seating against flat surface 15 . Bracket 5 also comprises a web portion 30 (FIGS. 2-4) for engaging the distal end surface 31 of post 10 (FIG. 3 ). Openings 35 are formed in the bracket's tubular wall portion 20 and web portion 30 for receiving fasteners (such as nails or screws or the like) for securing bracket 5 to post 10 . Openings 40 are formed in flange portion 25 for securing flange portion 25 to substantially flat surface 15 . The exact number of openings 35 and openings 40 which are provided in bracket 5 will depend on the application. For many applications, it has been found that four openings 35 and four openings 40 work well, although more or less than that number may be provided. In fact, holes 35 may be provided only in tubular wall portion 20 and not in web 30 , or they may be provided in web 30 and not in tubular wall portion 20 , or they may be omitted altogether. It will be appreciated that, by securing post 10 to the bracket's tubular wall portion 20 , and by securing the bracket's flange portion 25 to flat surface 15 , post 10 will be effectively secured to flat surface 15 .
Looking next at FIGS. 5 and 6, there is shown a second type of bracket 5 A. Bracket SA is substantially the same as bracket 5 shown in FIGS. 1-4, except that with bracket 5 A, openings 35 are omitted from the bracket's tubular wall portion 20 , and openings 35 and openings 40 are disposed in different numbers and in locations about flange portion 25 .
Looking next at FIGS. 7 and 8, there is shown a third type of bracket 5 B. Bracket 5 B is substantially the same as bracket 5 shown in FIGS. 1-4, except that with bracket 5 B, tubular wall portion 20 B is much shorter than the tubular wall portion 20 provided for bracket 5 , and tubular wall portion 20 B lacks openings 35 . In effect, in bracket 5 B, tubular wall portion 20 B comprises a shallow rib for stabilizing the distal end 21 of post 10 relative to bracket 5 B.
Alternatively, if desired, tubular wall portion 20 B can be replaced by forming a corresponding sort of recess 41 (FIG. 8A) in the proximal surface 42 of the bracket's flange portion 25 , with the recess being sized and shaped so as to receive and seat the distal end 21 of post 10 .
Looking next at FIGS. 9 and 10, there is shown a fourth type of bracket 5 C. Bracket 5 C is substantially the same as bracket 5 shown in FIGS. 1-4, except that with bracket 5 C, web 30 is omitted entirely and the bracket's flange portion 25 simply surrounds the open distal end of tubular wall portion 20 . This design can be advantageous where the distal end surface 43 of post 10 does not lie substantially perpendicular to the longitudinal axis of post 10 , such as is schematically illustrated in FIG. 9 .
The brackets shown in FIGS. 1-10 are preferably formed out of cast aluminum, although plastic, wood, steel, or any other rigid material can also be used to form the brackets.
Looking next at FIG. 11, there is shown a post cap 45 for capping the top end of post 10 . Post cap 45 comprises a wall portion 50 for fitting over a proximal end 44 of post 10 , and an end portion 55 for closing off the proximal end of wall portion 50 . Openings 60 are formed in wall portion 50 for receiving fasteners (such as nails or screws or the like) for securing post cap 45 to post 10 . Post cap 45 is preferably cast as a single piece out of aluminum or some other satisfactory material, and surrounds the proximal end 44 of post 10 with a secure band of material so as to prevent the proximal end of the post from splitting.
Brackets generally similar to those heretofore described are particularly applicable to post and rail fences, and allow the fence rails to be placed at any height along the fence posts, and facilitate easy replacement of a bad or broken rail.
More particularly, and looking now at FIG. 12, such brackets 65 may be attached to each end of a rail 70 , and then the complete rail assembly slipped into place, without disturbing the posts 80 or the other rails 70 . Then the brackets are nailed or screwed to the posts 80 at the desired height along the post.
Looking now at FIGS. 12-14, post and rail bracket 65 may comprise a cylindrical portion 85 for receiving the end of rail 70 . Holes 90 preferably are formed in cylindrical portion 85 whereby bracket 65 can be attached to rail 70 . Bracket 65 also comprises the flange portion 91 for attachment to post 80 . Holes 100 preferably are formed in flange portion 91 whereby flange portion 91 can be attached to post 80 . The exact number of holes 90 and holes 100 which are provided in bracket 65 will depend on the fencing application. For many fencing applications, it has been found that two holes 90 and two holes 100 work well, although more or less than that number may be provided.
In one preferred embodiment, the post and rail bracket 65 is made of cast aluminum, but plastic, wood, steel, or any rigid material can also be used to form the bracket.
For a uniform appearance, brackets 65 should be used for the entire construction of the fence. However, if desired, brackets 65 can be used to replace one or more damaged rails in an existing fence.
One or more nails or screws (not shown) preferably are used to secure the bracket's cylindrical portion 85 to the rail end. One or more thin ribs 105 (FIG. 13) may be formed on the inner diameter of the bracket's cylindrical portion 85 to prevent rail 70 from rotating once it has been placed into bracket 65 . Two or more nails or screws are preferably used to secure the bracket's flange portion 91 to post 80 . Flange portion 91 of bracket 65 is typically provided with a flat back 110 (FIG. 14) for placement against post 80 . Such an arrangement works well with rectangular posts and with many circular posts. However, if desired, flange portion 91 of bracket 65 may also be formed with a curved back (not shown) for use on round posts.
The present invention is also applicable to stockade-type fences of the type where vertical barrier members are hung on a post and rail skeleton. With such stockade-type fences, the present invention can be used to attach the skeleton rails to the skeleton posts (not shown), whereupon the remainder of the fence can then be mounted to the skeleton elements. It is to be appreciated that the mounting brackets of the present invention can be used with stockade-type fences for both initial construction purposes and/or repair purposes.
In FIG. 15 there is shown a bracket 65 A which is similar to the bracket 65 shown in FIGS. 13 and 14, except that the flange portion 91 A comprises a plurality of discrete flange members 115 . Bracket 65 A can have as many discrete flange members 115 as may be desired.
As noted above with respect to bracket 65 , bracket 65 A can be formed out of a cast material such as aluminum or plastic. However, if desired, the bracket 65 A shown in FIG. 15 can be formed out of tubular stock, such as in the manner illustrated in FIG. 15 A. In this situation the discrete flange members 115 can be cut from the tubular stock and then bent outward at a right angle so as to form the desired structure.
Alternatively, the bracket 65 A shown in FIG. 15 can also be formed out of punched stock and then curled on itself so as to form bracket 65 A. More particularly, and looking now at FIGS. 15B-15D, a flat part 116 (FIG. 15B) may be punched from a flat sheet of virgin metal stock, and then this flat part 116 curled (FIG. 15C) so that it forms the complete bracket 65 A (FIG. 15 D). In such a situation, where the bracket 65 A is to have four flange members 115 , five flanges 115 will preferably be formed on flat part 116 , whereby one of the flanges 115 will overlie another of the flanges 115 on the assembled bracket 65 A. Of course, it will also be appreciated that flange members 115 need not necessarily overlie one another when flat part 116 is curved into the bracket 65 A, in which case only as many flange members 115 will be formed as the bracket 65 A is to have.
Bracket 65 A can also be formed with a rectangular cross-section is desired.
In FIGS. 16 and 17, there is shown a bracket 65 B wherein the bracket is provided with a wall portion 85 B defining a sleeve 120 which is rectangular rather than cylindrical, for receiving rectangular rails. If desired, wall portion 85 can be formed sufficiently large that the ends of the rails do not have to be tapered down to fit in the sleeve 120 .
Referring to FIG. 18, it will be seen that bracket 65 C may be provided with wall portion 85 C of a frustoconical configuration, allowing rails 70 to extend from posts 80 at other than right angles. Thus, for example, rails may be angled from a post on relatively high ground to a post on relatively low ground. Alternatively, rails 70 can be angled to follow a curved path, e.g., about a circular driveway.
FIG. 18A illustrates how a side land 121 may be added to wall portion 85 C to form a secure attachment to rails 70 about a hole 90 C. More than one side land 121 may be provided if desired.
The conical shape of bracket 65 C may also be utilized in others of the brackets formed in accordance with the present invention, e.g., it may be utilized in the bracket 5 shown in FIGS. 1-4.
FIG. 19 discloses a stair rail assembly including stair rail posts 125 and stair rails 130 fixed to posts 125 by brackets 5 D, shown in greater detail in FIGS. 20 and 21. Bracket 5 D is similar to bracket 5 of FIGS. 1-4 except that its wall portion 20 D is inclined from the plane of its flange portion 25 D, permitting the rails 130 to follow the incline of the stairs 140 . The web 30 of bracket 5 may or may not be incorporated in bracket 5 D, as desired. FIG. 21 shows bracket 5 D formed without a web 30 . It should also be appreciated that brackets 50 may be positioned against vertical objects other than stair rail posts 125 . By way of example, brackets 5 D can be placed against the sides of buildings, trees, etc.
In FIGS. 22 and 23, there is shown a stair tread assembly 145 including stringers 150 between which extend stair treads 155 . The ends of each stair tread 155 are nested in brackets 5 E which are similar to the bracket 5 D of FIGS. 20 and 21, but in which the wall portion 20 E extends normal to flange portion 30 E. Brackets 5 E are fixed to stringers 150 by screws or other fasteners which extend through holes 40 E which extend through the flanges of the brackets.
Preferably brackets 5 E are formed out of a suitable cast material, e.g., cast aluminum, although they may also be fabricated in other ways consistent with the present invention, e.g., out of stamped metal which is appropriately bent into the desired shape. If desired, the bottom side 160 of flange portion 30 E may be enlarged somewhat relative to the top side 165 of flange portion 30 E, so that more screws or nails may be applied to the underside of the bracket and thereby provide improved attachment to the stringer 150 . See, for example, FIG. 24, which shows a bracket 5 E joining a stair tread 155 to a stringer 150 , where bracket 5 E is formed out of stamped sheet metal and where the bottom side 160 of the bracket's flange portion 30 E is enlarged somewhat relative to the topside 165 of flange portion 30 E.
There are thus provided several embodiments of brackets for interconnecting posts and horizontal surfaces, rails and posts, stair rails and stair rail posts, and staircase stringers and treads. While such uses of the brackets disclosed herein are of demonstrable value, it will be apparent to those skilled in the art that many uses not mentioned herein are within the scope of the invention, it being the thrust of the invention to provide brackets for fixing together two structural objects. Accordingly, the invention is by no means limited to the particular constructions herein disclosed and/or shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims.
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A bracket for mounting on a surface and for retaining an end of an elongated object, wherein the bracket includes a flange portion for connection to the surface, and a tubular wall portion extending from the flange portion and having an open end for receiving the end of the elongated object, the tubular wall portion being continuous and endless circumferentially of the tubular wall portion for completely surrounding the end of the elongated object.
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A MEDICINAL AEROSOL FORMULATION
This application claims priority from U.S. provisional application Ser. No. 60/201,058 filed May 1, 2000, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a medicinal aerosol formulation, and more particularly, to a medicinal aerosol formulation comprising a rosiglitazone maleate.
2. Description of the Related Art
Delivery of drugs to the lung by way of inhalation is an important means of treating a variety of conditions, including such common local conditions as cystic fibrosis, pneumonia, bronchial asthma and chronic obstructive pulmonary disease and some systemic conditions, including hormone replacement, pain management, immune deficiency, erythropoiesis, diabetes, etc. Anti-diabetic drugs, e.g. an insulin, are among the drugs that are administered to the lung for such purposes. Such drugs are commonly administered to the lung in the form of an aerosol of particles of respirable size (less than about 10 μm in diameter). The aerosol formulation can be presented as a liquid or a dry powder. In order to assure proper particle size in a liquid aerosol, particles can be prepared in respirable size and then incorporated into a colloidial dispersion either containing a propellant as a metered dose inhaler (MDI) or air, such as in the case of a dry powder inhaler (DPI). Alternatively, formulations can be prepared in solution form in order to avoid the concern for proper particle size in the formulation. Solution formulations must nevertheless be dispensed in a manner that produces particles or droplets of respirable size.
For MDI application, once prepared an aerosol formulation is filled into an aerosol canister equipped with a metered dose valve. In the hands of the patient the formulation is dispensed via an actuator adapted to direct the dose from the valve to the patient.
What is needed and desired is a stable aerosol formulation for the treatment of diabetes and conditions related thereto.
SUMMARY OF THE INVENTION
It has surprisingly been found that a novel and stable medicinal aerosol formulation of an anti-diabetic or hypoglycemic medicament can be obtained without the use of a surfactant, such as sorbitan trioleate. The medicament is rosiglitazone and its salts or esters, such as, for example, maleate, hydrochloride, etc., or other pharmaceutically acceptable forms. This medicament may be used alone or combined with a suitable β-cell hypoglycemic selected from the group consisting of an amylin and insulin; as well as other medicament agents possessing antidiabetic activity, including the α-cell hypoglycemic glucagon, acetohexamide, chlorpropamide, tolazamide, tolbutamide, and glipizide, as well as any mixture of any two or three of the foregoing β-cell hypoglycemic medicaments may be generally included.
DETAILED DESCRIPTION OF THE INVENTION
This application makes reference to U.S. application serial No. 09/209,228 filed Dec. 10, 1998, which is incorporated hereinto by reference in its entirety.
This invention involves a stable aerosol formulation suitable for delivery which comprises (a) a rosiglitazone maleate, such as rosiglitazone maleate (AVANDIA®), and (b) a suitable fluid carrier. The rosiglitazone maleate may be present as a single drug or in combination with a suitable β-cell hypoglycemic such as an amylin and an insulin and their derivatives, and the α-cell hypoglycemic glucagon.
A suitable β-cell hypoglycemic medicament is one selected from either an amylin or insulin and any of their derivatives. A suitable synthetic, antidiabetic agent is one selected from an acetohexamide, chlorpropamide, tolazemide, tolbutamide, glipizide, glyburide, glucophage, phentolamine, etc., and a mixture of any two or three of the foregoing medicaments.
The term “insulin” shall be interpreted to encompass natural extracted human insulin, recombinantly produced human insulin, insulin extracted from bovine and/or porcine sources, recombinantly produced porcine and bovine insulin and mixtures of any of these insulin products. The term is intended to encompass the polypeptide normally used in the treatment of diabetics in a substantially purified form but encompasses the use of the term in its commercially available pharmaceutical form, which includes additional excipients. The insulin is preferably recombinantly produced and may be dehydrated (completely dried) or in solution.
The terms “insulin analog,” “monomeric insulin” and the like are used interchangeably herein and are intended to encompass any form of “insulin” as defined above wherein one or more of the amino acids within the polypeptide chain has been replaced with an alternative amino acid and/or wherein one or more of the amino acids has been deleted or wherein one or more additional amino acids has been added to the polypeptide chain or amino acid sequences which act as insulin in decreasing blood glucose levels. In general, the “insulin analogs” of the present invention include “insulin lispro analogs,” as disclosed in U.S. Pat. No. 5,547,929, incorporated hereinto by reference in its entirety, insulin analogs including LysPro insulin and humalog insulin, and other “super insulin analogs”, wherein the ability of the insulin analog to affect serum glucose levels is substantially enhanced as compared with conventional insulin as well as hepatoselective insulin analogs which are more active in the liver than in adipose tissue. Preferred analogs are monomeric insulin analogs, which are insulin-like compounds used for the same general purpose as insulin, such as insulin lispro, i.e., compounds which are administered to reduce blood glucose levels.
An “amylin” includes natural human amylin, bovine, porcine, rat, rabbit amylin, as well as synthetic, semi-synthetic or recombinant amylin or amylin analogs, including pramlintide and other amylin agonists, as disclosed in U.S. Pat. No. 5,686,411, and U.S. Pat. No. 5,854,215, both of which are incorporated hereinto by reference in their entirety.
For purposes of the formulations of this invention, which are intended for inhalation into the lungs, the rosiglitazone maleate medicament and the other medicaments (when present) are preferably micronized whereby a therapeutically effective amount or fraction (e.g. ninety percent or more) of the medicament is particulate. Typically, the particles have a diameter of less than about 10 micros, and preferably less than about 5 micros, in order that the particles can be inhaled into the respiratory tract and/or lungs.
The particulate rosiglitazone maleate medicament or drug is present in the inventive formulations in a therapeutically effective amount, that is, an amount such that the drug can be administered as a dispersion or an aerosol, such as topically, or via oral or nasal inhalation, and cause its desired therapeutic effect, typically preferred with one dose, or through several doses. The rosiglitazone maleate medicament is administered as an aerosol from a conventional valve, e.g., a metered dose valve, through an aerosol adapter also known as an actuator.
The term “amount” as used herein refers to quantity or to concentration as appropriate to the context. The amount of the rosiglitazone maleate medicament or mixture of medicaments including rosiglitazone maleate that constitutes a therapeutically effective amount varies according to factors such as the potency of the particular medicament or medicaments used, the route of administration of the formulation, and the mechanical system used to administer the formulation. A therapeutically effective amount of rosiglitazone maleate, alone or combined, can be selected by those of ordinary skill in the art with due consideration of such factors. Generally a therapeutically effective amount of rosiglitazone maleate will be from about 0.001 parts by weight to about 5 parts by weight based on 100 parts by weight of the fluid carrier e.g. propellant.
A suitable fluid carrier is selected. A suitable fluid carrier includes air, a hydrocarbon, such as n-butane, propane, isopentane, etc. or a propellant. A suitable propellant is any fluorocarbon, e.g. a 1-6 hydrogen containing flurocarbon, such as CHF 2 CHF 2 , CF 3 CH 2 F, CH 2 F 2 CH 3 and CF 3 CHFCF 3 ; a perfluorocarbon, e.g. a 1-4 carbon perfluorocarbon, such as CF 3 CF 3 , CF 3 CF 2 CF 3 ; or any mixture of the foregoing, having a sufficient vapor pressure to render them effective as propellants. Some typical suitable propellants include conventional chlorofluorocarbon (CFC) propellants such as propellants 11, 12 and 114 or a mixture of any of the foregoing propellants. Non-CFC propellants such as 1,1,1,2-tetrafluoroethane (Propellant 134a), 1,1,1,2,3,3,3-heptafluoropropane (Propellant 227) or mixtures thereof are preferred. The propellant is preferably present in an amount sufficient to propel a plurality of the selected doses of the drug from an aerosol canister.
Optionally, a suitable stabilizer is selected. A suitable stabilizer is a “water addition”. As used herein a “water addition” is an amount of water which (1) is added, either initially with other components of the aerosol formulation, e.g. medicament, rosiglitazone maleate and fluid carrier, or after the other components, e.g. medicament, fluid carrier, are combined and processed, (2) is in addition to the water which is always present and which develops during processing and/or storage of the aerosol formulation, i.e. “developed” or “nascent” formulation water, and (3) is present in an amount which further stabilizes a medicinal aerosol formulation, e.g. rosiglitazone maleate having nascent formulation water.
An aerosol formulation preferably comprises the water addition in an amount effective to more effectively stabilize the formulation relative to an identical formulation not containing the water addition, i.e. containing only nascent formulation water, such that the drug e.g., rosiglitazone maleate, does not settle, cream or flocculate after agitation so quickly as to prevent reproducible dosing of the drug. Reproducible dosing can be achieved if the formulation retains a substantially uniform drug concentration for about fifteen seconds to about five minutes after agitation.
The particular amount of the water addition that constitutes an effective amount is dependent upon the particular fluid carrier, e.g. propellant, and on the particular drug or drugs used in the formulation. It is therefore not practical to enumerate specific effective amounts for use with specific formulations of the invention, but such amounts can readily be determined by those skilled in the art with due consideration of the factors set forth above. Generally, however, the water addition must be present in a formulation in an amount in excess of the concentration of the nascent formulation water. Such concentration of nascent formulation water typically ranges up to 300 parts by weight per one million parts by weight of the total weight of the aerosol formulation. Accordingly, the water addition in excess of this nascent water concentration typically ranges from about 10 parts by weight to 5000 parts by weight per one million parts by weight of the total aerosol formulation weight. Most preferred is that the concentration of the water addition in excess of this nascent water concentration is from 500 parts by weight to 5000 parts by weight per one million parts by weight of the total weight of the medicinal aerosol formulation.
It is to be emphasized that this is an amount which exceeds the amount of nascent or developed formulation water. It is also to be stressed that preferably this amount of water addition can be added and initially combined with the other components of the formulation, e.g. rosiglitazone maleate and fluid carrier, e.g. 1,1,1,2-tetrahydrofluoroethane. However, the water addition can be added to the resultant formulation after these other components have been processed, e.g. prior to or subsequent to storage.
It has surprisingly been found that the rosiglitazone maleate formulation of the invention is stable without the necessity of employing a cosolvent, such as ethanol, or surfactants. However, further components, such as conventional lubricants or surfactants, cosolvents, ethanol, etc., can also be present in an aerosol formulation of the invention in suitable amounts readily determined by those skilled in the art. In this regard, reference is made to U.S. Pat. No. 5,225,183, which is incorporated hereinto by reference in its entirety. Typically, a co-solvent such as ethanol is added in an amount ranging from 0.5 to 10% by weight of the total weight of the formulation.
A most preferred formulation comprises the rosiglitazone maleate medicament, the fluid carrier, the ethanol cosolvent and the water addition, for example, rosiglitazone maleate, 1,1,1,2-tetrafluoroethane, ethanol and the water addition.
Generally the formulations of the invention can be prepared by combining (i) the rosiglitazone maleate drug or drugs in an amount sufficient to provide a plurality of therapeutically effective doses; (ii) the fluid, e.g. propellant, in an amount sufficient to propel a plurality of doses, e.g. from an aerosol canister; (iii) optionally, the water addition in an amount effective to further stabilize each of the formulations; and (iv) any further optional components e.g. ethanol as a cosolvent; and dispersing the components. The components can be dispersed using a conventional mixer or homogenizer, by shaking, or by ultrasonic energy as well as by the use of a bead mill or a microfluidizer. Bulk formulations can be transferred to smaller individual aerosol vials by using valve to valve transfer methods, pressure filling or by using conventional cold-fill methods. It is not required that a component used in a suspension aerosol formulation be soluble in the fluid carrier, e.g. propellant. Those that are not sufficiently soluble can be coated onto the drug particles in an appropriate amount and the coated particles can then be incorporated in a formulation as described above.
Aerosol canisters equipped with conventional valves, preferably metered dose valves, can be used to deliver the formulations of the invention. It has been found, however, that selection of appropriate valve assemblies for use with aerosol formulations is dependent upon the particular component and other adjuvants used (if any), on the fluid, e.g. propellant, and on the particular drug being used. Conventional neoprene and buna valve rubbers used in metered dose valves for delivering conventional CFC formulations often have less than optimal valve delivery characteristics and ease of operation when used with formulations containing HFC-134a or HFC-227. Therefore certain formulations of the invention are preferably dispensed via a valve assembly wherein the diaphragm is made of a nitrile rubber such as DB-218 (American Gasket and Rubber, Schiller Park, Ill.) or an EPDM rubber such as Vistalon™ (Exxon), Royalene™ (UniRoyal), bunaEP (Bayer). Also suitable are diaphragms fashioned by extrusion, injection molding or compression molding from a thermoplastic elastomeric material such as FLEXOMER™ GERS 1085 NT polyolefin (Union Carbide).
Conventional aerosol canisters, coated or uncoated, anodized or unanodized, e.g., those of aluminum, glass, stainless steel, polybutyl or polyethylene terephthalate, and coated canisters or cans with epon, epoxy, etc., can be used to contain a formulation of the invention.
The formulation of the invention can be delivered to the respiratory tract and/or lung by oral inhalation in order to treat and a diabetes related condition susceptible of treatment by inhalation. The formulations of the invention can also be delivered by nasal inhalation in order to treat, e.g., diabetes (systemic), or they can be delivered via oral (e.g., buccal) administration in order to treat, e.g., diabetes and a diabetes related condition.
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This invention relates to a medical aerosol formulation and more particularly, to a medicinal aerosol formulation containing a rosiglitazone maleate and a fluid carrier.
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FIELD OF THE INVENTION
[0001] The invention relates to decorative torches in general and, more particularly, to decorative torches having multiple modes of use.
BACKGROUND OF THE INVENTION
[0002] Consumers have had access to liquid fuel burning decorative torches for some time. Some of these are user refillable and may provide utility beyond mere decoration, such as pest repellence. However, many liquid fuel burning torches are unsuitable for indoor use. In addition, users may have had to choose between a large flame, and other decorative aspects that can be provided from a smaller, more recessed flame, such as back lighting of a decorative pattern.
[0003] Light emitting diode (LED) devices can be utilized for decorative purposes, and are now sufficiently efficient to provide many hours of illumination from a single battery or set of batteries. However, most LEDs sufficiently powerful to provide usable lighting effects are not pleasant for direct viewing. They are highly efficient but still do not replicate the visually pleasing spectrum of a combusting fuel. Moreover, LEDs do not directly provide utility beyond their appearance. By design and due to their inherent efficiency, they do not produce sufficient waste heat to activate insect repellants, scents, or other chemicals.
[0004] What is needed is a system for addressing the above, and related, concerns.
SUMMARY OF THE INVENTION
[0005] The invention of the present disclosure, in one aspect thereof, comprises a multifunction decorative torch having a base providing an upwardly directed light. A cap supports a liquid fueled torch insert having a wick and a fuel reservoir. An outer wall supports the cap and defines an interior space between the base and cap. The upwardly directed light illuminates the outer wall from within the interior space. The liquid fueled torch is supported by the cap such that the wick burns outside the interior space between the base and cap and the fuel reservoir is at least partially inside the interior space between the base and cap.
[0006] In some embodiments, a lighting insert interposes the outer wall and the upwardly directed light such that the upwardly directed light shines through the insert to illuminate the outer wall. The lighting insert may be decorative so as to impart a pattern to the light shining therethrough. The outer wall may be transparent. In other embodiments, the outer wall provides a pattern therein that is viewable outside the wall the when the outer wall is illuminated by the upwardly directed light.
[0007] In some embodiments, the upwardly directed light comprises a plurality of light emitting diodes (LEDs) selectively emitting a plurality of different visible colors. A battery compartment may be located in the base. The base may include a user control for selectively activating the LEDs.
[0008] The liquid fueled torch may further comprise a skirt that fits onto the cap and retains the liquid fueled torch a predetermined distance above the base. The skirt may have a threaded and removable connection to the fuel reservoir. The skirt may define a wick holder for the wick.
[0009] The invention of the present disclosure, in another aspect thereof, comprises a multifunction decorative torch having a base with a plurality of lights, a cap with a liquid fueled torch having a wick and a fuel reservoir, and an outer wall supporting the cap above the base and defining an interior portion. The reservoir is supported at least partially inside the interior portion. The reservoir remains a predetermined distance above the base and has a predetermined width sufficiently less than the width of the interior portion that the plurality of lights in the base fully illuminates the outer wall along the interior portion that is occupied by the reservoir.
[0010] In some embodiments, the plurality of lights comprise a plurality of light emitting diodes (LEDs) that selectively illuminate the interior portion with a plurality of different visible colors. A user control may be provided on the base that selectively activates the plurality of LEDs.
[0011] The device may further comprise a decorative insert placed next to the outer wall in the interior portion such that the plurality of lights illuminate the decorative insert. The outer wall may provide a pattern thereon that is viewable outside the wall the when the outer wall is illuminated from the interior portion.
[0012] The invention of the present disclosure, in another aspect thereof, comprises a multifunction decorative torch with a cylindrical outer wall defining an interior and an exterior of the multifunction decorative torch, a base supporting the cylindrical outer wall and having a plurality of user activated LEDs placed within the base to selectively illuminate the interior portion, and a liquid fuel burning insert having a fuel burning wick at least partially inserted into a axially symmetric fuel reservoir, the fuel reservoir being supported relative to the outer wall and situated at least partially within the interior defined by the cylindrical outer wall. The fuel reservoir is sized and supported such that every portion of the outer wall adjacent to the fuel reservoir may be illuminated by at least one of the plurality of LEDs without shadow from the fuel reservoir.
[0013] In some embodiments, the multifunction decorative torch further comprises a cap interposing the liquid fuel burning insert and the outer wall. The cap supports the fuel burning insert relative to the wall and the base. A decorative insert may be provided adjacent to the outer wall such that the decorative insert is selectively illuminated by the plurality of LEDs. The outer wall may be masked to provide an illuminated pattern to the exterior when the interior is illuminated. The LEDs may illuminate the interior from within the base through an opening in the base provided with a protective cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a side view of a multifunction decorative torch according to aspects of the present disclosure.
[0015] FIG. 2 is a perspective view of the torch of FIG. 1 .
[0016] FIG. 3 is a side cutaway view of the torch of FIG. 1
[0017] FIG. 4 is a top down view taken along the line 4 - 4 of FIG. 2 .
[0018] FIG. 5 is a perspective view of another a multifunction decorative torch according to aspects of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring now to FIG. 1 , a side view of a multi-function decorative torch according to aspects of the present disclosure is shown. Referring also to FIG. 2 , a side perspective view of the torch of FIG. 1 is shown. The torch 100 comprises a wall 102 . The wall 102 may comprise glass or plastic or another transparent or translucent material. In the illustrated embodiments, the wall 102 is cylindrical. However, in other embodiments, the wall 102 may take on other shapes, (e.g., it could be rectilinear). The wall 102 defines interior ( 302 FIG. 3 ) and an exterior of the torch 100 .
[0020] Behind the wall 102 , within the interior 302 , a lighting insert 104 may be provided. The insert 104 may be a decorative insert comprising plastic, paper, or another decorative material. It may be partially transparent or translucent and may have decorative patterns printed or otherwise provided thereon. In some embodiments, the insert 104 may simply be a flat, rectangular sheet of material that is rolled and placed inside the cylindrical wall 104 where it will remain adjacent to the wall 102 for decorative purposes, as described herein. The insert 104 may be viewed through the transparent wall 102 or it may be selectively illuminated from within as described further below.
[0021] The wall 102 is supported by a base 106 . The base 106 may be constructed from a polymer or a metal alloy or a combination thereof. The base 106 provides a supporting platform for the wall 102 and the insert 104 . The base 106 can be painted or decorated as well. In some embodiments, the wall 102 may be affixed to the base 106 by a glue or other means.
[0022] Atop the wall 102 , opposite from the base 106 , may be a cap 110 . The cap 110 may be a metal, a polymer, or a combination thereof, and can also be decorated. In some embodiments, the cap 110 is affixed onto the wall 102 by an adhesive or other means. In normal use, the cap 110 may remain affixed to the wall 102 , and may retain the decorative insert 104 in place within the outer wall 102 .
[0023] The cap 110 may support and provide location for a liquid fuel burning torch insert 112 . From the views provided in FIGS. 1 and 2 , it can be seen that the insert 112 provides a skirt 114 that also functions as a cap or lid for the insert 112 . The skirt 114 also rests upon the cap 110 . A neck 116 is provided on the skirt 114 and provides a wick holder 118 into which a wick 120 may be placed for burning liquid fuels. The skirt 114 and neck 116 may be integrally formed and may comprise, for example, rolled sheet metal. The skirt 114 and other components of the insert 112 may be painted other otherwise decorated. The wick 120 may be a long-term use fiberglass wick. In some embodiments, a cap or snuffer 122 may be provided for protecting the wick 120 and/or extinguishing the flame. In some embodiments, the snuffer 122 may be tethered to the insert 112 via a chain 124 , for example.
[0024] The base 106 may provide certain illumination features, as described in greater detail below. To that end, a user control 108 may be provided on the exterior of the base 106 . In the present embodiment, the control 108 is a push button. However, in other embodiments, the control 108 could be a switch, slider, or other control mechanism. In some embodiments, the illumination effects are battery powered. The base 106 may also provide a user accessible battery compartment 126 .
[0025] Referring now to FIG. 3 , a side cutaway view of the torch 100 is shown. In FIG. 3 , the relationship between the outer wall 102 and the decorative 104 can be better appreciated. The interior portion defined by the outer wall 102 is denoted at 302 in FIG. 3 . It can also be appreciated from FIG. 3 that the decorative insert 104 lies generally against the interior surface of the outer wall 102 such that the interior portion 302 is generally empty.
[0026] The skirt 114 of the fuel burning insert 112 can be seen supporting a fuel reservoir 306 . The fuel reservoir 306 is supported, at least partially (and up to substantially), within the interior portion 302 defined by the outer wall 102 . In the present embodiment, the fuel reservoir 306 is radially symmetric (neglecting any printing or other superficial external features). The reservoir 306 has a predetermined diameter or width “W” such that, even though it may substantially occupy a portion of the interior 302 , a void or annulus 304 will exist between the reservoir 306 and the insert 104 and/or outer wall 102 .
[0027] The insert 112 may be user serviceable. To that end, it may be removable from the cap 110 . In some embodiments, the insert 112 is held in place simply by gravity. The neck 116 of the skirt 114 may have interior threads that fit onto a threaded neck 307 affixed to the fuel reservoir 306 . With the insert 112 is removed from the cap 110 , the skirt 114 (or lid) may be unscrewed from the fuel reservoir 306 to facilitate filing or refilling.
[0028] The reservoir 306 may contain a quantity of liquid torch fuel 308 . The wick 120 may be held at least partially within the fuel supply 306 via the wick holder 118 . The wick holder 118 may provide a friction fit for the wick 120 . As the wick 120 may be a long lasting fiberglass type wick, it is not contemplated that frequent adjustments of the wick are needed.
[0029] The base 106 can be seen to contain a light board 310 and a control circuit 312 . The light board 310 may be a circuit board onto which are mounted a plurality of lights 314 . In the present embodiment, the lights 314 are surface-mount type light emitting diodes (LEDs). However, various embodiments of the present disclosure would work equally well, if perhaps less efficiently, with incandescent type bulbs. The lights 314 may be affixed to the board or otherwise placed such that they provide light above the base 106 (e.g., they are upwardly shining or upwardly directed).
[0030] The control circuit 312 may be integral with the light board 310 and may provide the necessary voltage regulation and control circuitry to operate the lights 314 . The control circuit 312 may interface with one or more batteries 316 in the battery compartment 126 and/or the user control 108 of FIGS. 1 and 2 .
[0031] The lights 314 may be at least partially recessed into the base 106 such that they shine through an internally defined opening 318 to illuminate the interior portion 302 . In some embodiments, a transparent, or at least translucent, cover 320 may be provided over the opening 318 . As discussed, the insert 112 may be removed from the torch 100 such that the interior 302 is accessible. The cover 320 prevents items from being lost into the base 106 and may also prevent a fuel spill from damaging the lights 314 , the control circuit 312 , or other components within the base 106 .
[0032] The lights 314 may be configured to selectively illuminate or provide various flashing or fading effects. For example, in one embodiment, a single press of the user control button 108 may activate a white light while a second press may activate a colored light and third press may turn the torch 100 off. It is understood that the embodiments of the present disclosure are not meant to be limited to any particular light color or lighting effect. For example, light effects may include steady state, strobing, flashing, fading, cross-color fading, and other effects.
[0033] In order to provide a device that is useful as both a liquid fuel burning apparatus and an electrically powered internally lighted device, it may be desirable to insure that substantially all of the outer wall 102 and/or decorative insert 104 can be illuminated even when the fuel burning insert 112 is in place. To that end, the dimensions of the various components of the device 100 and their relationship to one another may be carefully selected. As described, the fuel reservoir 306 has a diameter or width “W”. However, the reservoir 306 , the skirt 114 , and/or the height of the wall 102 may be such that a minimum distance “D” is provided between the bottom of the reservoir 306 and the top of the lights 314 . The dashed lines “B” of FIG. 3 illustrate how even the most remote light 314 from an opposite wall will at least partially illuminate the relevant portion of the wall 102 . This is owing in part to the free space or annulus 304 between the fuel reservoir 306 and the decorative insert 104 or wall 102 , and the distance from the bottom of the fuel reservoir 306 to the light board B. The present disclosure is not meant to be limited to particular dimensions so long as those dimensions function as claimed herein.
[0034] The lines D′ illustrate how the lights 314 can also illuminate all or substantially all of the wall 102 and/or decorative insert 104 near where they affix to the base 106 . In order to eliminate or minimize any shadows resulting from the base at the lower portion of the wall 102 , the lights 314 and/or light board 310 may elevated towards the opening 318 .
[0035] Referring now to FIG. 4 , a top down view of the torch 100 taken along the line 4 - 4 of FIG. 2 is shown. From the viewpoint of FIG. 4 , the cylindrical wall 102 appears circular. The decorative insert 104 can be seen to lie interior to the wall 102 and adjacent thereto. Where the decorative insert 104 is a single rectangular sheet, it may be rolled and inserted into the wall 102 where it joins back to itself, for example, at 105 .
[0036] The light board 310 can be seen through the opening 318 and the base 106 . The cover 320 may serve to cover and protect the light board 310 . In the present embodiment, four surface-mounted LEDs are provided as lights 314 . The embodiments of the present disclosure are not meant to be limited to any particular number of lights 314 . More or fewer than four could be utilized. The spacing and location of the lights 314 on the board 310 may be somewhat important, depending upon the embodiment, to insure that substantially all of the interior 302 can be at least partially illuminated. As discussed with respect to FIG. 3 , the present embodiment, utilizing four lights 314 , can be made to satisfy this criteria.
[0037] Referring now to FIG. 5 , a perspective view of another multi-function decorative torch 500 according to aspects of the present disclosure is shown. The torch 500 is substantially identical to the torch 100 of FIGS. 1-4 , except as described below. The torch 500 comprises an outer wall 502 with a pattern provide therein. The wall 502 may have an opaque or translucent layer over a glass layer to provide the pattern shown. In some embodiments, the wall 502 is a single layer with no glass layer underneath.
[0038] Some embodiments include the decorative insert 104 while others do not. It will be appreciated that, when the torch 500 is illuminated from within, the pattern on the wall 502 may be viewed. Where the lights 314 are sufficiently powerful, the pattern on the wall 502 may be projected onto adjacent walls or other surfaces. It should be understood that the present disclosure is not meant to be limited to the illustrated patterns on either the decorative insert 104 or the outer wall 502 .
[0039] The torch 500 also includes a decorative ring 504 that attaches to the cap 110 . The decorative ring 504 may have a pattern cut therein such that the light from the liquid fueled flame shines therethrough and/or casts decorative shadows into adjacent areas. In other embodiments, the ring 504 may be sized and shaped so as to promote large flame effects from the fuel burning insert 112 .
[0040] 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 multifunction decorative torch comprising has a base providing an upwardly directed light, a cap supporting a liquid fueled torch insert having a wick and a fuel reservoir, and an outer wall supporting the cap and defining an interior space between the base and cap. The upwardly directed light illuminates the outer wall from within the interior space. The liquid fueled torch insert is supported by the cap such that the wick burns outside the interior space between the base and cap and the fuel reservoir is at least partially inside the interior space between the base and cap.
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BACKGROUND OF THE INVENTION
This invention relates to a composition for absorbing electromagnetic radiation and, particularly, for absorbing the electromagnetic radiation over a wide range of frequencies from sub-GHz to GHz (10 6 to 10 10 hertz) band regions.
It is well-known that magnetic materials such as soft ferrites, carbonyl iron or metallic iron may be used for absorbing electromagnetic radiation (hereinafter referred to as “EMR”). In order to use as an EMR absorbing barriers, such materials are divided into fine particulates or powders, dispersed in a suitable binder and then fabricated into sheets. Since such magnetic materials are capable of absorbing EMR mainly in frequency ranges in the order of several GHz, absorption of EMR in sub-GHz frequency ranges requires the finished sheets to have so large thickness that makes the sheets too heavy and difficult to manufacture.
JP-A-10308596 discloses an EMR absorbing laminate capable of operating in both VHF and UHF band regions. The laminate comprises, in the direction of incident radiation, a dielectric layer containing barium titanate, a second layer containing carbonyl iron or ferrites and a short circuiting metal plate. The first dielectric layer may be formed of sintered or resin-bound barium titanate particles having a thickness from 0.1 to 1.5 mm. The second layer may be formed of resin-bound carbonyl iron particles having a thickness from 1.0 to 4.0 mm. Alternatively, the second layer may be formed of sintered or resin-bound ferrite particles having a thickness from 4.0 to 10.0 mm. This laminate suffers from the same disadvantage as above in terms of large thickness and weight and difficulties in manufacture.
JP-A-11289188 assigned to the assignee of this application discloses an EMR absorbing composition comprising titanium slug. This composition exhibits maximum EMR attenuation at a frequency of around 4.3 GHz.
A need exists, therefore, for an EMR absorbing composition which may be fabricated into an EMR absorbing sheet or layer capable of absorbing EMR over a wide range of frequencies from sub-GHz to several GHz band regions with a relatively small thickness in non-composite structure.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an EMR absorption curve of the composition of Example 1 (the invention);
FIG. 2 shows a similar curve of the composition of Comparative Example 1; and
FIG. 3 shows a similar curve of the composition of Comparative Example 2.
SUMMARY OF THE INVENTION
Surprisingly, it was found that when titanium slug powder is blended with iron or carbonyl iron powder in certain proportions, the maximum attenuation frequency of titanium slug shifts from at around 4.3 GHz to sub-GHz region and that the blend absorbs EMR over a wide frequency range from sub-GHz to several GHz band regions.
Based on this finding, the present invention provides a composition for absorbing electromagnetic radiation comprising a blend of 5 to 30% by weight of particulate titanium slug and the balance of particulate carbonyl iron or iron metal dispersed in a polymeric binder said titanium slug having a titanium content calculated as TiO 2 from 70 to 90% by weight.
The polymeric binder may be either thermosetting or thermoplastic depending upon the method of fabricating shaped articles from the composition. Thermosetting resins are used in the compression molding process while thermoplastic resins or elastomers are used in the production of continuous sheets of the EMR absorbing composition of the present invention by the extrusion process and the like. The thermoplastic resin may be a vehicle resin of a coating composition prepared from the EMR absorbing composition of the present invention.
The present invention also relates to articles fabricated from the EMR absorbing composition of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
“Titanium slug” is produced by smelting desulfurized ilmenite ore in the presence anthracite in an electrical furnace, separating from the resulting molten pig iron, cooling and dividing into particles of a suitable size. Because of its higher titanium content normally as high as 70-95% as TiO 2 , a large quantity of titanium slug is consumed for the production of titanium dioxide pigments and metallic titanium and titanium alloys. For use in the present invention, particulate titanium slug preferably has an average diameter from 1 to 100 microns, more preferably from 1 to 50 microns.
Particulate metallic iron and particulate carbonyl iron having comparable average diameters are commercially available and may be used in the present invention to advantage. The proportions of particulate titanium slug and particulate metallic iron or carbonyl iron in their blend are 5 to 30% by weight, preferably 10 to 30% by weight for titanium slug, and the balance for metallic iron or carbonyl iron.
In order to fabricate into shaped articles such as sheets by the compression molding process, the blend is further mixed with an amount of thermosetting resins such as phenol resins, melamine resins, epoxy resins and the like. The binder resin is preferably in the form of dry or semi-dry powder to allow dry blending of the three components to produce a molding compound. The amount of resins must be sufficient to impart the molded products with a satisfactory mechanical strength but not in excess. This amount generally ranges from 5 to 60% by combined weight of the three components. The resulting molded products, if necessary, may further be treated with heat to complete the curing reaction of the binder resin. The thermosetting binder resin may be a liquid resin such as unsaturate polyester resins used in the production of FRP. In this case the molding compound may be shaped and thermally cured in a mold without compression.
Thermoplastic resins or elastomers such as polythylene, polypropylene, ethylene-propylene rubber or chlorinated polyethylene may be used for producing continues sheets of the EMR absorbing composition of the present invention using the extrusion or calendering process known in the plastic processing industry.
Finally, the EMR absorbing composition may be formulated into a coating composition or paint. In this case the coating composition may be produced in a manner analoguous to the production of conventional decorative or protective paint formulations using the blend of particulate titanium slug and metallic iron or carbonyl iron in place of conventional paint pigments. The binder resin component may be the same as those used in conventional paints as vehicle resins in the form of a solution in a volatile organic solvent or an emulsion or dispersion in an aqueous medium. The coating formulation of the present invention is useful for forming an EMR absorbing layer onto an object on site.
Fabricated articles made of the EMR absorbing composition of this invention exhibits improved capability of absorption of EMR at sub-GHz frequency region while retaining the desired absorptive capability in several GHz region. For example, compression-molded articles made from the composition of this invention are comparable in the absorptive capability of sub-GHz EMR without use of short-circuiting metallic plate to corresponding articles made of ferrite particles having about double thickness. Thus, the composition of this invention finds use in shielding a variety of objects from EMR at a wide range of frequencies in both sub-GHz and GBz band regions.
EXAMPLE
The following examples are offered to illustrate this invention without limiting its scope thereto. Unless otherwise indicated, all parts and percentages are by weight.
1. Preparation of Test Specimen
Particulate titanium slug available from RTZ Iron & Titanium Inc., Canada (titanium content as TiO 2 90%, average diameter 1000 microns) was used. 1 kg of particulate titanium slug was milled by the wet process in a stainless steel-ball mill for 48 hours. The resulting slurry was transferred to a vat and dried at 105° C. for 24 hours. 200 g of this dry powder was taken in an alumina-mortar and further milled for 30 minutes using a pestle made of alumina.
The titanium slug powder thus prepared was mixed with iron carbonyl powder (EW, BASF) or metallic iron powder (300M-200, Kobe Steel Ltd.) and thermosetting resin powder (FINEDIC A-56-102, Dainippon Ink and Chemicals, Inc.) in proportions shown in Table 1 below.
An amount the mixture was compression-molded into a block at a pressure of 3.3 ton/cm 2 and the molded block was cured at 180° C. for 30 minutes. After cooling, the block was machined into a troidal core shape having an inner diameter of 8.66 mm and an outer diameter of 19.94 mm.
For comparative purposes, similar specimens were produced from titanium slug alone and carbonyl iron alone.
2. Measurement Method
A network analyzer (Model 37269A available from WILTRON) was used in the measurement. Each specimen was placed in the network analyzer and tested for EMR absorbing performance by the open short method.
Example 1 and Comparative Examples 1-2
TABLE 1
Material, parts
Ex. 1
Com.Ex.1
Com.Ex.2
Titanium slug
10
100
—
Carbonyl iron
90
—
100
Binder resin
7
7
7
Test results of specimens of Example 1, Comparative Example 1 and Comparative Example 2 are shown in FIG. 1, FIG. 2 and FIG. 3, respectively. A remarkable absorption of EMR at sub-GHz region is seen in the curve of FIG. 1 while such absorption is not seen in the curves of FIG. 2 and FIG. 3 .
Example 2 and Comparative Examples 3-4
Analogous to the preceding Example and Comparative Examples, specimens were made from a 10:90 blend of titanium slug and metallic iron powder (Example 3), titanium slug alone (Comparative Example 3) and iron powder alone (Comparative Example 4), respectively, with varying amounts of binder resin and specimen thickness. The EMR absorptive performance of these specimens were evaluated in a similar manner as above and are reported in Tables 2-4 below.
TABLE 2
Example 2 (titanium slug:iron powder = 10:90)
Specimen
Peak absorption
Attenuation
% Binder*
thickness (mm)
frequency (GHz)
(dB)
20
10.80
1.2350
−11.98
20.30
0.5240
−14.60
25.90
0.4270
−16.60
30
10.30
1.6550
−18.35
15.00
1.0090
−19.37
20.30
0.7500
−33.48
25.30
0.5890
−41.26
40
10.80
1.2350
−11.99
20.30
0.5240
−14.57
25.90
0.4270
−16.60
*Based on the total weight of specimen
TABLE 3
Comparative Example 4 (titanium slug alone)
Specimen
Peak absorption
Attenuation
% Binder*
thickness (mm)
frequency (GHz)
(dB)
20
10.20
1.3960
−13.58
17.70
0.7829
−10.39
27.85
0.4920
−9.73
30
10.20
1.7310
−9.46
15.00
1.0960
−8.52
20.20
0.8590
−7.29
25.25
0.6776
−7.22
40
5.20
4.0450
−8.30
10.30
2.0410
−7.44
15.05
1.4010
−6.10
20.30
1.0330
−4.74
25.30
0.8390
−4.85
*Based on the total weight of specimen
TABLE 4
Comparative Example 4 (iron powder alone)
Specimen
Peak absorption
Attenuation
% Binder*
thickness (mm)
frequency (GHz)
(dB)
20
10.25
1.4610
−14.06
20.40
0.6210
−18.54
25.45
0.4922
−20.06
30
10.30
2.0100
−28.89
14.90
1.3320
−30.47
20.20
0.9440
−23.27
25.30
0.7180
−21.18
40
5.20
5.6200
−13.29
10.00
2.6880
−13.75
15.25
1.6530
−14.96
20.45
1.1700
−13.52
25.25
0.9440
−12.55
*Based on the total weight of specimen
The above test results indicate that the peak absorption frequencies of the specimens of a 10:90 blend of titanium slug and iron powder (Example 2) have shifted toward lower frequency side in comparison with specimens of titanium slug alone (Comparative Example 3) or specimens of iron powder alone (Comparative Example 4).
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A blend of 5 to 30% by weight of particulate titanium slug and the balance of particulate carbonyl iron or metallic iron absorbs electromagnetic radiation over a wide frequency range from sub-GHz to several GHz band regions. The blend is processed into a molding compound or coating formulation by mixing with a polymeric binder.
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FIELD OF THE INVENTION
The present invention relates to electromechanically actuated valves, and more particularly to intake and exhaust valves employed in an internal combustion engine.
BACKGROUND OF THE INVENTION
Conventional engine valves (intake or exhaust) used to control the flow into and out of the cylinders of internal combustion engines, are controlled by camshafts that fix the amount of lift as well as the opening and closing times of the valves relative to a crankshaft position. While this may be generally adequate, it is not optimal, since the ideal intake and exhaust valve timing and lift vary under varying operating conditions of the engine. Variable valve timing and lift can account for such conditions as throttling effect at idle, EGR overlap, etc., to substantially improve overall engine performance. Although some attempts have been made to allow for variable timing based upon adjustments in the camshaft rotation, this is still limited by the individual cam lobes themselves.
Consequently, some others have attempted to do away with camshafts altogether by individually actuating the engine valves by some type of electromechanical or electrohydraulic means. These systems have not generally proven successful, however, due to substantial costs, increased noise, reduced reliability, slow response time, or increased energy consumption of the systems themselves. Further, although some systems allow for extensive control of valve timing, they are limited as with the conventional camshaft systems to a single valve lift distance that does not fully take advantage of engine efficiencies that can be had, or variable lift is achieved with degradation in valve performance.
One type of electromechanical system attempted employs simple solenoid actuators. But these have proven inadequate because they do not create enough magnetic force for speed needed to operate the valves without an inordinate amount of energy input. This is particularly true in light of the fact that the force profile is not desirable. The magnetic force increases as an armature disk approaches the electromagnet, causing a slap at end of stroke, creating noise and wear concerns, but not much force is available for acceleration at the beginning of the stroke, creating slow response time. Further, they are typically limited to a single amount of valve lift.
U.S. Pat. No. 5,222,714 attempts to overcome some of the deficiencies of an electromagnetic system by providing a spring to create an oscillating system about a neutral point wherein the spring is the main driving force during operation, and electromagnets provide holding forces in the opened and closed position, while also making up for frictional losses of the system. However, this system is still not able to fully utilize the possible efficiencies of the engine. A major drawback is that although this system allows for extensive control of valve timing, it is limited as with the conventional camshaft systems to a single valve lift distance, thus not fully taking advantage of engine efficiencies that can be had.
Hence, a simple, reliable, fast yet energy efficient actuator for engine valves is desired, with the flexibility to vary both valve timing and lift to substantially improve engine performance, without degrading valve performance with varying lift.
SUMMARY OF THE INVENTION
In its embodiments, the present invention contemplates an engine valve assembly for an internal combustion engine having a cylinder head. The engine valve assembly includes an engine valve having a head portion and a stem portion, adapted to be slidably mounted within the cylinder head, and an actuator housing adapted to be mounted to the engine and surrounding a portion of the valve stem. A first electromagnet is fixedly mounted relative to the actuator housing, encircling a portion of the valve stem, a second electromagnet is slidably mounted relative to the actuator housing, encircling a portion of the valve stem farther from the head of the engine valve than the first electromagnet, and a third electromagnet is fixedly mounted relative to the actuator housing, encircling a portion of the valve stem farther from the head of the engine valve than the second electromagnet and spaced from the second electromagnet to form a gap. A disk is fixedly mounted to the engine valve stem and located between the second and third electromagnet. The engine valve assembly also includes first biasing means for biasing a portion of the second electromagnet away from the first electromagnet, second biasing means for biasing the disk away from the second electromagnet, and third biasing means for biasing the disk toward the second electromagnet. Stop means limit the sliding of the portion of the second electromagnet away from the first electromagnet, allowing for a variable gap between the second electromagnet and third electromagnet, whereby variable engine valve lift may be achieved.
Accordingly, an object of the present invention is to provide an electromechanically actuated engine valve having variable timing and lift which is capable of operating at speeds required by internal combustion engine operation, with minimal energy consumption.
An advantage of the present invention is the ability to provide dual valve lifts through electromagnetic actuation, while minimizing the energy needed by using resonant mode behavior of a spring system, i.e., acceleration of the valve from rest and then deceleration to a low velocity, thus avoiding impacts among components, to reduce potential noise and wear concerns.
An additional advantage of the present invention is that it has a movable electromagnet which automatically adjusts the equilibrium point of the oscillating spring system in the valve actuator to the middle of either a mid-open or a full open position; thus allowing for a two open position operation, but without sacrificing the resonant mode operation that will cause the valve to seat softly against the valve seat with minimal energy dissipation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a Schematic view of an engine valve assembly, with the valve shown in a fully open position, in accordance with the present invention;
FIG. 2 is a schematic view similar to FIG. 1, but with the valve shown in its closed position;
FIG. 3 is a schematic view similar to FIG. 1, but with the valve shown in its mid-open position;
FIG. 4 is a schematic view similar to FIG. 1, but illustrating a second embodiment of the present invention;
FIG. 5 is a Schematic view similar to FIG. 1, but illustrating a third embodiment of the present invention; and
FIG. 6 is a schematic view similar to FIG. 1, but illustrating a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 illustrate a first embodiment of the present invention. An engine valve 12, intake or exhaust as the case may be, is slidably mounted within an insert 17, secured in a cylinder head 14 of an internal combustion engine 16. The insert 17 and cylinder head 14 define a port 19, again either intake or exhaust, and a valve seat 21. The insert 17 allows for easier assembly of components into the cylinder head 14, and later servicing, as a module, but if preferred, the insert portion can be integral with the cylinder head 14.
The engine valve 12 includes a head portion 13, which seats against the valve seat 21 in its closed position, and a stem portion 15. This engine valve 12 controls the fluid flow into or out of a cylinder (not shown) within the engine 16.
An electromechanical actuator assembly 18 engages the valve stem portion 15 and drives the engine valve 12. The actuator assembly 18 includes a housing 20 mounted to the cylinder head insert 17, or cylinder head 14, if so desired. Within the housing 20 is mounted a first electromagnet 22, which is fixed relative to the housing 20. The first electromagnet 22 includes an annulus shaped first core member 24, made of a magnetically conductive material, encircling a portion of the valve stem 15. The first electromagnet 22 also includes a first coil 26, extending circumferentially through the core member 24 forming an annulus shape near the upper surface of the core member 24, and an annulus shaped permanent magnet 27 located radially outward from the coil 26. The permanent magnet 27 is embedded in the flux path of first electromagnet 22.
An annulus shaped, second core member 28, also made of a magnetically conductive material, is mounted in and can slide relative to the housing 20 and forms part of a second electromagnet 30. A second coil 34 extends circumferentially through the second core member 28 forming an annulus shape near the upper surface of the second core member 28. A third electromagnet 32 includes a third core member 33, which is fixed relative to the housing 20. A third coil 36 extends circumferentially through the third core member 33 forming an annulus shape near the lower surface of the third core member 33. The three coils are connected to a conventional source of electrical current (not shown), which can be selectively turned on and off to each one independently by a conventional type of controller, such as an engine computer (not shown).
Mounted to the valve stem 15 is a ferrous, annular disk 38, which is fixed relative to and moves with the stem 15. This disk 38 is located between the upper surface of the second electromagnet 30 and the lower surface of the third electromagnet 32. Also an annular protrusion 40 extends radially inward from the second core member 28. A stop ring 42 is mounted to and extends radially inward from the housing 20, and is located between the second electromagnet 30 and the third electromagnet 32. This stop ring limits the amount of travel of the second electromagnet 30 toward the third electromagnet 32.
A first spring 48 is mounted between the cylinder head insert 17 and the bottom surface of the annular protrusion 40, a second spring 50 is mounted between the top surface of the annular protrusion 40 and the disk 38, while a third spring 52 is mounted between the top surface of the disk 38 and the housing 20. The first spring 48 biases the second electromagnet 30 toward the stop ring 42, and only acts to shift the operating mode from full open to mid-open. The second and third springs 50, 52 are biased such that each counteracts the force of the other to cause the neutral or resting position of the engine valve 12 to be a partially opened position. These two spring 50, 52 have substantially identical spring constants and are positioned to hold the disk 38 half way between the second electromagnet 30 and the third electromagnet 32. This half-way position occurs, for instance, when the engine 16 is not operating, and thus, the electromagnets are not activated. By having this half-way position, an oscillating system can be created by the two springs during engine valve operation such that, when the disk 38 is released, by either electromagnet 30, 32, the force of the springs 50, 52 is such as to accelerate, then decelerate, the valve 12 so that, neglecting friction and length tolerances, the valve 12 comes to a stop at the other electromagnet 30, 32 without impact.
The operation of the electromechanical actuator 18 and resulting valve motion will now be described. When the engine is not in operation, the engine valve 12 rests in a neutral position, partially open, with the disk 38 half-way between the second and third electromagnets 30, 32. To initiate valve opening from the neutral position, the coil 34 in the second electromagnet 30 is energized, causing the disk 38 to be pulled downward towards it, compressing the second spring 50. Engine valve 12, as a result, is pulled to its open position, as is illustrated in FIG. 1. The second electromagnet 30 stays energized to hold this position against the bias of the second spring 50. The compressed spring 50 now stores potential energy for the oscillating system which will drive most of the engine valve movement during engine operation.
FIG. 1 shows a full open position for the engine valve 12, with the permanent magnet 27 holding the second electromagnet 30 against the bias of the first spring 48. With this approach, a pulse of current is applied to the first coil 20 in a direction such as to enhance the flux provided by the permanent magnet 27. The large magnetic field is enough to pull the second electromagnet 30 downward. Once the two electromagnets are in contact, the field from the permanent magnet 27 alone is sufficient to hold the second electromagnet 30 in place.
The first electromagnet 22 may also be energized to a low level if needed to assist the permanent magnet's holding power. This depends upon the size of the permanent magnet 27 and spring force of the first spring 48. Generally, though, it is preferred that the permanent magnet 27 is strong enough to hold the second electromagnet 30 in position even in the absence of flux provided by the first coil 26.
To begin to close the engine valve 12, the second electromagnet 30 is de-energized, allowing the second spring 50 to push the disk 38 upward. To finish closing the engine valve 12 and hold it there, the third coil 36 is energized, causing the disk 38 to be pulled upward towards it by magnetic force. As a result of this, the disk 38 compresses the third spring 52. The third electromagnet 32 stays energized to hold the engine valve 12 in the closed position against the bias of the third spring 52, as is illustrated in FIG. 2.
The oscillating type of system described herein creates a situation where the work done by the electromagnets is mostly used to hold the valve 12 in a particular position, while most of the work of moving the valve 12 is done by the springs. Only a small portion of the work of moving the valve 12 is done by the electromagnets, to make up for friction effects and other energy losses in the system. In this way, the energy needed to drive this electromagnetic actuator 18 is minimized.
In order to operate the engine valve 12 in its mid-open position mode, the second electromagnet 30 is released from the first electromagnet 22. To release the second electromagnet 30, a pulse of current is once again applied to the coil 26 of the first electromagnet 22, but this time in a direction such as to cancel the flux from the permanent magnet 27.
The second electromagnet 30 is now free to slide within the housing 20, and consequently, the first spring 48 pushes it upward to the stop ring 42, see FIG. 3. So, in essence, the second electromagnet 30 causes the second and third springs 50, 52 to be compressed by an equal amount. Thus, the equilibrium point of engine valve 12 is still in the center of the now narrower gap between these electromagnets. The second and third electromagnets 30, 32 operate the same as with the full open mode, but with the valve traveling through a shorter distance since the second electromagnet 30 is held against the stop ring 42 by the first spring 48.
In this way, the valve 12 still oscillates between the closed position and mid-open position, coming to a controlled stop at each end of its stroke. The mid-open position can be any fraction of the full open position depending upon the characteristics and operating conditions desired of the particular engine. Moreover, the second electromagnet 30 moves only once during each switch between full and mid-open operation, minimizing the significance of any noise or wear concerns resulting from impact of the second electromagnet 30 against the stop ring 42.
To begin to open the valve 12 from the closed position, the third coil 36 is de-energized, allowing the third spring 52 to push the engine valve 12 downward. The second electromagnet 30 is energized to pull the disk 38 downward and lock the valve 12 in its open position. This is the same procedure for both full and mid-open positions.
By utilizing the resonance of the two springs in the actuator 18 to accomplish much of the movement, the response time is improved over merely providing electromagnets, and with less power consumption. Further, the springs allow for a system with softer landings, for the closed and two open positions, than a pure electromagnet actuated system, thus reducing the noise that otherwise may be generated. The multiple valve lifts are also determined by simple on/off commands of the electromagnets rather than attempting to precisely adjust and control the electric current used to power the magnets or other complex means that may be used to create mid-opened positions.
A second embodiment of the present invention is illustrated in FIG. 4. In this embodiment, like elements with the first embodiment will be similarly designated, while changed elements will also be similarly designated but with 100-series designations. There is now no permanent magnet to hold the second electromagnet 30 against the first electromagnet 122. The first electromagnet 122 can now be integral with the insert 117 in order to ease assembly of components. The advantage of eliminating the permanent magnet is that generally, it has to be shielded from the high temperatures of the engine head by some means, such as a gasket, etc. Further, a disadvantage of employing a permanent magnet as in the first embodiment is that the permanent magnet appears like an air gap to the flux generated by the first coil 26. Thus, higher currents need to be used to generate the same magnetic field. However, for this embodiment, when the valve 12 is operating in the full open mode, the first electromagnet 122 must be energized at all times to hold the second electromagnet 30.
A third embodiment of the present invention is illustrated in FIG. 5. This is the same as the second embodiment, with the removal of a permanent magnet and integral first electromagnet 122 with the insert 117. In addition, spring loaded pins 54 and corresponding solenoid actuators 56 are mounted to the actuator housing 120. The solenoids 56 are electrically connected to a conventional source of electric current (not shown), which can be selectively turned on and off by a conventional controller, such as an engine computer (not shown). The pins 54 act just like the stop ring 42 to hold the second electromagnet 30 in position once the first electromagnet 122 has drawn the second electromagnet 30 down. Thus, the pins 54 take the place of the permanent magnet by holding the second electromagnet 30 against the bias of the first spring 48 without requiring the first electromagnet 122 to remain energized. To release the second electromagnet 30, the solenoids 56 are pulsed to briefly withdraw the pins 54, allowing the second electromagnet 30 to slide up to the stop ring 42 for mid-open valve operation.
FIG. 6 illustrates a fourth embodiment of the present invention. In this embodiment, like elements with the first embodiment will be similarly designated while changed elements will also be similarly designated but with a 200-series designation. The second electromagnet 230 now extends around the first electromagnet 222 toward the insert 217, forming a stop member 242, which replaces the stop ring. Also, the first spring 248 is mounted between the stop member 242 and the first electromagnet 222, now pushing downwards, rather than upwards, on the second electromagnet 230. Although, in this embodiment, the first spring 248 is optional.
In this embodiment, the first electromagnet 222 is energized during mid-open valve operation rather than during full-open operation. This is beneficial if less time is spent in the mid-open mode, than the full open mode. Depending upon whether the full open or mid-open operating mode is the most prevalent operating mode, the energy consumption for the first embodiment varies. In embodiment 1, the mid-open operating condition uses less energy than the full open since the first electromagnet 222 may be always on during full open operation, while in this embodiment the situation is reversed. Energy consumption is minimized in either embodiment since the electromagnet only needs to supply a low holding force, rather than a higher energy transient force used to pull the second electromagnet towards it.
While certain embodiments of the present 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 as defined by the following claims.
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An electromechanically actuated valve (12) for use as an intake or exhaust valve in an internal combustion engine. The valve (12) is actuated by a electromechanical actuator assembly (18) which includes a first electromagnet (22), second electromagnet (30) and third electromagnet (32). A disk (38) is fixedly mounted to the valve (12) in a gap between the second and third electromagnets. The second electromagnet (30) is slidable between the first electromagnet (22) and a stop (42), allowing the gap between the second electromagnet (30) and the third electromagnet (32) to vary. This allows for multiple valve lifts. A second spring (50), mounted between the second electromagnet (30) and disk (38), and a third spring (32), mounted between the disk (44) and an actuator housing (20), create a balanced oscillatory system which drives most of the valve movement during engine operation, thus reducing power requirements to actuate the valves while increasing the responsiveness of the valves.
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FIELD OF THE INVENTION
The present invention relates to apparatus and methods for purifying water. More particularly, the present invention relates to apparatus and methods for adsorbing perchlorate in water and then destroying it.
BACKGROUND OF THE INVENTION
Since the mid-1940s, perchlorate, and in particular ammonium perchlorate, has been used in the production of solid rocket fuel for military and space applications. Additionally various perchlorate salts have been used in a wide variety of non-military applications. For example, perchlorate salts are used in the production of matches, safety flares, fireworks and other pyrotechnics.
That past use of perchlorate has given rise to a significant present problem of perchlorate contamination of soil and ground water. The perchlorate contamination is a significant problem because it is potentially toxic. In particular, ingested perchlorate interferes with the thyroid gland's ability to utilize iodine, an essential nutrient. As a result, production of thyroid hormones that regulate metabolism and growth may be disrupted. Although short-term fluctuations in thyroid hormone levels are normal and the body has a certain capacity to cope and adjust for these small changes, continuous thyroid disruption may cause an imbalance, especially when a body is already under stress.
Since the perchlorate contamination threat was identified, various efforts have been initiated with the purpose of establishing goals and regulatory standards. In 2004 , the California Office of Environmental Health Hazard Assessment published a public health goal of 6 ppb. In addition, the U.S. Environmental Protection Agency has proposed a limit for perchlorate of 24.5 ppb and the Massachusetts Department of Environmental Protection has proposed a limit of 2 ppb.
In view of the existing and impending restrictions on perchlorate in potable water, various attempts have been made to provide apparatus and methods for removing perchlorate from water. Various attempts have been made to remove perchlorate from water using microorganisms. For example, the bacterium, Perc 1 ace, has been used in a flow-through system to reduce perchlorate in water. In that system, contaminated ground water flowed through a bacterially active zone of a bioreactor and was exposed to Perc 1 ace. Although the bacterium was effective in reducing perchlorate, the presence of microorganisms creates various disadvantages. One disadvantage is that the costs are increased due to precautions that must be taken when handling the microorganism, including additional and potentially costly disinfection procedures. Furthermore, systems without microorganisms are easier to handle and more responsive to varying operational conditions.
Another example of a system for removing perchlorate is provided in U.S. Pat. No. 6,531,065 to Gurol et al. In that patent it was shown that zero-valent iron particles can reduce perchlorate to chloride ion, and furthermore that ultra-violet (“UV”) radiation can serve as a catalyst for the reduction process. The process involved adding large scale particles of zero-valent iron (in the millimeter range) to perchlorate-containing water in special reactors that accommodate UV radiation tubes.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide apparatus and methods for removing perchlorate from water.
It is another object of the present invention to provide apparatus and methods for removing perchlorate from water and subsequently destroying the perchlorate.
It is another object of the present invention to provide apparatus and methods for removing perchlorate from water and destroying the perchlorate without the use of microorganisms.
It is another object of the present invention to provide apparatus and methods for removing perchlorate from water and destroying the perchlorate that can be used as a stand-alone process or in conjunction with various physical separation processes.
It is another object of the present invention to provide apparatus and methods for removing perchlorate from water and destroying the perchlorate for small-scale individual well-head treatment applications or as part of a large water treatment plant.
Embodiments of the present invention allow reduction of the reactor size by about 99%.
Embodiments of the present invention allow reduction of metallic iron requirements from 100 gram/L to about 1 gram/L.
Embodiments of the present invention allow elimination of UV radiation that may be employed in other systems.
Embodiments of the present invention allow elimination in reactor configurations of restrictions due to UV penetration.
Embodiments of the present invention allow extreme reduction in ferrous formation, and thus elimination of sludge problems.
Embodiments of the present invention allow extreme reductions in the acids and bases needed for pH adjustments.
Embodiments of the present patent application use the basic principle of chemical reduction of perchlorate by zero-valent iron particles to remove perchlorate from water and to destroy the perchlorate.
In an embodiment, a method of removing perchlorate includes filtering perchlorate-polluted water through a column of adsorbents. The column is removed after the capacity of the adsorbent is exhausted. After the exhausted column is removed a new column of adsorbent is installed so that removal of perchlorate may be continued. In an aspect of this embodiment, the column of exhausted adsorbent is subjected to a regeneration process so that it may be reused.
In some embodiments, the major reaction product is chloride ion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic of an embodiment of the perchlorate removal process of this invention.
FIG. 2 shows a schematic of a perchlorate destruction reactor of an embodiment of the invention.
FIG. 3 is a chart demonstrating perchlorate regeneration from granular activated carbon, particularly the effect of borohydride concentration on regeneration.
FIG. 4 is a chart demonstrating perchlorate regeneration from granular activated carbon, particularly the effect of NaOH on regeneration.
FIG. 5 is a chart demonstrating perchlorate regeneration from granular activated carbon, particularly the effect of temperature on regeneration.
FIG. 6 is a chart demonstrating nano-scale iron concentration during perchlorate destruction.
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of an embodiment of the invention is provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, the specific details disclosed herein are not to be interpreted as limiting, but rather as a representative basis for teaching one skilled in the art how to employ the present invention in virtually any detailed system, structure, or manner.
Turning first to FIG. 1 , an exemplary embodiment of a process for the removal of perchlorate from a fluid and for the subsequent destruction of the perchlorate (ClO 4 − ) is described. While the present embodiment relates to the removal of perchlorate from water, one skilled in the art will recognize that the present process may also be applied to the removal of perchlorate from other fluids, either liquid or gaseous.
Polluted water 10 , that is, water containing perchlorate in excess of a predetermined amount (e.g., 6 ppb), is fed into adsorbent column 12 , which contains an adsorbent material, for example, granular activated carbon (GAC). One skilled in the art will recognize that the size of adsorbent column 12 , and the granulometry and morphology of the adsorbent, will be selected to maximize contact sites between the adsorbent and polluted water 10 , so that all perchlorate dissolved in polluted water 10 receives maximum exposure to the surface of the adsorbent material.
As a result, the adsorbent material captures and retains on its surface essentially all the perchlorate present in polluted water 10 , producing treated water 14 that exits adsorbent column 12 containing a perchlorate content below the maximum predetermined amount. If the treated water 14 is intended for potable use, treated water 14 exiting adsorbent column 12 will contain perchlorate in a ppm amount below the maximum amount allowed by the relevant health authorities.
The interaction between the adsorbent surface and the perchlorate is summarized by the following formula (1):
≡Surface+ClO 4 − →≡Surface−ClO 4 − (1)
Over time, the adsorbent material becomes saturated with perchlorate, losing adsorbing capacity. For example, typical GAC may have approximately 0.1-0.2 mg/gram of perchlorate adsorption capacity, and when such adsorption capacity is substantially exhausted, column 12 is taken out of service and polluted water 10 is diverted to a fresh new column of adsorbent, in order to continue producing water that is essentially perchlorate-free. Typically, GAC can produce perchlorate free water for water equivalent to 1000 BV (bed volume).
The Applicants also showed that the capacity of GAC for perchlorate can be increased substantially if the GAC is pretreated with a non-hazardous surface active agent (surfactant), such as tetradecyldtrimethylammonium bromide, cetylpyridinium chloride, or other such surfactants known in the art. The capacity of GAC can be increased by one hundred times to have 10 mg perchlorate per gram GAC if GAC is treated with surfactants. This increases the service time of the GAC to 100,000 BV.
Exhausted adsorbent column 16 is then subjected to a regeneration process on site by pumping a regenerant through the column. One such regenerant is a solution of sodium borohydride (NaBH 4 ), a water soluble reducing agent. As will be discussed in greater detail below, perchlorate is desorbed readily from the surface of the adsorbent material under appropriate environmental conditions (pH, oxidation reduction potential, concentration of the sodium borohydride, flow rate, and temperature) and is concentrated in the regenerant solution according to a process that can be summarized by the following formula (2):
≡Surface−ClO 4 − +NaBH 4 →≡Surface+ClO 4 − +NaBH 4 (2)
Regenerant solution 18 is preferably a solution of NaBH 4 at very low oxidation reduction potential, which is pumped through exhausted adsorbent column 16 to desorb the perchlorate at ambient temperature. Furthermore, the efficiency of perchlorate desorption by NaBH 4 is increased significantly by using a stabilizer, such as NaOH. Better results were in fact obtained with 0.05 N NaOH combined with 1 g/L of NaBH 4 . In addition, the regenerant was recirculated to reduce the total volume requirement. It was demonstrated that the column can be regenerated with a regenerant volume of equivalent to only 2.5 times the Bed Volume (BV).
The amount of perchlorate in stream 20 exiting exhausted adsorbent column 16 is measured by perchlorate sensor 22 . Three way valve 24 is situated downstream of exhausted adsorbent column 16 and adjusted to be in an open or closed condition according to the perchlorate level measured by perchlorate sensor 22 . In particular, if the perchlorate level measured by perchlorate sensor 22 is determined to be below a predetermined level (e.g., less than 100 ppb), stream 20 is directed to a regenerant collection tank 26 , where the regenerant is collected and the remainder solution is recycled into polluted water 10 . Instead, if the perchlorate level measured by perchlorate sensor 22 is determined to be above a predetermined level (e.g., higher than 100 ppb), water stream 20 is directed to perchlorate destruction reactor 28 , which operates in a batch mode at controlled temperature, pH, pressure and ORP conditions, preferably at T=70-90° C., pH=6-7 , P=0-50 psig, and ORP<−0.1 V.
The small volume of regenerant is treated with a ferric salt (such as iron chloride, sometimes referred to as ferric chloride, or FeCl 3 ) to produce in situ nano-particles of zero-valent iron according to the following unbalanced reaction (3):
NaBH 4 +FeCl 3 +H 2 O→Fe°+B(OH) 3 +Na + +Cl − +H 2 (3)
The nano-particles of zero-valent iron produced in situ then react with perchlorate in the reduced environment according to the following unbalanced reaction (4):
ClO 4 − +Fe°→Cl − +Fe +2 (4)
In Applicants' experimental work, the first order rate constant for destruction of perchlorate varied from 0.0035 to 0.14 hr −1 , at various temperature, pH, and concentration of iron particles.
FIG. 2 illustrates one embodiment of a reactor for perchlorate destruction 30 . The reactor is sealed and equipped with a mixer 44 actuated by a motor 46 , pressure sensor 34 and pressure gauge 36 , pressure release valve 58 , pH probe 38 and temperature sensors 40 , and a sampling port 42 . The reactor could be fed through a ball valve 56 and be heated by heating tapes 46 receiving energy from a heater 48 and protected by insulation 50 or by other measures. The data in pH, T and P are continuously fed to computer 54 via a control system 54 monitoring performance of the system. Computer 52 has a data acquisition program.
As a result of the above described process steps, perchlorate concentration is decreased in perchlorate destruction reactor 28 to a level of approximately 100 ppb. The regenerant is then sent through a set of additional small-size adsorbents 32 for the removal of iron and boric acid, preferably through greensand for iron and GAC for boric acid. Alternatively, iron can be removed by oxidation and filtration of ferric precipitates. The treated regenerant is then sent to regenerant collection tank 26 , becoming mixed with the low perchlorate contents of the tank. When the GAC is pretreated with a surfactant to increase its service life to years, the effluent of the perchlorate reactor can easily be blended with incoming polluted water without any additional treatment for removal of iron and boric acid. That is because the volume of the regenerant will be extremely small (2.5 BV) compared to the water to be treated (100,000BV), hence the dilution factor will be 1/40,000.
The contents of regenerant collection tank 26 are finally bled into polluted water 10 , diluting such contents by at least one hundred times. Typically, the perchlorate concentration in tank 26 is diluted to less than 10 ppb perchlorate with the incoming water stream 10 . This mixture is successively treated by adsorbent column 12 to reduce the perchlorate in the treated water below the adopted local standards or guidelines.
A person skilled in the art will recognize that embodiments of the present invention can be used as a stand-alone apparatus or process or in conjunction with physical separation processes, e.g., GAC, ion exchange, or RO, to treat either the regenerant or the reject.
It should be noted that numerous experiments performed by Applicants have yielded several conclusions on relevant process parameters, and FIGS. 3-6 provide experimental data that support these conclusions. First, of eight different kinds of activated carbon tested, US Filter AC 830 was observed to have the highest capacity for perchlorate and highest efficiency of regeneration by NaBH 4 . In addition, using NaBH 4 solution as a regenerant allows ClO 4 − to be concentrated from 100 ppb to 10-20 ppm. FIG. 3 illustrates graphically the effect of borohydride concentration on GAC regeneration without additional NaOH. As shown in FIG. 3 , the regenerant can recover perchlorate from the GAC at 95-100% efficiency with only 2-3 Bed Volume (BV). This is less than 1% of the total amount of water treated. With the use of surfactant, that is less than 0.0025% of the total amount of water treated.
FIG. 4 illustrates graphically the effect of NaOH on GAC regeneration, where NaOH is expressed in N, and NaBH 4 in g/L. As shown in FIG. 4 , the use of low concentrations of NaOH (0.01-0.05 N) in the regenerant together with NaBH 4 increases the efficiency of the regeneration process and reduces the regenerant volume. Furthermore, the impact of anions in water, including sulfate, chloride and nitrate on GAC adsorption or desorption by NaHB 4 was found to be relatively small. Nano-scale particles of metallic iron are formed directly in the reactor by adding the exact amount of FeCl 3 solution to the regenerant solution (NaBH 4 solution). The concentration of NaBH 4 may vary between 0.5-1.2 g/L to produce nano-iron at concentrations between 0.24 to 1.29 g/L.
As shown in FIGS. 5 and 6 , the reaction of perchlorate reduction is very sensitive to temperature. The rate constant increases by 6 times and by 24 times at temperatures of 75 and 90° C. as compared to 60° C. The activation energy of the reaction was calculated to be 103 kJ/mole. More particularly, FIG. 6 demonstrates reactions with a nano-scale iron concentration of 1.29 g/L and a pH of 6.5.
As shown in Table 1 , the rate of the reaction is strongly dependent on the nano-scale metallic iron concentration. An increase in nano-iron concentration by a factor of five (from 0.24 to 1.20 g/L) produces a seven times increase in perchlorate destruction rate.
TABLE 1
The rate constants for perchlorate destruction at pH 6.6
Nano iron concentration (g/L)
Temperature (° C.)
Rate Constant (hr −1 )
0.24
75
0.0035
0.70
75
0.0104
1.20
75
0.0250
1.20
90
0.1000
0.48
85
0.0089
The reaction is of the first-order with respect to both perchlorate and nano-iron concentration. Accordingly, the reduction reaction is faster for higher concentrations of perchlorate. When the GAC is treated with a surfactant, the desorption process by the same regenerant is not affected significantly, still allowing 80-100% of the perchlorate to be recovered in the regenerant. The majority of the surfactant remained on the GAC (85-95%), very little surfactant leaching into the regenerant. However, the rate of perchlorate destruction in the reactor may be reduced in the presence of the surfactant, leading to longer treatment cycles.
While the invention has been described in connection with the above described embodiment, it is not intended to limit the scope of the invention to the particular forms set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the scope of the invention. Further, the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art.
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A method and apparatus for adsorbing perchlorate in a fluid and successively destroying it. Perchlorate in the fluid is removed by adsorption on an adsorbent in a column. The adsorbent is then regenerated by desorbing perchlorate, and the perchlorate in the regenerant is then chemically destroyed.
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[1] 1. This application is a continuation-in-part application of U.S. patent application Ser. No. 09/283,680, filed Apr. 1, 1999, which claims priority from co-pending U.S. Provisional Patent Application Serial No. 60/081,813, filed Apr. 15, 1998.
FIELD OF THE INVENTION
[2] 2. This invention relates to intraocular lenses. In particular, the present invention relates to intraocular lenses for reducing the risk of posterior capsule opacification.
BACKGROUND OF THE INVENTION
[3] 3. Foldable intraocular lens (“IOL”) materials can generally be divided into three categories: silicone materials, hydrogel materials, and non-hydrogel acrylic materials. Many materials in each category are known. See, for example, Foldable Intraocular Lenses , Ed. Martin et al., Slack Incorporated, Thorofare, N.J. (1993). Biocompatibility varies among different IOL materials within and among each category.
[4] 4. One measure of biocompatability for an IOL can be the incidence of posterior capsule opacification (“PCO”). A number or factors may be involved in causing and/or controlling PCO. For example, the design and edge sharpness of an IOL may be a factor. See, Nagamoto et al., J. Cataract Refract. Surg., 23:866-872 (1997); and Nagata et al., Jpn. J. Ophthalmol., 40:397403 (1996). See, also, U.S. Pat. Nos. 5,549,670 and 5,693,094. Another factor appears to be the lens material itself. See, for example, Mandle, “Acrylic lenses cause less posterior capsule opacification than PMMA, silicone IOLs,” Ocular Surgery News, Vol. 14. No. 15, p. (1996). See, also, Oshika, et al., “Two Year Clinical Study of a Soft Acrylic Intraocular Lens,” J. Cataract. Refract. Surg., 22:104-109 (1996); and Ursell et al., “Relationship Between Intraocular Lens Biomaterials and Posterior Capsule Opacification,” J. Cataract Refract. Surg., 24:352-360 (1998).
[5] 5. One method of addressing the PCO problem involves administering a pharmaceutical agent to the capsular bag area at the time of, or immediately after, extracapsular cataract extraction. See, for example, U.S. Pat. Nos. 5,576,345 (pharmaceutical agent=the cytotoxic agent taxol or an ophthalmically acceptable derivative); 4,515,794; and 5,370,687. Alternatively, the pharmaceutical agent may be tethered to the surface of the IOL material. See, for example, U.S. Pat. No. 4,918,165. The pharmaceutical agents are intended to kill or prevent the growth of proliferating cells that might cause PCO or “secondary cataracts.” Yet another method involves the physical destruction or removal of lens epithelial cells. See, Saika et al., J. Cataract Refract. Surg., 23:1528-1531 (1997).
[6] 6. Another method of addressing PCO is the prophylactic laser therapy method disclosed in U.S. Pat. No. 5,733,276. According to this method, the lens capsule is irradiated with laser irradiation to destroy cells which remain in the lens capsule after extraction of a cataract.
[7] 7. Other methods theorized for reducing the risk of PCO involve adhering the posterior capsule to the IOL at the time of implantation, as in U.S. Pat. No. 5,002,571. According to the '571 patent, a non-biological glue or, preferably, a biological glue, such as fibrin, collagen, or mussel glue, is used to adhere the posterior lens capsule to the posterior surface of an IOL. The glue may be applied over the entire posterior surface of the IOL or just as an annulus around the outer perimeter of the posterior surface of the IOL.
[8] 8. In contrast, U.S. Pat. No. 5,375,611 discloses a method of reducing the risk of PCO by preventing the adherence of the posterior capsule to the IOL. According to the '611 patent, the posterior surface of the lens capsule itself is chemically modified at the time of extracapsular cataract extraction. The chemical modification is achieved by depositing a water-insoluble stable or permanent layer of a cell attachment preventing compound onto the posterior surface of the lens capsule. The stable or permanent layer may be a polymer, such as polyethylene glycol, polysaccharides, polyethylenepropylene glycol, and polyvinyl alcohols.
SUMMARY OF THE INVENTION
[9] 9. The present invention relates to a method of selecting an IOL material for reducing the risk of posterior capsule opacification. IOL materials having a certain tack are more likely to reduce the risk of posterior capsule opacification than are materials having a lower tack. Tack is determined by measuring the maximum load required to separate two pieces of the same material.
DETAILED DESCRIPTION OF THE INVENTION
[10] 10. According to the present invention, IOL optic materials are selected based on their tack. Tack is the maximum load required to separate two pieces of the same material that gave been placed in contact with each other. The maximum load required to separate two pieces of the same material varies with a number of factors, including the contact surface area, the shape of the material samples, the length of time the materials are held in contact with each other prior to separation and the weight, if any, placed on the materials after they are contacted with each other.
[11] 11. IOL materials having a tack greater than that of an IOL material consisting of 65% (w/w) 2-phenylethyl acrylate, 30% (w/w) 2-phenylethyl methacrylate, 3.2% (w/w) 1,4-butanediol diacrylate and 1.8% (w/w) 2-(2″-hydroxy-3′-methallyl-5′-methylphenyl)benzotriazole, wherein this IOL material has been cured at 80° C. for 2 hours, then 100° C. for 2 hours using 1% (w/w) di-(4-t-butylcyclohexyl)peroxydicarbonate as a polymerization initiator, reduce the risk of posterior capsule opacification when implanted into the human lens capsule. To determine the tack of an IOL material (“test material”) and compare it to that of the IOL material specified immediately above (“standard material”), all that is necessary is that both the test material and standard material be of the same size and shape and the testing parameters be identical. The standard material does not have to be exactly the material defined above, but can be any material having an approximately equivalent tack. The ratio of the tack of the test material to that of the standard material is defined as the “Tack Quotient.” According to the present invention, IOL materials are selected that have a Tack Quotient of 1 or greater, provided that the IOL material does not consist essentially of (i) 2-phenylethyl acrylate and 2-phenylethylmethacrylate or (ii) ethyl acrylate, ethyl methacrylate and trifluoroethylmethacrylate. IOL materials having a Tack Quotient higher than about 3 generally present handling problems that may make them unsuitable for use as a foldable IOL material. The IOL materials are preferably chosen so that they have a Tack Quotient of about 1-2, and more preferably about 1-1.5.
[12] 12. A preferred method of measuring tack is as follows. Two 6-mm diameter, 1-mm thick flat disks of an IOL material are prepared (“Test Disks”). Each Test Disk is then secured to the flat surface of a T-shaped post adapted for use with the tensile testing machine. For example, the T-shaped posts can be made of polycarbonate materials and have the shape shown in FIG. 1. The Test Disks are secured to the T-shaped posts using any glue that does not imbibe into the lens material, swelling it and changing the material's surface properties. The glue is preferably a quick-setting glue so that minimal penetration is allowed. In the case of foldable acrylic IOL materials, such as those described in U.S. Pat. No. 5,290,892 and 5,693,095, suitable glues include epoxy resins. The glue should be chosen and used in an amount such that the Test Disks do not separate from the T-shaped posts during the tack test.
[13] 13. Once the Test Disks are secured to the T-shaped posts, the glue should be allowed to dry thoroughly. In the case of epoxy resins, the drying time could be approximately 15 hours or so. After the glue has thoroughly dried, the Test Disks are placed in contact with each other, under an appropriate weight, preferably a weight of about 200 g. The Test Disks are held in contact with each other for approximately two minutes, after which time the weight is removed and the maximum load required to separate the Test Disks is measured by pulling the Test Disks apart using a crosshead speed of about 1 mm/min. In a preferred embodiment, the tensile testing machine's assembly for holding the T-shaped posts is configured to allow a weight to rest on the bottom of an inverted T-shaped post, as shown in FIG. 2. This test is preferably conducted at ambient conditions, with n=3−6. The tensile testing machine pulls the T-shaped posts away from each other until separation. The maximum load recorded prior to separation is the tack. For example, the tensile testing machine can be an Instron Material Tester (Model No. 4442 or equivalent). Maximum load is can be expressed in a number of ways, including being expressed in Newtons.
[14] 14. Although the method of the present invention could be applied to silicone and hydrogel IOL materials, such materials are generally not tacky to the extent that only a minimal load, if any, is required to separate them from themselves. The method of the present invention is preferably used to select IOL materials from the family of ophthalmically acceptable foldable acrylic materials. Most preferred are the foldable acrylic materials comprising one or more monomers of the formula
[15] 15. wherein:
[16] 16. X is H or CH 3 ;
[17] 17. m is 0-10;
[18] 18. Y is nothing, O, S, or NR wherein R is H, CH 3 , C n H 2n+1 (n=1−10) iso OC 3 H 7 , C 6 H 5 , or CH 2 C 6 H 5 ;
[19] 19. Ar is any aromatic ring which can be unsubstituted or substituted with CH 3 , C 2 H 5 , n-C 3 H 7 , iso-C 3 H 7 , OCH 3 , C 6 H 11 , Cl, Br, C 6 H 5 , or CH 2 C 6 H 5 .
[20] 20. Monomers of Formula I are known and include, but are not limited to: 2-phenoxyethyl acrylate; 2-phenylethylthio acrylate; 2-phenylethylamino acrylate; phenyl acrylate; benzyl acrylate; 2-phenylethyl acrylate; 3-phenylpropyl acrylate; 3-phenoxypropyl acrylate; 4-phenylbutyl acrylate; 4-phenoxybutyl acrylate; 4-methylphenyl acrylate; 4-methylbenzyl acrylate; 2-2-methylphenylethyl acrylate; 2-3-methylphenylethyl acrylate; 2-4-methylphenylethyl acrylate; and their corresponding methacrylate compounds. These acrylic/methacrylic monomers and others are disclosed in U.S. Pat. No. 5,290,892, the entire contents of which are hereby incorporated by reference. Suitable IOL materials for screening using the method of the present invention also include, but are not limited to, those disclosed in U.S. Pat. No. 5,331,073, the entire contents of which are hereby incorporated by reference.
[21] 21. Preferred monomers of Formula I are those where m is 2-4; Y is nothing or O; and Ar is phenyl. Most preferred are 2-phenylethyl acrylate; 2-phenoxyethyl acrylate; 3-phenylpropyl acrylate; 3-phenoxypropyl acrylate; 4-phenylbutyl acrylate; 4-phenoxybutyl acrylate; and their corresponding methacrylate compounds.
[22] 22. Using the preferred method of testing tack described above and an Instron Materials Tester Model No. 4442, the following results are obtained:
[23] 23. 1. IOL material=78 wt. % 2-phenylethyl acrylate; 18 wt. % 2-phenylethyl methacrylate; 2 wt. % of 1,4-butanediol diacrylate; 1 wt. % 2-(2′-hydroxy-3′-methallyl-5′-methyl phenyl) benzotriazole; and 1 wt. % of di-(tert-butylcyclohexyl) peroxydicarbonate. Results (max. load, N)=approx. 7−8±1.2.
[24] 24. 2. IOL material=74.2 wt. % 2-phenylethyl acrylate; 16.8 wt. % 2-phenylethyl methacrylate; 5 wt. % N-vinyl pyrrolidone; 2 wt. % of 1,4-butanediol diacrylate; 1 wt. % 2-(2′-hydroxy-3′-methallyl-5′-methyl phenyl) benzotriazole; and 1 wt. % of di-(tert-butylcyclohexyl) peroxydicarbonate. Results (max. load, N)=approx. 13.4±2.4.
[25] 25. 3. IOL material=74.1 wt. % 2-phenylethyl acrylate; 6.9 wt. % 2-phenylethyl methacrylate; 15 wt. % polyethylene oxide (wt. avg. molecular weight of 1000) dimethacrylate; 2 wt. % of 1 ,4-butanediol diacrylate; 1 wt. % 2-(2′-hydroxy-3′-methallyl-5′-methyl phenyl) benzotriazole; and 1 wt. % of di-(tert-butylcyclohexyl) peroxydicarbonate. Results (max load, N)=approx. 0.
[26] 26. Preferably, IOL materials are also substantially free of glistenings in a physiologic environment and for which the amount of collagen IV that remains adhered to the material in step (d) is about 30-100 % of the amount that remains adhered in step (b). Glistenings are the result of condensation of water vapor within the lens. Although glistenings have no detrimental effect on the function or performance of IOLs made from acrylic materials, it is nevertheless cosmetically desirable to minimize or eliminate them. IOL materials are substantially free of glistenings in a physiologic environment if they have an average of no more than approximately 1-2 glistenings per mm 2 when evaluated in the test described below. Preferably, the average number of glistenings per mm 2 will be much less than 1.
[27] 27. The presence of glistenings is measured by placement of a lens sample into a vial and adding deionized water or a balanced salt solution. The vial is then placed into a water bath preheated to 45° C. Samples are to be maintained in the bath for 24 hours. The sample is then placed either in a 37° C. bath or at room temperature and allowed to equilibrate for 2 hours. The sample is removed from the vial and placed on a microscope slide. Visualization of glistenings is done with light microscopy using a magnification of 50 to 200×.
[28] 28. Furthermore, IOL materials are preferably selected so that they possess the following refractive index, T g , and elongation properties, which make the materials particularly suitable for use in IOLs which are to be inserted through incisions of 5 mm or less.
[29] 29. The IOL material preferably has a refractive index of at least about 1.50 as measured by an Abbe' refractometer at 589 nm (Na light source). IOL optics made from materials having a refractive index lower than 1.50 are necessarily thicker than optics of the same power which are made from materials having a higher refractive index. As such, IOL optics made from materials having a refractive index lower than about 1.50 generally require relatively larger incisions for IOL implantation.
[30] 30. The glass-transition temperature (“Tg”) of the IOL material, which affects the material's folding and unfolding characteristics, is preferably between about −20 to +25° C., and more preferably between about −5 and +16° C. Tg is measured by differential scanning calorimetry at 10° C./min., and is determined at the midpoint of the transition of the heat flux curve.
[31] 31. The IOL material should also have an elongation of at least about 150%, preferably at least 200%, and most preferably about 300-600%. This property indicates that an IOL optic made of the material generally will not crack, tear or split when folded. Elongation of polymer samples is determined on dumbbell shaped tension test specimens with a 20 mm total length, length in the grip area of 4.88 mm, overall width of 2.49 mm, 0.833 mm width of the narrow section, a fillet radius of 8.83 mm, and a thickness of 0.9 mm. Testing is performed on samples at ambient conditions using an Instron Material Tester (Model No. 4442 or equivalent) with a 50 Netwon load cell. The grip distance is set at 14 mm and a crosshead speed is set at 500 mm/minute and the sample is pulled until failure. The elongation (strain) is reported as a fraction of the displacement at failure to the original grip distance.
[32] 32. The invention has been described by reference to certain preferred embodiments; however, it should be understood that it may be embodied in other specific forms or variations thereof without departing from its spirit or essential characteristics. The embodiments described above are therefore considered to be illustrative in all respects and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description.
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A method of selecting an intraocular lens material for reducing the risk of posterior capsule opacification is disclosed. The method comprises determining the tack of the material.
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BACKGROUND
1. Technical Field
The present invention relates to an electrolytic apparatus, an ice making apparatus incorporating the electrolytic apparatus, and an ice making method, in particular, to an electrolytic apparatus, an ice making apparatus, and an ice making method that suppress a growth of mold (fungi) or bacteria in the ice making apparatus over a subsequent operation of the apparatus during startup of the ice making apparatus.
2. Related Art
Methods of performing electrolysis using a silver electrode for an anode, and a silver electrode or an inert electrode or other electrodes for a cathode based on dilute electrolyte solution containing chloride or tap water as raw water to generate electrolytic silver or silver nitrate are widely known techniques. For a long time, silver has been said to have bactericidal capacity, used for control of mold and bacteria, such as anti-bacteria, and used from the viewpoint of hygiene, such as sterilized water (for example, JP 2007-85699 A).
The bacterial control using silver ions of JP 2007-85699 A, an electrolyzed water generation mechanism is installed on a raw water side of the ice making apparatus. The electrolyzed water generation mechanism generates silver ions by applying direct current to a pair of silver electrodes. An internal path and ice are sterilized by supplying the electrolyzed water (ice making water) containing silver ions into the ice making apparatus to make ice.
However, JP 2007-85699 A suggests the use of electrolytic raw water, that is, tap water obtained by performing dechlorination or the like as electrolytic solution. In addition, since the reaction is slow in silver ionized water, there are problems in that mold and bacteria are likely to occur in the apparatus during startup of the ice making apparatus, and slime due to the growth of mold and bacteria is likely to occur on a bottom surface of an ice making water tank.
SUMMARY
An object of the invention is to provide an electrolytic apparatus, an ice making apparatus incorporating the electrolytic apparatus, and an ice making method for solving the above-described problems of the prior art that suppress the growth of mold or bacteria in the ice making apparatus over a subsequent operation of the apparatus during startup of the ice making apparatus.
As a result of extensive studies on the above-described problems, the present inventors or the like have found the followings.
In the electrolytic apparatus, when a silver electrode is used in the anode, silver is dissolved as silver ions and reacts with chloride ions, nitric acid ions or the like of anion in the raw water, thereby producing silver salt such as silver chloride and silver nitrate. When the silver salt is silver chloride, most of silver chloride form insoluble colloidal salt due to low solubility. When the silver chloride is excessively generated, a precipitate is also formed. The electrolyzed water containing the insoluble colloidal silver chloride also has a function of realizing sterilization in a small amount, similarly to soluble silver ion electrolyzed water. However, since the reaction is slow, the time taken until mold and bacteria die is long.
In addition, since an oxidation-reduction potential of ozone is 2.07 V, ozone is generated by applying the potential of 2.07 V or more to the electrode using an inert electrode such as platinum or a platinum alloy in the anode to oxidize and electrolyze water. Electrolytic generation of ozone has been known for a long time, and ozone water obtained by dissolving ozone in water has been widely used. The electrolytic generation ozone water has been mainly used in the control of mold and bacteria such as sterilization, used in tap water, pool water or the like, and used in the control of mold and bacteria.
The inventors or the like configured an electrolytic apparatus in which three electrode plates are arranged in an order of an anode (I), a cathode (II), and an anode (III), a silver electrode is used in the anode (I), an inert electrode such as platinum and a platinum alloy is used in the cathode (II) and the anode (III), and an electrode pair of the anode (I)—the cathode (II) and an electrode pair of the cathode (II)—the anode (III) are set as electrical circuits for independently supplying electrolytic current, respectively. The inventions have found that when the apparatus is incorporated into an ice making apparatus, it is possible to generate ozone water during startup of the ice making apparatus, and generate electrolyzed water containing insoluble colloidal silver chloride during a subsequent operation, and as a result, it is possible to suppress growth of mold or bacteria in the ice making apparatus during startup of the ice making apparatus by ozone water, and it is possible to suppress subsequent growth of mold and bacteria by silver chloride colloidal water, and thus have accomplished the present invention.
To accomplish the above-described object, the invention is described below.
[1] An electrolytic apparatus comprising:
an electrolytic bath in which an anode (I) of a silver electrode—a cathode (II) of an inert electrode—an anode (III) of an inert electrode are arranged in this order in parallel to one another, and an electrode pair of the anode (I)—the cathode (II) and an electrode pair of the cathode (II)—the anode (III) have an electrical circuit configured to independently supply electrolytic current;
an electrolytic raw water supply pipe configured to supply electrolytic raw water into the electrolytic bath; and
an electrolyzed water extraction pipe configured to extract the electrolyzed water in the electrolytic bath to the outside.
[2] An electrolytic apparatus comprising:
an electrolytic bath in which an anode (I) of a silver electrode—a cathode (II) of an inert electrode—an anode (III) of an inert electrode are arranged in this order in parallel to one another, the cathode (II) partitions the interior of the cell into a space having an electrode pair of the anode (I)—the cathode (II) and a space having an electrode pair of the cathode (II)—the anode (III) in a liquid-tight manner, and the electrode pair of the anode (I)—the cathode (II) and the electrode pair of the cathode (II)—the anode (III) have an electrical circuit configured to independently supply electrolytic current;
an electrolytic raw water supply pipe configured to supply the electrolytic raw water between the electrode pair of the anode (I)—the cathode (II) and between the electrode pair of the cathode (II)—the anode (III) in the electrolytic bath; and
an electrolyzed water extraction pipe configured to extract the electrolyzed water between the electrode pair of the anode (I)—the cathode (II) and between the electrode pair of the cathode (II)—the anode (III) in the electrolytic bath to the outside.
[3] An electrolytic apparatus comprising:
an electrolytic bath in which an anode (I) of a silver electrode—a cathode (II) of an inert electrode—an anode (III) of an inert electrode are arranged in this order in parallel to one another, the cathode (II) partitions the interior of the cell into a space having an electrode pair of the anode (I)—the cathode (II) and a space having an electrode pair of the cathode (II)—the anode (III) in a liquid-tight manner, and the electrode pair of the anode (I)—the cathode (II) and the electrode pair of the cathode (II)—the anode (III) have an electrical circuit configured to independently supply electrolytic current;
a communicating pipe that connects one end side of the space having the electrode pair of the anode (I)—the cathode (II) and one end side of the space having the electrode pair of the cathode (II)—the anode (III) in the electrolytic bath;
an electrolytic raw water supply pipe configured to supply the electrolytic raw water to one of the other end side of the space having the electrode pair of the anode (I)—the cathode (II) and the other end side of the space having the electrode pair of the cathode (II)—the anode (III) in the electrolytic bath; and
an electrolyzed water extraction pipe configured to extract the electrolyzed water outward to the other side of the other end side of the space having the electrode pair of the anode (I)—the cathode (II) and the other end side of the space having the electrode pair of the cathode (II)—the anode (III) in the electrolytic bath.
[4] An electrolytic apparatus comprising:
an ice making apparatus housing;
an ice stocker attached to a bottom of the ice making apparatus housing;
an ice making water tank disposed above the ice stocker;
a water spray tank disposed above the ice making water tank, and having a through-hole formed through a bottom wall of the water spray tank;
a freezing pipe which is inserted into the through-hole of the water spray tank at an interval spaced from the inner wall of the through-hole at one end side of the freezing pipe, and disposed toward the upper surface of the ice making water tank at the other end side of the freezing pipe;
a water supply pipe configured to connect the ice making water tank and the water spray tank, and interposing a water supply pump configured to supply a predetermined amount of ice making water in the ice making water tank to the water spray tank;
an ice making water supply pipe configured to supply the ice making water to the ice making water tank;
a medium supplying means configured to alternately supply refrigerant or heat medium into the freezing pipe; and
the electrolytic apparatus according to any one of [1] to [3] interposed in the ice making water supply pipe and/or the water supply pipe.
[5] An ice making method using the ice making apparatus according to [4], wherein
during startup of the ice making apparatus, electric current is applied to the electrode pair of the cathode (II)—the anode (III) to generate ozone water, and after a predetermined time of the startup of the ice making apparatus, the generation of ozone water is stopped and electric current is applied to the electrode pair of the anode (I)—the cathode (II) to generate silver chloride colloidal water.
According to the invention, the electrolytic apparatus is configured such that three electrode plates are arranged in the order of the anode (I), the cathode (II), and the anode (III), the silver electrode is used in the anode (I), and an inert electrode such as platinum and a platinum alloy is used in the cathode (II) and the anode (III), and the electrolytic current is independently applied to the electrode pair of the anode (I)—the cathode (II) and the electrode pair of the cathode (II)—the anode (III), respectively. Accordingly, it is possible to supply ozone water, and silver-containing water at arbitrarily timing in a single electrolytic apparatus. When the electrolytic apparatus is incorporated into the ice making apparatus, ozone water of sterilization immediate effect can be generated during startup of the ice making apparatus, and the electrolyzed water containing insoluble colloidal silver chloride having sterilization slow-acting properties can be generated during the subsequent operation. Thus, it is possible to suppress growth of mold and bacteria in the ice making apparatus during startup of the ice making apparatus by ozone water, and suppress preventing the subsequent growth of mold and bacteria by silver chloride colloidal water.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram illustrating a configuration of a positional relation among three electrode plates in one example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water;
FIG. 2 is a schematic diagram illustrating a configuration of a positional relation among three electrode plates in another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water;
FIGS. 3A and 3B are schematic diagrams illustrating a configuration of a positional relation among three electrode plates in still another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water, and the flows of electrolytic raw water and electrolyzed water being in opposite directions to each other in FIGS. 3A and 3B ;
FIG. 4 is a schematic diagram illustrating a configuration of a positional relation among three electrode plates in still another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water;
FIG. 5 is a schematic explanatory diagram illustrating of an operation of the electrolytic apparatus of the invention based on the example of FIG. 1 ; and
FIG. 6 is a schematic diagram illustrating a configuration of an example of an ice making apparatus of the invention incorporating the electrolytic apparatus of the invention.
DETAILED DESCRIPTION
Hereinafter, the present invention will be described in detail.
An electrolytic apparatus of the invention will be described with reference to examples of FIGS. 1 to 4 .
FIG. 1 is a schematic diagram illustrating a configuration of a positional relation among three electrode plates in one example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water. In FIG. 1 , an electrolytic apparatus 2 has an electrolytic bath 4 , an electrolytic raw water supply pipe 6 , and an electrolyzed water extraction pipe 8 .
In the electrolytic bath 4 , an anode (I) of a silver electrode—a cathode (II) of an inert electrode—an anode (III) of an inert electrode are arranged in this order in parallel to one another. An electrode pair of the anode (I)—the cathode (II) and an electrode pair of the cathode (II)—the anode (III) have an electrical circuit configured to independently supply electrolytic current, respectively. Electric current can be individually or simultaneously applied to the electrode pairs. As the inert electrode, it is possible to use platinum-based electrodes such as platinum or platinum alloy.
When raw water is taken in an R direction from the electrolytic raw water supply pipe 6 , when only the anode (I) of the silver electrode and the cathode (II) of the platinum-based electrode are applied with electric current, silver ions are generated, the silver ions react with chlorine ions in the raw water, and thus most of the silver ions form an insoluble silver chloride colloid. Meanwhile, when only cathode (II) of the platinum-based electrode and anode (III) of the platinum-based electrode are applied with electric current, oxygen and ozone are generated from the anode. In FIG. 1 , reference numeral G is an arrow indicating a flow direction of the electrolyzed water.
FIG. 2 is a schematic diagram illustrating a positional relation among three electrode plates in another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water. In FIG. 2 , an electrolytic apparatus 12 has an electrolytic bath 14 , an electrolytic raw water supply pipe 16 including an electrolytic raw water supply main pipe 16 t and branch pipes 16 a and 16 b thereof, and an electrolyzed water extraction pipe 18 including an electrolyzed water extraction main pipe 18 t and branch pipes 18 a and 18 b thereof. In the electrolytic bath 14 , the anode (I) of the silver electrode—the cathode (II) of the inert electrode—the anode (III) of the inert electrode are arranged in this order in parallel to one another, and the interior of the electrolytic bath 14 is divided into a space having the electrode pair of the anode (I)—the cathode (II) and a space having the electrode pair of the cathode (II)—the anode (III) the by cathode (II) in a liquid-tight manner.
In the electrolytic apparatus 12 thus configured, water taken in the R direction passes through the space having the electrode pair of the anode (I)—the cathode (II) and the space having the electrode pair of the cathode (II)—the anode (III) by divided flows Ra and Rb, respectively. During passage, in the example of FIG. 2 , silver ionized water and ozone water are generated, respectively, based on the same principle as the example of FIG. 1 .
That is, in the electrolytic apparatus 12 , raw water is taken in the R direction from the electrolytic raw water supply pipe 16 , then, when the raw water passes through only the anode (I) of the silver electrode and the cathode (II) of the platinum-based electrode, silver ionized water (divided flow Ga) is generated from the divided flow Ra of the raw water R, the silver ions react with chloride ions in the raw water, and most of the silver ions form an insoluble silver chloride colloid. Meanwhile, when the electric current is applied only to cathode (II) of platinum-based electrode and anode (III) of the platinum-based electrode, electrolyzed water (divided flow Gb) containing oxygen and ozone is generated from the divided flow Rb of the raw water R.
FIGS. 3A and 3B are schematic diagrams illustrating a configuration of a positional relation among three electrode plates in still another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water. In both FIGS. 3A and 3B , an electrolytic apparatus 22 and an electrolytic bath 24 are illustrated.
In the electrolytic bath 24 , the anode (I) of the silver electrode—the cathode (II) of the inert electrode—the anode (III) of the inert electrode are arranged in this order in parallel to one another, and the electrolytic bath 24 is divided into a space having the electrode pair of the anode (I)—the cathode (II) and a space having the electrode pair of the cathode (II)—the anode (III) by the cathode (II) in a liquid-tight manner.
The electrolytic apparatus 22 has the electrolytic bath 24 , a communicating pipe 26 that connects one end side of the space having the electrode pair of the anode (I)—the cathode (II) and one end side of the space having the electrode pair of the cathode (II)—the anode (III), a connecting pipe 28 a attached to the other end side of the space having the electrode pair of the anode (I)—the cathode (II), and a connecting pipe 28 b attached to the other end side of the space having the electrode pair of the cathode (II)—the anode (III).
In FIGS. 3A and 3B , the flows of the electrolytic raw water and the electrolyzed water are in the opposite directions.
Therefore, in FIG. 3A , raw water is taken in the R direction from the connecting pipe 28 a of the space having the electrode pair of the anode (I)—the cathode (II), and the electric current is applied only to cathode (II) of the platinum-based electrode and anode (III) of the platinum-based electrode. After passing through the space having the electrode pair of the anode (I)—the cathode (II) in a Ra direction, the taken raw water R passes through the space having the electrode pair of the cathode (II)—the anode (III) in a Rb direction via the communicating pipe 26 . Electrolyzed water containing oxygen and ozone is generated from the raw water during passage in the Rb direction, and the electrolyzed water is extracted in a G direction via the connecting pipe 28 b of the space having the electrode pair of the cathode (II)—the anode (III). In the example of FIG. 3A , the connecting pipe 28 a plays the role of an electrolytic raw water supply pipe, and the connecting pipe 28 b plays the role of an electrolyzed water extraction pipe.
On the other hand, in FIG. 3B , raw water is taken in the R direction from the connecting pipe 28 b of the space having the electrode pair of the cathode (II)—the anode (III), and electric current is applied only to the anode (I) of the silver electrode and the cathode (II) of the platinum-based electrode. After passing through the space having the electrode pair of the cathode (II)—the anode (III) in the Rb direction, the taken raw water R passes through the space having the electrode pair of the anode (I)—the cathode (II) in the Ra direction via the communicating pipe 26 . Silver ionized water is generated from the raw water during passage in the Ra direction, the silver ions react with the chlorine ions in the raw water, and most of the silver ions form insoluble silver chloride colloid. The obtained silver chloride colloidal water is extracted in the G direction via the connecting pipe 28 a of the space having the electrode pair of the anode (I)—the cathode (II). In the example of FIG. 3B , the connecting pipe 28 b plays the role of an electrolytic raw water supply pipe, and the connecting pipe 28 a plays the role of an electrolyzed water extraction pipe.
FIG. 4 is a schematic diagram illustrating a configuration of a positional relation among three electrode plates in still another example of the electrolytic apparatus of the invention, and flows of electrolytic raw water and electrolyzed water. In FIG. 4 , an electrolytic apparatus 32 has an electrolytic bath 34 , an electrolytic raw water supply pipe 36 including an electrolytic raw water supply main pipe 36 t and branch pipes 36 a and 36 b thereof, a connecting pipe 38 a of a space having an electrode pair of the anode (I)—the cathode (II), and a connecting pipe 38 b of a space having an electrode pair of the cathode (II)—anode (III). In the electrolytic bath 34 , the anode (I) of the silver electrode-the cathode (II) of the inert electrode—the anode (III) of the inert electrode are arranged in this order in parallel to one another, and the interior of the electrolytic bath 34 is divided into the space having the electrode pair of the anode (I)—the cathode (II) and the space having the electrode pair of the cathode (II)—the anode (III) by the cathode (II) in a liquid-tight manner.
In the electrolytic apparatus 32 configured as described above, electric current is simultaneously applied to the electrode pair of the anode (I) of the silver electrode and the cathode (II) of the platinum-based electrode, and the electrode pair of the cathode (II) of the platinum based electrode and the anode (III) of the platinum-based electrode. Therefore, when the raw water taken in the R direction passes through the space having the electrode pair of the anode (I)—the cathode (II) and the space having the electrode pair of the cathode (II)—the anode (III) by the divided flows Ra and Rb, silver ionized water and ozone water are simultaneously generated and separately extracted.
That is, in the electrolytic apparatus 32 , when raw water is taken from the electrolytic raw water supply pipe 36 in the R direction, since electric current is applied to the anode (I) of the silver electrode and the cathode (II) of the platinum-based electrode, silver ionized water is generated from the divided flow Ra of raw water R, the silver ions react with the chlorine ions in the raw water, and most of the silver ions form an insoluble silver chloride colloid. The obtained silver chloride colloidal water is extracted in the Ga direction via the connecting pipe 38 a of the space having the electrode pair of the anode (I)—the cathode (II).
Further, since electric current is also applied to the anode (II) of the platinum-based electrode and the cathode (III) of the platinum-based electrode, electrolyzed water containing oxygen and ozone is also generated from the divided flow Rb of raw water R, and extracted in the Gb direction via the connecting pipe 38 b of the space having the electrode pair of the cathode (II)—the anode (III).
As illustrated in the examples of FIGS. 1 to 4 , according to the electrolytic apparatus of the invention, it is possible to separately generate silver ionized water and ozone water in a single electrolytic bath, to generate mixed generation water of silver ions and ozone, or to separately generate silver ionized water and ozone water at the same time.
FIG. 5 is a schematic explanatory diagram illustrating the operation of the electrolytic apparatus of the invention based on the example of FIG. 1 .
As illustrated in FIG. 5 , in three electrode plates including the anode (I) of the silver electrode, the cathode (II) of the platinum-based inert electrode, and the anode (III) of the platinum-based inert electrode in the electrolytic bath 4 , the electrode pair of the anode (I)—the cathode (II), and the electrode pair of the cathode (II)—the anode (III) have an independent electrical circuit, respectively, and raw water is incorporated in the R direction from the electrolytic raw water supply pipe 6 . The raw water may be suitable for drinking in a dilute electrolyte solution, and may be, for example, tap water or the like.
When silver ionized water is collected as electrolyzed water, by turning on the electrical circuit between a wiring PI of the anode (I) and a wiring NIIa of the cathode (II) and turning off the electrical circuit between a wiring NIIb of the cathode (II) and a wiring PIII of the anode (III) to perform electrolysis, it is possible to extract only silver ionized water in the G direction from the electrolyzed water extraction pipe 8 as the electrolyzed water.
On the other hand, when the electrical circuit between a wiring NIIb of the cathode (II) and a wiring PIII of the anode (III) is turned on, and the electrical circuit between a wiring PI of the anode (I) and a wiring NIIa of the cathode (II) is turned off, ozone generation is obtained, and it is possible to extract electrolyzed water in the G direction from the electrolyzed water extraction pipe 8 as ozone water.
In FIG. 5 , Ra is an arrow indicating a direction of flow of electrolytic raw water passing through the space having the electrode pair of the anode (I)—the cathode (II), and Rb is an arrow indicating a direction of flow of electrolytic raw water passing through the space having the electrode pair of the cathode (II)—the anode (III).
FIG. 6 is a schematic diagram illustrating a configuration of an example of the ice making apparatus of the invention incorporating the electrolytic apparatus of the invention. In FIG. 6 , an ice making apparatus 42 includes:
an ice making apparatus housing 44 ,
an ice stocker 46 attached to a bottom of the ice making apparatus housing 44 ,
an ice making water tank 48 disposed above the ice stocker 46 ,
a water spray tank 50 disposed above the ice making water tank 48 , and having a through-hole 51 formed through a bottom wall of the water spray tank 50 ,
a freezing pipe 52 which is inserted into the through-hole 51 of the water spray tank 50 at an interval spaced from the inner wall of the through-hole 51 at one end side of the freezing pipe 52 , and disposed toward the upper surface of the ice making water tank 48 at the other end side of the freezing pipe 52 ,
a water supply pipe 54 configured to connect the ice making water tank 48 and the water spray tank 50 , and interposing a water supply pump 56 configured to supply a predetermined amount of ice making water in the ice making water tank 48 to the water spray tank 50 ,
an ice making water supply pipe 58 configured to supply the ice making water to the ice making water tank 48 ,
a medium supplying means configured to alternately supply refrigerant or heat medium into the freezing pipe 52 (including refrigerant supplying means 60 and a heat medium supplying means 62 in FIG. 6 ), and
the electrolytic apparatus 64 (interposed in the ice making water supply pipe 58 in FIG. 6 ) interposed in the ice making water supply pipe 58 and/or the water supply pipe 54 .
An example of the ice making method of the invention using the ice making apparatus of the invention will be described below according to the example of FIG. 6 .
As illustrated in FIG. 6 , tap water applied to the ice making water supply pipe 58 from a faucet 66 is electrolyzed in the incorporated electrolytic apparatus 64 of the invention, converted to ice making water, and applied to the ice making water tank 48 . A water supply electromagnetic valve 68 is preferably provided in the ice making water supply pipe 58 .
In the electrolytic apparatus 64 , as described above, during startup of the ice making apparatus 42 , electric current is applied to the electrode pair of the cathode (II)—the anode (III) to generate ozone water, and the ozone water is used as the ice making water. After a predetermined period of time elapses from the startup of the ice making apparatus 42 , the generation of ozone water is stopped and electric current is applied to the electrode pair of the anode (I)—the cathode (II) to generate silver chloride colloidal water, and the silver chloride colloidal water is used as the ice making water. A predetermined time after the startup of the ice making apparatus 42 is preferably in a range of 30 seconds to 5 minutes, and in a range of ozone concentration of 0.3 ppm to 1.2 ppm.
The ice making water is stored in the ice making water tank 48 , and a predetermined amount thereof is applied to the water spray tank 50 provided above the ice making water tank 48 from the ice making water tank 48 by the water supply pump 56 . On the bottom wall of the water spray tank 50 , a through-hole 51 having an inverted trapezoidal cross-section including a through shaft to pass through the bottom wall, and one end of the freezing pipe 52 is inserted into the through-hole 51 . The other end of the freezing pipe 52 reaches the upper surface of the ice making water tank 48 .
A gap is formed between the through-hole 51 and one end of the freezing pipe 52 inserted thereto, and the ice making water in the water spray tank 50 flows down through the gap, and flows down along the surface of the freezing pipe 52 . The freezing pipe 52 is hollow tubing, and a sphere and a cylinder are continuous as a shape of the tubing.
Refrigerant and heat medium are alternately applied to the freezing pipe 52 . Ice making water flows down the surface of the freezing pipe 52 into which refrigerant such as cooling gas is conveyed and cooled, and freezes on the surface of the freezing pipe 52 . The refrigerant is produced by the refrigerant supplying means 60 placed on a shelf of the upper housing 44 of the ice making apparatus 42 , and conveyed into the freezing pipe 52 via a refrigerant conveying pipe (not illustrated).
When the sprayed ice making water is cooled on the surface of the freezing pipe 52 and a predetermined amount of ice 70 is grown, the water supply of the ice making water supply pipe 58 and the water supply pipe 54 is stopped. Thereafter, heat medium such as hot gas replacing the refrigerant is conveyed into the freezing pipe 52 to detach the ice 70 grown on the surface of the freezing pipe 52 from the freezing pipe 52 surface. Similarly to the refrigerant, the heat medium is produced by the heat medium supplying means 62 placed on the upper shelf of the housing 44 of the ice making apparatus 42 , delivered into the freezing pipe 52 via a heat medium conveying pipe (not illustrated), and replaced with the refrigerant.
The ice 70 detached from the surface of the freezing pipe 52 is stored in the ice stocker 46 disposed below the housing 44 of the ice making apparatus 42 .
Silver chloride colloid concentration in the electrolyzed water generated in the electrolytic apparatus 64 after a predetermined time of the startup of the ice making apparatus 42 is controlled by at least one of an electric conduction amount and an electric conduction time in the electrolytic apparatus 64 . The electric conduction amount and the electric conduction time of the electrolytic apparatus 64 are adjusted by a combination of a timer, current or the like starting from the electric conduction timing of the respective components of the ice making apparatus 42 , and the silver chloride colloid concentration of the electrolyzed water is preferably controlled to a range of 10 to 800 ppb.
The silver chloride colloid has a bactericidal action, and exhibits its effects at a low concentration. When the ice making water containing a predetermined amount of silver chloride colloid is sprayed and applied from the water spray tank 50 , silver chloride colloidal water flowing along the surface of the freezing pipe 52 is partially scattered to the periphery to sterilize the attachment surface attached to the surface of the inner wall of the housing 44 . In addition, when the ice 70 grown on the surface of the freezing pipe 52 is detached by heat medium, unfrozen silver chloride colloidal water is scattered to the periphery, and scattered to the top surface of the inner wall of the ice stocker 46 and the surface of the inner wall of the housing 44 , which contributes to the sterilization of the surfaces thereof.
In the above description, the electrolytic apparatus 64 is attached to the supply pipe 58 . However, the electrolytic apparatus 64 can be attached to any position of the water supply pipe 54 and the supply pipe 58 without being limited thereto. Furthermore, the electrolytic apparatus 64 may be attached to a plurality of positions.
A wall material in the housing 44 of the ice making apparatus 42 , and inner and outer wall surfaces of the water spray tank 50 and the ice making water tank 48 are preferably an antibacterial material.
REFERENCE SIGNS LIST
2 , 12 , 22 , 32 , 64 : electrolytic apparatus
4 , 14 , 24 , 34 : electrolytic bath
6 , 16 , 36 : electrolytic raw water supply pipe
8 , 18 , 38 : electrolyzed water extraction pipe
16 t , 36 t : electrolytic raw water supply main pipe
16 a , 16 b , 36 a , 36 b electrolytic raw water supply branch pipe
18 t : electrolyzed water extraction main pipe
18 a , 18 b : electrolyzed water extraction branch pipe
26 : communicating pipe that connects a space having an electrode pair of the anode (I)—the cathode (II) and a space having an electrode pair of the cathode (II)—the anode (III)
28 a , 38 a : connecting pipe of a space having an electrode pair of the anode (I)—the cathode (II)
28 b , 38 b : connecting pipe of a space having an electrode pair of the cathode (II)—the anode (III)
I: anode of a silver electrode
II: cathode of an inert electrode
III: anode of an inert electrode
PI: wiring of the anode (I)
NIIa, NIIb: wiring of the cathode (II)
PIII: wiring of the anode (III)
G, Ga, Gb: arrow indicating a flow direction of electrolyzed water
R, Ra, Rb: arrow indicating a flow direction of electrolytic raw water
42 : ice making apparatus
44 : ice making apparatus housing
46 : ice stocker
48 : ice making water tank
50 : water spray tank
51 : through-hole
52 : freezing pipe
54 : water supply pipe
56 : water supply pump
58 : ice making water supply pipe
60 : refrigerant supplying means
62 : heat medium supplying means
66 : faucet
68 : water supply electromagnetic valve
70 : ice
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The present invention discloses an electrolytic apparatus comprising:
an electrolytic bath in which an anode (I) of a silver electrode—a cathode (II) of an inert electrode—an anode (III) of an inert electrode are arranged in this order in parallel to one another, and an electrode pair of the anode (I)—the cathode (II) and an electrode pair of the cathode (II)—the anode (III) have an electrical circuit configured to apply a potential of 2.07 V or more to the electrode pair of the cathode (II)—the anode (III) to supply electrolytic current, when independently supplying the electrolytic current; an electrolytic raw water supply pipe configured to supply electrolytic raw water into the electrolytic bath; and an electrolyzed water extraction pipe configured to extract the electrolyzed water in the electrolytic bath to the outside.
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BACKGROUND OF THE INVENTION
This invention relates to a swimming pool cleaning system and more particularly to a swimming pool cleaning system, wherein a plurality of rotary jet nozzles are disposed adjacent inner surfaces of the pool to wash the inner surfaces, and also to maintain deleterious matter in suspension in the water so that it may be carried outward through the main drain or the skimmer inlets of the pool water circulating apparatus.
Many devices and methods have been used for cleaning deleterious matter from the interior of a swimming pool. Some of them include manually operated vacuum pickups, others include snake-like water jets tubes of flexible character which operate in a generally sinusoidal movement, and rub the bottom of the pool while moving around and creating jet streams along the inner surfaces of the pool.
Other prior art devices have included nozzles adjacent the inner surfaces of the pool structure, and these nozzles have been unidirectional or monodirectional, and have been partially successful; however, most prior art pool-cleaning systems have required a substantial amount of attention, labor, and/or maintenance.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 3,675,252 discloses a system for cleaning the inner surface of a swimming pool employing a rotary jet delivery head adapted to constantly rotate 360 degrees.
U.S. Pat. No. 3,616,468 discloses a radial tube which is rotatable about a vertical axis at the pool center adjacent the pool bottom to prevent debris from collecting on the pool bottom.
U.S. Pat. No. 3,449,772 discloses an automatically cycling swimming pool cleaning system wherein automatically extending and retracting water driven jets are rotated slowly about two revolutions per minute in discrete increments through the intermittent impact imparted to the nozzle by a circulating ball carried by a stream of water in route to the nozzle of the cleaning head.
SUMMARY OF THE INVENTION
In accordance with the invention claimed, an improved and greatly simplified rotary water dispensing pop-up head for a water delivery and pool cleaning system is provided which rotates in a non-uniform sequential manner to maintain deleterious matter in suspension in the water so that it may be removed by the pool water circulating system.
It is, therefore, one object of this invention to provide a new and improved rotatable pop-up water delivery head for a pool cleaning system.
Another object of this invention is to provide a new and improved rotatable pop-up water delivery head disposed adjacent the inner surface of the pool for washing the interior pool surfaces, the water pressure to which is interrupted periodically to cause the jet dispensing portion of the head to rotate in non-uniform arcuate amounts.
A further object of this invention is to provide a new and improved pop-up rotatable water jet delivery head which delivers a jet stream of recirculated water at an acute angle with the adjacent surface of the pool and at sequentially different arcuate positions with the rotating axis of the head.
A still further object of this invention is to provide a new and improved pop-up rotating jet producing head which rotates under the action of the varying pressure of the water recirculating system of the pool in non-uniform arcuate angles without any gears or other angularly movement controlling mechanisms.
A still further object of this invention is to provide a novel swimming pool cleaning system employing a plurality of improved rotary jet delivery heads.
A still further object of this invention is to provide an economically producible and efficiently operable novel rotary jet delivery means for a swimming pool recirculating water system which will maintain foreign matter in suspension until it is collected by the swimming pool filtering system.
Further objects and advantages of the invention will become apparent as the description proceeds and the features of novelty which characterize this invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may be more readily described by reference to the accompanying drawing, in which:
FIG. 1 is a fragmentary perspective view showing a swimming pool with a water circulating and filtering means employing jet dispensing rotary heads embodying the invention;
FIG. 2 is a cross-sectional view of FIG. 1 taken along the line 2--2;
FIG. 3 is an exploded perspective view of the jet dispensing rotary head of the pool cleaning system shown in FIG. 2;
FIG. 4 is a bottom view of FIG. 5 showing a modification of the rotary jet producing nozzle or head shown in FIGS. 1-3; and
FIG. 5 is a partial perspective view illustrating a modification of the moveable portion of the jet producing head shown in FIGS. 1, 3 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing by characters of reference, FIG. 1 discloses diagrammatically a swimming pool structure 10 having inner side surfaces 11 and 12, a bottom surface 13 and end surfaces 14 and 15. Embedded in the side, bottom and end surfaces 11-15, respectively are a plurality of water jet delivery assemblies 16, hereinafter described in detail.
Communicating with each of the jet delivery assemblies is a conduit 17 adapted to deliver the water under pressure necessary to operate the rotary jet assemblies. This conduit 17 is disposed to communicate with the outlet of a filter 18. An electric motor driven pump assembly 19 delivers water under pressure to the filter and receives water through a conduit 20 communicating with a main drain 21 and with a conduit 22 communicating with a skimmer 23.
Pump assembly 19 pulls water from main drain 21 and skimmer 23 and forces it through filter 18 and conduit 17 to the rotary jet delivery assemblies 16.
As shown in FIGS. 2 and 3, the rotary jet delivery assembly 16 comprises a plumbing connection end 24 adapted to be connected to conduit 17 by conventional plumbing fittings such as an elbow coupling 25. Suitably mounted to or on the coupling 25 is a shell or cylindrical hollow housing 26 within which the remaining parts of the rotary jet delivery assembly 16 are detachably mounted.
As shown in FIG. 2, housing 26 is provided with a flange 27 extending around its outer periphery at a suitable point between its ends to anchor the housing in the pool walls with its exposed end 28 arranged substantially flush with the interior surface 29 of the pool.
The assembly further comprises a generally cylindrical housing 30 the threaded end 24 of which is adapted to be connected to coupling 25 with coupling 25 being connected to the outlet ends of conduit 17 communicating with filter 18 through an on/off pump assembly pulser valve or interrupting means 31. Each housing of the rotary jet delivery assemblies 16 is provided with an upper open outlet end 32 having a peripheral edge 33 disposed substantially flush with one of the inner surfaces of the pool structure 10 and the exposed end 28 of housing 26 when its other end is threadedly attached to coupling 25 of conduit 17.
The open end of housing 26 may be provided with an inwardly extending flange 34 which individually or in combination with an O-ring 35 provides a substantially wateright connection or at least a dirt shield between the inside periphery of housing 26 and the outside periphery of housing 30.
As shown in FIG. 3, the peripheral edge 33 of housing 30 is provided with diagonally positioned key slots 36 for engaging the edge of a suitable tool (not shown) for threadedly attaching or removing housing 30 from coupling 25 in a well known manner.
Within housing 30 and slidable therewith for reciprocal motion therealong is a pair of cooperating hollow cylindrical head and piston members 37 and 38, respectively. Cylindrical member 38 is open at both of its ends 39 and 42 and is provided with a flange 40 extending outwardly thereof for engaging with an internal flange 41 mounted within the hollow interior of housing 30. Cylindrical member 37 is closed at its end 44 and arranged to telescopically fit over the outside of end 42 of cylindrical member 38 when both cylindrical members are fitted together in housing 30 as shown in FIG. 2.
Cylindrical members 37 and 38 are fitted together in a tight frictional manner or glued together, if so desired, to act when assembled in housing 30 as a unitary structure. To assemble them together cylindrical member 37 is pushed into housing 30 until its open end engages flange 41. Cylindrical member 38 is then pushed into the threaded end of housing 30 and into the open end of cylindrical member 37 until the end 42 of cylindrical member 38 engages a shelf or flange 48 formed around the inside periphery of cylindrical member 37.
Thus, when water pressure is applied to conduit 17 and in turn to the lower flat inner surface 43 of end 44 of cylindrical member 37, the unitary piston structure formed by cylindrical member 37 and 38 is driven outwardly of housing 30 until flange 40 of cylindrical member 38 engages the lower surface of flange 41 of housing 30. At this time the piston structure assumes the dash line position shown in FIG. 2.
The closed end 44 of cylindrical member 37 is of sufficient thickness such that a passageway 45 may be formed therein opening outwardly of the peripheral side of cylindrical member 37 and defining an exit port 46. Passageway 45 also opens inwardly of the hollow interior of cylindrical member 37 through surface 43 of its closed end 44 forming an inlet port 47.
It should be noted that passageway 45 is positioned to extend parallel with end 44 starting at inlet port 47 which is spaced from the axial center of cylindrical member 37 a given distance D and terminating in an exit or outlet port 46 spaced a given distance D' from the axial center of cylindrical member 37. This position of passageway 45 and its exit and inlet ports 46 and 47, respectively, aids in causing counterclockwise or clockwise rotation of cylindrical members 37 and 38 in housing 30 when water under pressure is ejected therefrom as hereinafter explained.
One working embodiment of the jet delivery assembly utilizes a two inch diameter cylindrical member 37 having a 1/4 inch passageway 45 extending in a straight line about 1/2 inch from the longitudinal axis of cylindrical member 37. Cylindrical member 37 and 38 are also of sufficient weight such that under the action of gravity and the force of the pool water on the pool exposed surface of end 44 cylindrical member 37 will move into housing 30 when the water pressure in conduit 17 is interrupted.
The movement of the combined cylindrical members 37 and 38 into housing 30 under the action of gravity and/or the pressure of the pool water drives these members back into housing 30 toward its threaded end 24 until the lower end 37' of cylindrical member 37 engages flange 41 of housing 30 as shown in FIG. 2.
Cylindrical member 37 and particularly port 46 is adapted to issue a water jet, as indicated by arrows 49 parallel to or at an acute angle with the adjacent inner surface area of the pool surrounding the rotary water jet delivery assembly 16.
The water from the jet produced by port 46 of cylindrical member 37 forces upwardly and maintains in suspension in the water deletrious matter, such as fine silt, bugs, leaves, grass and other matter until eventually withdrawn from the pool through the main drain or skimmer of the pool structure by pump means 19. This deleterious matter is then collected in the filter and the clean water passes back through conduit 17 to further operate the rotary jet delivery assemblies 16. Each of these assemblies operates a jet stream nozzle or outlet port 46 disposed usually parallel to and in close adjacent relationship with the inner surfaces of the pool structure 10.
Each of the parts of the rotary jet delivery assemblies are displaced to issue a jet stream in parallel scrubbing relation with an inner surface of the pool structure 10 and in as much as the combined cylindrical members 37, 38 and are free to rotate throughout 360 degrees an entire area surrounding the jet delivery assembly may be cleaned by their rotation.
The rotating of the combined cylindrical members 37 and 38 are accomplished by the unique arrangement disclosed and claimed herein.
To cause the rotation of the piston structure formed by cylindrical members 37 and 38 in housing 30, the water pressure to the jet delivery assembly 16 is interrupted in a selected and predetermined manner. This function is provided by any suitable valving arrangement or pulser 31 which either temporarily interrupts the water flow under pressure to the jet delivery assemblies 16 or sequentially interrupts the flow of electrical current to the electric driven motor pump assembly 19 to stop and start the motor of the pump assembly. Since these pulser or motor interrupting means are known in the art, they will not be further described. It is believed sufficient for the purposes of this invention to state that the water periodically is interrupted to the jet delivery assembly.
It should be noted that each time the water pressure to the jet delivery assembly is interrupted the piston structure comprising the combined cylindrical members 37 and 38 will drop back or be forced into housing 30 at a different angular position within housing 30 from the position that it previously had occupied prior to the interruption of water pressure in conduit 17.
Rotation of the unitary structure formed by cylindrical members 37 and 38 relative to housing 30 occurs through the reaction of the pool water with the generation and/or interruption of the jet stream of water out of port 46 of cylindrical member 37. This starting and stopping of the jet stream of water out of port 46 of cylindrical member 37 causes the combined cylindrical members 37 and 38 to rotate an arcuate amount relative to housing 30. Since there is no mechanical connection between these combined cylindrical members 37 and 38 and housing 30, the amount of movement of them relative to housing 30 is a random amount depending, inter alia, on the water impulse in conduit 17, movement of pool water around the jet delivery assemblies etc. Nevertheless, each interruption of water pressure in conduit 17 results in a different but reasonably similar arcuate change in the position of the cylindrical members 37 and 38 relative to housing 30.
The cylindrical members 37 and 38 rotate during the time they move up to their extended position when water pressure is applied to the assembly and while these members are moving down into their housing when the water pressure to this assembly is interrupted. During their movement up or down in their housing, some water is being ejected from exit port 46 causing the cylindrical members to rotate. When in their fully extended position the cylindrical members 37 and 38 are locked in that position and do not rotate. When they are in their lower position and the water pressure is off they also do not rotate for lack of water pressure.
Thus, over a period of time a jet of water is caused to issue from outlet port 46 covering a 360 degree sweep of the interior pool surface around the various jet delivery assemblies.
FIGS. 4 and 5 disclose a modification of the jet delivery assembly shown in FIGS. 1-4 wherein the cylindrical member 37 is merely provided with an insert 50 for placement in passageway 45 so that a particular nozzle opening 51 may be provided. If desired, various openings 51 may be provided by drilling different size holes in end 44 of cylindrical member 37 in forming passageway 45.
It should be noted that the component parts of the rotatable pop-up water delivery head are shown in the drawing as formed of plastic materials, however, any one or all of the parts may be formed of other materials such as suitable metals and still fall within the scope of this invention.
Although but a few embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A swimming pool mounted rotatable head for a water jet pool cleaning system adapted to rotate in a non-uniform sequential manner during a pool cleaning operation to maintain deleterious matter in suspension in the water so that it may be removed by the main drain or skimmer inlets of the pool water circulation system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates broadly to methods of chemically treating articles in solutions. In a preferred embodiment, this invention relates to uniformly dispersing ophthalmic lenses in a chemical treatment solution.
2. Description of the Related Art
Hydrophilic contact lenses may be treated with a variety of solutions in a variety of ways to modify the lens properties. For example, contact lenses are typically subjected to extraction processes during the manufacture of the lens in order to remove undesirable solvents originating from the polymerization or molding steps. A contact lens may also be exposed to a treatment solution containing a reactive dye, in order to impart ultraviolet (UV) light absorbing properties or visible light absorbing properties to the lens. Another example of contact lens treatment involves exposure of the lens to a monomer solution with graft polymerization being induced to alter the surface properties of the lens.
Conventional means of tinting contact lenses may be divided into bath processes and printing processes. In the printing process, a silicone rubber printing head conveys a reactive dye to the surface of the lens. In the bath process, the lens, or a portion of the lens, is immersed in a solution containing a reactive dye.
In order to efficiently and economically tint lenses, one may treat many lenses at one time by placing the lenses in a container holding the reactive dye solution in a static state. A problem with this method of treatment is that the lenses may cup or coalesce (i.e., two or more lenses may adhere to one another), thereby promoting localized dye concentration gradients. Also, the lens may rest against the container, again resulting in the lens experiencing different dye concentrations across the surface. These concentration gradients result in non-uniform tinting of the lens, sometimes causing serious discolorations in the lens-surface. Further, lens coalescing generates problems with separating the lenses because of the strong adhesion between lenses.
The lenses may also be treated by placing each lens in a separate well or compartment within a tray having numerous wells. Typically, the lenses are placed concave-side up in wells which are adapted to hold the lens (i.e., the wells are typically concave-shaped to match the convex surface of the lenses). Such a tray holding numerous lenses may be immersed in a tinting or monomer grafting solution in order to efficiently treat many lenses at once. Although this technique eliminates the coalescing problems, there remain problems associated with the lenses resting against the tray wells. For example, an extended contact period of the lens with the tray causes concentration gradients, resulting in lenses which are non-uniformly tinted or non-uniformly surface-modified.
Thus, there is a need for a method of exposing contact lenses to a treatment solution in an efficient, economical, and uniform manner. There also remains a need for an apparatus which simultaneously contacts numerous lenses with a treatment solution in a uniform manner.
SUMMARY OF THE INVENTION
An object of the invention is to provide a method of suspending an article in treatment solution for an extended time period.
Another object of the invention is to provide a method of uniformly contacting an article with a chemical treatment solution for an extended period.
A further object of the invention is to provide a method of uniformly tinting an ophthalmic lens by application of a tinting solution to the entire lens surface.
Yet another object of the invention is to provide a method of increasing the efficiency of a contact lens tinting process.
Yet a further object of the invention is to provide a method of efficiently and uniformly graft-polymerizing monomers or macromers to the surface of an ophthalmic lens.
One embodiment of the invention is a method for uniformly contacting articles with a chemical treatment solution. The method includes suspending the article in a solution within a container such that the article does not experience substantial or extended contact with the container interior. A predetermined flow of solution is passed into the container, thereby providing an upward force which, in conjunction with the buoyancy force, overcomes the downward gravitational force on the article, when the article is more dense than the solution. Alternatively, if the article has a lower density than the treatment solution, the flow is generated at the top of the container, to produce a substantially steady state effect.
In one preferred embodiment, the solution flow is applied in an oscillatory fashion, so that the article moves up and down within the container but does not contact the container for an extended time period. In another embodiment, the flow is pulsed, i.e., turned on and off, such that an oscillatory flow pattern is achieved. In a preferred embodiment, the solution flow is passed through a dispersion member, thereby uniformly distributing the upward force across the cross-section of the container and eliminating dead space.
In a preferred embodiment, a method of treating contact lenses is disclosed. The method includes placing a contact lens in a container including a treatment solution, e.g. a tinting solution, or a monomeric or macromeric solution. The method further includes applying solution flow from the bottom of the container (if the article is more dense than the solution), thereby generating an upward force on the lens sufficient to prevent the lens from coalescing or contacting the container for an extended time period. In a more preferred embodiment, the method includes applying solution flow to the container in a cyclic fashion, including a point of maximum upward flow and a point of no flow, through a dispersion member located across a section of the container which is perpendicular to the direction of gravity.
In another embodiment, articles having substantially the same density as a treatment solution are dispersed within the treatment solution within a container, maintaining the articles away from the container walls. In this embodiment, applied forces are exerted from both the top and bottom of the container, by passing solution into the container from both above and below the articles.
The invention further includes contact lenses formed by uniformly dispersing the lenses within a chemical treatment solution while preventing the lenses from having substantial contact with the container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a contact lens treatment system having lenses dispersed in bulk in a treatment solution.
FIG. 2 is a plan view of a contact lens treatment system of the present invention including a lens-retaining tray.
FIG. 3 is a side sectional view of the contact lens treatment tray of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to enhance the reader's understanding of the invention, select terms will be defined prior to the detailed description of the invention.
An "article", as used herein, refers to a wide variety of components which may be treated in a treatment solution. For example, an article includes, without limitation thereto, ophthalmic lenses, medical devices such as transdermal patches having hydrogel components, capsules or pills or components thereof, articles of clothing, decorative and aesthetic polymeric components, and foodstuffs. Thus, while the present invention is discussed with reference to the preferred article of treatment, i.e., ophthalmic lenses, the invention is not limited to the treatment of lenses.
An "ophthalmic lens", as used herein, refers to any lens intended for use in intimate contact with the eye of the user. This includes, without limitation, intraocular lenses, ocular implants, hard contact lenses, and soft contact lenses. The preferred treatment article of the present invention is a hydrophilic contact lens.
A "chemical treatment solution", as used herein, means a solution intended for contact with an article in order to change the characteristics of the article. Thus, a"chemical treatment solution" includes treatment solutions having chemical species which are reactive, or are intended for reaction with, the article, such as reactive dyes (e.g., halotriazine or vinyl sulfone dyes) or hydrophilic or hydrophobic monomers or macromers or the like. "Chemical treatment solution" also includes solvents such as alcohols, saline solutions, or sterile water, which are intended to extract chemical species from the article to be treated.
A "container", as the term is used herein, means any structure shaped such that it is capable of retaining liquid therein. Containers include, without limitation thereto, wells in a tray which are shaped to receive and retain a contact lens and sufficient solution to fully immerse the contact lens. Containers also include those receptacles capable of receiving and retaining a plurality of lenses and treatment solution sufficient to fully immerse the plurality of lenses.
"Surface modification", as used herein, refers to treating an article to alter its surface properties. For example, the surface modification of a contact lens includes, without limitation, the grafting of monomers or macromers onto polymers to make the lens biocompatible, deposit resistant, more hydrophilic, more hydrophobic, or to impart antimicrobial or antifungal properties.
"Tinting", as used herein, refers to treating an article to change the article's light-absorbing properties. For example, the tinting of a contact lens includes, without limitation, reducing the ultraviolet, infrared, or visible light transmission through the contact lens.
"Stagnant force", as used herein, is the vector sum of the force of gravity and the buoyancy force on an article in solution, absent applied forces from external fluid flow. The buoyancy force is the upward force which a solution exerts on an article in contact with the solution. For example, if an article is more dense than a solution in which it is immersed, the gravitational force is larger than the buoyancy force, so the direction of stagnant force on the article is downward, and the article will sink, absent applied forces.
Broadly speaking, the invention is a method of increasing the uniformity of treatment of an article in a treatment solution retained within a treatment container. The treatment uniformity is enhanced by applying an upward force on the article, such that the article is suspended in the treatment solution and does not rest against the treatment container. While this may be accomplished by a number of techniques, the preferred method involves pumping solution into the container from a point either (1) below the article to be treated, if the article is more dense than the solution, or (2) above the article, if the article is less dense than the solution. This provides an upward (or downward) force on the article which, in conjunction with the upward buoyancy force on the article, counterbalances the downward gravitational force. This flow maintains the article in a substantially steady state, immersed-within the solution, but held away from the container walls. In addition, the pump generates mild solution mixing, thereby reducing localized concentration gradients and further improving treatment uniformity.
A preferred embodiment of the invention is a method of uniformly treating ophthalmic lenses, especially contact lenses. The method involves suspending the lenses in the treatment solution without allowing the lenses to coalesce or contact the container for an extended period of time. An "extended period of time", as used herein, means a time sufficient to allow the lenses to be treated non-uniformly such that the aesthetic or functional utility of the lens is substantially impaired. For example, if after the tinting process is complete, the lens has a mark which can be visually detected with the naked eye, the lens has been in contact with the container or another lens for an extended period of time.
Contact lenses may be treated in accordance with the teachings of this invention by treatment "in bulk", i.e., where many lenses are treated in a single container which allows lens-to-lens contact. FIG. 1 illustrates a bulk lens treatment system in which a plurality of lenses are simultaneously suspended in a treatment solution. The FIG. 1 system is designed to treat lenses which have a density greater than the treatment solution, by providing an upward flow to balance the downward gravitational force on the lenses. Treatment system 10 includes a container 14 in which treatment solution 22 suspends lenses 12. The container includes a dispersion member 16 located near the bottom of the container. Feed line 18 connects pump 20 to dispersion member 16. Return line 21 provides feed solution to pump 20 from the top of container 14.
In operation, pump 20 provides fluid flow through feed line 18 into dispersion member 16. A substantially uniform pressure is provided to the container by passing solution through dispersion member 16, thereby avoiding dead space, i.e., areas of little or no solution flow. The upward force generated by this fluid pressure enables lenses to remain in suspension in the solution. In addition, the solution flow minimizes the possibility of lens coalescing. Further, the solution flow causes mixing Which enhances the uniformity of the solution concentration.
While contact lenses may be treated in a bulk suspension, as illustrated in FIG. 1, a preferred method of treating contact lenses requires the use of a plurality of separate lens-retaining containers affixed to one another for convenience of bulk processing. For example, one method involves placing each lens in an individual well in a tray which includes a plurality of wells. This method has certain advantages, such as entirely eliminating the possibility of lens coalescence and facilitating quality inspections of individual lenses.
Referring to FIG. 2, a preferred contact lens treatment system is shown. System 30 includes tray 32 having a plurality of wells 34 formed therein. Wells 34 are sized large enough to receive a contact lens and sufficient treatment solution to immerse the lens. Also, wells 34 are preferably sized sufficiently large to allow the lens (not shown) to move slightly up and down during the treatment process.
FIG. 3 is a side sectional view of the treatment system of FIG. 2, showing pump 38 connected via feed conduit 36 to dispersion member 40. Return conduit 42 provides return flow of solution to pump 40. Dispersion member 40 is located in intimate contact with tray 32 all along one surface of the tray. Thus, a fluid path extends from pump 38 through conduit 36 and dispersion member 40 to each well 34 of tray 32.
Pump 38 may be selected from a wide variety of liquid pumps, including without limitation, centrifugal pumps and diaphragm pumps. However, the preferred pump is a pump capable of generating a pulsed or variable force on the lens in the well. A preferred pump is capable of delivering an outward solution flow in a repetitive cycle, thereby causing the lenses to remain in a substantially steady state movement pattern within the solution. More preferable is a pump capable of delivering flow rates in a sinusoidal cycle, such that there exists a maximum outward flow amplitude and a minimum flow amplitude in each cycle. Thus, a preferred pump is a diaphragm pump.
A diaphragm pump is also preferred because such a pump can generate a sinusoidal flow rate regime, i.e., a plot of flow rate v. time is sinusoidal in shape. The sinusoidal flow allows the fluid conditions to pass from turbulent to laminar in a repeating cycle. The sinusoidal flow regime is believed to enhance the mixing of the solution within the tray wells, thereby minimizing localized concentration gradients which can result in non-uniform lens treatment.
In operation, pump 38 forces fluid through conduit 36 into dispersion member 40. Dispersion member 40 allows the force of the fluid flow from the pump to be uniformly dispersed across the cross-sectional area of the tray. In this way, each of the lenses in each of the wells receives an equal pressure. Also, the pressure across each well is uniform. This uniformity prevents the lens from migrating to one side of the well and remaining there.
Dispersion member 40 may be formed from a wide variety of materials suited to distributing the flow uniformly across the dispersion member. Thus, the dispersion member may be formed from a glass or ceramic frit material, i.e., a inert material having a plurality of pores having a small diameter, usually ranging from 10 microns to 1 millimeter. Alternatively, the dispersion member may be a plate including a series of uniformly-dispersed preformed openings having a predetermined geometry (e.g., a metal plate having circular holes formed therethrough)
In another embodiment of the invention, the articles to be treated have substantially the same density as a treatment solution (i.e., the article density is within about 1% of the solution density) In order to disperse the articles within the treatment solution applied forces are exerted from both the top and bottom of the container. This may be accomplished by means described above, with the difference being that solution is passed into the container from both above and below the articles. Return flow conduits may be positioned above the upper inlet and below the lower inlet, thereby generating an eddy effect, without causing the article to be attracted to the return conduit port. However, a wide variety of other configurations may be possible.
The previous disclosure will enable one having ordinary skill in the art to practice the invention. In order to better enable the reader to understand specific embodiments and the advantages thereof, reference to the following examples is suggested.
EXAMPLE I
Thirty vilfilcon hydrophilic contact lenses containing about 55% water are placed in a 6 liter cylinder having a cross-sectional area of about 78 cm 2 . The cylinder contains about 3 liters of deionized water. The output of a centrifugal pump (TE-5C-Md, March, Glenview, Ill.) is connected by tubing to a jet nozzle having a diameter of 0.5 cm. which is located on the side of the cylinder near the bottom. The feed line to the pump is connected via tubing to the top of the cylinder. The Reynold's Number, i.e. ρvD/μ, is about 6000, placing the fluid flow exiting the nozzle in the turbulent regime.
This arrangement maintains the lenses separate from each other and from the container. In addition, the lenses are in continuous motion, and the treatment solution is well mixed.
EXAMPLE II
An arrangement similar to that of Example I is prepared, with the exception that a diaphragm pump is used in place of a centrifugal pump. The diaphragm pump (Pulsa 680, Pulsa Feeder, Rochester, N.Y.) produces an impulse jet fluid flow, i.e., a plot of the flow rate versus time yields a sinusoidal function. In this flow pattern, the Reynold's Number varies from laminar to turbulent in a cyclic fashion, with the pulse and frequency rate being adjustable.
Thirty lenses are placed in the cylinder described in Example I with three liters of distilled water. As the pulse rate is increased to about 150 cycles per minute, the steady state location of the group of lenses moved up the cylinder. However, the lenses remain well dispersed within the water, and separated from one another and the cylinder walls.
EXAMPLE III
A coarse porous glass disc is placed in the bottom of a 300 milliliter cylinder having a cross-sectional area of 12 cm 2 , with the glass disc spanning the cross-section of the cylinder. The glass disc is sized such that no substantial flow can pass from below the glass disc to above the disc without passing through the disc. About 200 milliliters of distilled water is placed in the cylinder. A contact lens is placed in the distilled water. A diaphragm pump is connected to the cylinder with the discharge of the pump at the bottom of the cylinder and the return at the top, as in Example I. The pump is turned on and the pulse frequency is adjusted so that the lens oscillates up and down slightly at a location near the center of the treatment fluid volume.
The porous glass disc enables the pressure exerted by the pump fluid to be uniformly distributed across the cylinder cross-section. This uniform pressure distribution prevents the development of a dead space, i.e., an area of static fluid, thereby further enhancing the uniformity of treatment.
COMPARATIVE EXAMPLE IV
This Example illustrates the problems associated with a conventional method of bath tinting a contact lens in a tray having numerous lens-retaining wells.
A contact lens is placed in a conventional contact lens tray having semi-spherical lens retaining wells with dimensions of about 15 mm inner diameter and a one mm gap. The lens tray is placed in the cylinder with a solution of reactive (vinyl sulfone) blue dye (RAMAZOL, Hoechst-Celanese Co.), which includes about 10 weight percent sodium phosphate tribasic to cause the dye to chemically bond to the lens polymer matrix. The temperature of the solution is held at about 45° C. The solution remains motionless while the tinting reaction occurs over about a 45 minute period. The lens rests against a portion of the well during the tinting process.
The resulting lens is tinted, but the lens has marks on the surface where there was extended contact with the well. The static nature of the solution contributes to the dye concentration gradient which the lens surface experiences when resting on the well.
EXAMPLE V
This Example illustrates a preferred method of uniformly tinting hydrophilic contact lenses.
A contact lens is placed in a conventional contact lens tray having semi-spherical lens retaining wells with dimensions of about 15 mm inner diameter and a one mm gap, as in EXAMPLE IV. The lens tray is placed in a cylinder having a porous glass disc at the bottom of the cylinder, as per EXAMPLE III. A solution of reactive blue dye and 10 weight percent sodium phosphate tribasic is pumped at a controlled frequency from a diaphragm pump through the glass disc and into the tray wells. The lens is exposed to the tinting solution at a temperature of about 45° C. for a period of about 45 minutes.
The resulting contact lens has a darker tint appearance than the lens produced in accordance with the Example IV procedure. The tint of the resulting lens is entirely uniform in appearance when evaluated by the naked eye. No markings appear on the lens surface.
The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognize that many of the previous components and parameters may be varied or modified to a certain extent without departing from the scope and spirit of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention. Accordingly, the intellectual property rights to this invention are defined only by the following claims.
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An apparatus and method for uniformly contacting an article with a treatment solution. Preferred embodiments are methods of uniformly tinting of contact lenses or uniformly surface modifying contact lenses. The method involves suspending the lens in the treatment solution by application of fluid flow, preferably sinusoidal or pulsed, in a direction opposite the stagnant force (i.e., sum of buoyancy and gravity forces) on the article. The fluid flow prevents the lens from contacting the container structure for periods sufficient to cause non-uniform treatment conditions, while continuously mixing the treatment solution to maintain uniform concentrations throughout.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 07/451,487, filed Dec. 14, 1989, abandoned. This application is related to a commonly-owned invention by the same inventors U.S. patent application Ser. No. 07/451,271, filed Dec. 14, 1989 which is directed to N-alkanoylstaurosporine derivatives, especially-N-acetylstaurospodne which are isolated from Saccharothrix aerocolonigenes subsp. copiosa subsp. nov. SCC 1951, ATCC 53856.
BACKGROUND
This invention relates to indolocarbazoles, excluding the N-alkanoylstaurosporine derivatives, isolated from an antibacterial/antifungal complex produced by fermentation of a biologically pure culture of Saccharothrix aerolonigenes subsps. copiosa subsp. nov. SCC 1951, ATCC 53856. The indolocarbazoles of this invention exhibit selective pharmacological activities, for example in cardiovascular disorders, especially anti hypertensive activity, against proliferation of tumor cells, on inflammation as well as on microbial infections such as caused by bacteria or fungi.
Various indolocarbazoles are known. The indolocarbazole, staurosporine (AM-2282) is disclosed in U.S. Pat. No. 4,107,297 as having antibiotic activity in yeast and fungi as well as having a therapeutic effect on hypertension, edema and ulcers. The indolocarbazoles, TAN-999 and TAN-1030A isolated from culture broths of Nocardiopsis dassonvillei and Streptomyces sp as well as the N-acetyl derivative of the amino-derivative of TAN-1030A are disclosed by diseases in which the inhibition of protein kinase C is of importance in a warm blooded animal as well as can be employed as medicaments for tumor-inhibition, inflammation-inhibition, immunomodulation and also in preparations for combating bacterial infections, arteriosclerosis, as well as other diseases of the cardiovascular system and of the central nervous system.
SUMMARY OF THE INVENTION
The present invention provides a compound represented by the formula I: ##STR4## wherein R is a straight or branched chain (C 1 -C 9 ) alkyl group and stereo-chemical isomers thereof or a pharmaceutically acceptable acid addition salt thereof. The present invention also provides a pharmaceutical composition comprising an effective amount of a compound of formula I and a pharmaceutically acceptable carrier. The pharmaceutical composition of this invention may be administered to warm-blooded animals to inhibit myosin light chain kinase, protein kinase C or tumor cell proliferation or to produce an anti-hypertensive effect or an anti-inflammation effect.
The present invention still further provides a method of treating a warm-blooded animal afflicted by hypertension, which ##STR5## wherein R a and R b are each H or ##STR6## wherein R 1 and R 2 are independently H or --OH or --OCH 3 and R 3 is OH, NHCH 3 , NCH 3 COCH 3 or NHCOCH 3 and R 4 is OH or H, and stereochemical isomers thereof with the provisos that (1) when R a and R b ═A, and R 1 ═H or OH, R 3 is not NHCH 3 ; (2) when R a and R b ═B, then R 1 ═R 4 ═OH or R 1 ═R 4 ═H; (3) when R a ═R b ═H, then R 1 ═--OCH 3 ; and (4) when R a and R b ═A, and R 1 ═H, and R 2 ═OCH 3 , then R 3 is not ##STR7## stereo-chemical isomers thereof or a pharmaceutically acceptable acid addition salt thereof. The present invention also provides a pharmaceutical composition comprising an effective amount of a compound of formula I and a pharmaceutically acceptable carder. The pharmaceutical composition of this invention may be administered to warm-blooded animals to inhibit myosin light chain kinase, protein kinase C or tumor cell proliferation or to produce an anti-hypertensive effect or an anti-inflammation effect.
The present invention still further provides a method of treating a warm-blooded animal afflicted by hypertension, which comprises administering to said animal a therapeutically effective amount of a compound represented by formula I sufficient to treat hypertension or a pharmaceutical composition thereof.
In addition, the present invention provides a method of inhibiting tumor cell proliferation, which comprises contacting said cells with a tumor cell anti-proliferation effective amount of a compound of formula I or a pharmaceutical composition thereof.
The present invention also provides a method of treating a warm-blooded animal afflicted with a disease in which the inhibition of protein kinase C is of importance which comprises administering to said animal a therapeutically effective amount of a compound of formula I or a pharmaceutical composition thereof.
The present invention further provides a method of treating inflammation in a warm-blooded animal which comprising administering to said animal an anti-inflammatory effective amount of a compound of formula I or a pharmaceutical composition thereof.
The compounds of this invention are novel indolocarbazoles which are isolated along with N-acetylstaurosporine and known indolocarbazoles such as staurosporine from an antibiotic complex produced by cultivating a strain of Saccharothrix aerocolonigenes subsp. copiosa subsp. nov, SCC 1951, having the identifying characteristics of ATCC 53856 in a pH and temperature controlled aqueous nutdent medium having assimilable sources of carbon and nitrogen under controlled submerged aerobic conditions until a composition of matter having substantial inhibition of myosin light chain kinase ("MLCK") activity is produced.
This invention also provides a process for producing the antibiotic complex of this invention which comprises cultivating an antibiotic complex producing strain of Saccharothrix aerocolonigenes subsp. copiosa subsp. nov. ATCC 53856 in an aqueous nutrient medium containing assimilable sources of carbon and nitrogen, under submerged aerobic conditions until substantial inhibition of MLCK activity is imparted to said medium and isolating said complex therefrom.
The preferred culture for producing a compound of formula I and the antibiotic complex containing the indolocarbazoles of formula I is a biologically pure culture of the microorganisms Saccharothrix aerocolonigenes subsp. copiosa subsp. nov having the identifying characteristics of ATCC 53856, said culture being capable of producing an antibiotic complex in a recoverable quantity upon fermentation, under aerobic conditions in an aqueous medium containing assimilable sources of nitrogen and carbon.
DETAILED DESCRIPTION OF THE INVENTION
The indolocarbazole compounds of this invention were isolated from an indolocabazole complex obtained from a culture broth produced by a fermentation under controlled conditions of a biologically pure culture of the microorganism, Saccharothrix aerocolonigenes subsp. copiosa subsp. nov. SCC 1951, ATCC 53856.
A viable culture of this microorganism has been deposited in the collection of the American Type Culture Collection (ATCC) in Rockville, Md., where it has been assigned accession number ATCC 53856. Should the deposited culture become lost, destroyed or non-viable during the longer of the thirty (30) year period from the date the culture was deposited or the five (5) year period after the last request for the deposited culture or the effective life of the patent which issues from this application the culture will be replaced upon notice by applicants or assignee(s) of this application. Subcultures of Saccharothrix aerocolonigenes subsp. copiosa subsp.nov. SCC 1951 ATCC 53856 are available during the pendency of this application to one determined by the Commissioner of Patents and Trademarks to be entitled thereto under 37 C.F.R. 1.14 and 35 U.S.C. 122 and will be available to the public without restriction once a patent based on this application is granted. Use of the microorganism is dependent on the U.S. Patent Laws.
DESCRIPTION OF PRODUCING STRAIN
GENERAL METHODS
Source materials used for these studies were frozen (-80° C.) preparations of pure cultures of the microorganism of this invention. Inoculum for the biochemical and physiological tests was prepared by adding 1.0 mL of thawed culture suspension to 10 mL of clear broth in a test tube which was placed on a rotary shaker (300 rpm) at 28°-30° C. for 3 to 5 days. The culture was harvested by centrifugation and washed three times with distilled water. The final pellet was resuspended in distilled water to 4 times the packed cell volume. Incubation temperature for the biochemical and physiological tests was 28° C. Readings of the results were made at various times up to 21 days for the plate media. Most of the tubed media were read at weekly intervals for 4 to 6 weeks.
MORPHOLOGY
Morphological observations were made on plates of water agar, soil extract agar, glucose-yeast extract agar, nutrient agar and ATCC medium 172. Plates were incubated at 28° C. and observed for 2 to 4 weeks.
Strain SCC 1951 was isolated from a soil collected in Spain and is a filamentous organism that forms a well developed, moderately branching substrate mycelium with hyphae approximately 0.4 μm to 0.6 μm in diameter. The vegetative mycelium fragments into coccoid to bacillary elements.
The aerial mycelium consists of very long, sparsely branched hyphae which completely fragment into spores. The spores are smooth walled, cyclindrical and irregular in size (approximately 0.6-0.7 μm wide and 0.9-4.8 μm long). The spore chains are straight to irregularly curved. A few short spore chains of less than 50 spores are usually present but most spore chains contain 50 to 100 spores or more. On many media characteristic clumps of interwoven aerial hyphae or "aerial colonies" are readily observed. No motile elements were present in either the vegetative or aerial mycelium.
CHEMOTAXONOMY
Purified cell wall preparations of SCC 1951 analyzed by the method of Becker [Becker et. al., Appl., Microbiol. 12, 421-423 (1964)] contain the meso-isomer of 2,-6-diaminopimelic acid, alanine, glutamic acid, glucosamine, muramic acid and galactose (Type III). Whole-cell hydrolysates analyzed by the method of Lechevalier [Lechevalier, M. P., J. Lab. Clin. Med. 71, 934-944 (1968)] contain galactose, glucose, mannose, ribose, rhamnose and a trace of madurose. The phospholipids present are diphosphatidylglycerol, phosphatidylinositol, phosphatidylinositol mannosides, phosphatidylethanolamine acylated to both hydroxy and branched chain fatty acids and a minor unknown (Type PII). [Lechevalier et al., Blochem. System. Ecol. 5, 249-260 (1977)]. No mycolates are present. The mole % guanine plus cytosine of the DNA is 71.2% (Tm).
PHYSIOLOGICAL AND BIOCHEMICAL CHARACTERISTICS
The taxonomic procedures were those cited by Gordon [Gordon, R. E., J. Gen. Microbiol. 45:355-364 (1966)], Luedemann and Brodsky, Antimicrob. Agents Chemother. 1964, p. 47-52 (1965)] and Horan and Brodsky [Horan and Brodsky, Int. J. Svst. Bacterial., 32:195-200 (1982)]. Physiological characteristics for SCC 1951 are presented in Table I. Acid production for SCC 1951 from carbohydrates is shown in Table II. Growth for Saccharothrix aerocolonigenes subsp. copiosa SCC 1951, ATCC 53856 occurs at temperatures in the range of about 10° to 40° C. on yeast extract-glucose agar. The optumum growth temperature is about 30° C. to 35° C. Variable growth occurs at 42° C.; no growth was observed at 45° C.
MACROSCOPIC DESCRIPTION OF SCC 1951
All plates were incubated at 28° C. and observed at intervals up to 28 days. The common names for the colors were chosen after comparison with color chips from the ISCC-NBS Centtold Colour Charts, or the Methuen Handbook of Color (Eyre Methuen, London, 1981). The substrate mycelium of SCC 1951 varies from cream to orange yellow to dark yellow brown to brownish black. The aerial mycelium is usually white and tends to be thin. On Czapek sucrose nitrate agar, the white aerial mycelium turns yellow as it ages and becomes moist. The soluble pigments produced vary from yellow to brownish orange to yellow brown. On the carbon utilization medium ISP 9 with trehalose, a reddish orange soluble pigment is present at 7 days. This pigment darkens to brownish orange at 2 to 3 weeks. Results are presented in Table II.
TABLE I______________________________________Physiological Characteristics of Saccharothrix aerocolonigenessubsp. copiosa SCC 1951, ATCC 53856.Test Results______________________________________Hydrolysis or Decomposition of:Adenine -Allantoin -Casein +Esculin +Gelatin +Guanine +.sup.1Hippurate VHypoxanthine +L-tyrosine +Starch +Urea +Xanthine -Xylan +Reduction of nitrates to nitrites +Production of catalase +Production of phosphatase +Resistance to lysozyme +Formation of melanin -Growth at: 10° C. +28° C. +35° C. +40° C. +42° C. V45° C. -Survival at 50° C. for 8 hours +______________________________________ + = positive; - = negative; V = variable 1 = after incubation for 6 weeks
TABLE II______________________________________Acid Production by Saccharothrix aerocolonigenes subsp. copiosaSCC 1951, ATCC 53856 from CarbohydratesCarbohydrate Acid Production______________________________________Adonitol +D-amygdalin +D-arabinose +L-arabinose +D-cellobiose +Dextrin +Dulcitol -i-Erythritol +D-fructose +L-fucose +D-galactose +Glucose +Glycerol +i-Inositol +Inulin -Lactose +Maltose +D-mannitol +D-mannose +D-melezitose -D-melibiose +α-methyl-D-glucoside +α-methyl-D-mannoside +D-raffinose -L-rhamnose +D-ribose +Salicin -D-sorbitol +L-sorbose +Sucrose +D-trehalose +D-xylose +______________________________________
TABLE III______________________________________Macroscopic Appearance of Saccharoxthfix aerocolonigenes subsp.copiosa SCC 1951, ATCC 53856 on Various Descriptive Media.MEDIUM RESULTS______________________________________Yeast Extract - G: good to excellentMalt Extract Agar AM: none to sparse, white(ISP 2) SC: sparse DFP: variably present; pale yellow- brown SMP: yellow-brownOatmeal Agar G: good(ISP 3) AM: moderate to abundant, white SC: abundant DFP: light yellow brown to brownish orange SMP: moderate yellowish brown (ISCC-NBS 77) to dark yellowish brown (ISCC-NBS 78)Inogranic Salts - G: goodStarch Agar (ISP 4) AM: sparse to moderate, white, coremia present SC: sparse DFP: yellow-brown to grayish yellow-brown SMP: moderate yellow-brown to dark yellowish brownGlycerol-Asparagine G: poorAgar (ISP 5) AM: sparse to abundant, white SC: moderate to abundant DFP: absent SMP: translucent - off white to pale yellow-brownWater Agar G: poor AM: none to abundant, white SC: none to abundant DFP: absent SMP: translucentBennett's Agar G: fair AM: sparse to moderate, white SC: abundant DFP: light yellow to pale yellow- brown SMP: translucent to moderate yellow (ISCC-NBS 87)Glucose Asparagine G: goodAgar AM: moderate, white, coremia present SC: sparse DFP: yellow SMP: light orange yellow (ISCC-NBS 70)ATCC Medium 172 G: excellent AM: sparse, white, coremia present SC: sparse DFP: yellow brown to brownish orange SMP: moderate yellowish-brown (ISCC-NBS 77)Czapek-Sucrose Agar G: good AM: sparse to abundant, white turning yellow, coremia present SC: sparce to moderate DFP: yellow brown to brownish orange SMP: dark orange yellow (ISCC- NBS 72)Glucose-Yeast Extract G: goodAgar AM: none to sparse, white SC: moderate to abundant DFP: yellow-brown SMP: yellow-brownCarbon Utilization Base G: excellent(ISP 9) with Lactose AM: bloom, white SC: absent DFP: yellow to yellow-brown SMP: cream, turning brownish- black (ISCC-NBS 65)Carbon Utilization Base G: good(ISP 9) with Trehalose AM: absent SC: absent DFP: reddish orange (Methuen 7A7) turning brownish orange (Methuen 7C8) SMP: brownish orange (Methuen 5C6)______________________________________ G = vegetative growth; AM = aerial mycelium; SC = spore chain; DFP = diffusible pigment; SMP = substrate mycelium pigmentation
On the basis of the above morphological and chemotaxonomic characteristics, SCC 1951 was placed in the genus Saccharothrix. The description of SCC 1951 was compared with the descriptions of those Saccharothrix species listed on the Approved Lists of Bacterial Names or found in the patent literature: Saccharothrix australiensis, S. espanaensis., and S. aerocolonigenes.
SCC 1951 is easily differentiated from S. australiensis and S. espanaensis. S. australiensis produces melanin, fails to grow on ISP 9 with any carbon source and does not hydrolyze starch or hypoxanthine or produce phosphatase. S. epanaensis has a Type PIV phospholipid pattern, strongly hydrolyzes adenine, does not hydrolyze tyrosine and does not produce acid from i-inositol, lactose, mannitol, or melibiose.
The description of SCC 1951, however, closely resembles that of S. aerocolonigenes and SCC 1951 was compared directly with S. aerocolonigene ATCC 23870, the type strain. SCC 1951 differs from ATCC 23870 in producing acid from erythritol and destroying the chromophore in phenol red. SCC 1951 also produces a reddish orange to brownish orange soluble pigment on carbon utilization medium ISP 9 with trehalose, galactose or ribose as the carbon source. These pigments were never observed on the ATCC 23870 plates.
In a survey of 14 strains of Saccharothrix (Nocardia) aerocolonigenes, including the type culture of the species, Gordon et. al. (J. Gen. Microbiol. 109: 69-78, 1978) found that none produced acid from erythritol. Strain SCC 1951 is a strong producer of acid from erythritol. We, therefore, consider SCC 1951 to be a new subspecies of Saccharothrix aerocolonigenes for which we propose the name Saccharothrix aerocolonigenes subsp. copiosa in reference to the large number of indolocarbazoles produced by this strain.
BIOLOGICAL ACTIVITY OF THE COMPOUNDS OF THIS INVENTION
Protein kinase C (PKC)is a Ca 2+ - and phospholipid-dependent protein kinase involved in mediating a wide variety of cellular responses to growth factors, hormones, oncogenes and other modulators of growth control. Numerous studies have indicated that the enzyme plays a central role in signal transduction and tumor promotion and that this control may occur through one arm of the phosphatidylinositol second messenger system. G. M. Housey et al. (Cell., (1988), Vol. 52, pp. 343-354) have recently shown that the overexpression of a full-length form of PKC (β1) causes dramatic morphologic and phenotypic changes in fibroblast cell lines consistent with transformation. These studies underscore the critical role of PKC in growth control and tumorigenesis. K. Tamaski et al., [Biochem. Biophys. Res. Commun., (1986), Vol. 135, pp. 397-402] and H. Kase et al., [(1987), ibid. Vol. 142, p. 436-440] disclose that staurosporine and related indolocarbazoles, K252a, and K252b are inhibitory to PKC (from rats' brains) with good potency, in the nanomolar range. Staurosporine has also been shown to inhibit the growth of cells at concentrations which correlate with in vitro PKC inhibition and to have antitumor activity in-vivo.
Indolocarbazoles such as staurosporine have high potency and thus are useful for biological studies but they have limited selectivity against protein kinases. H. Nako et al. [J. Antibiot., (1987) Vol. 40, pp. 706-708] disclose that staurosporine, for example, will inhibit cyclic AMP-dependent protein kinase, myosin light chain kinase (MLCK) and p60 v-src tyrosine kinase with similar potencies.
The compounds of this invention are potent inhibitors of PKC with increased selectivity compared to staurospodne as evidenced by comparison of inhibition of PKC to that of MLCK. Staurosporine and K-252a have nanomolar potencies with MLCK to PKC ratios of 1.2 and 1.3 respectively. The compounds of this invention exhibit selective inhibition of MLCK with IC 50 's in the range of 138 to >1000 nM and PKC with IC50's in the range of 19 to 854 nM and MLCK to PKC ratios 1.2 to 18.8. The PKC was partially purified from rat brain and assayed in the presence of its activators: Ca 2+ , phosphatidylserine and 1-oleoyl-2-acetylglycerol. Histone III-S was used as phosphate acceptor. The MLCK was native enzyme from chicken gizzard fully activated by calmodulin. Kemptamide was used as phosphate acceptor. The compounds with good potency for PKC inhibition as well as selectivity of PKC inhibition relative to other protein kinases indicate in vivo utility as potential antitumor agents.
In agreement with the in vitro kinase activity, the compounds of this invention inhibited (a) serotonin release in human platelets which were prelabelled with [ 3 H] serotonin. Serotonin release from human platelets (IC 50 ranged from 0.95 to >50 μM) was measured following stimulation for one min. with various doses of thrombin or at various times following addition of 1 unit/ml of thrombin. [T. Tohmatsu et al. Thrombosis Research, (1987), Vol. 47, pp. 25-35], (b) phorbol ester induced c-fos expression in cultured mouse BALB/C 3T3 cells which were exposed to the compounds of this invention for 20 hours prior to serum stimulation. The IC 50 's ranged from 0.6 μM to 5.4 μM. [T. Maniatio et al., "Molecular. Cloning: A Laboratory Manual" (1982), Cold Spring Harbor, N.Y.,] and (c) superoxide release in human neutrophils which were stimulated with either the chemotactic peptide f-met-leu-phe (fMLP) or the phorbol ester, phorbol myristate acetate (PMA). Superoxide release (IC 50 for fMLP ranged from 0.1 to 9 μM and IC 50 for PMA ranged from 0.2 to 5 μM) was measured 15 min. after stimulation as superoxide dismutase-inhibitable reduction of cytochrome c. [D. P. Clifford and J. E. Repine, "Methods in Enzymology", (1984), Vol. 105, p. 393 [51].]
The antibiotic complex as well as the individual indolocarbazoles of this invention isolated therefrom were shown to be myosin light chain kinase inhibitors and phosphodiesterase inhibitors and as such have utilation in treating cardiovascular disorders.
H. Kase et al. J. Antibiot.[(1986) Vol. 39, pp. 1059-65] disclosed that the indolocarbazole, K-252a lowers blood pressure in SHR and DOC-rats. The indolocarbazoles of this invention lower blood pressure and thus the compounds of this invention exhibit pharmacological activity against cardiovascular disorders and have potent antihypertensive activity.
The compounds of this invention exhibit antimicrobial properties and like K-252 indolocarbazoles exhibit diuretic properties.
THERAPEUTIC USES
The compounds of this invention exhibit selective inhibition of MLCK and PKC and thus exhibit anti-proliferation activity against tumors cells.
Thus, in another aspect, the present invention also provides a method of inhibiting tumor cell proliferation, which comprises contacting said tumor cells with an anti-tumor cell proliferation effective amount of a compound of this invention represented by formula I or a pharmaceutical composition thereof.
In another aspect, the present invention also provides a method of treating a warm-blooded animal afflicted by hypertension which comprises administering to said animal a therapeutically effective amount of a compound represented by formula I sufficient to treat hypertension, or a pharmaceutical composition of a compound represented by formula I.
In still another aspect, the present invention provides a method of treating a warm-blooded animal afflicted with diseases wherein the inhibition of protein kinase C is of importance which comprises administering to said animal a therapeutically effective amount of a compound represented by formula I or a pharmaceutical composition thereof.
D. P. Clifford and J. E. Repine, supra. disclose that inhibition of superoxide indicates anti-inflammatory activity. Compounds of this invention inhibited superoxide release in human neutrophils which had been stimulated with either fMLP (IC 50 in the range=0.1 to 9 μM) or PMA (IC 50 in the range=0.2 to 5 μM).
Thus, the present invention provides a method of treating inflammation (arthritis, bursitis, tendonitis, gout as well as other inflammatory conditions) in a warm-blooded animal by administering to such an animal an anti-inflammatory effective amount of a compound of formula I or a pharmaceutical composition thereof.
In yet another aspect, the present invention provides a pharmaceutical composition comprising a compound of this invention represented by formula I or a pharmaceutically acceptable salt thereof, in racemic or optically active form and an inert pharmaceutically acceptable carrier or diluent.
Typical suitable pharmaceutically acceptable salts are acid addition salts formed by adding to the compounds of this invention an equivalent of a mineral acid such as HCl, HF, HNO 3 , H 2 SO 4 or H 3 PO 4 or an organic acid, such as acetic, propionic, oxalic, valeric, oleic, palmitic, stearic, lauric, benzoic, lactic, para-toluenesulfonic, methane-sulfonic, citric, maleic, fumaric, succinic and the like.
The pharmaceutical compositions may be made up by combining the compounds of this invention or a pharmaceutically acceptable salt thereof with any suitable, i.e., inert pharmaceutical carrier or diluent and administered orally, parentally or topically in a variety of formulations.
Examples of suitable pharmaceutical compositions include solid compositions for oral administration such as tablets, capsules, pills, powders and granules, liquid compositions for oral administration such as solutions, suspensions or emulsions. They may also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, physiological saline or some other sterile injectable medium immediately before use.
It will be appreciated that the actual preferred dosages of the compounds of this invention or pharmaceutically acceptable salts thereof will vary according to the particular compound being used, the particular composition formulated, the mode of application and the particular situs, host and disease being treated. Many factors that modify the action of the drug will be taken into account by the attending clinician, e.g. age, body weight, sex, diet, time of administration, rate of excretion, condition of the host, drug combinations, reaction sensitivities and severity of the disease. Administration can be carried out continuously or periodically within the maximum tolerated dose. Optimal application rates for a given set of conditions can be readily ascertained by the attending clinician using conventional dosage determination tests.
The following examples illustrate the claimed invention.
GENERAL METHODS
Solvents, Reagents and Instruments
Solvent used for column chromatography, and high pressure liquid chromatography ("HLPC") were HPLC grade and not redistilled. Water refers to in-house deionized water passed through a Millipore Milli-Q purification system. The CHP-2OP resin was purchased from Mitsubishi. Thin layer chromatography was carried out on Whatman LK6 DF silica gel plates (20×20 cm). Compounds were visualized as a purple spots with 366 nm UV light or by using anisaldehyde spray reagent. High pressure liquid chromatography was carried out using Waters model 510 HPLC pumps controlled by a Waters automated gradient controller. Compounds were monitored at 300 nm using a Hewlett Packard 1040A photodiode array ultraviolet (UV) detector. Ultraviolet spectra were measured on the Hewlett Packard 1040A photodiode array detector or on a Hewlett Packard 845OA UV/Vis spectrophotometer. Infrared spectra were measured on a Nicolet 10-MX instrument. 1 H and 13 C NMR spectra were measured on a Varian 400 instrument at 400 and 100 mHz, respectively. Assignments were made by comparison with published data. Fast atom bombardment-mass spectra (FAB-MS) were measured on a VG-ZAB-SE double focusing mass spectrometer.
Analytical HPLC
Analytical HPLC was carried out on a YMC C 18 reverse phase column (120 Å, 5μ, 4.6×150 mm) using a linear gradient of 30-40% aqueous acetonitrile (aq. ACN) over 22 minutes followed by 40% aq. ACN for 8 minutes (flow rate, 1 mL/min). A photodiode arrray-UV detector monitoring at 300 and 220 nm was used to observe the indolocarbazoles.
EXAMPLE 1
The indolocarbazoles of this invention were isolated from an indolocarbazole complex which was produced by fermentation of a biologically pure culture of Saccharothdrix aerocolonigenes subsp. copiosa subsp. nov. SCC 1951, ATCC 53856.
A. Fermentation
The fermentation, which produces the complex, was started using two or more inoculum stages. Medium for the inoculum stages are listed below. The inoculum and fermentation stages were conducted at a pH from about 6.4 to about 8.5, preferably about 7.0 for the inoculum stage and 7.5 for the fermentation stage.
A temperature of about 27° C. to 35° C. was used to grow the inoculum stages, and to conduct the fermentation stage a temperature of about 27° C.-35° C. was used
The media employed were sterilized and cooled prior to inoculation and fermentation in the examples listed below.
Stock cultures were stored as frozen whole broths at sub-zero temperatures.
Inoculum Preparation
(First Stage)
Inoculum preparation was carried out in two stages for large scale fermentations (10 L to 100 L). Suitable nutrients for preparing the inocula are listed below:
______________________________________Inoculum MediumIngredient g/L______________________________________Beef extract 3.0Tryptone 5.0Yeast extract 5.0Cerelose 1.0Potato starch 24.0Calcium carbonate 2.0Tap water 1 L______________________________________
Two and a half milliliters of freshly-thawed whole broth were used to inoculate 70 mL of the above-listed inoculum medium in 250 mL Erlenmeyer flasks. The flasks were incubated at 30° C. for 48 hours on a shaker at 300 rpm and having a 2 inch throw.
Second Inoculum Preparation
Twelve 2 L Erlenmeyer flasks containing 500 mL of sterile inoculum medium were inoculated using a 5% inoculum from the first stage. The procedure for the first inoculum stage was followed.
Production (fermentation) Stage
The following fermentation medium has been found to produce the indolocarbazole complex:
______________________________________Fermentation MediumIngredient g/L______________________________________Soluble starch 15.0Sucrose 5.0Dextrose 5.0Soy Peptone 7.5Corn steep liquor 5.0 mLK.sub.2 HPO.sub.4 1.5NaCl 0.5Mineral Solution *Tap water 1 LPost sterilization pH 7.0______________________________________ * 10 mL of a mineral solution containing the following salts in a final concentration (mg/L) of: --ZnSO.sub.4.7H.sub.2 O, (28); ferric ammonium citrate, (27.8); CuSO.sub.4.6H.sub.2 O, (1.25); MnSO.sub.4.H.sub.2 O, (10); CoCl.sub.2.6H.sub.2 O, (1); Na.sub.2 B.sub.4 O.sub.7.H.sub.2 O, (0.88); Na.sub.2 MoO.sub.4.2H.sub.2 O, (0.5).
Five liters of the second stage inoculum were used to inoculate 100L of the fermentation medium. The fermentation was conducted for 66 hours at 30° C. in a 150 L NBS Fermatron with agitation and aeration at 270 rpm and 1.8 cfm, respectively.
No pH adjustment was made to the fermentation but the pH ranged from 6.8 to 7.5 over the course of the 66 hour fermentation.
Production of the complex was monitored over time by HPLC analysis of ethyl acetate extracts of the complex.
B. Isolation of Complex and Separation of the Indolocarbazoles
The culture produced small quantities of a very complex mixture of indolocarbazoles. In an analytical HPLC chromatogram of a partially purified sample of the complex mixture, about 20 indolocarbazole components including N-acetyl staurosporine were detected. The isolation of the indolocarbazole complex was accomplished through a series of silica gel and reverse-phase chromatographies. The individual components were then obtained using size exclusion and reverse-phase semi-preparative HPLC. An exemplary procedure followed for vadous batch sizes is given hereinbelow.
The procedure for a 1000 L batch is described. 1000 L of the fermentation broth was extracted two times with equal volumes of ethyl acetate. The organic solutions were combined and the solvent was removed under vacuum. The resulting oil was then placed on a 25 L silica gel column. The column was eluted with 200 L (4×5 OL) of a 10% methanol in dichloromethane solution followed by 50 L of a 1:1 mixture of methanol and dichloromethane. The active fractions, which were detected by analytical HPLC and exhibited inhibition of myosin light chain kinase, were combined and the solvent was removed. The oil was then subjected to a second silica gel column (6-7 L) using 5% methanol in dichloromethane (v/v) as eluant; 1 L cuts were taken and analyzed as above. The active fractions were then passed through a CHP-20P (IL) reverse-phase column and then eluted with 30, 50, 75 and 100% aq. ACN, the activity was found in the 50 and 75% fractions. The material in the active fractions were subjected to chromatography using a second CHP-20P column using a continuous gradient of 30 to 100% aqueous acetonitdle as solvent to produce partially purified material. The isolation of 2-3 component mixtures were achieved using LH-20 chromatography with 1:1 dichloromethane/acetonitrile as solvent. Twenty-five mL fractions were collected and assayed by analytical HPLC. The final step in purification was semi-preparative HPLC which was carried out on a YMC, C 18 reverse-phase column (15μ, 120 A, 30×500 mm) using a 30-40% aqueous acetonitrile gradient (UV at 375 nm, 35 mL/min flow rate). From 1000 L batches, the indolocarbazole components (150 mg total) were isolated varying in weight from 1-30 mg including about 20 mg of N-acetyl-staurosporine.
The structures for the indolocarbazoles of this invention were determined by analysis of the following physiochemical data including: UV, MS (high resolution as well as FAB-MS), 1 H and 13 C NMR and IR spectra and are listed hereinafter as Examples 2-14.
EXAMPLE 2 ##STR8##
FAB-MS: 484 (M+H), 466 (--H 2 O), 440, 343, 299, 242
MOLECULAR FORMULA: C 27 H 21 N 3 O 6
UV (MEOH): 207 (35,000), 230 (31,000), 253 (26,000), 270 (sh, 27,000), 281 (sh, 31,000), 292 (55,000), 299 (56,000), 337 (11,000) 353 (10,000), 370 (11,000)
IR (KBR): 3400, 1760, 1720, 1680, 1630, 1580, 1460, 1390, 1360, 1315, 1290, 1270, 1195, 1130, 1070, 740 1 H NMR: 9.14 (d, 1H, J=8, H-4), 8.86 (s, 1H, NH), 8.39 (d, 1H, J=9, H-8),
(DMSO) 7.92 (d, 1H, J=8.3 , H-11), 7.89 (d, 1H, J=8Hz, H-1), 7.50 (t, 1H, J=8), 7.47 (t, 1H, J=8, H-10), 7.31 (t, 1H, J=8, H-9), 7.27 (t, 1H, J=8, H-3), 7.12 (dd, 1H, J-7, 4.5, H-6'), 6.52 (d, 1H, J=20, 7-OH), 6.42 (d, 1H, J=20, H-7), 6.36 (s, 1H, OH), 3.92 (s, 3H, COOCH 3 ), 3.40 (dd, 1H, J=14, 8, H.sub.β -5'), 2.02 (dd, J=14, 4.5, H.sub.α -5), 2.16 (s, 3H, 2'-Me)
13 C NMR: 172.8, 170.2, 140.1, 137.0, 135.2, 130.0, 128.6, 125.6, 125.4,
(DMSO) 125.1, 124.6, 123.8, 122.9, 122.4, 120.1, 119.6, 118.8(?), 115.5, 115.4, 114.6, 109.1, 99.3, 84.9, 78.5, 52.6, 42.4, 22.8
EXAMPLE 3 ##STR9##
FAB-MS: 470 (M+H) + , 452 425 365 337 310 281, 242
MOLECULAR FORMULA: C 27 H 23 N 3 O 5
UV MEOH): 207 (26,000), 239 (19,000), 292 (sh, 24,000), 301 (30,000), 330 (7,000), 358 (6,000), 375 (6,000)
IR (KBR): 3400, 1680, 1455, 1350, 1315, 1115, 1020, 745
1 H NMR: 9.20 (d, 1H, J=8, H-4), 8.70 (s, 1H, NH), 8.34 (d, 1H, J=8, H-8), 7.98 (d, 1H, J=8, H-11), 7.58 (d, 1H, J=8, H-1), 7.46 (t, 1H, J=7.5, H-2), 7.38 (t, 1H, J=7.8, H-10), 7.28 (t, 1H, J=7.6, H-3), 7.26 (t, 1H, J-8, H-9), 6.76 (d, 1H, J=5.5, H-6'), 7.40 (d, 1H, J=10, 7-OH), 7.32 (d, 1H, J=10, H-7), 4.26 (m, 1H), 4.18 (d, 1H, J=3, OH), 3.80 (d, 1H, J=2.5, H-3), 3.41 (s, 3H, OMe), 2.58 (m, 1H, H.sub.β -5), 2.41 (m, 1H, H.sub.α -5), 2.30 (s, 1H, 2'-Me)
13 C NMR: 170.6, 139.8, 136.3, 134.2, 129.6, 125.3, 124.9, 124.2, 123.4, 122.4, 122.3, 119.2, 119.0, 117.8, 115.4, 114.4, 113.6, 108.6, 90.7, 82.2, 79.4, 78.4, 58.7, 56.3, 33.7, 29.8
EXAMPLE 4 ##STR10##
FAB-MS: 454 (M+H), 366, 323, 311, 295
HR-MS EXACT MASS: (M+H) + FOUND: 454.1740 CALCULATED: 454.1769
MOLECULAR FORMULA: C 27 H 23 N 3 O 4
UV (MEOH): 205, (30,000), 238 (sh, 20,000), 244 (sh, 19,000) 265 (sh, 19000), 292 (40,000), 321 (8,000), 336 (9,000), 355 (7,000), 373 (8,000)
IR (KBR): 3400, 3280, 1685, 1630, 1585, 1360, 1350, 1275, 1230, 1150, 1110, 1020, 1010, 740
1 H NMR: 9.34 (d, 1H, J=8.0, H-4), 7.96 (d, 1H, J=7.8), 7.88 (d, 1H,
(CDCl 3 ) J=7.3), 7.46 (t, 1H, J=7.1), 7.41 (t, 1H, J=7.1), 7.40 (t, 1H, J=7.3), 7.35 (t, 1H, J=7.4), 7.20 (d, 1H, J=7.8), 6.57 (d, 1H, J=5.13, H-6'), 6.17 (s, 1H, NH), 4.73 (AB, J=17, H 2 -7), 4.43 (m, 1H, H-4'), 3.73 (d, 1H, J=2.9, H-3'), 3.60 (s, 3H, 3'-OMe), 2.80 (dd, 1H, J=14.6, 3, H.sub.β -5'), 2.51 (m, 1H, H.sub.α -5'), 2.34 (s, 3H, 2'-Me), 2.29 (s, 1H, OH)
13 C NMR: 172.1, 139.6, 131.9, 129.4, 126.1, 125.4, 124.6, 124.0, 123.8, 122.5, 120.5, 119.5, 118.8, 118.5, 115.6, 114.0, 113.4, 108.5, 90.8, 82.2, 79.4, 58.7, 56.4, 45.3, 33.8, 29.8
EXAMPLE 5 ##STR11##
FAB-MS: 456 (M+H) + , 438 (--H 2 O) 391, 309
HR-MS EXTRACT MASS: (M+H) + FOUND: 456.1532 CALCULATED: 456.1559
MOLECULAR FORMULA: C 26 H 21 N 3 O 5
UV (MEOH): 208 (24,000), 239 (15,000), 292 (sh, 20,000), 301 (27,000) 340 (sh, 4,000), 358 (4,000), 376 (4,000)
IR (KBR): 3400, 1690, 1640, 1580, 1450, 1350, 1320, 1150, 1120, 1025, 750
1 H NMR: 9.23 (d, 1H, J=7.6, H-4), 8.74 (s, 1H, NH), 8.37 (d, 1H,
(DMSO) J=7.0), 8.07 (d, 1H, J=7.5), 7.59 (d, 1H, J=8.3), 7.46 (t, 1H, J=8.1, 7.1), 7.38 (t, 1H, J=8.4, 7.1), 7.27 (t, 1H, J=8.0, 7.1), 7.24 (t, 1H, J=8.3, 7.1), 6.74 (d, 1H, J=4.9, H-6'), 6.43 (d, 1H, J=10.5, 7-OH), 6.36, (d, 1H, J=10.5 , H-7), 5.45 (d, 1H, J=7.1, H-3'), 4.10 (m, 2H, OH), 3.96 (m, 1H, H-4'), 2.63 (1H, m, H-5'), 2.40 (dd, 1H, H-5'), 2.27 (s, 3H, 2'-Me)
13 C NMR: 170.6, 140.1, 136.4, 134.2, 129.7, 126.9, 125.2, 124.9, 124.2,
(DMSO) 123.4, 122.4, 119.2, 118.9, 118.0, 117.8, 115.6, 114.5, 113.6, 108.5, 92.2, 79.3, 78.4, 63.9, 48.5, 34.2, 29.7
EXAMPLE 6 ##STR12##
FAB-MS: 511 (M+H) + , 493, 364, 299
HR-MS EXACT MASS: (M+H) + FOUND: 511.2008 CALCULATED: 511.1981
MOLECULAR FORMULA: C 29 H 26 N 4 O 5
UV (MEOH): 206 (40,000), 238 (29,000), 293 (sh, 43000), 300 (54,000), 325 (sh, 10,000), 339 (sh, 9,000), 357 (8,000), 374 (9,000)
IR (KBR): 3390, 3360, 1680, 1635, 1580, 1450, 1340, 1320, 1120, 1020, 740
1 H NMR: 8.7 (d, 1H, J=8.0, H-4), 8.64 (d, 1H, J=7.0, H-8), 7.68 (d, 1H,
(CDCl 3 ) J=7.4 Hz, 7.4 (t, 1H, J=7.0), 7.35 (t, 1H, J=7.6), 6.90 (d, J=3.9, 2H), 6.55-6.7 (m, 4H), 4.7 (d, 1H, J=6.1, H NCOCH 3 ), 4.38 (m, 1H, H-4'), 3.7 (d, 1H, J=4.3, H-3'), 3.08 (s, 3H, --OCH 3 ), 2.75 (1H, H-5'), 2.47 (s, 3H, CH 3 ), 2.38 (m, 1H, H-5'), 0.6 (s, 3H, COCH 3 )
13 C NMR: 173.1, 169.9, 139.8, 135.8, 133.7, 128.0, 125.6, 125.4, 125.1
(CDCl 3 ) 124.8, 123.9, 123.7, 122.1, 120.6, 120.0, 117.7, 116.1, 114.9, 114.2, 107.2, 90.8, 81.5, 80.2, 57.3, 40.5, 30.3, 29.9, 22.2
EXAMPLE 7 ##STR13##
FAB-MS: 525 (M+H) + , 507, 410, 393, 364, 337
MOLECULAR FORMULA: C 30 H 28 N 4 O 5
UV (MEOH): 206 (31,000), 238 (21,000), 293 (sh, 31,500), 300 (37,000), 340 (6,600), 356 (6,000), 374 (6,000)
IR (KBR): 3400, 1690, 1660, 1460, 1350, 1320, 1120, 1020, 740
1 H NMR: 8.8, (d, 1H, J=8.1, H-4), 8.62 (d, 1H, J=7.8, H-8), 7.51 (d, 1H,
(CDCl 3 ) J=7.8), 7.4 (td, 1H, J=8.0 1.4), 7.35 (dd, 1H, J=8.0,1.0), 7.04 (t, 1H, J=7.6), 6.8 (d, 1H, J=8.1, H-1), 6.7 (brs, 1H, NH), 6.72 (d, 1H, J=7.0, H-6'), 6.51 (dd, 1H, J=12.4, 1.0, H-7), 5.32 (d, 1H, J=12.8, 7-OH), 4.93 (m, 1H, J=13.5, 1.2, H-4'), 3.7 (s, 1H, H-3'), 2.7 (s, 3H, OMe), 2.4 (s, 3H, Me), 2.4 (H-5'), 2.27 (ddd, 1H, J=12.9, 12.9, 3.5, H-5'), 2.1 (s, 3H, NCH 3 ), 1.6 (s, 3H, NCOCH 3 )
13 C NMR: 170.3, 168.8, 138.8, 136.5, 134.5, 129.3, 126.1, 125.4, 125.0,
(DMSO) 123.5, 123.3, 122.3, 119.9, 119.4, 115.9, 114.9, 114.4, 108.8, 93.2, 81.7, 81.2, 78.4, 60.1, 43.7, 29.1, 28.8
EXAMPLE 8 ##STR14##
FAB-MS: 440 (M+H) + , 366, 311, 293, 291
MOLECULAR FORMULA: C 26 H 21 N 3 O 4
UV (MEOH): 206 (30,000), 238 (22,000), 263 (sh, 20,000), 293 (40,000) 319 (11,000), 337 (10,000), 357 (7,000), 373 (8,000)
IR (KBR): 3410, 1660, 1450, 1350, 1320, 1150, 1110, 1010, 740
1 H NMR: 9.38 (d, 1H, J=7.4 Hz, H-4), 8.50 (brs, 1H, NH), 8.09 (d, 1H, J=8.5), 7.95 (d, 1H, J=6.9), 7.59 (d, 1H, J=8.1), 7.45 (td, 1H, J=7.7, 1.0), 7.40 (td, 1H, J=8.5, 1.0), 7.27 (td, 2H, J=7.5), 6.76 (d, 1H, J=5.1, H-6'), 5.45 (d, 1H, J=7.1, OH), 4.93 (AB, 2H, J=17 Hz, H-7), 4.1 (m, 2H), 3.98 (m, 1H), 2.62 (m, 1H, J=15, H-5'), 2.38 (m, 1H, J=15, 3, H-5'), 2.3 (s, 3H, 2'-Me)
13 C NMR: 172.1, 139.8, 136.0, 132.0, 129.4, 126.2, 125.4,125.4, 124.6, 124.0, 123.8, 122.5, 120.6, 119.5, 118.8, 118.5, 115.7, 114.0, 108.4, 92.2, 79.2, 63.9, 57.6, 45.3, 34.3, 29.6
EXAMPLE 9 ##STR15##
FAB-MS: 495 (M+H) + , 394, 362, 348, 338
HR-MS EXACT MASS: (M+H) FOUND: 495.1996 CALCULATED: 495.2032
MOLECUIAR FORMULA: C 29 H 26 N 4 O 4
UV (MEOH): 204 (34,000), 237 (sh, 25,000), 243 (25,000), 264 (sh, 25000), 291 (54,000), 319 (12,000), 334 (14,000), 354 (9,000), 372 (10,000)
IR (KBR): 3420, 3320, 1680, 1635 (sh), 1455, 1340, 1315, 1270, 1225, 1120, 1020, 760, 740
1 H NMR: 9.4 (d, 1H, J=7.9 Hz, H-4), 7.98 (d, 1H, J=8.6), 7.94 (d, 1H, (CDCl 3 ) J=8.8), 7.50 (td, 1H, J=6.9, 1.2), 7.48 (td, 1H, J=7.0, 1.4), 7.39 (td, 2H, J=7.9, 1.0), 7.27 (d, 1H, J=8.3), 6.60 (d, 1H, J=4.4, H-6'), 6.50 (s, 1H, NH), 5.17 (d, 1H, J=6.1, N--H), 5.05 (AB, 2H, H 2 -7), 4.60 (m, 1H, H-4'), 3.91 (d, 1H, J=4.4, H-3'), 3.41 (s, 3H, 3'-OMe), 3.09 (ddd, 1H, J=15, 3.9, 1.2, H-5'), 2.53 (ddd, 1H, J=14.9, 5.6, 4.2, H-5') 2.38 (s, 3H, 2'-Me), 0.80 (s, 3H, COCH 3 )
13 C NMR: 173.3, 170.2, 140.0, 136.8, 132.2, 128.3, 126.6, 125.9, 125.3,
(CDCl 3 ) 125.0, 124.7, 123.2, 121.0, 120.9, 120.4, 119.4, 116.2, 115.6, 114.7, 107.6, 91.3, 81.3, 80.2, 57.2, 46.0, 40.6, 30.7, 29.8, 22.4
EXAMPLE 10 ##STR16##
FAB-MS: 484 (M+H) + , 452 (-MeOH), 425, 396, 364, 336, 309, 281
HR-MS EXACT MASS: (M+H) FOUND: 484.1854 CALCULATED: 484.1872
MOLECULAR FORMULA: C 28 H 26 N 3 O 5
UV (MEOH): 208 (29,000), 239 (25,000), 293 (sh, 36,000), 301 (49,000), 340 (75,000), 359 (7,000), 375 (8,000)
IR (KBR): 3390, 1690, 1680, 1650, 1630, 1450, 1350, 1325, 1115, 1090, 1055 745
1 H NMR: 9.21 (d, 1H, J=8.0, H-4), 8.93 (brs, 1H, NH), 8.22 (d, 1H, J=7.5,
(DMSO) H-8), 8.00 (d, 1H, J=8.5, H-11), 7.61 (d, 1H, J=8.2, H-1), 7.50 (t, 1H, J=7.3, H-2). 7.41 (t, 1H, J=7.3, H-10), 7.31 (t, 1H, J=7.4, H-3), 7.27 (t, 1H, J=7.3, H-9), 6.78 (d, 1H, J=4.7, H-6'), 6.45 (brs, 1H, H-7), 4.27 (m, 1H, H-4'), 4.20 (d, 1H, J=2.9, OH), 3.83 (d, 1H, J=2.4, H-3'), 3.43 (s, 3H, 3'-OMe), 3.22 (s, 3H, 7-OMe), 2.60 (m, 1H, H-5'), 2.40 (m, 1H, H-5'), 2.31 (s, 3H, 2'-Me)
13 C NMR: 171.2, 140.0, 136.4, 130.3, 129.6, 127.2, 125.2, 125.1, 124.4,
(DMSO) 123.3, 122.2, 121.8, 119.4, 118.6, 115.6, 114.5, 113.8, 108.7, 90.8, 84.1, 82.2, 79.5, 58.6, 56.4, 151.0, 33.6, 29.8
EXAMPLE 11 ##STR17##
FAB-MS: 342 (M+H) + , 310, 283, 255
MOLECULAR FORMULA: C 21 H 15 N 3 O 2
UV (MEOH): 206 (24,000), 234 (23,000), 252 (sh, 33,500), 296 (45,600), 332 (8,000), 344 (6,500), 361 (4,700)
IR (KBR): 3250, 1670, 1650, 1580, 1450, 1405, 1290, 1020, 1000, 760
1 H NMR: 11.0 (s, 1H, NH), 10.7 (s, 1H, NH), 9.26 (d, 1H, H-4), 8.38 (d, 1H), 7.2-7.8 (m, 6H), 6.54 (s, 1H, H7), 3.20 (s, 3H, OMe)
13 C NMR: 171.4, 139.4, 139.2, 131.3, 128.0, 126.3, 125.3, 125.2, 123.4, 122.4, 122.2, 122.0, 119.8, 119.1, 118.7, 115.1, 114.8, 111.7, 11.4, 84.2, 51.1
EXAMPLE 12 ##STR18##
FAB-MS: 452 (M+H) + , 368, 337, 311, 253
MOLECULAR FORMULA: C 27 H 21 N 3 O 4
UV (MEOH): 206 (27,000), 230 (21,000), 243 (sh, 19,000), 267 (sh, 21,000), 281 (sh, 30,000), 290 (44,000), 321 (sh, 9,000), 334 (11,000), 352 (8,000), 370 (9,000)
IR (KBR): 3410, 1740, 1690, 1670, 1630, 1460, 1450, 1310, 1270, 1145, 1125, 1110, 740
1 H NMR: 9.42 (d, 1H, H-4), 7.90 (d, 1H), 7.65 (d, 1H), 7.2-7.6 (m, 5H, ar), 7.02 (d, 1H, H-5'), 6.5 (br s, 1H, NH), 4.97 (s, 2H, H 2 -7), 4.30 (s, 1H), 3.75 (dd, 1H, H-4'), 3.45 (s, 3H, COOCH 3 ), 2.83 (d, H-4'), 2.34 (s, 3H, 2'-Me)
EXAMPLE 13 ##STR19##
FAB-MS: 484 (M+H) + , 452, 364, 309, 281, 255
HR-MS EXACT MASS: (M+H) FOUND: 484.1845 CALUATED: 484.1972
MOLECULAR FORMULA: C 28 H 26 N 3 O 5
UV (MEOH): 207 (28,000) 239 (24,000), 292 (SH, 34,000), 301 (44,000), 336 (sh, 7,000), 357 (6,000), 376 (7,000)
1 NMR: 9.35 (d, 1H, J=7.6, H-4), 8.44 (d, lB, J=7.8, H-8), 7.91 (d, (CDCl 3 ) J=8.5, H-11), 7.51 (t, 1H, J=7.2), 7.45 (t, 1H, J=7.0), 7.36 (t, 1H, J=7.1), 7.32 (t, 1H, J=7.1), 7.26 (d, 1H, J=8.1, H-1), 6.59 (d, 1H, J=1.3 Hz, H-7), 6.57 (d, 1H, J=4.4, H-6'), 6.29 (s, 1H, NH), 4.39 (m, 1H, H-4'), 3.72 (d, 1H, J=2.9, H-3'), 3.56 (s, 3H, 7-OMe), 3.05 (s, 3H, 3'-OMe), 2.76 (dd, 1H, J-15, 4, H-5'), 2.50 (m, 1H, H-5'), 2.34 (s, 3H, 2'-Me)
13 C NMR 171.7, 140.3, 137.0, 130.0, 129.8, 127.2, 126.6, 125.7, 124.8,
(CDCl 3 ) 124.1, 123.1, 122.8, 120.4, 120.2, 119.3, 115.6, 115.3, 107.3, 90.6, 84.1, 83.0, 79.3, 60.3, 57.4, 49.7, 33.3, 30.2
EXAMPLE 15 ##STR20##
FAB-MS: 470 (M+H) + , 452, 425, 382, 365, 337, 310, 283, 255
MOLECULAR FORMULA: C 27 H 23 N 3 O 5
UV (MEOH): 207, 239, 292, 300, 330, 358, 375
1 H NMR: 9.25 (d, 1H), 8.33 (d, 1H), 7.77 (d, 1H)
(CDCl 3 ) 7.53 (t, 1H), 7.3 (t, 2H), 7.2 (t, 1H) 6.4 (d, 1H), 6.3 (1H), 6.29 (1 H), 4.0 (d, 1H), 3.8 (d, 1H), 3.6 (1 H), 3.53 (s, 3H) 2.3 (s, 3H), 2.2 (1 H), 1.8 (1 H)
These indolocarbazole of the Example is probably a C-7 isomer of the indolocarbazole of Example 3.
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N-alkanoyl derivatives of staurospodne represented by the formula I ##STR1## wherein R a and R b are each H or ##STR2## wherein R 1 and R 2 are independently H or --OH or --OCH 3 and R 3 is OH, NHCH 3 , NCH COCH 3 or NHCOCH 3 and R 4 is OH or H and, stereochemical isomers thereof with the provisos that (1) when R a and R b ═A, and R 1 ═H 2 or OH R 3 is not NHCH 3 ; (2) when R a and R b ═ B, then R 1 ═R 4 ═OH or R 1 ═R 4 ═H; (3) when R a ═R b ═H R 1 ═--OCH 3 , and (4) when R a and R b ═A, and R 1 ═H and R 2 ═OCH 3 , then R3 is not and ##STR3## pharmaceutical compositions thereof useful for inhibiting myosin light chain kinase, protein kinase C or tumor cell proliferation as well as producing an antihypertensive effect and an anti-inflammatory effect in warm-blood animals such as man are disclosed.
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FIELD OF THE INVENTION
The present invention relates to looms, and more particularly to weaving mechanisms incorporated in looms.
The invention can be used to utmost advantage in a wave-type shedding loom, i.e., in a loom where several sheds are formed simultaneously of the warp threads, and the beating-up of a weft thread is effected by toothed discs.
BACKGROUND OF THE INVENTION
At present, there are widely used in the art of weaving such mechanisms which have a reed formed by a plurality of toothed discs, the discs being successively mounted on a shaft in an angularly staggered fashion, so that their teeth and valleys define helical surfaces of the same pitch.
To prevent sagging and vibration of the discs, underlying them are support or back-up rollers engaging the apices of the teeth of the discs.
However, this mode of engagement between the support rollers and the teeth of the discs more often than not results in deformation of the teeth, which affects the quality of the beating-up of the weft threads, and, ultimately, affects the quality of the cloth being woven.
Such deformation of the teeth of the discs can be precluded by having the support rollers with helical lugs defining a helical surface engaging the helical surface defined by the valleys of the discs and having a pitch equalling that of the helical surface defined by the teeth of the discs. Then, in order to provide for proper cloth formation, i.e., for the desired pattern of the motion of the discs of the reed, the support rollers are to be rotated in synchronism with the shaft of the discs, by an individual drive.
However, the incorporation of such a drive complicates the structure of the weaving mechanism. Moreover, in mechanisms of this kind, there is an eventuality of the support rollers slipping relative to the teeth of the discs, should the driving chain of the drive be somehow impaired, which affests the synchronism in the rotation of the shaft of the discs and of the support rollers, with the eventual breakdown of the discs. This, in turn, cannot but affect the quality of the cloth being woven.
BRIEF DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide a weaving mechanism of a wave-type shedding loom, which should have a simple structure.
Another object of the present invention is to provide a weaving mechanism offering facilitated operation and maintenance.
Still another object of the present invention is to provide a weaving mechanism ensuring high quality of the cloth being woven.
These and other objects are attained in a weaving mechanism of a wave-type shedding loom, comprising a reed defined by toothed discs adapted to beat up a weft thread to the fell of the cloth being woven and mounted successively on a shaft in a staggered fashion, so that their teeth and valleys define respective helical surfaces of the same pitch, and support rollers with helical lugs defining a helical surface engaging the helical surface defined by the valleys of the discs and having a pitch equalling the pitch of the helical surface defined by the teeth of the discs, in which mechanism, in accordance with the present invention, the helical surface defined by the valleys of the discs has a portion of a varying radius diminishing axially in the direction of the advancing motion of the helical surfaces of the discs.
Preferably, the portion of the varying radius is of a conical or tapering shape. The provision of the portion of the varying radius provides for synchronous rotation of the shaft of the discs and of the support rollers and enables to restore the rotational speed of the latter, should it vary on account of eventual slipping of these rollers relative to the helical surface defined by the valleys of the discs. This has been made possible by selecting the taper angle of the above portion to correspond to this eventual slip, in which way self-adjustment of the support rollers has been provided for, whereby an individual drive of the support rollers has become redundant. This significantly simplifies the structure of the mechanism, facilitates its operation and maintenance.
To enhance the reliability of operation of the mechanism it is expedient, in accordance with further features of the present invention, that the helical surface defined by the lugs of the support rollers should have a portion of a varying radius, similar to the portion of the varying radius of the helical surface defined by the valleys of the discs, and that the mean radii of the two portions should be equal.
The self-adjustment of the support rollers and the positively maintained synchronism of the rotation of these rollers and of the shaft of the discs become even more dependable when, in accordance with yet another feature of the present invention, each portion of the varying radius of a respective helical surface of the discs and of the support rollers is adjoined by another portion having a cylindrical shape.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The present invention will be further described in connection with embodiments thereof, with reference being had to the accompanying drawings, wherein:
FIG. 1 is a sectional side view of a weaving mechanism in accordance with the invention;
FIG. 2 is a front view illustrating the relative positions of the shaft of the discs and of the support rollers;
FIG. 3 is a sectional side view of FIG. 2;
FIG. 4 shows schematically an embodiment of the portions of the helical surfaces defined by the valleys of the discs and by the support rollers;
FIG. 5 is another embodiment of the portions of the helical surfaces defined by the valleys of the discs and by the support rollers.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, the herein disclosed weaving mechanism comprises a reed defined by discs 1 (FIG. 1) with teeth 2, 3 and 4 intended to move a weft thread 5 and to beat it up to the fell 6 of the cloth being woven. The weft thread 5 is paid off a carrier 7 propelled by the teeth 2 of the discs 1. The latter are mounted in succession on a riven shaft 8 in an angularly staggered fashion so that their teeth 2, 3 and 4 define a helical surface 9 (FIG. 2), while the valleys between the teeth define a helical surface 10, the two helical surfaces 9 and 10 having the same pitch "t".
Mounted intermediate the adjacent ones of the discs 1 (FIG. 1) on the shaft 8 are spacer rings 11 intended to provide spaces between the discs, to accommodate warp threads 12 shiftable by healds 13 to form a shed for the travel of the carrier 7 therethrough.
The shaft 8 is associated with any suitable known per se drive means, its direction of rotation being indicated in the drawing by arrow "A".
To prevent sagging of the drive shaft 8 and vibration of the discs 1 (FIGS. 2 and 3), mounted to underlie the latter are support or back-up rollers 14 having on their surface helical lugs 15 defining the helical surface 16. The surface 16 engages the helical surface 10 defined by the valleys of the discs 1 and has a pitch "t 1 " equalling the pitch "t". The support rollers 14 are mounted in a housing 17 for rotation brought about by the engagement of the helical surfaces 16 and 10, the rotation of the support rollers 14 being thus synchronous with the rotation of the shaft 8 of the discs 1.
To reduce the wear of the teeth 2. . .4 of the discs 1, the radial height of each lug 15 of the support rollers 14 is in excess of the radial depth of the valley between the discs 1.
The slant angle "α" of the helical surface 9 with respect to the axis 18 of rotation of the shaft 8 is smaller than the slant angle "β" of the helical surface 16 with respect to the axis 19 of rotation of the support rollers 14, and this precludes engagement of the apices of the teeth 2, 4 with the surface of the lugs 15, which otherwise might have caused breakdown of the discs 1.
The helical surface 10 (FIG. 4) defined by the valleys between the teeth 2 and 4 has a portion 20 of a varying radius R which attains values R max corresponding to the maximum radial depth of the valleys, R min corresponding to the minimum radial depth of these valleys, and the mean value R m intermedite the values R max and R min . In the presently described embodiment, the portion 20 has a tapering shape, which is provided for by shaping the helical surface 10 with a radius R (FIG. 1) from a centre "O" offset by a distance "e" from the axis 18 of rotation of the shaft 8 toward the tooth 2. This is done in the course of manufacture of the discs 1. Then, with the discs 1 mounted on the shaft 8, there is formed the helical surface 10 defined by the valleys between the teeth, having the tapering portion 20 (FIG. 4) of which the radius R diminishes along the axis 18 in the direction of the advance of the helical surfaces 10 and 9. This advance of the surfaces 10 and 9 is indicated in the drawing with arrow "B".
In the presently described embodiment, the helical surface 16 of the support rollers 14 likewise has a portion 21 of a varying radius "r", having a tapering shape. The mean values of the radii R m and r m of the two portions 20 and 21, respectively, are equal, whereby self-adjustment of the rollers 14 is provided.
Should the rollers 14 slip in operation, the speed of their rotation diminishes, whereby the helical surface 16 of the lugs 15 becomes displaced parallel to the axis 18 of the shaft 8 relative to the helical surface 10 defined by the valleys, toward the R max portion.
Accordingly, the speed of rotation of the support rollers increases, whereby the displacement of the rollers along the valley toward the greater radius R max is arrested, and the rollers attain such a position between the teeth 2 and 4 whereat the surfaces 10 and 16 engage each other by their respective tapering portions 20 and 21 in the area of the radius R max , this radius being in excess of the radius "r" of the helical surface 16 defined by the lugs 15 by a value "a" corresponding to the slip value.
It has been observed that the value of the slip of the helical surface 16 (FIG. 4) of the lugs 15 at the helical surface 10 defined by the valleys is small, whereby the difference between the values R max and R min can be correspondingly small, e.g. of about 0.2 mm to 0.3 mm.
Illustrated in FIG. 5 of the appended drawings is an embodiment wherein each portion 20 and 21 of the respective helical surface 10 and 16 is adjoined by another respective portion 22 and 23, both portions 22 and 23 being of a cylindrical shape. In this embodiment, R min = r max .
However, taking into consideration that the slip value is small, and the difference between the radii R max and R min is accordingly small, it is practically feasible to have a single cylindrical portion 23 provided on the helical surface 16 of the lugs 15.
PRINCIPLE OF OPERATION
With the shaft 8 rotated, the discs 1 are rotated thereby, the teeth 2 propelling the carrier 7 of the weft thread 5, and the teeth 3 and 4 beating up the weft thread 5 to the fell 6 of the cloth being woven.
The support rollers 14 having their helical surface 16 engaging the helical surface 10 of the valleys of the discs 1 are also rotated by said engagement, preventing sagging of the driven shaft 8 and vibration of its discs 1.
With the surfaces 10 and 16 engaging each other, they are in contact with their tapering portions 20 and 21, and, owing to the equality of the mean radii R m and r m of these respective portions, the support rollers 14 rotate in synchronism with the shaft 8, at the same speed.
Should the rollers 14 slip, their speed of rotation diminishes, i.e., the rollers 14 lag in their rotation behind the shaft 8, and their lugs 15 become displaced by the value "a" toward the maximum radius R max . This displacement takes place until the speed of rotation of the support rollers 14 equals the speed of rotation of the shaft 8, which is provided for by the interaction of the tapering portions 20 and 21. This self-adjustment of the support rollers 14 in case of their slip ensures their being reliably driven by friction by the valleys of the discs. The greater the slip, the greater the resulting displacement "a", but it has been found that for practical reasons a proper mode of the driving of the support rollers 14 is provided for with the difference between R max and R min being as small as 0.2 to 0.3 mm.
In an embodiment wherein the helical surfaces 10 and 16 are provided, respectively, with the portions 20 and 22, 21 and 23, the self-adjustment of the support rollers 14 upon their slipping takes place, as follows.
With the cylindrical portions 22 and 23 engaging each other, the support rollers 14 slow down, owing to the slip, whereby there takes place a displacement along the axis 18 of the shaft 8 toward the greater radius R max . Consequently, the tapering portions 20 and 21 come into engagement, i.e., the minimum radius r min engages the maximum radius R max . In this way, the speed of rotation of the support rollers 14 is increased, until a moment comes when the relative displacement of the support rollers 14 along the valley toward the greater radius ceases; in other words, there takes place the same process of self-adjustment which has been described above in connection with the embodiment wherein the helical surfaces 10 and 16 have the single tapering portion, either 20 or 21.
The herein disclosed weaving arrangement with the self-adjusting support rollers 14 is simple both in manufacture and in operation, since the manufacture of the helical surfaces 10 defined by the valleys between the teeth of the discs 1 is effected simultaneously with one of the operations of shaping these discs 1 (a pressing operation), while the manufacture of the support rollers 14, e.g. with the helical cylindrical surface 16 of the lugs 15 involves either simple turning operations, or pressure-moulding of the entire rollers from a plastic material.
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The invention relates to weaving mechanisms and can be used to advantage in wave-type shedding looms. The mechanism includes a plurality of toothed discs mounted in a staggered fashion on a shaft and defining a helical surface having a portion of a varying radius diminishing axially in the direction of the advancing motion of the helical surface. Underlying the discs are support rollers with lugs defining a helical surface engaging the helical surface defined by the valleys of the discs and likewise having a portion of a varying radius, engaging the corresponding portion of the helical surface defined by the valleys. Such an embodiment simplifies the structure of the mechanism and obviates the need in a drive of the support rollers.
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This application claims the benefit of copending application Ser. No. 10/336,368, filed Jan. 2, 2003.
BACKGROUND OF THE INVENTION
This invention relates to foam blowing agent blends containing trans-1,2-dichloroethylene (“Trans 12”) and one or more hydrofluorocarbons (“HFCs”), and to foam compositions containing such blends. Trans 12 is useful to improve the fire performance (that is, to suppress flame spread and smoke generation, as measured by ASTM E 1354 in terms of reduced rate of mass loss and reduced specific extinction area upon ignition) of HFC-blown, closed cell polymer (insulation) foams, such as polystyrene, phenolic and polyurethane foams.
Chlorofluorocarbons (“CFCs”) had been used as blowing agents for rigid, closed cell insulation foams for many years because they offer outstanding fire resistance in addition to good thermal insulation, since the CFCs are non-flammable. However, CFCs have been phased out because they are said to be detrimental to the ozone layer. Hydrochlorofluorocarbons (“HCFCs”) such as 1,1 -dichloro-1-fluoroethane (“HCFC-141b”) with low ozone depletion potential (“ODP”) have been alternatives for CFCs. However, HCFCs are also being phased out under the Montreal Protocol. The next generation of foam blowing agents must have zero ODP. For fluorochemical blowing agents, these are generally the HFCs such as 1,1,1,3,3-pentafluorobutane (“HFC-365mfc”). However, HFCs are typically more flammable than the CFCs or HCFCs, so that the new formulations will usually require higher levels of flame retardants in order to achieve the same levels of flammability. This increased level of flame retardant creates a problem because upon burning the flame retardants increase smoke levels. Thus, as disclosed by Albemarle Corporation in its website, Albemarle.com/saytexfr_polyurethane.htm, the addition of a brominated reactive polyol (RB-79) increases the smoke density of foam when subjected to fire tests. It has been reported that the use of 245fa alone will result in foams which generate high smoke density. What is thus needed is a means to achieve satisfactory blowing with HFCs while reducing the amount of fire retardant so as to reduce smoke density and lower overall cost. While Trans 12 has been disclosed as a foam blowing agent, as for example in U.S. Pat. No. 5,126,067, its use to reduce flame spread or smoke density has not been previously disclosed.
BRIEF SUMMARY OF THE INVENTION
An HFC-based foam blowing agent composition is provided, which composition contains Trans 12 in an amount effective to enhance the fire performance of the blown foam, as well as polyurethane foam compositions comprising a polyol, an isocyanate and the blowing agent composition. Preferred HFCs include HFC-365mfc, 1,1,1,3,3-pentafluoropropane (“EHFC-245fa”) and 1,1,1,2-tetrafluoroethane (“134a”). Typical Trans 12 levels are from about 5 to 40% by weight, based on the total blowing agent weight.
DETAILED DESCRIPTION
Trans 12 improves the fire performance (suppresses smoke development and mass loss rate) of HFC blown foams, as well as lowering the global warming potential of the blends compared to HFC alone and lowering the overall cost of the foam formulation by reducing the amount of required flame retardant. As noted above, these blends are particularly useful for making closed cell polymer (insulation) foams having improved fire performance, such as polystyrene, phenolic and polyurethane foams.
Trans 12 generally makes up 5–40 weight % of the blends. In the polyurethane foam compositions, the effective concentrations of the blends are typically about 0.1–25 weight % (preferably 0.5–15 weight %), based on the weight of the total polyurethane foam formulation.
The blowing agent can be distributed between the “A” and “B” sides of the foam composition. All or a portion of it can also be added at the time of injection. The Trans 12/HFC blends can also contain additional blowing agents such as water or pentane(s).
The other components of the premix and foam formulations may be those which are conventionally used, which components and their proportions are well known to those skilled in the art. For example, fire retardants, surfactants and polyol are typical components of the B-side, while the A-side is primarily comprised of polyisocyanate. Water is frequently used as a coblowing agent. The A and B sides are typically mixed together, followed by injection of the catalyst, after which the mixture is poured into a mold or box.
The practice of the invention is illustrated in more detail in the following non-limiting examples which compare the performance of HFC-blown foam, using 245fa or 365mfc alone, to the performance of such foams wherein the blowing agent contains 10, 30 or 50 mole % of Trans 12. The formulations used (all having an Iso Index of 275) each contained 156.3 parts D-44V70, a polymeric methane diphenyl diisocyanate (polymeric MDI) available from Bayer Corporation; 100 parts PS2412, a polyester polyol having a hydroxyl number of 230–250 available from the Stepan Company; 0.17 part PC-5, which is pentamethyldiethylenetriamine, a catalyst available from Air Products; 2.71 parts K-15, potassium octoate in dipropylene glycol, a catalyst available from Air Products; 2 parts B-8465, a polysiloxane-polyether copolymer surfactant available from Goldschmidt Chemical Corporation; and about 34–44 parts blowing agent, as more specifically set forth in the table below; all parts are by weight.
The A-side (D-44V70) and B-side (a mixture of the polyol, surfactant and blowing agent) were each cooled to 10° C., then mixed, after which the catalyst mixture was injected. After further mixing for about 15–18 seconds, the mixture was poured into a box. The fire behavior of the foams was tested with a cone calorimeter, according to standard test protocols (ISO 5660 or ASTM E 1354). In this test the foam specimens are ignited with a conical radiant heater, the thermal flux applied on the specimen surface being 50 kilowatts per square meter. The specimens tested had a size of 100 mm by 100 mm with a thickness of 50 mm; they were wrapped in aluminum foil in order to have only the upper surface exposed to the radiant heater. Two specimens were used for each measurement and the results were averaged. The total smoke development in 580 seconds (reported according to ASTM E 1354 as the specific extinction area or “SEA”) and the mass loss rate (an indication of the rate of heat release), when calculated between 10 to 90% of weight loss, are reported in the table below:
Mass loss rate SEA (in grams per (in square Foam ID (with parts of second per meters per blowing agent) square meter) kilogram) 245 fa only (39.4) 10 852 245 fa (35.46) + Trans 12 8 898 (2.85 or 10 mole %) 245 fa (27.58) + Trans 12 4 507 (8.56 or 30 mole %) 245 fa (19.7) + Trans 12 3 585 (14.26 or 50 mole %) 365 mfc only (43.51) 4 621 365 mfc (39.16) + Trans 12 4 507 (2.85 or 10 mole %) 365 mfc (30.46) + Trans 12 3 556 (8.56 or 30 mole %) 365 mfc (21.76) + Trans 12 3 579 14.26 or 50 mole %)
The improvement with the use of Trans 12 is more dramatic when added to 245fa since the 365mfc by itself produces a less flammable foam than 245fa.
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Foam blowing agent blends containing trans-1,2-dichloroethylene and one or more hydrofluorocarbons are provided, as are foam compositions containing such blends. The resulting foams exhibit dramatic improvement in fire performance.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The invention relates to a driver circuit of an inkjet print head and, more particularly, to a driver circuit-integrated driver transistor structure of an inkjet print head and the method for making the same.
[0003] 2. Related Art
[0004] The inkjet printer is a common peripheral device of a computer. There is usually a print head for ejecting ink droplets in the machine, e.g. a thermal bubble inkjet print head. The basic structure of a normal print head includes an ink channel, a nozzle and an orifice plate for ejecting ink, an actuator for ink ejection and a proper driver circuit. When the inkjet printer is printing, the ink is propelled by the actuator, such as a heater, and is ejected from the nozzle on the orifice plate to form ink dots on paper. Generally speaking, the thermal bubble inkjet print head uses a heater as the actuator device, which heats up the ink in the ink channel to produce thermal bubbles to jet the ink.
[0005] In order to improve performance in terms of resolution and printing speed, one needs a large number of nozzles on each inkjet print head. Currently, the thermal bubble inkjet print head uses a design with serial driver transistors and heaters. An active driver array is incorporated in the driver circuit and is integrated into the circuit structure of the inkjet print head chip. This is the so-called IDH (integrated driver head) chip. If there are N electrical joints between the inkjet print head chip and the printer, the chip can drive and control (N/2) 2 nozzles. The above mentioned driver transistor is a current driver. It has to adopt a comb or grating MOSFET gate structure, or a bipolar transistor base structure to connect several sets of transistors in parallel. As shown in FIG. 1, the driver transistor structure has several MOSFET elements 21 connected in parallel. Each MOSFET element includes a source region 211 , a drain region 212 and a gate 213 . The gates 213 of the MOSFET elements are connected in parallel to form a comb gate structure 22 . A body contact region 20 ′ is formed outside the active region 20 . The body contact region 20 ′ is formed with a plurality of body contacts (or substrate contacts) 23 . The locations and areas of the body contacts 23 can be defined by the barrier layer 24 of a polysilicon doped layer. In the prior art, the body contacts 23 and the source of the MOSFEL element maintain electrical contact to maintain the substrate of the MOSFET element at the lowest level or ground. The driver transistor structure uses tetraethosiloxane (Si(OC 2 H 5 ) 4 , TEOS) silicon oxide, PSG, or BPSG (Boron Phosphorus Silicon Glass) as an interlayer dielectric by CVD (Chemical Vapor Deposition). The interlayer dielectric is etched to form contact holes 25 of gates, drains, sources and body contacts.
[0006] To supply a sufficient driving current, the driver transistor structure adopts the MOSFET design of a large channel W/L (Width-to-Length) ratio. The width of the active region 20 has to be between 400 micrometers and 900 micrometers to provide a working voltage of 10V and a working current above 200 mA. However, such a design makes the active region far from the body contacts (over 400 micrometers). This cannot guarantee that all channels in the MOSFET elements inside the active region are perfectly grounded, resulting in secondary breakdowns and lowering the tolerance of the elements. As to the manufacturing and structure of the driver transistor of a conventional 300 dpi or 600 dpi IDH chip, the heater, MOSFET elements, and field region with body contacts are integrated together. The body contacts are installed in the thick oxide field layer (with a thickness between 9000 A to 17500 A). In this structure, a basic body contact structure is about 15×15 μm 2 , excluding the gaps in between. A MOS driver transistor structure is roughly 80×600 μm 2 , excluding the body region. 18 body contacts along with the gaps in between occupy 80×150 μm 2 . On the average, each driver transistor provides ⅙ to ⅓ of its area for the body contact region of the field oxide. The body contact occupies a large portion of the area.
[0007] Current products usually have 200 to 400 driver transistors on an inkjet print head. These driver transistors occupy a large portion of the area in the chip. With the increase of resolution of the inkjet print head, the number of driver transistors on a single inkjet print head chip has to be increased along with the number of heaters and nozzles. Although scaling down the MOSFET elements can accommodate more driver transistors in a unit area, the scaled-down MOSFET elements and other loops have higher parasitic resistance and the heat generated from each unit area also increases. Therefore, it requires a higher chip manufacturing cost.
[0008] Thus, how to minimize the area occupied by each driver transistor without decreasing the sizes of MOSFET elements while increasing the reliability of elements in the driver transistor structure design of an inkjet print head chip is a subject worth further research and exploration.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, an objective of the invention is to provide a driver transistor structure of an inkjet print head chip and its manufacturing method. The invention can lower the resistance R B from the MOSFET channel in the active region to the body contact, avoiding secondary breakdowns and increasing element reliability.
[0010] Another objective of the invention is to provide a driver transistor structure of an inkjet print head chip and its manufacturing method that can minimize the area occupied by each driver transistor on the inkjet print head chip without increasing parasitic resistance and manufacturing costs.
[0011] To achieve the above objectives, the invention distributes several body contacts in a large area MOSFET active region so that the equivalent resistance R B between the MOSFET channel and the body-contact greatly decreases as the distance is reduced. Therefore, it can prevent the occurrence of secondary breakdowns. Furthermore, the body contacts are installed in the active region of the driver transistor structure. For example, the body contacts are embedded in the source, the so-called BES (Body-contact Embedded in Source) structure, without defining in advance the body region and making the body contacts in the field oxide region outside the active region. Accordingly, such a BES MOSFET driver transistor structure can save about 20% area without decreasing the sizes of MOSFET elements in the active region. This method can also increase the number of inkjet print head chips on each wafer, thus lowering the average manufacturing cost of each chip.
[0012] In accordance with the disclosed driver transistor structure of an inkjet print head chip, at least one body contact is installed in an active region of the driver transistor. The active region has a plurality of MOSFET elements connected in parallel. These MOSFET's are used to control an ink actuator (e.g. current supply of a heater) in electrical contact with the driver transistor in the inkjet print head chip. The body contact can be embedded in or next to the source of the MOSFET element. The minimum distance between the dopant region of the body contact and the region of the source region with another type of dopant can be less than 5 μm. The body contact and the source of the MOSFET element in the active region are connected using a conductor to keep them at the same level.
[0013] According to the disclosed manufacturing method of the driver transistor of an inkjet print head chip, at least one body contact is installed in the active region of the driver transistor. The method forms at least one dopant barrier layer to define a dopant barrier region during the formation of the MOSFET element in the active region. The dopant barrier layer is used to prevent drain and source dopants (e.g. N+ dopants) from entering the dopant barrier region during the diffusion or ion implantation process. Afterwards, the dopant barrier layer is etched to define a dopant region for body contact. In the dopant region of body contacts, a body-contact dopant of a type opposite to the drain and source dopant is implanted in the body contact dopant region by ion implantation or diffusion to obtain the body-contact.
[0014] In particular, the dopant barrier layer can be a polysilicon layer or other materials that can stop or resist dopants, for example, a dielectric layer, refractory metal or alloy will work. The dopant barrier layer can be formed while depositing the gate polysilicon in the MOSFET element or during another deposition or coating process. Furthermore, the region of the dopant barrier layer can be defined by an etching step the same as or different from the gate polysilicon layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic top view of a driver transistor structure of a conventional inkjet print head chip, where a plurality of body contacts is installed in a body region outside the active region;
[0016] [0016]FIG. 2A is a top view of an embodiment of the driver transistor structure of the disclosed inkjet print head chip, where the body contacts are distributed in the source region of the MOSFET element in the active region;
[0017] [0017]FIG. 2B is a local exploded view of FIG. 2A;
[0018] [0018]FIG. 2C is an exploded top view of a body contact structure;
[0019] [0019]FIGS. 3A through 3D show cross-sectional views of the procedure in an embodiment of the manufacturing method for a driver transistor of the inkjet print head chip;
[0020] [0020]FIGS. 3E through 3F show another embodiment of the manufacturing method for a driver transistor of the inkjet print head chip, where the size of the body contact holes is smaller than the body dopant region; and
[0021] [0021]FIGS. 4A through 4D show cross-sectional views of the procedure in yet another embodiment of the manufacturing method for a driver transistor of the inkjet print head chip, where the dopant barrier layer extends to the field oxide to make the body contact close to the source.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Please refer to FIG. 2 for a BES (Body contacts Embedded in Source) driver transistor structure in an inkjet print head chip. Several body contacts 50 are installed inside the active region 20 of the driver transistor. The active region 20 has many MOSFET elements 21 connected in parallel. Each of the MOSFET elements includes a source region 211 , a drain region 213 and a gate 213 . The body contacts 50 are disposed in the source region 211 at a proper distance. The source regions 211 , the drain regions 212 , the gates 213 and the body contacts 50 are formed with appropriate contact holes 26 . Each of the MOSFET elements 21 uses a large channel W/L (Width-to-Length) ratio design; that is, the channel width is far larger than the channel length. Usually, the width of the active region 20 is over 400 μm. The gate 213 can be made of polysilicon. The long gates 213 in the active region 20 are connected on both ends in parallel. Since the body contacts 50 are distributed in the source region of the active region 20 , the distance and internal resistance between the body contact 50 and the MOSFET channel can be greatly reduced. All channels of the MOSFET element inside the active region 20 can be perfectly grounded, preventing secondary breakdowns. As the body contacts 50 are not necessarily installed in the field oxide region outside the active region 20 , the area occupied by the driver transistor can be largely saved, which is good for minimizing the inkjet print head chip and reducing manufacturing costs.
[0023] With reference to FIG. 2B, the location and shape of the body contacts 50 are defined by a dopant barrier layer 24 formed on the source region 211 . In other words, the dopant barrier layer 24 can be a polysilicon layer formed in the same deposition step for forming the gate 213 . Its region can also be defined in the same etching step as the gate 213 . The source contact hole 26 a and the body contact hole 26 b in the source region 212 can be separately designed as shown in the drawing.
[0024] Please refer to FIGS. 3A through 3D. As shown in FIG. 3A, an active region 20 is defined on the surface of a substrate 25 by silicon oxide and silicon nitride. The LOCOS procedure is further used to grow a thick field oxide layer 32 outside the active region 20 . The substrate 25 in this embodiment is a p-type Si substrate and the thickness of the LOCOS field oxide layer 32 is between 8000 A and 18000 A. Afterwards, the silicon oxide and silicon nitride are removed and a gate insulator 27 is grown by dry oxidation, or the silicon oxide and silicon nitride can be directly used as the gate insulator 27 by removing the silicon oxide and silicon nitride on the source region 33 and the drain source 34 only. Afterwards, a polysilicon layer is formed on the gate insulator 27 by CVD. It is preferable to define the gate polysilicon layer 28 and the body-contact dopant barrier layer 28 ′ inside the active region by photolithography and polysilicon etching. The dopant barrier layer 28 ′ occupies some area in the source region 33 , forming a dopant barrier region 35 in the source region. The dopant barrier layer 28 ′ is used as a barrier layer again the diffusing or implanting n+ dopants (e.g. P or As) for the source region 33 and the drain region 34 . This ensures that the region for body-contact 35 in the source region is not implanted by n+ dopants. In the current embodiment, though the dopant barrier layer 28 ′ is made of a polysilicon layer, the invention is not limited to this. The dopant barrier layer can be made of other materials for blocking dopants. The dopant barrier layer can be formed in the same deposition step as the gate polysilicon or in another deposition or coating process. In addition, the region of the dopant barrier layer can be defined in the same or in a different etching step for the gate polysilicon layer 28 .
[0025] With reference to FIG. 3B, photolithography and etching procedures are performed to define the region of a body contact dopant 29 by developing on a photo resist layer and etching polysilicon. The body contact dopant region 29 is doped with p+ dopants, such as boron dopants, by ion implantation or diffusion 31 .
[0026] As shown in FIG. 3C, remove the photo resist layer 60 tetraethosiloxane (Si(OC 2 H 5 ) 4 , TEOS) silicon oxide, PSG, or BPSG as an interlayer dielectric 36 of the driver transistor by CVD (Chemical Vapor Deposition). Reflow is employed to improve the topographical smoothness. Lithography and etching are used again to open appropriate electrode contact holes on the interlayer dielectric 36 , including the gate, source contact holes (not shown in the drawing), drain contact holes 26 c and body contact holes 26 b . A body contact 50 can be obtained in the source region 33 . The distance between the dopan region of the body contact and the source region with the other type of dopant can be less than 5 μm.
[0027] As shown in FIG. 3D, a heater layer 44 and a conductive layer 40 are formed on the interlayer dielectric 36 and the electrode contact holes 26 b , 26 c by sputtering or evaporation. The heater layer 44 and the conductive layer 40 can be also defined by lithography and etching, thereby forming a heater 48 and a wire connecting the drain region 34 and the heater 48 . At the same time, a metal conductor connecting the body contact 50 and the source region 33 is defined. The driver transistor structure of the inkjet print head chip in the embodiment is thus completed.
[0028] The size of the body contact hole 26 b in the above-mentioned embodiment is larger than the body-contact dopant region. As shown in FIG. 2C, the size of the body contact hole 26 b in the AA′ direction is greater than the body-contact dopant region 29 but smaller than the region of the dopant barrier layer 24 .
[0029] The size of the body contact hole 26 b can be smaller than the body contact dopant region 29 . As shown in the drawing, the size of the body contact hole 26 b in the BB′ direction is not larger than the body contact dopant region 29 . The interlayer dielectric 36 corresponding to the body contact dopant region 29 can open smaller contact holes 26 b using the method illustrated in FIGS. 3E through 3F, followed by the procedure of forming the heater layer 44 and the conductive layer 40 . The body contact hole and the source contact hole use the design of shared contact holes.
[0030] [0030]FIGS. 4A through 4D show another embodiment for making the driver transistor. With reference to FIG. 4A, an active region 20 is defined on a substrate surface 25 in the same way as the previous embodiment and a thick field oxide layer 32 is grown outside the active region 20 using the LOCOS procedure. The substrate 25 is a p-type Si substrate and the thickness of the LOCOS field oxide layer is between 8000 A and 18000 A. Afterwards, a gate insulator 27 is formed and a polysilicon layer is formed by CVD. It is preferable to define the gate polysilicon layer 28 and the dopant barrier layer 28 ′ inside the active region by photolithography and polysilicon etching. The dopant barrier layer 28 ′ occupies some area in the source region 33 , forming a dopant barrier region 35 in the source region. The dopant barrier layer 28 ′ can extend to the field oxide layer adjacent to the source region 33 . The dopant barrier layer 28 ′ is used as a barrier layer against diffusing or implanting n+ dopants (e.g. P or As) for the source region 33 and the drain region 34 . This ensures that the region for body-contact 35 in the source region is not implanted with n+ dopants. The dopant barrier layer 28 ′ can be made of a polysilicon layer or any other material that stops or resists dopants. The dopant barrier layer can be formed in the same deposition step as the gate polysilicon or in a different deposition or coating step. In addition, the dopant barrier layer can be defined in the same or in a different etching step for the gate polysilicon layer 28 .
[0031] With reference to FIG. 4B, photolithography and etching procedures are performed to define the body contact dopant region 29 by developing on a photo resist layer 60 and etching polysilicon. The body contact dopant region 29 is doped with p+ dopants, such as boron dopants, by ion implantation or diffusion 31 .
[0032] As shown in FIG. 4C, remove the photo resist layer 60 , and then deposit a layer of the tetraethosiloxane (Si(OC 2 H 5 ) 4 , TEOS) silicon oxide, PSG, or BPSG as an interlayer dielectric 36 of the driver transistor by CVD (Chemical Vapor Deposition). Reflow is employed to improve the topographical smoothness. Lithography and etching are used again to open appropriate electrode contact holes on the interlayer dielectric 36 , including the gate, source contact holes (not shown in the drawing), drain contact holes 26 c and body contact holes 26 d . A body contact 50 can be obtained in the source region 33 . The distance between the dopant region of the body contact and the source region with another type of dopant can be less than 5 μm.
[0033] As shown in FIG. 4D, a heater layer 44 and a conductive layer 40 are formed on the interlayer dielectric 36 and the electrode contact holes 26 c , 26 d by sputtering or evaporation. The heater layer 44 and the conductive layer 40 can also be defined by lithography and etching, thereby forming a heater 48 and a wire connecting the drain region 34 and the heater 48 . At the same time, a metal conductor connecting the body contact 50 and the source region 33 is defined. The driver transistor structure of the inkjet print head chip in the embodiment is thus completed.
[0034] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, intended that the appended claims will cover all modifications that fall within the true scope of the invention.
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A driver transistor structure of an inkjet print head chip and the method for making the same. Having several body contacts distributed all over the source of an active region of a large area MOSFET (Metal Oxide Semiconductor Field Effect Transistor), an equivalent R B from the MOSFET channel to the body contact is greatly diminished as the distance between them is reduced, thereby preventing the occurrence of a secondary breakdown. Since the body contact is installed inside the active region without defining in advance a body contact region and making the body contact in the field oxide layer outside the active region, about 20% of the driver transistor structure can be saved to lower the average manufacturing cost of each chip.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based on and claims the benefit of priority from earlier Japanese Patent Application No. 2009-106554 filed Apr. 24, 2009, the description of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates to an engine starting apparatus which is able to engage a pinion of a starter with a freewheeling ring gear in the course of an engine stop process to restart the engine.
2. Related Art
Providing vehicles with an idle stop system is an important approach to reducing CO 2 as one of the countermeasures against global warming. The idle stop system is a system, for example, that stops fuel injection to an engine to automatically stop the engine when the vehicle is stopped at an intersection due to a stop signal or in pause due to traffic jam or the like.
Conventional idle stop systems have been configured to automatically stop an engine after the vehicle has been fully stopped. In order to further improve the effect of reducing CO 2 , it is effective to elongate an engine stop period. Elongating the engine stop period may be specifically achieved by a system that stops an engine before the vehicle speed runs out (i.e. during the deceleration preceding the vehicle stop), converting from the conventional systems that stop the engine after the vehicle has been fully stopped. It is expected that such a system that elongates the engine stop period may significantly improve the effect of reducing CO 2 , compared to the conventionally used idle stop systems.
However, this system raises an issue incurred in a potential restart of an engine after the engine has entered an engine stop process. Specifically, in conventional starters, the pinion of the starter cannot be engaged with the ring gear of the engine unless the engine is fully stopped. This means that, in the case where an engine is restarted using a conventional starter, the engine cannot be restarted from the point when the engine has entered the engine stop process up to the point when the engine is completely stopped. There may be a situation, for example, that the traffic light at an intersection is red and the vehicle is decelerated accordingly followed by the output of a stop command to allow the engine to enter the engine stop process, and that, then, the traffic light quickly turns green. In such a situation, conventional starters cannot immediately restart the engine, which may cause trouble to the following vehicle and impose a psychological burden on the user. Accordingly, in order to use the idle stop function while the vehicle is decelerating, it is essential to enable restart of the engine when the engine is in the engine stop process.
In order to realize restart during the engine stop process, the pinion of the starter is required to be in engagement with a ring gear in rotation. A technique as a method of realizing such a restart is disclosed in WO2007/101770. Specifically, this patent document discloses a method of restarting an engine using a starting device that includes a first RPM detecting means that detects the number of revolutions of a ring gear, a second RPM detecting means that detects the number of revolutions of the pinion of a starter or the number of revolutions of a motor, and a motor revolution control driver that controls the number of revolutions of the motor. In this starting device, the number of revolutions of the pinion is controlled by the motor revolution control driver based on the number of revolutions detected by the first and second RPM detecting means, for synchronization with the number of revolutions of the ring gear. As a result, the pinion is engaged with the ring gear.
The method disclosed in WO2007/101770 (the method of synchronizing the number of revolutions of a pinion with that of a ring gear to establish engagement between the gears) is an ideal method in the case where gears distanced from each other are brought into engagement with each other. However, this method has a large problem of requiring a motor revolution control driver that controls the number of revolutions of a motor. Generally, an MOS transistor as a control element is used as a motor revolution control driver to perform voltage control (e.g., pulse width control, so-called PWM control). However, starter motors have a low voltage (usually 12 V) in spite of having a large output. Therefore, this necessitates the use of an MOS transistor having a large current capacity exceeding 500 A and thus greatly raises the cost as a result.
In addition, achieving synchronization between the numbers of revolutions of a pinion and a ring gear may require feedback control of the numbers of revolutions. As a result, a long time will be taken for the synchronization. Therefore, in many cases, there is a concern that synchronization is unlikely to be completed during the very short time in which the engine speed is decreasing.
SUMMARY OF THE INVENTION
The present invention has been made in light of the problems set forth above and has as its object to provide an on-vehicle engine starting apparatus which is able to engage a starter's pinion with an engine's ring gear, which is in the state of decreasing revolutions, during the short time of an engine stop process to thereby restart the engine.
In order to achieve the object, an engine starting apparatus is provided which comprises an electric motor which receives current to generate a rotational force, an output shaft that has an outer periphery surface and rotates by the rotational force, a one-way clutch that is helical-spline-fitted to the outer periphery surface of the output shaft, a pinion that receives the rotational force via the one-way clutch, a pinion pushing device that pushes, together with the one-way clutch, the pinion toward a ring gear of an engine, the one-way clutch having an idling torque smaller than a torque of the ring gear that tries to turn the pinion when the pinion is pushed to the ring gear, and a current switching device that turns on/off the current supplied to the motor. The apparatus further comprises a revolution speed detecting device that detects a revolution speed of the ring gear, and a control device. The control device enables the pinion pushing device to operate when the revolution speed of the ring gear detected by the revolution speed detecting device is larger than a revolution speed of the pinion acquired from a revolution speed of the motor and a relative revolution speed between the revolution speed of the ring gear and the revolution speed of the pinion is a desired value. This control device is able to control the operations of the pinion pushing device and current switching device independently from each other.
In the case where engine restart is requested while the number of revolutions of the ring gear is decreasing in an engine stop process, the engine starting apparatus of the present invention actuates the pinion pushing device when the ring gear and the pinion rotate at predetermined relative numbers of revolutions (the number of revolutions of the ring gear>the number of revolutions of the pinion) to thereby allow the pinion to be pushed to the ring gear side integrally with the one-way clutch.
The actuation of the pinion pushing device brings the end face of the pinion into contact with the end face of the ring gear. When the pinion is pressed against the ring gear being applied with a predetermined load, the number of revolutions of the pinion instantaneously synchronizes with that of the ring gear with the idling of the one-way clutch. This is because the rotational torque of the one-way clutch in an idling state is set smaller than the rotational torque with which the ring gear attempts to rotate the pinion.
From the instance of the synchronization as well, the revolutions of the ring gear still continue decreasing. In this case, however, the pinion will not decrease revolutions synchronized with the revolutions of the ring gear because the one-way clutch is on the connecting side (torque transmitting side). Accordingly, the ring gear will separate from the pinion in the direction opposite to the direction of revolutions, whereby engagement is established between the pinion and the ring gear.
It should be appreciated that the engine speed does not have to be directly detected, but a crank angle sensor or the like may be used.
It is preferred that, in the foregoing configuration, the output shaft provides an axial direction which is along a longitudinal direction of the output shaft, the ring gear has a first periphery surface on which a plurality of teeth are formed, the teeth of the ring gear having a first axial end face facing the pinion and being directed in the axial direction, the pinion has a second periphery surface on which a plurality of teeth are formed, the teeth of the pinion having a second axial end face facing the ring gear and being directed in the axial direction, and recesses are formed on at least one of the first axial end face and the second axial end face and formed in a direction crossing a rotational direction of the ring gear and the pinion.
With this configuration, the pinion is pushed with the actuation of the pinion pushing device. Then, when the end face of the pinion comes into contact with the end face of the ring gear, the recess formed in the pinion end face, for example, will be caught by the teeth of the ring gear. In this way, the revolutions of the pinion can instantaneously follow (synchronize with) those of the ring gear, thereby promptly establishing engagement.
It is also preferred that frictional coefficient increasing means is formed on at least one of the first axial end face and the second axial end face to increase a frictional force thereon.
With this configuration, the pinion is pushed with the actuation of the pinion pushing device. Then, when the end face of the pinion comes into contact with the end face of the ring gear, frictional force between the both end faces will be increased by the frictional coefficient increasing means. In this way, the revolutions of the pinion can instantaneously follow (synchronize with) those of the ring gear, thereby promptly establishing engagement.
Preferably, the recesses are chamfered portions formed at least one of the ring gear and the pinion, the chamfered portions being at least one of i) chamfered portions crossing both the first periphery surface and the first axial end face and ii) chamfered portions crossing both the second periphery surface and the second axial end face.
With this configuration, it is highly probable that the teeth of the pinion and the teeth of the ring gear are caught with each other after in the axial direction after the pinion has come into contact with the ring gear. Thus, reliability in the synchronization of the revolutions between the pinion and the ring gear can be enhanced. In a vehicle having an idle stop function, it is required to consider the case where the engine may be started without using the idle stop function, i.e. started in a conventional manner, for a certain number of times. In this regard, formation of the chamfered portions can ensure the engagement performances based on both of the startup using the idle stop function and the startup in the conventional manner.
Still preferably, the frictional coefficient increasing means is composed of a plurality of grooves. It is preferred that each of the grooves has a depth which is smaller than a module of the pinion and the ring gear. For example, the depth is smaller than 1/n of the module (n is a positive integer of 9 or less). The module is a size (i.e., height) of each tooth of each of the pinion and ring gear.
With this configuration, the frictional coefficient increasing means can be easily formed using a means, such as a knurling tool, which can facilitate processing.
It is also preferred that the motor is a brush type of DC motor having an armature, a rectifier arranged at the armature, a brush made in contact with a surface of the rectifier, and a spring pushing the brush to the surface of the rectifier, wherein the armature has a torque larger than the idling torque of the one-way clutch.
With the actuation of the pinion pushing device, the pinion is pressed by the ring gear and thus the revolutions of the pinion will follow and synchronize with the revolutions of the ring gear. After the synchronization as well, the ring gear still continues decreasing the number of revolutions. Thus, the torque of the ring gear works on the pinion such that the revolutions of the pinion are decreased. In this regard, since the one-way clutch structured integrally with the pinion is on the connecting side (torque transmitting side), the torque that works on the pinion such that the revolutions of the pinion are decreased will be transmitted to the motor side.
Meanwhile, in the motor of the present invention, a braking force works on the revolutions of the armature when the brush is pressed against the surface of the rectifier by the brush spring. Accordingly, the armature is unlikely to be rotated from the ring gear side. As a result, the pinion will not decrease its revolution speed synchronizing with the decreasing revolutions of the ring gear. This will permit easy deviation between the teeth of the pinion and the teeth of the ring gear. Thus, the time required for achieving engagement between the pinion and the ring gear can be shortened.
Preferably, the engine starting apparatus further comprises a reduction device which reduces a rotational speed of the motor and transmits the reduced rotational speed of the motor to the output shaft.
The torque of the ring gear, which works on the pinion such that the revolutions of the pinion are decreased, may be transmitted to the motor side. In such a case, an arrangement of the reduction gear between the motor and the output shaft may allow the armature to be more unlikely to be rotated from the ring gear side. Thus, it is ensured that the teeth of the pinion and the teeth of the ring gear are easily deviated (separated), whereby the time taken for completing engagement between the pinion and the ring gear is further shortened.
Preferably, the control device includes a delay device that allows the current switching device to start to operate when a predetermined period of time has passed since the start of a pushing operation of the pinion.
According to the present invention, the pinion can be fully engaged with the ring gear and then, in this fully engaged state, current is passed to the motor to start the engine. Thus, the pinion and the ring gear can be prevented from being damaged due to potential incomplete engagement therebetween when the revolutions of the ring gear are decreasing in the engine stop process. As a result, the life of each of the gears can be improved in a vehicle having an idle stop function, in which the starter is actuated for a number of times.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a general view, with partly cut, illustrating a starter incorporated in an engine starting apparatus according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view illustrating a pinion-pushing solenoid and a motor electrification switch of the starter;
FIG. 3 is an electric circuit diagram illustrating the engine starting apparatus of the starter;
FIGS. 4A to 4D are explanatory views illustrating an operation in a first situation, in which a pinion engages with a ring gear which is decreasing revolutions in an engine stop process;
FIGS. 5A to 5D are explanatory views illustrating an operation in a second situation, in which a pinion engages with a ring gear which is decreasing revolutions in an engine stop process;
FIG. 6 is a graph illustrating engine speed in an engine stop process with time being indicated on the horizontal axis;
FIG. 7 is a diagram illustrating the ring gear and the pinion as viewed from the axial direction;
FIG. 8 is a diagram illustrating an example of a frictional coefficient increasing means formed in a pinion end face; and
FIG. 9 is a schematic diagram illustrating the configuration of a motor with a brush.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the accompanying drawings, hereinafter will be described embodiments of an engine starting apparatus according to the present invention.
Referring to FIGS. 1 to 9 , an embodiment of the engine starting apparatus will now be described.
The engine starting apparatus is used for an idle stop system that automatically controls stop and restart of an on-vehicle engine. The engine starting apparatus includes a starter 1 (shown in FIG. 1 ), an ECU (electronic control unit) 2 (shown in FIG. 3 ), and an RPM detector 4 (shown in FIG. 3 ). The starter 1 starts an engine (i.e., internal combustion engine) mounted on a vehicle. The ECU 2 controls the operation of the starter 1 . The RPM detector 4 detects a signal indicative of the number of revolutions of a ring gear 3 attached to a crank shaft of the engine and outputs the detected signal to the ECU 2 .
As shown in FIG. 1 , the starter 1 includes an electric motor 5 , an output shaft 6 , a pinion movable body (described later), a shift lever 7 , a pinion-pushing solenoid 8 , a battery 9 , and a motor electrification switch 10 . In the present embodiment, directions can be defined such that longitudinal directions of the output shaft 6 are axial directions AX, radially extending directions from the output shaft 6 along a plane perpendicular to the axial directions are radial directions RA, and directions circulating around the axial directions along the plane perpendicular to the axial directions are circumferential directions CR.
The motor 5 generates torque in response to current supply thereto. The output shaft 6 rotates being transmitted with the torque generated by the motor 5 . The pinion movable body is provided such that it is axially movable on the outer periphery of the output shaft 6 . The pinion-pushing solenoid 8 has a function of pushing the pinion movable body in the direction opposite to the motor (leftward in FIG. 1 ) via the shift lever 7 . The motor electrification switch 10 opens/closes a motor contact which is provided at a motor circuit to pass current from the battery 9 (see FIG. 3 ) to the motor 5 .
The motor 5 is an electric dc motor with a brush, including a field magnet 11 , armature 14 and a brush 16 . The field magnet 11 is configured by a plurality of permanent magnets. The armature 14 includes an armature shaft 12 with its one end being provided with a rectifier 13 . The brush 16 is arranged being in contact with an outer peripheral surface of the rectifier 13 (hereinafter referred to as a “rectifier surface”) and pressed against the rectifier surface by a brush spring 15 (see FIG. 9 ). The field magnet 11 of the motor 5 , which is made up of the permanent magnets, may be replaced by a field electromagnet made up of a field coil.
The output shaft 6 is arranged being aligned with the armature shaft 12 via a reduction gear 17 . Thus, the revolutions of the motor 5 are transmitted being reduced by the reduction gear 17 .
The reduction gear 17 is a known planetary reduction gear, for example, in which a planetary carrier 17 b that picks up the orbital motion of a planetary gear 17 a is provided being integrated with the output shaft 6 .
The pinion movable body is configured by a clutch 18 and a pinion 19 .
The clutch 18 includes a spline sleeve 18 a , an outer 18 b , an inner 18 c , a roller 18 d and a roller spring (not shown). The spline sleeve 18 a is helical-spline-fitted to the outer periphery of the output shaft 6 . The outer 18 b is provided being integrated with the spline sleeve 18 a . The inner 18 c is relatively rotatably arranged at the inner periphery of the outer 18 b . The roller 18 d is located between the outer 18 b and the inner 18 c to connect/disconnect torque therebetween. The roller spring has a role of biasing the roller 18 d . The clutch 18 is provided as a one-way clutch that unidirectionally transmits torque from the outer 18 b to the inner 18 c via the roller 18 d.
The pinion 19 is integrated with the inner 18 c of the clutch 18 and relatively rotatably supported by the outer periphery of the output shaft 6 via bearings 20 .
The pinion-pushing solenoid 8 and the motor electrification switch 10 have a solenoid coil 21 and a switch coil 22 , respectively, each of which forms an electromagnet when current is passed. A fixed core 23 is arranged between the solenoid coil 21 and the switch coil 22 so as to be commonly used by these coils. The outer periphery of the pinion-pushing solenoid 8 is covered with a solenoid yoke 24 , while the outer periphery of the motor electrification switch 10 is covered with a switch yoke 25 . The solenoid yoke 24 and the switch yoke 25 are integrally and continuously formed in the axial directions AX to provide a single overall yoke. In other words, as shown in FIG. 1 , the solenoid 8 and the switch 10 are integrally configured in series in the axial directions AX, disposed being parallel to the motor 5 , and fixed to a starter housing 26 .
FIG. 2 is a cross-sectional view illustrating the pinion-pushing solenoid 8 and the motor electrification switch 10 of the starter 1 . As shown in FIG. 2 , the overall yoke has a bottomed cylindrical shape with one axial end (first end E 1 ) (left side in FIG. 2 ) being provided with an annular bottom and the other axial end (second end E 2 ) being opened. The outer diameter of the overall yoke is made even from the first end E 1 to the second end E 2 . However, the inner diameter of the switch yoke 25 is ensured to be larger than that of the solenoid yoke 24 . Accordingly, the thickness of the switch yoke 25 is smaller than that of the solenoid yoke 24 . In other words, the inner peripheral surface of the overall yoke has a step between the solenoid yoke 24 and the switch yoke 25 .
The fixed core 23 is inserted from an open end that is the second end E 2 of the overall yoke (open end of the switch yoke 25 ) into the inside of the switch yoke 25 . The inserted fixed core 23 has a radially outer end face on the first end E 1 side. This radially outer end face is brought into contact with the step provided at the inner peripheral surface of the overall yoke, between the solenoid yoke 24 and the switch yoke 25 , to determine the axial position of the fixed core 23 .
Referring to FIGS. 2 and 3 , hereinafter is described the configurations of the pinion-pushing solenoid 8 and the motor electrification switch 10 , except for the overall yoke (the solenoid yoke 24 and the switch yoke 25 ) and the fixed core 23 .
The pinion-pushing solenoid 8 includes the solenoid coil 21 , a plunger 27 and a joint 28 . The solenoid coil 21 is arranged along the inner periphery of the solenoid yoke 24 that forms a part of the overall yoke on the first end E 1 side. The plunger 27 is disposed being opposed to one radially inner attractive surface S 1 of the fixed core 23 and is permitted to be axially movable along the inner periphery of the solenoid coil 21 . The joint 28 transmits the movement of the plunger 27 to the shift lever 7 .
FIG. 3 is an electric circuit diagram illustrating the engine starting apparatus of the starter 1 . As shown in FIG. 3 , the solenoid coil 21 has an end connected to a connector terminal 29 and the other end grounded being fixed to a surface of the fixed core 23 , for example, by welding or the like. An electrical wiring connected to a starter relay 30 is connected to the connector terminal 29 .
The starter relay 30 is subjected to on/off control of the ECU 2 . When the starter relay 30 is controlled and turned on, current is passed from the battery 9 to the solenoid coil 21 via the starter relay 30 .
When the fixed core 23 is magnetized with the supply of current to the solenoid coil 21 , the plunger 27 is attracted to the attractive surface S 1 of the fixed core 23 against the reaction force of a return spring 31 disposed between the fixed core 23 and the plunger 27 . Then, when the current supply to the solenoid coil 21 is stopped, the plunger 27 is pushed back by the reaction force of the return spring 31 in the direction opposite to the fixed core 23 (leftward in FIG. 2 ). The plunger 27 has substantially a cylindrical shape with a cylindrical hole being formed at its radially central portion. The cylindrical hole is open at one axial end of the plunger 27 and bottomed at the other end thereof.
The joint 28 having a shape of a rod is inserted into the cylindrical hole of the plunger 27 together with a drive spring (not shown). Thus, the joint 28 has an end portion projected from the cylindrical hole of the plunger 27 . This end portion of the joint 28 is formed with an engagement groove 28 a with which one end portion of the shift lever 7 engages. The other end portion of the joint 28 is provided with a flange portion. The flange portion has an outer diameter that enables the flange portion to be slidably movable along the inner periphery of the cylindrical hole. The flange portion, being loaded by the drive spring, is being pressed against the bottom face of the cylindrical hole.
With the movement of the plunger 27 , an end face 19 a (see FIG. 1 ) of the pinion 19 pushed in the direction opposite to the motor comes into contact with an end face 3 a (see FIG. 1 ) of the ring gear 3 . Then, the drive spring is permitted to bow while the plunger 27 is permitted to move and attracted to the attractive surface S 1 of the fixed core 23 . Thus, the drive spring accumulates reaction force that allows the pinion 19 to engage the ring gear 3 .
The motor electrification switch 10 includes the switch coil 22 , a movable core 32 , a contact cover 33 , two terminal bolts 34 and 35 , a pair of fixed contacts 36 , and a movable contact 37 . The switch coil 22 is arranged along the inner periphery of the switch yoke 25 forming a part of the overall yoke on the second end E 2 side. The movable core 32 faces the other radially inner attractive surface 52 of the fixed core 23 and is permitted to be movable in the axial directions AX of the switch coil 22 . The contact cover 33 , which is made of resin, is assembled, blocking the open end, i.e. the second end E 2 , of the overall yoke (the open end of the switch yoke 25 ). The two terminal bolts 34 and 35 are fixed to the contact cover 33 . The pair of fixed contacts 36 are fixed to the two terminal bolts 34 and 35 . The movable contact 37 electrically connects/disconnects between the pair of fixed contacts 36 .
As shown in FIG. 3 , the switch coil 22 has one end connected to an external terminal 38 , and the other end grounded being fixed, for example, to a surface of the fixed core 23 by welding or the like. The external terminal 38 is provided being projected out of an axial end face of the contact cover 33 , for connection to an electrical wiring connected to the ECU 2 .
The switch coil 22 has a radially outer peripheral side on which an axial magnetic path member 39 is arranged to form a part of a magnetic path. Also the switch coil 22 has an axial side opposite to the fixed core, on which a radial magnetic path member 40 is arranged to form a part of the magnetic path.
The axial magnetic path member 39 has a cylindrical shape and is inserted into the switch yoke 25 along the inner periphery thereof with substantially no gap being provided therebetween. The axial magnetic path member 39 has an axial end face on the first end E 1 side, which axial end face is brought into contact with a radially outer end face of the fixed core 23 to determine the axial position of the member 39 .
The radial magnetic path member 40 is arranged perpendicular to the axis of the switch coil 22 . The radial magnetic path member 40 has a radially outer end face on the first end E 1 side, which surface is brought into contact with an axial end face of the axial magnetic path member 39 to constrain the position of the member 40 with respect to the switch coil 22 . The radial magnetic path member 40 has a round opening at its radial central portion so that the movable core 32 can move therethrough in the axial directions AX.
The fixed core 23 is magnetized upon supply of current to the switch coil 22 . Then, the movable core 32 is attracted to the attractive surface S 2 of the fixed core 23 against the reaction force of the return spring 41 disposed between the fixed core 23 and the movable core 32 . When the current supply to the switch coil 22 is stopped, the movable core 32 is pushed back in the direction opposite to the fixed core 23 (rightward in FIG. 2 ) by the reaction force of the return spring 41 .
The contact cover 33 has a cylindrical leg portion 33 a . The leg portion 33 a is inserted into the switch yoke 25 along the inner periphery thereof, the switch yoke 25 forming a part of the overall yoke on the second end E 2 side. The contact cover 33 is arranged, with the end face of the leg portion 33 a being in contact with a surface of the radial magnetic path member 40 , and caulked and fixed to the open end, i.e. the second end E 2 , of the overall yoke.
The terminal bolt 34 , one of the two terminal bolts, is a B terminal bolt 34 to which a battery cable 42 (see FIG. 3 ) is connected. The terminal bolt 35 , the other of the two terminal bolts, is an M terminal bolt 35 to which a motor lead 43 (see FIGS. 1 and 3 ) is connected. The pair of fixed contacts 36 , which are provided separately from (or may be provided integrally with) the two terminal bolts 34 and 35 , are electrically in contact with the two terminal bolts 34 and 35 inside the contact cover 33 and mechanically fixed to the contact cover 33 .
The movable contact 37 is arranged so that the distance from the movable contact 37 to the movable core is larger than the distance from the pair of fixed contacts 36 to the movable core (rightward in FIG. 2 ). The movable contact 37 is in reception of the load of a contact-pressure spring 45 and pressed against an end face of a resin rod 44 fixed to the movable core 32 . It should be appreciated that the initial load of the return spring 41 is set larger than that of the contact-pressure spring 45 . Therefore, when the switch coil 22 is de-energized, the movable contact 37 is seated on an inner seat 33 b of the contact cover 33 , with the contact-pressure spring 45 being contracted.
The motor contact mentioned above is formed of the pair of fixed contacts 36 and the movable contact 37 . Being biased by the contact-pressure spring 45 , the movable contact 37 comes into contact with the pair of fixed contacts 36 with a predetermined pressing force. Resultantly, current is passed across the pair of fixed contacts 36 via the movable contact 37 to thereby dose the motor contact. When the movable contact 37 is drawn apart from the pair of fixed contacts 36 , the current across the pair of fixed contacts 36 is shut down to thereby open the motor contact.
a) Referring to FIGS. 4A to 4D and FIGS. 6 to 9 , an operation is described taking as an example a first situation in which engine restart is requested while the number of revolutions of the ring gear 3 is decreasing in an engine stop process.
FIG. 4A illustrates a process in which the pinion 19 moves forward to the ring gear 3 which is decreasing the number of revolutions. FIG. 4B illustrates a state where the end face 19 a of the pinion 19 is in contact with the end face 3 a of the ring gear 3 . FIG. 4C illustrates a process in which the positions of the pinion 19 and the ring gear 3 are relatively deviated in the direction of revolutions. FIG. 4D illustrates a state where the pinion 19 is brought into engagement with the ring gear 3 in a decelerating state.
FIG. 6 is a graph illustrating engine speed Neg in the engine stop process with time being indicated on the horizontal axis. In FIG. 6 , “X” indicates a point of generation of an engine stop signal, “Cm” indicates a point when an engine restart request is given by the driver's free will, “Sp” indicates an actuation start point of the pinion-pushing solenoid 8 , “δN” indicates relative numbers of revolutions of the ring gear 3 and the pinion 19 , and “Mp” indicates an actuation start point of the motor electrification switch 10 .
After generation of an engine stop signal at the point X of FIG. 6 , an engine restart request may be given by the driver at the point Cm. Then, the ECU 2 permits the RPM detector 4 to input the number of revolutions of the ring gear 3 at the time the request has been given. If the number of revolutions of the ring gear 3 is lower than a predetermined number of revolutions, the starter relay 30 is controlled and turned on at the point (point Sp of FIG. 6 ) when the relative numbers of revolutions of the ring gear 3 and the pinion 19 have reached δN. At this point, the number of revolutions of the motor 5 is “0” because the motor electrification switch 10 has not been actuated (no current is passed to the switch coil 22 ). Accordingly, the relative numbers of revolutions will be expressed as: δN=the number of revolutions of the ring gear 3 .
When the starter relay 30 is closed, current is supplied from the battery 9 to the solenoid coil 21 of the pinion-pushing solenoid 8 . Then, the plunger 27 is moved, being attracted to the magnetized fixed core 23 . With the movement of the plunger 27 , the pinion movable body (the clutch 18 and the pinion 19 ) is pushed in the direction opposite to the motor via the shift lever 7 . Then, as shown in FIGS. 4A and 4B , the pinion 19 moves forward to the ring gear 3 which is decreasing the number of revolutions. As a result, the end face 19 a of the pinion 19 is pressed against the end face 3 a of the ring gear 3 applied with a predetermined load F 1 . In this case, a rotational torque T 1 with which the ring gear 3 attempts to rotate the pinion 19 can be expressed by the following Formula (1):
T 1= F 1× rp×μ 1 (1)
where μ1 is a frictional coefficient between the end face 19 a of the pinion 19 and the end face 3 a of the ring gear, rp is a pitch circle radius of the pinion 19 (see FIG. 7 ).
In this case, a rotational torque T 2 of the clutch 18 in an idling state may be set smaller than the rotational torque T 1 (T 1 >T 2 ). Thus, the revolutions of the pinion 19 catch up and synchronize with the revolutions of the ring gear 3 . In this regard, at least either the end face 19 a of the pinion 19 or the end face 3 a of the ring gear 3 may be formed with a frictional coefficient increasing means, so that the frictional coefficient may be increased at each of the teeth of either the pinion 19 or the ring gear 3 .
For example, as shown in FIG. 8 , which is an illustration of the end face 19 a of the pinion 19 , a plurality of grooves 19 b may be formed in the end face 19 a . In this case, each of the grooves 19 b may have a depth which is smaller than a module of the pinion and the ring gear. Preferably, the depth is smaller than 1/n of the module (n is a positive integer of 9 or less). The module is defined as a size (i.e., height) of each tooth of each of the pinion and ring gear. Thus, the frictional force between the end face 19 a of the pinion 19 and the end face 3 a of the ring gear 3 will be increased when both of the end faces are brought into contact with each other. Accordingly, the revolutions of the pinion 19 can instantaneously synchronize with the revolutions of the ring gear 3 .
From the point of synchronization as well, the ring gear 3 still continues decreasing revolutions. However, since the clutch 18 is now on the connecting side (torque transmitting side), the rotational torque which is received by the pinion 19 from the ring gear 3 will be a torque T 3 that rotates the armature 14 of the motor 5 . FIG. 9 is a schematic diagram illustrating the configuration of the motor 5 with a brush. As shown in FIG. 9 , in the case where the brush 16 is pressed against the outer periphery of the rectifier 13 having a radius rc with a frictional coefficient μc, the rotational torque T 3 that rotates the armature 14 can be expressed by the following formula (2):
T 3= F 2× rc×μc (2)
In this case, the rotational torque T 3 for rotating the armature 14 may be set larger than the rotational torque T 2 of the clutch 18 in an idling state (T 3 >T 2 ). Thus, the frictional force caused between the end faces of the pinion 19 and the ring gear 3 will be smaller than the rotational torque T 3 that rotates the armature 14 . Therefore, the pinion 19 will not decrease the number of revolutions keeping synchronization with the revolutions of the ring gear 3 . Instead, as shown in FIG. 4C , the ring gear 3 will be deviated with respect to the pinion 19 in the direction opposite to the direction of revolutions (rightward in FIG. 4C ). As a result, as shown in FIG. 4D , each of the teeth of the pinion 19 is pushed between the teeth of the ring gear 3 to thereby achieve engagement between the pinion 19 and the ring gear 3 .
After completion of the engagement between the pinion 19 and the ring gear 3 and then after expiration of a predetermined time (point Mp of FIG. 6 ), the ECU 2 outputs a turn-on signal to the motor electrification switch 10 .
When current is passed through the switch coil 22 of the switch 10 , the movable core 32 is attracted to the fixed core 23 to allow the movable contact 37 to come into contact with the pair of fixed contacts 36 . Then, being biased by the contact-pressure spring 45 , the motor contact is closed. As a result, current is supplied from the battery 9 to the motor 5 to generate torque in the armature 14 . The torque is then transmitted to the output shaft 6 via the reduction gear 17 . Further, the torque of the output shaft 6 is transmitted to the pinion 19 via the clutch 18 . Since the pinion 19 has already been in engagement with the ring gear 3 , the revolutions of the pinion 19 , as they are, are transmitted to the ring gear 3 . In this way, as plotted with the broken line in the graph of FIG. 6 , the engine speed Neg increases, whereby the engine is restarted.
b) Referring to FIGS. 5A to 5D , an operation is described taking as an example a second situation in which engine restart is requested while the number of revolutions of the ring gear 3 is decreasing in an engine stop process.
In the second situation, when the pinion movable body (the clutch 18 and the pinion 19 ) is pushed to the ring gear side with the actuation of the pinion-pushing solenoid 8 , a chamfered portion 19 c formed in each of the teeth of the pinion 19 is caught by a chamfered portion 3 b formed in each of the teeth of the ring gear 3 . The chamfered portion 19 c of the pinion 19 and the chamfered portion 3 b of the ring gear are also examples of the recesses recited in claim 2 of the present invention. As shown in FIG. 5B , the chamfered portion 19 c is formed at a corner of each tooth of the pinion 19 , and the chamfered portion 3 b is formed at a corner of each tooth of the ring gear 3 . These chamfered portions (the recesses of the present invention) may be formed in either one of the pinion 19 and the ring gear 3 .
As shown in FIG. 5B , in the second situation, when each chamfered portion 19 c of the pinion 19 is caught by each chamfered portion 3 b of the ring gear 3 , the revolutions of the pinion 19 instantaneously synchronize with the revolutions of the ring gear 3 . In this regard, similar to the first situation, the rotational torque T 2 of the clutch 18 in an idling state is set smaller than the rotational torque T 1 that rotates the pinion 19 from the ring gear 3 side, while the rotational torque T 3 that rotates the armature 14 is set larger than the rotational torque T 2 of the clutch 18 in an idling state.
Even from the instant when the revolutions of the pinion 19 synchronize with the revolutions of the ring gear 3 , the number of revolutions of the ring gear 3 still continues decreasing. Accordingly, as shown in FIG. 5C , the ring gear 3 will be deviated with respect to the pinion 19 in the direction opposite to the direction of revolutions (rightward in FIG. 5C ). As a result, as shown in FIG. 5D , each of the teeth of the pinion 19 is pushed between the teeth of the ring gear 3 to thereby achieve engagement between the pinion 19 and the ring gear 3 . After completion of the engagement between the pinion 19 and the ring gear 3 and then after expiration of a predetermined time (point Mp of FIG. 6 ), the ECU 2 outputs a turn-on signal to the motor electrification switch 10 . Resultantly, the torque of the motor 5 is transmitted from the pinion 19 to the ring gear 3 , whereby the engine is restarted.
In the engine starting apparatus of the present invention, the pinion-pushing solenoid 8 is actuated to permit the end face 19 a of the pinion 19 to be in contact with the end face 3 a of the ring gear 3 . With this contact, the end face 19 a of the pinion 19 is pressed against the end face 3 a of the ring gear 3 with the predetermined load F 1 . Meanwhile, the rotational torque T 2 of the clutch 18 in an idling state is set smaller than the rotational torque T 1 with which the ring gear 3 in a decelerating state attempts to rotate the pinion 19 . Therefore, the revolutions of the pinion 19 can instantaneously synchronize with the revolutions of the ring gear 3 . As a result, engagement can be promptly established between the ring gear 3 and the pinion 19 .
According to the configuration and scheme described above, the expensive motor revolution control driver disclosed in WO2007/101770 will not be needed. Accordingly, the engine starting apparatus can be provided at low cost.
In the conventional art disclosed in WO2007/101770, the number of revolutions has to be fed back in permitting the number of revolutions of the pinion 19 to synchronize with that of the ring gear. However, with the engine starting apparatus of the present invention, the revolutions of the pinion 19 can be instantaneously synchronized with the revolutions of the ring gear 3 . Thus, the number of revolutions does not have to be fed back. In addition, when engine restart is requested while the number of revolutions of the ring gear is decreasing, the pinion 19 can be reliably brought into engagement with the ring gear to restart the engine in a short time.
The engine starting apparatus of the present invention is different from the conventional engine starting apparatuses using starters (i.e. the apparatuses in which the end face 19 a of the pinion 19 comes into contact with the end face 3 a of the ring gear 3 being applied with a predetermined load, and then engagement is forcibly established by the torque of the motor 5 ). Specifically, the engine starting apparatus of the present invention utilizes the inert revolutions (i.e., revolutions due to inertia) of the ring gear 3 in the engine stop process, for the engagement of the pinion 19 with the ring gear 3 . Therefore, the load imposed between the teeth of the pinion 19 and the teeth of the ring gear 3 is mitigated, exerting an effect of significantly reducing wearing between the ring gear 3 and the pinion 19 . Thus, the engine starting apparatus of the present invention can be appropriately used for an idle stop system in which the number of actuations of the starter 1 is significantly increased.
In the conventional engine starting apparatuses using starters, the pinion 19 has been brought into engagement with the ring gear that remains stationary, utilizing the torque of the motor 5 . Therefore, if the engagement is unsuccessful once, the relative numbers of revolutions of the pinion 19 and the ring gear 3 will be increased with time, no longer enabling engagement. In this regard, with the engine starting apparatus of the present invention, the revolutions of the pinion 19 are synchronized with those of the ring gear 3 during the process in which the number of revolutions of the ring gear 3 is decreasing, and then engagement is established. Thus, the relative numbers of revolutions of the pinion 19 and the ring gear 3 will be approximated with time, whereby engagement can be easily achieved. Accordingly, compared to the conventional engine starting apparatuses using starters, the engine starting apparatus of the present invention can significantly and highly reliably reduce the probability of failure of engagement between the pinion 19 and the ring gear 3 .
(Modifications)
In the embodiment described above, the starter relay 30 has been turned on to actuate the pinion-pushing solenoid 8 (at this point, current has not yet been supplied to the switch coil 22 of the motor electrification switch 10 ) under the conditions where: the number of revolutions of the ring gear 3 at the point when engine restart is requested is lower than a predetermined number of revolutions; and the relative numbers of revolutions of the ring gear 3 and the pinion 19 have reached δN (the number of revolutions of the ring gear 3 =δN). However, when the number of revolutions of the ring gear 3 at the point when engine restart is requested is higher than the predetermined number of revolutions, the switch 10 may be actuated prior to the actuation of the solenoid 8 , followed by actuating the solenoid 8 at the point when the relative numbers of revolutions of the ring gear 3 and the pinion 10 have reached δN. In this case, it is not required to wait for the number of revolutions of the ring gear 3 to become equal to or lower than the predetermined number of revolutions. Accordingly, engine restart can be carried out in a short time.
In this modification, the relative numbers of revolutions of the ring gear 3 and the pinion 19 can be determined based on the number of revolutions of the ring gear 3 detected by the RPM detector 4 , and a predetermined logic set according to an estimated ascending curve of the number of revolutions of the motor (rising curve of the motor 5 ).
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In an engine starting apparatus, together with a one-way clutch, a pinion is pushed toward a ring gear of an engine mounted in a vehicle. The one-way clutch has an idling torque smaller than a torque of the ring gear that tries to turn the pinion when the pinion is pushed to the ring gear. By a control device, a pinion pushing device is enabled to operate when i) the revolution speed of the ring gear is larger than a revolution speed of the pinion and ii) a relative revolution speed between the revolution speed of the ring gear and the revolution speed of the pinion is a desired value.
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FIELD OF THE INVENTION
This invention relates to apparatus for the wet processing of fabrics in rope form of the type in which the fabric in endless rope form, together with the processing bath, is moved continuously through a closed, pressurised or non-pressurised circuit, along an outgoing path wherein the fabric circulates at a higher rate of travel, mainly contained in a transport conduit, and along a return path where the fabric circulates at a slower rate of travel, contained in a storage chamber portion which, at any one time, contains the major portion of the fabric to be processed, there being hydraulic means for propelling the fabric along the transport conduit and possibly mechanical means, adapted to cooperate with said hydraulic means to remove the fabric from the storage chamber portion and prepare it anew to be propelled by the hydraulic propelling means, this fabric circuit being combined with a circuit for propelling, conditioning and distributing the processing bath.
In known apparatus of the above type, high processing bath ratios have been used up to now, whereas lower bath ratios are presently being used.
One of the solutions adopted to be able to work with low bath/fabric ratios has been to shape the storage chamber portion in such a way that at least in a part thereof the fabric contained therein is submerged in the processing bath and that, in said part, the bath volume is sufficient to propel the fabric rope along by flotation thereof in the bath, as described in U.S. Pat. No. 4,143,527 of the same applicant.
However, currently these low bath/fabric ratios are still high for the present circumstances wherein they have excessive repercussions on the energy cost of heating large masses of water and the purification of the resulting waste liquors.
Two systems have been adopted to provide for the circulation of the fabric rope through the storage chamber portion without the requirement of a sufficient bath volume allowing it to float. One of them comprises disposing the storage chamber portion in an annular form and causing it to rotate around its circumferential axis, said chamber being formed by two independent parts separated by a complete peripheral space and having dimensions so as to allow for the entry of the fabric and to contain it throughout the whole of the storage stage, as described in the German patent application No. P 24 27 415.5 of Alfred Thies junior. Another system consists of disposing the floor of the storage chamber portion containing the fabric rope as a conveyor belt circulating in an opposite direction to that of the transport conduit, whereby the fabric is moved on said conveyor belt without need of any processing bath, as described in German Utility Model specification No. GM 75 19948 of Messrs Espa Edelstahl-Apparatebau, GmbH.
The object of the invention is to provide for the movement of the fabric rope in the storage chamber portion by way of a mechanical arrangement differing from those described above and independent of the level of processing bath in said storage chamber portion.
SUMMARY OF THE INVENTION
In accordance with the foregoing, the invention is characterised in that the storage chamber portion is constituted by an open ended tubular body capable of rotation about a longitudinal axis, said ends being arranged respectively with the leading end and the trailing end of the higher speed portion of the fabric rope circuit, said rotary circular body being provided with means adapted for causing the rotary movement of said tubular body to propel the fabric rope situated therein in the longitudinal direction thereof.
BRIEF DESCRIPTION OF THE DRAWING
To facilitate the understanding of the foregoing, reference is made hereinafter to the accompanying drawing, which is to be deemed as devoid of any limitative effect. In the drawing:
FIG. 1 is a diagrammatic longitudinal section view of a fabric rope wet processing apparatus according to the invention of the pressurisable type.
FIG. 2 is a diagrammatic longitudinal section view of a modified embodiment of the apparatus according to the invention, also of the pressurisable type.
FIG. 3 is a diagrammatic longitudinal section view of a further modified embodiment of the apparatus according to the invention.
FIG. 4 is a partial diametral section view of a rotary tubular section moulded from plastics material and which may be self-supporting or be supplemented by a metal bearing structure.
FIG. 5 is a view of a rotary tubular portion formed by the association of two independent tubular portion.
FIG. 6 is a partial diametral section view of a rotary tubular portion having a perforated wall, in which the lefthand portion does not have helical ribs, whereas the righthand portion does have such helical ribs.
FIG. 7 is a partial diametral section view of a rotary tubular portion having a lattice wall, in which the lefthand portion does not have helical ribs, whereas the righthand portion does have such helical ribs.
FIG. 8 is a partial diametral section view of a rotary tubular portion having a wall formed by cross-braced helical rib to constitute a self-supporting body.
FIG. 9 is a partial diametral section view of a rotary tubular portion, in which the pitch of the spiral formed by the helical ribs is not constant.
FIG. 10 is a partial diametral section view of a rotary tubular portion in which the helical ribs form two spirals.
FIG. 11 is a section view along the lines XI--XI of FIG. 1; and
FIG. 12 is a partial section view along the lines XII--XII of FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of FIG. 1 comprises a conventional closed vessel 1, adapted for working under pressure or in open bath, comprising a centre tubular portion 2, forming the storage chamber for the fabric rope 3. Attached to said centre portion 2 there are a terminal tapered portion 4 through which the fabric 3 is delivered to the portion 2 and an exit elbow portion 5 curved upwardly and attached in turn to an upper portion 6 provided with a loading and unloading cover 7. The fabric rope 3 moves relatively slowly through the storage chamber.
The upper portion 6 and the terminal tapered portion 4 are in communication with one another by way of a transport conduit 8 through which the fabric rope is propelled relatively rapidly. The conduit 8 extends below the storage chamber and within the upper portion 6 it forms a mouth 9 forming, together with a chamber 10, a hydraulic arrangement for propelling the fabric by overflow.
On the other hand, the said transport conduit 8 is provided, at a point outside the upper portion 6, with an annular jet chamber 11 which constitutes a hydraulic device for propelling the fabric by jetting. Both chambers 10 and 11 are in communication, through respective control valves 12 and 13, with the processing bath circuit which comprises, also, a heat exchanger 14, pump 15 and conduit 16 for withdrawing the bath from inside the closed vessel.
Moreover, the apparatus is provided with a winch 17, which may be fitted with a motor, to assist in feeding the fabric rope 3 from the storage chamber to the transport conduit 8.
The apparatus of FIG. 2 also comprises conventially a closed vessel 20, provided with a cover 21 and adapted for pressurised operation. In the interior thereof there is a transport conduit 22 for the fabric 23, provided with a hydraulic device 24 for propelling the fabric by jetting, a storage chamber 25 for the fabric 23, a baffle 26 and a winch 27, which may be equipped with a motor. The hydraulic jet device 24 is in communication through a control valve 28 with a heat exchanger 29, pump 30 and a conduit 31 for withdrawing the bath from inside the closed vessel 20.
Both of the above described apparatus are provided with a rotary tubular body 40, within the fabric rope storage chamber portion thereof, which actually constitutes the said storage chamber portion which, in the prior art, consisted of the centre tubular body 2 itself or of a trough or the like situated in the bottom of the closed vessel 20.
The rotary tubular body 40 is provided with means for propelling the fabric rope 3, 23 contained in said rotary tubular body 40, in the longitudinal direction of said rotary tubular body 40, as the latter rotates around its longitudinal axis, without requiring that the processing bath level be sufficiently high to cause flotation of the fabric and to allow it to be pulled along from one end by the combined action of the winch 17, 27 and the hydraulic propelling means 10, 11, 24.
The said fabric rope propelling means through the storage chamber portion comprise the disposal of helical ribs 42 or 42A on the inner surface of the rotary tubular body 40 so that the rotation around the longitudinal axis 41 thereof causes the fabric rope contained in the transport conduit 8, 22 to move along.
These means may also be formed by a spatial disposition of the rotary tubular body 40, consisting of locating its longitudinal axis on an inclined plane, as in the apparatus shown in FIG. 3, in which the longitudinal axis 41A forms an angle a with the horizon. This apparatus is similar to that of FIG. 2, the most outstanding differences being the inclined position of the rotary tubular body 40A and a lower wall 43 for reducing the processing bath chamber, with a view to retaining a minimum level sufficient for connecting the suction conduit 31 of the pump 30. This inclination of the axis is compatible with the presence of the helical ribs 42, 42A.
In the embodiments of the invention, the horizontal rotary tubular body 40 and inclined rotary tubular body 40A are provided with means for enabling their rotation around their longitudinal axes 41 and 41A, there being shown in the Figures means consisting of running rings 44 bearing on rollers, it being possible to use any other conventional mechanical means.
The rotary tubular body 40 or 40A may be made from plastics material (FIGS. 4 and 5) or from metal.
Said rotary tubular body 40, 40A may also be constituted by the association of two or more tubular bodies 40a and 40b, as shown in FIG. 5, in the case of a rotary tubular body having a horizontal axis 41, it also being possible to apply this arrangement to the inclined axis embodiment. Said bodies 40a and 40b may be arranged for independent rotation.
The rotary tubular body 40, 40a may have solid surface walls (FIGS. 1, 2, 4, 9, 10, 11 and 12) or may have a perforated wall 45 (FIG. 6). The rotary tubular body may also be enclosed with a lattice formed by stringers 47 and hoops 48 (FIG. 7). Likewise, the said wall may be constituted by a strong section 49 disposed helically and longitudinally braced with stringers 50 to form a self-supporting body (FIG. 8).
In the case of a horizontal rotary tubular body 40, there are helical ribs 42 as shown in FIGS. 1 and 2 and at the righthand side of FIGS. 6 and 7, such ribs consisting of separate sections attached to the inner surface of the tubular body (FIGS. 1, 6 and 7) or stampings 42A made in the sheet material of the rotary tubular body 40 (FIG. 2).
When helical ribs 42, 42A are provided, the spiral they form may cover the full length of the tubular body (FIG. 1) or a portion thereof (FIG. 2) at the same time as, in both cases, the pitch between two consecutive loops of the spiral may be constant or variable as seen in FIG. 9, wherein one part has a pitch "p" and the other a pitch "2p" and, in turn, the number of spirals formed by the helical ribs may be more than one, as seen in FIG. 10, in which two spirals 42a and 42b of equal pitch pa and pb are seen.
Finally, in FIGS. 1, 11 and 12 there is shown an embodiment of the rotary drive of the rotary tubular body 40 and 40A, by way of a crown sprocket wheel 51, a roller chain 52 and a sprocket pinion 53 mounted on a shaft 54 driven by a drive unit 55.
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Apparatus for the wet processing of fabric in rope form wherein the storage chamber portion containing the major portion of the fabric to be processed comprises a tubular portion capable of rotation about its longitudinal axis and having means for producing the longitudinal feed of the fabric rope, a low bath ratio between the processing bath and fabric being obtained.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of weather modification. More specifically, the present invention relates to methods for modifying and suppressing the spawning of tropical storms, and modification of the dynamics of hurricanes and diminishing their intensity.
BACKGROUND INFORMATION
[0002] The world's oceans and seas typically have temperature versus depth profiles that can be characterized generally as shown in FIG. 1 . For example, the upper layer is usually at a uniform temperature as a result of wind and wave mixing. The temperature is determined by the intensity and duration of solar radiation, as well as the efficiency of wind driven surface mixing. Although the depth of the upper layer varies depending on the season, a nominal depth for the upper layer is approximately 50 meters. Deeper water is usually significantly colder, approximately 10° C. colder than the upper layer. The transition between upper and lower layers is referred to as the thermocline. The thermocline has a nominal thickness of approximately 20 meters. Although these dimensions vary depending on the time of year and geographic location, the numbers presented are for illustrative purposes.
[0003] It is well-known that hurricanes which travel to North America originate from tropical storms that are spawned in the tropical waters of the eastern Atlantic, near the Western coast of Africa. It also is understood that the originating tropical storms, and the hurricanes which develop from them, are fueled by the energy content of the warm, upper layers of the ocean. There is a strong correlation between the frequency and strength of such storms and the energy content of those upper, heated layers of the ocean.
[0004] Accordingly, decreasing the temperature of this upper layer of ocean water could diminish the occurrence and intensity of tropical storms. In addition, decreasing the temperature of the upper, warmer layer of ocean in the path of a hurricane could (1) diminish, or quench, the strength of a hurricane; or (2) alter the course of a hurricane.
[0005] U.S. Pat No. 4,470,544 and U.S. Pat. No. 5,492,274 disclose methods for slowly mixing layers of sea water to achieve greater rainfall in the Mediterranean basin. Slowly mixing layers of a large body of water increases the potential solar energy captured by the water, and increases the intensity of storms fueled by the energy content of the water. To diminish the strength of a hurricane or alter its course, however, rapid mixing of ocean layers is required.
SUMMARY OF THE INVENTION
[0006] The present invention provides an exemplary method for affecting the strength and/or direction of a storm, such as a hurricane, by cooling the upper, warmer layer of a large body of water and mixing it with the significantly cooler water that exists below the relatively warmer upper layer. The displacement and resulting mixing is achieved, for example, by submarines or other suitable vessels operating in the thermocline, the transition layer between the upper warm layer and the deeper cold layer of ocean.
[0007] In one exemplary embodiment of the present invention, relatively large areas of East Atlantic tropical waters are cooled to reduce the intensity and/or frequency of tropical storms.
[0008] In a second exemplary embodiment of the present invention, sections of upper ocean layers in the vicinity of a hurricane, or in the vicinity of the expected path of a hurricane, are rapidly cooled to alter the course of a hurricane, slow the speed of a hurricane, or reduce the intensity of a hurricane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a diagram depicting the water depth of the thermocline for various months of the year.
[0010] FIG. 2 is a diagram depicting the warmer, upper layer of a large body of water and the cooler, lower layer of the large body of water.
[0011] FIG. 3 is a diagram of a submarine with a bluff-shaped obstacle mounted at the bow of the submarine according to an exemplary embodiment of the present invention.
[0012] FIG. 4 is a diagram of a submarine with a bluff-shaped obstacle mounted on the submarine at a location that is downstream from the bow of the submarine according to an exemplary embodiment of the present invention.
[0013] FIG. 5 is a diagram of a submarine with bluff-shaped obstacles towed behind the submarine according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0014] A simple calculation suffices for determining the work required to cool the upper layer of a section of a large body of water by mixing it with water from a lower layer. For illustrative purposes, the large body of water is assumed to be the Atlantic Ocean. FIG. 2 depicts the approximate heights, densities and temperatures of two layers of the ocean as (H u ,ρ u ,T u ) and (H l ,ρ l ,T l ) respectively for the upper and lower layers. If a 1 m 2 column height H l is raised to the average height of H u /2 the work, W, required to displace such a column of ocean water can be estimated by the equation
W = g 2 ( ρ l - ρ u ) H l H u
where g represents acceleration due to gravity (approximately 10 m/s 2 ). The resulting 1 m 2 column of height H l +H u will be at the approximate temperature
T _ = H u T u + H l T l H u + H l
[0015] The heavy, colder, lower layer of the ocean is approximately 0.2% heavier than the warm, upper layer of the ocean as explained in the Handbook of Chemistry and Physics, 1973 at D221, which is hereby incorporated by reference. As is known in the art, the nominal density of seawater in the upper layer is approximately 1025 kg/m 3 and the nominal density of seawater in the colder, lower layer is approximately 1027 kg/m 3 . Therefore, for
H u =50 m, H l =20 m( g= 10 m/s 2 , ρ l −ρ u =2 kg/m 3 ),
the work required to displace the colder water into the upper warmer water is approximately W=10 4 joules. Under summer conditions, the water temperature of the new upper layer will be about 5° C. colder as a result of mixing the lower layer of colder water into the upper layer. For a nominal surface area of ocean of 10 10 m 2 (roughly 3600 sq. miles), the work needed to mix the upper and lower layers in this fashion would be approximately W =10 14 joules.
[0016] Mixing Layers of Large Bodies of Water
[0017] Submarines offer a highly efficient means of ocean travel. Unlike surface ships, submarines create virtually no wave drag. Although performance information on nuclear submarines remains largely confidential, typical cruise speeds are reasonably assumed to be in excess of 30 knots, or approximately 15 m/sec. Nuclear submarines are highly streamlined, but only limited data is available in the literature concerning their performance and drag characteristics. See Polmar & Moore, Cold War Submarines (2003). However, a consensus value for the coefficient of drag of a nuclear submarine is c f 0 ≈0.4 as understood by those skilled in the art.
[0018] Nuclear submarines can remain submerged for very long periods of time. Also, underwater travel is relatively unaffected by surface conditions. Hurricanes do not significantly affect submarine dynamics at a depth of approximately 50 m.
[0019] On this basis, the power output of a submarine with an effective cross-sectional area A cruising at speed U 0 is
P = 1 2 ρ U 0 3 c f 0 A ,
where c f 0 is the drag coefficient. For U 0 =30 knots (15 m/sec) and A=100 m 2
P≈5×10 7 joules/sec (50 MW)
[0020] The streamlined features of a submarine makes it less than optimal for rapidly mixing layers of the ocean. In order to achieve rapid mixing of ocean layers, turbulent flow with eddy generation in the 5-10 m diameter range is desirable. As shown in FIGS. 3 and 4 , such eddy generation can be achieved, for example, by (1) mounting on the bow of the submarine a bluff-shaped obstacle capable of generating the necessary eddy turbulence, such as a 10 m×10 m flat plate (normal to the direction of travel); or (2) mounting at some other location downstream of the bow of the submarine a bluff-shaped obstacle capable of generating the necessary eddy turbulence.
[0021] Turbulence devices such as bluff shaped objects may be mounted on the submarine so that they lie flat along the outer surface of the submarine, or so that they are located within the hull of the submarine, when turbulence generation is not desired (e.g. when the submarine is traveling to the section of the large body of water to be cooled). When turbulent flow is desired, the bluff shaped objects could fold away from the surface of the submarine or extend outward from the surface of the submarine to generate the necessary eddy turbulence.
[0022] As shown in FIG. 5 , eddy generation also can be achieved, for example, by towing behind the submarine one or more bluff-shaped obstacles capable of generating the necessary eddy turbulence. Towing the bluff-shaped obstacles would also add more fluctuations. The towed obstacles may be attached to the submarines by cables, ropes, rods, chains, or similar means.
[0023] A nominal drag coefficient for a flat plate moving normal to itself is 1.6. If we denote the coefficient of drag of the above modified submarine by c f b , and assume that the cross-sectional area of the modified submarine is equal to the original cross-sectional area of the submarine, it follows that under constant power, the speed of the modified submarine, U b , is reduced by a factor of
( U b U 0 ) = ( c f 0 c f b ) 1 / 3 ( ≈ 0.63 )
[0024] Given a speed of U 0 =30 knots (kts) for an unmodified submarine, a modified submarine would travel at an approximate speed of U b ≈18 kts, a speed which easily outruns typical hurricanes.
[0025] Diminishing the Intensity and Frequency of Tropical Storms
[0026] On the basis of the above estimates, a 100 km×100 km section of ocean surface can be cooled 5° C. by one submarine in approximately 24 days. For example,
W _ P = 10 14 5 × 10 7 sec ≈ 24 days
A more substantial section of ocean surface, say 300 km×300 km (15,000 sq. miles), could be cooled by, for example, nine submarines in the same 24 day period. To minimize the number and strength of hurricanes in a given year, a desired number of submarines could cool the section of ocean a few weeks before the hurricane season.
[0027] Particular deployment of submarines can be optimized according to simulation models. Several factors support the proposition that the above mixing times can be achieved by, for example, nine submarines traveling at the depth of the thermocline. For example, the Reynolds number for typical submarine movement is 0(10 8 ), and the diameter of the turbulent wake is known to expand proportionally to x 1/3 to x 1/2 where x marks the distance traveled, as explained in Carmody, J. Basic Engng. Trans. A.S.M.E. (1964), Chevray, The turbulent wake of a body of revolution, J. Basic Engineering, Vol. 90 (1968), and Jiménez, et al., Preliminary velocity measurements in the wake of a submarine model, 4th International Symposium of Particle Image Velocimetry, Sep. 17-19, 2001, which are hereby incorporated by reference. After a suitable initial time, measured in minutes, to allow the submarines to develop sufficient eddy generation, 9 submarines traveling in parallel, roughly 500 meters apart from each other, could well mix 2,500 km 2 in roughly 18 hours.
[0028] Two additional effects enhance the turbulence intensity and aid in retarding natural turbulence decay. First, vertical stratification enhances the horizontal spread of eddies. This effect, sometimes referred to as “wake collapse,” facilitates the lateral spread of turbulence. Second, the ocean surface itself acts as a reflecting surface for turbulent eddy spread, hence also enhancing horizontal spread of the turbulent eddies.
[0029] Alteration of Hurricane Paths and Intensity.
[0030] Current modeling and simulation provide reasonable forecasts for hurricane paths for up to 5 days. The core region of a hurricane, which accounts for energy uptake of the upper warmer layer of ocean, generally spans an area approximately 50 km×50 km. Such a region can be cooled 5° C. by 9 submarines in approximately 18 hours.
[0031] The above determined 18 kts modified submarine speed permits the submarines to outrun the hurricane. An interactive strategy of ocean cooling and renewed path forecasting provides a dynamic program for quenching and/or redirecting hurricanes. Under natural conditions, the path of a hurricane is determined by available warm surface waters to fuel its movement and intensity. Therefore, selective cooling of the upper layer of ocean water can be used to redirect the path to areas less vulnerable than populated cities, such as the open ocean.
[0032] The possibility also exists for cooling the upper layers of the ocean surrounding the core region of a hurricane, thereby stalling the hurricane at sea. By continuing to encircle the hurricane, the intensity of the hurricane may be reduced and the hurricane may be completely quenched.
[0033] Although certain preferred exemplary embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.
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Modification of tropical storms or hurricanes by mixing the upper layer of a section of a body of water with water from a lower section of the body of water. Rapidly mixing the warmer upper layer with the cooler lower layer cools the surface of the water, thereby reducing the amount of heat energy available to fuel the intensity and movement of storms. By cooling selected sections of water, the frequency, intensity or direction of storms may be altered. In one embodiment of the invention, a bluff shaped object is attached to a submarine to facilitate rapid mixing of the upper and lower layers of the body of water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the production by transmetalation of organoalkali metals.
2. Prior Art
Organoalkali metal compounds are well known for their excellent performance as catalysts for the polymerization of olefins and diolefins and as intermediate for the synthesis of various organometallic compounds.
The principles of transmetalation contemplated hereunder may be represented by the formula:
R.sup.⊕ M.sup.⊖ + R'H⃡R'.sup.⊕ M.sup.⊖ + RH
where M is an alkali metal and R and R' are the respective hydrocarbon residues.
The above reaction is analogous to an acid-base reaction wherein a salt of a weak acid R.sup.⊕ M.sup.⊖ is reacted with a strong acid R'H to form a salt of a strong acid and a weak acid, respectively. This reaction is utilized for the determination of the order of acidity of hydrocarbon compounds, reference here being made to the review of Avery A. Morton appearing on the Chemical Reviews, 35 (1944), from which it is known that the greater is the disparity in acidity between R'H and RH, the easier is the transmetalation.
However, considerable difficulties have been encountered with transmetalation where the difference in acidity between R'H and RH is relatively small, in which instance extremely severe reaction conditions are required.
SUMMARY OF THE INVENTION
Whereas, it is the primary object of the present invention to provide an improved process for the production of organoalkali metals at increased yield.
It is another related object of the invention to provide an improved process which will enhance transmetalation under relatively mild reaction conditions even where the disparity in acidity between R'H and RH is small.
It has been ascertained in the course of continued research on the reaction of transmetalation that oxygen has a striking effect on the speed of such reaction as hereinafter more fully described.
Briefly stated, the process according to the invention comprises transmetalation between organoalkali metal compounds represented by the general formula:
RM
where R is a hydrocarbon residue having a carbon number of 1 to 20 and a pKa value of RH exceeding 21, and M is an alkali metal selected from the group consisting of sodium, potassium, rubidium and cesium; and hydrocarbon compounds represented by the general formula:
R'H
where R' is an organic residue having a carbon number of 1 to 20 and a pKa value of R'H exceeding 21 but lower than the pKa value of RH, characterized by the addition of oxygen in an amount of 0.01 to 10 mol % based on the organoalkali metal compounds, whereby organoalkali metals of the general formula R'M is produced.
The invention will be described in fuller detail with reference to the following embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The organoalkali metal compounds employed in accordance with the invention are represented by the general formula RM where M is an alkali metal selected from the group of sodium, potassium, rubidium and cesium, and R is a hydrocarbon residue of 1 to 20 carbon atoms such as for example an alkyl group, an aryl group and an alkaryl group and having a pKa value of RH (which is a compound having hydrogen attached to the hydrocarbon residue) exceeding 21. pKa here is obtained from the equation:
pKa = -log[R⊕] × [H⊖]/[RH]
in the dissociation of RH ⃡ R⊕ + H⊖.
The above-defined organoalkali metal compounds are readily available from the reaction of halogenated hydrocarbons with alkali metal compounds, typical examples of such reaction products being butylsodium, amylsodium, phenylsodium, butyllithium, butylpotassium, and diphenylmethylpotassium.
The hydrocarbon compounds according to the invention are represented by the general formula R'H where R' is a hydrocarbon residue having a carbon number of 1 to 20 such as an alkyl group, an aryl group and an alkaryl group, and a pKa value of R'H exceeding 21. Typical examples of such hydrocarbon compounds include toluene, xylenes, cumene, diphenylmethane, triphenylmethane, fluorene and indene.
Needless to say, for the reaction to proceed as desired, the pKa value of the compound RH should be greater than that of the compound R'H.
Reaction temperature varies with the difference in acidity between RH and R'H. With increased acidity difference, the reaction can progress fast enough even at room temperature. Conversely, with reduced acidity difference, the reaction temperature must be raised. This temperature usually is in the range of 0° to 150° C., preferably 20° to 100° C.
There may be used inert solvents in the process of the invention, but no such solvents are required where the starting R'H compounds are liquid at reaction temperature. When inert solvents such as hydrocarbon solvents are to be used, the pKa value of the solvent should be greater than that of RH constituted by the hydrocarbon residues of the organoalkali metals. The starting hydrocarbons and the solvents should be preferably well dried with use of silica alumina or other desiccants usually used for hydrocarbons.
As previously stated, the transmetalation reaction can be effected at increased rate of speed with high yields of the intended organoalkali metals by the addition of oxygen. This oxygen may be absolutely pure, but for the sake of operating safety, it should be preferably in the form of air or a gaseous mixture of pure oxygen and pure nitrogen. The oxygen thus defined may be dissolved in the hydrocarbon or solvent to be assigned to the reaction system. It has been found that only small amounts of oxygen are required to advance the desired transmetalation reaction to completion. Excess oxygen would result in decomposed organoalkali metals or other objectionable side reactions and would further involve the danger of explosion.
It has now been found that the amount of oxygen to be used in the transmetalation process of the invention should be from 0.01 to 10 mol %, preferably from 0.5 to 5 mol %, based on the starting organoalkali metal compounds.
There is no particular limitation imposed on the pressure to be employed in the process of the invention. It may be from 0 to 100 atmospheric pressure, standard pressure or vapor pressure developed in the reaction systems at reaction temperature.
The invention will be further illustrated by way of the following examples.
Inventive Examples 1, 2 and 3, and Comparative Example 1
To nitrogen-purged and dried 500 c.c. autoclave were charged 269 c.c. of dry benzene containing 0.182 mol of phenylsodium, followed by the addition of 0.265 mol toluene and oxygen in the specific amounts listed in the following table. The reaction was effected at 80° C., and there was obtained benzylsodium. In order to examine the reaction speed in each of the Examples, samples were taken 10 minutes after raising the temperature and analyzed to reveal the results tabulated below.
______________________________________ Amount of Air Yield of (O.sub.2 in mol % based Benzylsodium on Phenylsodium) (%)______________________________________ComparativeExample 1 0 13InventiveExample 1 0.2 25InventiveExample 2 0.4 34InventiveExample 3 0.8 42______________________________________
The above data is a clear evidence of the distinct advantages of the present invention that remarkably high yields of benzylsodium are obtainable by transmetalation with the supply of predetermined amounts of oxygen.
Inventive Example 4
To a 500 c.c. autoclave were charged, under nitrogen stream, 105 c.c. sodium dispersion containing 0.4 mol sodium and benzene (dispersant), 0.918 mol toluene and 172 c.c. benzene. With reaction temperature maintained at 25° to 30° C., 0.178 mol monochlorobenzene was added in droplets over about an hour, and for approximately 15 minutes thereafter, the reaction temperature was set at 30° C., followed by the charge into the autoclave of a gas containing pure oxygen and pure nitrogen at a ratio of 1:9. The amount of oxygen added corresponded to 1 mol % of phenylsodium. The temperature was increased up to 70° C. with a lapse of about 3 minutes. The yield of benzylsodium determined 10 minutes after the temperature was raised, was 76%. Whereas, benzylsodium yields were only 32% in a similar reaction but without any oxygen.
Inventive Example 5
The procedure of Example 4 was followed, in which amylsodium was prepared from a sodium dispersion (ethylbenzene dispersant) and amylchloride. In this reaction mixture were present 0.1 mol amylsodium and about 23 mols ethylbenzene. A gas containing air and nitrogen at a ratio of 1:1 was introduced into the reaction mixture while the latter was stirred at room temperature, the amount of oxygen being held at 0.001 mol. Reaction was continued at 90° C. for 3 hours, until there was obtained 68% yield of the following product: ##STR1## This yield was only 21% where no oxygen was used.
Inventive Example 6
0.1 mol amylsodium was prepared from the reaction of a sodium dispersion (n-octane dispersant) and amylchloride. To the resulting amylsodium was added 1 mol diphenylmethane. While the admixture was stirred, there was introduced at room temperature such amounts of air which correspond to 0.0005 mol oxygen. Reaction was continued at 40° C. for 30 minutes, until there was obtained 95% of the following product: ##STR2## This yield was 78% in a similar reaction at 60° C. and for a period of 30 minutes but without the use of oxygen.
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A process of transmetalating organoalkali metals is disclosed, wherein organoalkali metal compounds are reacted with hydrocarbon compounds in the presence of predetermined amounts of oxygen.
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BACKGROUND OF THE INVENTION
This invention relates to a method for controlling the operation of a burner and, more particularly, to controlling the fuel/air ratio of burners used to melt copper to avoid incorporating unwanted oxygen and/or hydrogen into the copper.
The melting of copper is a very important commercial process. As is well-known in the art and as discussed in U.S. Pat. No. 3,199,977 issued to A. J. Phillips et al. on Aug. 10, 1965, the disclosure of which is incorporated by reference, copper cathodes are the predominant form of copper produced industrially and the cathodes are generally flat rectangular shapes about one inch thick by about 25 inches to 40 inches, although larger or smaller sizes may be produced.
Although the cathodically deposited copper is commercially pure except for the usual impurities and unavoidable minor amounts of electrolyte (sulphates) physically present on the surface of the cathodes or occluded therein, the copper cathodes generally are not used per se because of their shape and physical properties, especially the grain structure of the deposited copper. To place them in more useful form, the cathodes must be melted and the molten metal cast into one or more semi-finished forms--for example, cakes, ingots, bars such as wire bars, billets and rods and similar shapes from which finished products are produced, such as for example, sheets, wire, tubes and the many other commercial products fabricated of commercially pure copper. However, it is important that the copper not become contaminated with commercially unacceptable amounts of oxygen and sulphur during the melting since from a commercial standpoint the melted . copper is essentially ruined and must be reprocessed through a series of steps to form a new cathode. This is a costly and time consuming procedure.
It is essential therefore, that the burners used to melt the copper not contaminate the copper with, for example, unwanted oxygen. In general, the fuel/oxygen (air) mixture is proportioned to contain insufficient oxygen to completely burn the fuel and the resulting melting flame is a reducing flame. For most industrial uses, the predetermined reducing conditions should be such that any oxygen incorporated into the copper is less than 0.05% by weight of the copper during the melting. Preferably, the predetermined reducing conditions are such that less than 0.035% and most preferably less than 0.01% by weight of oxygen are incorporated into the molten copper.
The burners described in Phillips et al. supra and U.S. Pat. No. 4,536,152 to Little and Thomas were specially designed to provide a high degree of fuel/air mixing to produce a uniform reducing flame to minimize unburned oxygen and possible copper contamination. The disclosure of U.S. Pat. No. 4,536,152 is hereby incorporated by reference.
While the prior art burners per se are important in the melting of copper, it is also very important to properly control the fuel/air mixture since an excess of fuel or air may produce a flame which will contaminate the copper and it is therefore an object of the present invention to provide a method for effectively melting copper and other metals and materials by controlling the fuel/air ratio of the burners used for the melting operation.
The predominant furnace for melting copper is the vertical shaft furnace using multiple burners as described in the Phillips et al. patent, supra., and the following description will be directed to this furnace for convenience.
SUMMARY OF THE INVENTION
It has now been discovered that fuel and air (oxygen) fed to burners used to melt, for example, cathode copper, may be effectively controlled to provide a fuel/air ratio within desired operating limits to produce, for example, a reducing flame having a hydrogen content of the combusted fuel at about by volume ±0.3% or less of the desired hydrogen value. The hydrogen value is usually maintained at between about 1% -3% by volume depending on the fuel used. Using natural gas the hydrogen content is about 1-2% whereas for propane the hydrogen content is about 0.3-0.9% because of the carbon-hydrogen ratio of the fuel, more CO being formed than H 2 for propane whereas with (natural gas) methane, equal parts of H 2 and CO are formed.
Broadly stated, the procedure for controlling a number of burners, e.g., around the periphery of a shaft furnace, comprises the steps:
(a) predetermining for a particular material (e.g., hydrogen) the set point amount (content) desired for each burner;
(b) sampling one burner's fuel-air mixture for analysis while fuel/air gas mixtures of the other burners are being drawn from each burner into a manifold;
(c) measuring the amount of the material in the sample;
(d) comparing the sampled amount with the predetermined desired amount;
(e) changing, if necessary, the amount of fuel and/or air; and
(f) repeating steps (b)-(e) for the other burners and continuing the steps (b)-(e) during the melting operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of apparatus according to the principles and teachings of the present invention.
FIG. 2 is a diagram of apparatus showing the fuel/air mixture sampling system for a multiple burner shaft furnace.
DETAILED DESCRIPTION OF THE INVENTION
The vertical (shaft) furnace may be any generally vertically disposed furnace of a desired shape or size which will support a column of any desired size and shape of the copper to be melted and allow the column, assisted by gravity, to move downwardly in the furnace as the copper is melted from the column. Thus, for example, the furnace may be generally square, rectangular or preferably circular in shape.
The furnace may be constructed in any desired manner of any desired material. Preferably, the side walls and bottom of the furnace are fabricated into a substantially gas-tight steel shell, as by welding, and the shell lined with an acid, neutral or basic refractory; a high alumina refractory being preferred.
In practicing the invention, the melting stream (flame) may be injected into the furnace as one or as a plurality of streams at one or a plurality of points or zones in the furnace and the uniting of the fuel and oxygen-containing gas may be accomplished in one or a plurality of steps. Also, ignition of the united stream or streams may be initiated at any time after the uniting step or steps and before the united stream or streams contact the copper to be melted. Thus, for example, the melting stream may be united in a single step and then delivered to a plurality of burners and ignited therein prior to injection into the furnace. While such a procedure may be used it is not one of the more preferred procedures because of the possibility of flash-back occurring in the melting stream. Likewise, the melting stream may be united in a single step and then burned and the hot products of combustion may then be delivered to a plurality of inlet ports in the furnace. While such a procedure may be used, it also is not one of the more preferred procedures since it would require the use of relatively long refractory conduits capable of withstanding extremely high temperatures. Preferably, the melting stream is composed of a plurality of unit streams each of which is injected into the furnace from its own burner body mounted on the furnace wall, each of the unit streams being ignited in its particular burner body and then injected into the furnace. In the most preferred procedure, a stream of fuel and a stream of the oxygen-containing gas are separately delivered to each burner body, each of which is provided with a uniting (mixing) section for receiving and uniting the separately delivered streams of fuel and the oxygen containing gas and then delivering the unit stream to an immediately adjacent burner section in the burner body wherein the unit stream is ignited and then injected into the furnace.
The burner or burners may be mounted in the furnace walls so that the gases discharged therefrom are aimed directly at, or generally tangentially to, the column of copper; direct discharge being preferred inasmuch as it has been found to provide a high melting rate. Preferably, a plurality of burners are mounted in the furnace walls in at least one bank in spaced relationship to each other about the furnace perimeter adjacent the bottom of the furnace. Preferably, such bank contains at least three burners. More preferably, a plurality of burners are mounted in the furnace walls in each of a plurality of banks with the burners in each bank in spaced relationship to each other about the furnace perimeter and each bank in spaced vertical relationship to each other with the lowermost bank adjacent the furnace bottom. This latter arrangement of the burners, especially in combination with inwardly sloping furnace walls in the bottom portion of the furnace is more preferred since it has been found that it assists in causing the bottom portion of the melting column of copper to assume a generally tapered shape, which in the case of a round furnace is a generally conical shape, such shape having also been found to provide a higher melting rate than would otherwise be obtained in its absence.
In addition, it has been found that, under any given conditions, the amount of heat absorbed by the copper as convection heat from the gases is dependent upon the temperature of the gases impinging upon the column and that increased temperature in the impinging gas increased the amount of heat that is absorbed by the copper as convection heat. Preferably, at least the stream of the oxygen-containing gas and more preferably also the fuel stream, are preheated as much as practicable. Preferably also where such gases are preheated, they are preheated to a temperature in the range of 150° to 540° C. In the most preferred procedure, at least the stream of the oxygen-containing gas is preheated by indirect contact with the hot flue gases from the furnace.
In general, the furnace is operated by adding copper to the top of the column as needed and the molten copper may be collected in a pool in the bottom of the furnace and tapped therefrom either continuously or intermittently through the tap hole. Preferably, no pool is employed and the molten metal is allowed to flow freely through an open tap hole as fast as the copper melts in the furnace. The molten metal from the furnace may be delivered in any suitable manner to any desired location for further use. Preferably, the metal is allowed to flow from the tap hole into a heated launder which delivers it directly to casting means located adjacent the furnace or to a holding furnace from which holding furnace it may be delivered to appropriate casting means. The heated launder and/or holding furnace may be heated using burners which are connected to the same burner control system used to control the furnace burners for melting the copper.
Any fuel, especially any fluid or fluidized fuel may be used in practicing the invention. Preferably, the fuel is a fuel comprising hydrogen and carbon monoxide, such as for example, water gas or producer gas, or the fuel is a hydro-carbonaceous fuel (i.e. a fuel comprising carbon and hydrogen). Natural gas is the most preferred fuel. When the preferred fuels are employed in practicing the invention to produce reducing constituents in the furnace atmosphere proper these will consist essentially of hydrogen and carbon monoxide as a result of the incomplete burning of the fuel. In general, the hydrogen amount is controlled by analyzing a combusted sample of the fuel and air and adjusting the fuel/air ratio to achieve the desired hydrogen amount. Regardless of the fuel used however, the method of the invention controls the predetermined set point amount of a desired material (e.g., hydrogen, CO, O 2 , N 2 , H 2 O, etc.) to within about ±0.3% by volume and usually to less than ±0.2% or ±0.1% by volume.
Referring to FIG. 1, there is shown a typical diagram of a single burner system. It should be appreciated as discussed hereinabove that there would usually be multiple burners in rows around the periphery of the furnace and each burner would use the same configuration of equipment as described in FIG. 1.
Fuel, such as natural gas, is fed from the fuel supply 10 to a zone regulator 11 to maintain a positive fuel pressure over the air pressure. The zone regulator has two tubes 11a and 11b which communicate with the fuel line and air manifold 19, respectively, to accomplish this positive pressure condition. The fuel then goes into a fuel manifold 12 and is fed to a zero regulator conventional diaphragm controlled valve 13. The valve 13 is also provided with tube 13a and tube 13b leading from the air line to the space above the diaphragm in the valve 13 so as to communicate the pressure of the air to the diaphragm. Tube 13b also has a bleed valve 20 and vent 21 associated therewith to adjust the amount of fuel or air based on the control system 26 as discussed hereinbelow. A preferred embodiment utilizes a motorized bleed valve 20 to provide accurate control over the fuel/air ratio, which motorized control vis-a-vis pressure control has been found to be very important in obtaining the excellent operating results achieved by the invention.
The fuel is then fed through an adjustable orifice 14 which serves to also adjust the amount of fuel fed to the burner. Usually, the adjustable orifice 14 is a gross manual adjustment for the fuel flow with the bleed valve 20 providing the final fine adjustment needed for close control of the fuel/air ratio. The fuel then goes into a mixing chamber 15 (usually part of the burner) to be mixed with the air.
Air is fed from air supply 17 through a butterfly valve 18 to air manifold 19 and through manifold valve 19a into mixer 15. The mixed fuel/air stream is fed into the burner 16 for combustion.
The ratio of fuel to air is preferably determined by taking a sample of the mixed fuel/air stream, burning it and analyzing the combustion products. Other means of sampling and analysis may be employed. This may be accomplished by using a three-way solenoid valve 22. With the valve 22 directed for sampling and analysis, the fuel/air mixture is fed through vacuum pump 23 to furnace 24 which burns the mixture under ideal conditions. This burnt mixture is then fed into analyzer cell 25 for analysis and the results inputted to control system 26. Depending on the analysis, an adjustment is made to the bleed valve 20 by decreasing the opening of the valve if more fuel is needed or increasing the opening of the valve if more air is needed. Other inputs to the control system 26 are the air pressure and fuel pressure from their respective manifolds.
When the fuel/air mixture is not being sampled for analysis, the solenoid valve 22 directs the mixture to a vacuum manifold 27 connected to a vacuum pump 28 and vent 29.
For the typical burner system having multiple burners in a row around the periphery of the furnace, each burner will have the same configuration from the fuel manifold 12 and air manifold 19 to the burner. Each burner will also have a three way solenoid valve associated therewith and the remaining equipment downstream from the solenoid valve will be used for all the burners regardless of the number of burners. Thus, for example, only one furnace 24 is generally used for the row of burners. Multiple furnaces, analyzer cells, etc. may be employed but this is not generally economical.
Referring to FIG. 2 which shows a shaft furnace having four (4) burners, in operation, a sample from mixer 15a will be taken and directed by valve 22a through line 23a to vacuum pump 23. From pump 23, the sample is burned in furnace 24, analyzed in cell 25 and the results inputted to control system 26. It is an important feature of the invention that while the gas mixture from mixer 15a is being sampled and analyzed, valves 22b, 22c and 22d are respectively, to vacuum manifold 27 by vacuum pump 28 and vented (29). When the sample from mixer 15a is analyzed and processed by control system 26, valve 22a is changed to direct the gas from mixer 15a to vacuum manifold 27 through line 27a and valve 22b changed to permit the gas mixture from mixer 15b to be sampled and analyzed by passing the sample through line 23b to the vacuum and analyzing system. Valves 22c and 22d remain as described above and their respective gas mixtures are fed into the vacuum manifold 27. The above procedure is repeated continually during operation of the furnace with all the burners being sampled repeatedly. Any sequence of sampling may be employed.
The above sampling and analyzing procedure significantly increases the number of samples and analyses per unit of time since a gas mixture sample is always available to be analyzed near the furnace 24 and cell 25 due to the use of the vacuum manifold 27. This can readily be understood by noting the distance a gas sample would have to travel from the mixer 15 to the sample combustion furnace 24 since the distance from the mixer 15 to the valve 22 is eliminated. In normal commercial operation the amount of samples and analysis are approximately doubled when compared to a system not using the vacuum manifold 27. This increase in sampling and analysis enables close control of the fuel/air ratio and consequent increased efficiency of the melting operation.
In a commercial operation melting copper cathodes using a shaft furnace having three rows of multiple burners, control of the fuel/air ratio using the method of the invention (including motorized bleed valves 20) resulted in significantly enhanced product quality because of the controlled hydrogen amounts in the burner flame (less than ±0.2% variance by volume from the desired hydrogen set points). Melting operations not using the invention had hydrogen amounts varying by ±0.5% from the desired concentration set points.
It will be apparent that many changes and modifications of the several features described herein may be made without departing from the spirit and scope of the invention. It is therefore apparent that the foregoing description is by way of illustration of the invention rather than limitation of the invention.
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A method is disclosed for melting copper without incorporating unwanted oxygen and/or hydrogen into the copper by effectively controlling the burners used to melt the copper within desired fuel/air ratio operating limits by employing a special fuel/air mixture sampling and control system.
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FIELD OF THE INVENTION
[0001] The present invention relates to a prescription medication dispensing apparatus for automatically effecting a physician prescribed medication program by selectively providing and withdrawing a prescribed dose of medication at desired times from a bulk medication loading format and also monitoring and communicating patient compliance with the medication program to a remote monitor or caregiver.
BACKGROUND OF THE INVENTION
[0002] Doctors commonly prescribe a regimen of pills to be taken by ill persons, for example, a regimen such as “take two of the blue pills every six hours and one of the green pills every four hours” or the like is not uncommon. For some persons, such a specific regimen or course of medication may be easily followed. For other persons however, confusion can arise both concerning the schedule and concerning whether or not the medication has been taken. This problem occurs frequently where a large number of different medications are prescribed or with elderly persons who may have suffered some loss of mental faculties.
[0003] A variety of automated dispensers of pills which are purportedly aimed at some aspects of this dispensing problem are described in the related art. According to their respective descriptions these dispensers are intended to provide for dispensing of pills according to some specified regimen. In addition, in some cases, they have some described means to permit a determination of deviations from their programmed regimen. These dispensers, however have shortcomings in their complexity, cost, flexibility, ease of use and error resistance for use in many conventional medication dispensing needs.
[0004] Many dispensers which overcome the above noted drawbacks are highly dependent upon attention and diligence by caregivers. Some apparatus require the caregiver to properly fill the medication cups and stack them in the appropriate order in the device for subsequent dispensing. Other apparatus require the care giver to place medication into small containers within the dispenser. Thus, the use of such a device requires substantial amounts of handling and effort by a knowledgeable caregiver which is expensive and susceptible to error.
SUMMARY OF THE INVENTION
[0005] Wherefore, it is an object of the present invention to overcome the above mentioned shortcomings and drawbacks associated with the prior art.
[0006] It is an object of this invention to provide an on-site medication dispensing unit that is readily programmable for dispensing pills to a patient over an extended period of time and which monitors patient compliance with the programmed medication regime.
[0007] Another object of this invention is to prevent overdosing or multiple dosages in the unit's output mechanism by having a visual and/or audible alerting feature which notifies the patient at a prescribed dosage time in accordance with the regimen that is programmed into the unit and then, and having a limited time window during which the patient must press a button or similar input device to activate the unit's output mechanism to effect a physical dispensing of the dosage from the unit. The time window is reprogrammable. If the patient has not pressed the button or activated the input device when the time window ends, the dosage is inaccessible to the patient. This missed medication can be reissued to the patient the following delivery or day if appropriate or will be locked away until the caregiver intervenes. A further feature of the unit alerts the patient in steps of escalating intensity, either audibly and visually, or both, if the button or similar input device is not activated.
[0008] It is another object of this invention to provide a medication dispensing unit which is directly linked to a 24-hour monitoring facility or directly to a caregiver if an occurrence that is defined by the unit's program to be an emergency situation arises. An example emergency situation is the patient's failure to activate the dispensing button which, as described above, causes the dosage to be inaccessible to the patient. If this occurs more than a predetermined number of times over a predetermined time duration, it would cause an alert to be sent directly to a caregiver and/or an alert to a monitoring facility.
[0009] Another object of the present invention is to provide a medication dispensing device which permits bulk loading of the device for at least a 30-day supply of medication.
[0010] A further object of the present invention is to provide a device which is capable of being resupplied from a chain pharmacy's managed care pharmacy division in a bulk loading format.
[0011] Yet another object of the present invention is to provide a bulk loading format where once the bulk medication is loaded in the device, no further human interaction with the medications is necessary to dispense the appropriate dosages of medications.
[0012] A still further object of the present invention is to select a desired prescribed medication dosage from the bulk loading format and deliver the dosage to the patient for only a prescribed period of time.
[0013] One embodiment of the on-site medication dispenser unit includes a rotating carousel wherein the canisters carried by the carousel may be loaded with at least a week's worth of a particular type of medication or types of medication. Anticipating when a medication dosage, or series of dosages is to be dispensed, the carousel is rotated so that the canister containing the appropriate pill is positioned at a selecting mechanism. The selecting mechanism selects a pill from the canister and drops it into a waiting receptacle, the selecting mechanism continues to select pills from individual canisters on the rotating carousel until a required dosage has been dropped into the receptacle.
[0014] At the prescribed dosage time the dispenser's program initiates an alert to the patient. As described above, when the patient is alerted, he/she is required to push a dispensing button within a programmable time window. If the button is pushed, the aligned receptacle releases its contents into a chute accessible to the patient. If the patient does not dispense the medication when alerted to do so, the dispenser first, for certain embodiments, steps through a progressive alerting of audio (tones and prerecorded voice messages) and visual alerts with increasing intensity, and if the medicine is not dispensed, the medication remains in the collection receptacle where it is inaccessible to the patient and the unit attempts to contact, in order, a preprogrammed list of caregivers and then if not successful, notifies the 24-hour central monitoring facility.
[0015] A still further embodiment of the invention provides a dispensing unit programmable to notify a patient to take a medication which is not dispensed by the unit. One example is the dispenser prompting the patient to take insulin using the above-identified visual display audible alarm and/or an audio message such as a prerecorded voice.
[0016] According to one example embodiment, the on-site dispensing unit is loaded by first filling the appropriate plurality of canisters, with the individual medication prescriptions, then transporting the filled canisters to the on-site unit, and loading them into the dispensing mechanism's canister carousel. The medication prescription canisters may be filled at the location of the on-site unit, or prefilled at a central distribution facility, or at a local station, such a place within a nursing home.
[0017] After loading the bulk medications into the canisters, the unit is programmed using one of the following three methods; call the central monitoring facility and have the unit programmed remotely, use a setup panel to select a preprogrammed standard, use a setup control panel to enter in a customized schedule.
[0018] A control panel for programming the dispensing unit is preferably located under a cover of the dispensing unit thereby, preventing accidental or other altering of the stored medication dosage schedule.
[0019] In addition to the medication dispensing and monitoring functions of the dispensing unit, a further embodiment includes a wireless communicating device worn by the patient which is communicatively linked with the dispenser to provide additional emergency protection to some patients. In an emergency, the patient can activate the wireless communication device which would communicate with the dispensing unit. The dispensing unit would, in turn, send an emergency message to the central monitoring station. The personal communication device may be a pendant worn around the neck or any other suitable device that can be worn on the patients body. The medication dispensing unit may optionally incorporate an emergency button that serves the same function as the personal communication device. Other embodiments of the wireless emergency communications device are a wall mounted wireless emergency button and a table top wireless emergency button.
[0020] The present invention also relates to a medication preparation and dispensing apparatus for selecting and delivering at least one prescribed medication from a plurality of bulk medication amounts to a patient, the preparation and dispensing apparatus comprising a housing accommodating a plurality of receptacles containing the bulk medication amounts and a selection mechanism for obtaining the at least one prescribed medication from at least one of the plurality of receptacles, a medication dosage holder for collecting the at least one prescribed medication from the selection mechanism, a dispenser for dispensing the at least one medication collected by the medication dosage holder to the patient within a desired time period, and wherein a programmable computer instructs the selection mechanism to obtain the at least one medication from the bulk medication amounts and deliver the at least one medication to the dosage holder, the computer also communicating with the dispenser to issue the at least one medication to the patient within the desired time period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention will now be described, by way of example, with reference to the accompanying drawings in which:
[0022] [0022]FIG. 1 is a schematic system diagram indicating the dispensing and monitoring functions of the medication delivery system;
[0023] [0023]FIG. 2 is a perspective view of the complete bulk medication dispenser;
[0024] [0024]FIG. 3 is a cross sectional view of the internal pill manipulating mechanisms;
[0025] [0025]FIGS. 4A and 4B are cross sectional views of the pill receptacles of a first embodiment;
[0026] [0026]FIGS. 5A, 5B and 5 C are a cross-sectional side view, a perspective view and a top planar view of a second pill receptacle embodiment;
[0027] [0027]FIGS. 6A and 6B are top planar views of the pill receptacle carousel of a first and second embodiment respectively; and
[0028] [0028]FIG. 7 is a block diagram of the functions of the apparatus computer controller.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] [0029]FIG. 1 is a high level system diagram of an example medication dispensing and monitoring system according to the present invention. The FIG. 1 system includes an on-site medication dispenser 2 which stores a plurality of canisters described in detail further below, each canister filled with one or several pills of one type or prescription for dispensing at a prescribed time. The canisters can be individually loaded or preloaded with medication and loaded into the on-site dispensing unit 2 by authorized persons from a visiting nurse facility (VNA) 8 or from a doctors office 6 , or by a pharmacy or local caregiver 4 . The specific apparatus and details of operation of the medical dispensing unit 2 are described further below in reference to FIGS. 2 - 6 .
[0030] The on-site dispensing unit 2 has a microprocessor-based controller 100 , which is described further below, the controller 100 having a standard data storage function (not shown). The dispenser unit 2 data storage receives and stores a dispensing program, or receives data entries into a pre-stored user-prompt program, representing the patient's prescribed medication regimen. The program or data is entered into the unit 2 manually, by either the patient or the caregiver 4 , or is received via a web based computer network from one of several remote sites including the patient's physician office 6 , a nursing facility 8 , a central control/monitoring facility 20 , or a pharmacy.
[0031] The on-site dispensing unit 2 then, by its example apparatus and operation described below, executes the entered dispensing program by alerting the patient, by a visual and/or audible means 3 , at each of the programmed dosing times and, concurrent with each alerting operation, places or assigns one of its internally selected and stored dosages into a ready-to-dispense mode or mechanical state. The controller 100 concurrently establishes a window of time, relative to the alerting signal, during which the patient can input a dispensing signal 5 via, for example, a button 31 , shown in FIG. 2, or other input device, such as a touchscreen (not shown). The duration of the time window is set by the entered program or by a default value. If the user input signal 5 is received before expiration of the time window, the assigned dosage is output from the unit, as shown by label 7 . The apparatus and method of the on-site dispensing unit 2 for carrying out the patient alerting and dispensing operations are described in further detail below.
[0032] If the patient has not yet responded, e.g. pushed the button 31 of the medication dispensing unit 2 , at the end of the time window, the unit 2 for the FIG. 1 embodiment immediately transmits an alert 14 via, for example, a unit modem and telephone to a first designated caregiver 16 . In addition to generating the alert 14 , the on-site dispensing unit 2 prevent missed medication from being delivered to the patient for this dose period by an apparatus and operation described in further detail below.
[0033] If no response is received by the unit 2 from that first designated caregiver, the unit 2 sends another alert 14 to a second designated caregiver for instance a retirement/nursing home monitoring facility 12 . Alerting sequences different from the example above are readily written into the dispenser unit 2 microprocessor-based controller 100 to achieve different priority sequences. A preferred example notifies the central monitoring facility when there is no valid response from any of the designated caregivers 16 or from the retirement home monitoring facility 12 .
[0034] Instead of a unit 2 modem and a computer network system communication with the remote sites, such as 16 , 12 and 20 can be realized by direct phone line or cellular phone connection. Regarding the specific form of receipt verification signal that the remote monitoring sites 16 , 12 and 20 transmit back to the on-site dispensing unit 2 , that is a simple design choice, with examples including a specific phone keypad entry, or sequence of entries, or a designated key (not shown). Further, the dispenser unit 2 may be equipped with a voice-recognition feature, recognizing, for example, “I'll be right over.” Various commercial voice recognition hardware/software modules, readily incorporated into a standard microprocessor-based controller 100 are available as off-the-shelf items.
[0035] In the description above of the FIG. 1 example system, the on-site dispensing unit immediately transmits an alert signal 14 if there has been no user input of the dispensing signal when the time window ends. A further embodiment, uses a plurality of, for example, two time windows during which the user may input the dispensing signal, e.g. press the button 31 . In that further embodiment, the audio or visual alarm is generated at a first intensity during the first time window. If that first time window ends and the user has not yet entered a dispensing signal, the unit increases the alarm level. The increased alarm level is continuous or, alternatively, is steadily increasing, until the end of the second time window. If the user, at the end of the second time window, has still not entered the dispensing signal then the unit 2 generates the alert signal 14 as described above.
[0036] Referring to FIG. 1, the central monitoring facility 20 is connected to the on-site medication dispenser 2 via a modem and the computer network system and, in addition to receiving alerts 14 from the unit 2 , unit 2 is optionally programmed for periodic reporting concerning the operation and status of the unit 2 . The information transmitted by such reporting is a design choice, preferably including a history of all dispensing operations over a set time period. In addition, the central monitoring facility may send a query to the on-site dispensing unit 2 over the computer system requesting information. Still, further, the patient's health care provider 6 may request a record of dosage schedule compliance from the central monitoring facility 20 to further enhance the treatment of the patient. Such records may be generated as hard paper copies or electronic files.
[0037] Turning now to FIG. 2, a general description concerning the medication dispensing unit 2 will now be provided. The medication dispensing unit 2 is a self contained, programmable and automated medication dispenser efficiently delivering at least a 30 day supply of medication to a patient with no human caregiver intervention. The unit 2 is functionally capable of selecting desired medications from a number of internal bulk pill bins or receptacles 21 within the apparatus and preparing a particular prescription for delivery to a patient at a desired programmed time. The unit 2 carries out these selection and dispensing functions in accordance with instructions programed into the controller 100 which also monitors patient compliance with the prescription regimen and communicates associated data to a remote caregiver via the central monitoring facility as previously described. A detailed description of the unit 2 follows below.
[0038] The dispensing unit 2 is encased within a removable housing cover 23 supported on a base 25 . The cover 23 encloses and protects the medication delivery mechanisms, the bulk medications and the dispensing cups into which the selected medications are delivered. The housing cover 23 may be provided with an opening M in a top most portion of the cover for allowing the bulk medication to be loaded into the apparatus, alternatively, the cover 23 may be made removable from the base 25 in its entirety for the same purpose or for servicing. An exit opening E is provided in a lower portion of the cover 23 or alternatively in the base 25 as shown for enabling the patient to retrieve the required dose of selected medications from the unit 2 .
[0039] Situated on the base 25 , and easily accessible to a user is a manual keypad 27 for programming instructions into the controller 100 . A visual indicator or warning light 29 may be provided to alert a user that a dosage is prepared and should be retrieved and a graphic display for any type of information pertinent to the particular function or dosage being delivered may be shown by a visual display window 32 . A dispensing button 31 is also positioned on the base, actuation of the button enabling a user to dispense the currently available dosage through the exit E.
[0040] Turning to FIG. 3, the medication dispensing mechanisms contained within the housing cover 23 for preparing and dispensing a dosage will now be described. The base 25 provides support not only for the housing cover 23 , but also for the internal medication dispensing mechanisms. Supported on the base 25 is a hollow center spindle 35 having a through passage 37 defined about a central axis A of the unit 2 . The center spindle 35 extends vertically upward from a lower end 39 , substantially supported at a central portion of the base 25 , to a top end 41 spaced from the base 25 .
[0041] At the lower end 39 of the center spindle 35 , a communicating tube 43 is attached to enable the communication of a vacuum pump 45 contained within the housing cover 23 with the hollow passage 37 of the center spindle 35 . A pressure sensor 46 is provided together with the vacuum pump to monitor vacuum pressure in the system by the internal computer 100 . Increased vacuum pressure indicates pickup arm 47 picks a pill properly from container 21 .
[0042] Connected to and communicating with the top end 41 of the center spindle 35 is a substantially flexible and vertically movable, hollow vacuum pickup arm 47 . The vacuum pickup arm 47 has a first end having an outer diameter which slidably fits inside the through passage 37 to facilitate the vacuum pressure extending through the pickup arm 47 while enabling the first end of the pickup arm 47 fitted within the through passage 37 to be axially slidable therein.
[0043] A remainder of the pickup arm 47 extends from the top end 41 of the central spindle 35 and is provided with a substantially 180 degree bend turning a second end of the pickup arm 47 vertically downwards to define an opening O, which, when the vacuum pump 45 is turned on creating a vacuum through the hollow passage 37 causes suction at the opening O strong enough to retain a pill or desired medication dosage selected from one of the receptacles 21 , a further description of which will be provided below.
[0044] The flexible pickup arm 47 is maintained as a 180 degree bend by a pickup arm support 49 . The support 49 is a rigid arm extending horizontally from a first end portion having slidable engagement with the center spindle 35 to a second end portion spaced from the center spindle and supporting the second end of the pickup arm 47 , specifically the opening O, in a desired pill engaging and retaining position. The support arm 49 is vertically moved up and down with respect to the center spindle 35 by a motor 75 , it can be appreciated that this motor 75 may be any type as known in the art, but in this embodiment is a screw motor mounted on the spindle 35 . As is to be appreciated, as the motor 75 raises and lowers the support arm 49 , due to the inherent flexibility, the second end of the pickup arm 47 , as well as opening O, secured at the second end of the support 49 is respectively vertically raised and lowered.
[0045] The opening O and the vacuum produced there engages and retains in general one pill at a time. Thus once a pill or medication is retrieved by the pickup arm 47 , the pill or medication is subsequently dropped into a waiting container or cup before another pill or medication can be obtained. Because the pick up arm 47 is vertically movable, the receptacles 21 containing the individual medications must be positioned underneath the opening O to permit retrieval of the pill or medication.
[0046] Supported about the central axis A and the central spindle 35 , a rotating carousel 51 supports and maneuvers a plurality of pill bins or receptacles 21 . The carousel 51 is provided with a horizontally extending planer surface supporting the pill receptacles 21 . The receptacles 21 , which may be permanent or removable, are each capable of receiving and containing a bulk amount of a required medication. The receptacles 21 are supplied with the bulk medication via the medication supply entrance M or by removal of the cover 23 . Each pill receptacle 21 is filled with a homogenous type of pill or medication such that when the opening O is brought into close proximity with the pills in a desired receptacle, only that type of pill can be engaged by the vacuum suction of the opening O. A further description of the pill receptacles 21 will be provided below.
[0047] The carousel 51 is rotatably driven about the central axis A by a carousel gear 65 located adjacent an outer rim of the carousel 51 . The carousel gear 65 is connected to and driven by a carousel motor 67 . Thus, the carousel motor 67 , establishes direct control over the rotation of the carousel 51 and the positioning of the pill receptacles 21 . In addition, to ensure the appropriate alignment of the receptacle 21 with the end 49 of the vacuum pick up arm, there is a position reader 71 which, via IR or any other means as is known in the art, is able to verify the correct positioning of the carousel 51 and the location of the desired receptacle 21 from which a dosage or medication is to be removed.
[0048] Turning now to FIGS. 4A and B, in the preferred embodiment of the invention, each pill receptacle 21 is designed having a main compartment 56 to which a bulk supply of a particular desired homogenous pill or medication can be supplied. The main compartment 56 may be of any desired size or volume to handle any number of desired pills or medications, the main compartment 56 can accommodate 0 to 500 pills, and usually about 50 to 300 and most preferably around 100-150 pills.
[0049] Each receptacle 21 is provided with an elongate vertically depending bottom cavity 58 at the bottom of the main compartment 56 . The bottom cavity 58 contains a compression spring 88 biasing a plunger 60 . The plunger has a first position wherein the plunger 60 is depressed and substantially withdrawn the main compartment 56 . In a second position shown in FIG. 4A, the plunger moves from its first position and extends upward through the bulk medication, extracting at least one of the bulk loaded pills or medications to a supported position above the bulk pills on a top surface 62 of the plunger 60 .
[0050] The extension of the plunger 60 pushes the extracted pill up above the bulk population of pills and brings it into close proximity of the opening O of the arm 47 . The top surface 62 of the plunger 60 may be shaped with a particular pill size depression which assists in extracting and maintaining a pill thereon, and for placement of the pill in close proximity to the arm 47 and opening O. The bottom cavity 58 and plunger 60 may also be cooperatively threaded in order to provide a rotation for the plunger 60 as it extends upwards and through the bulk pill population facilitating the engagement of one pill positioned on the top surface 62 of the plunger 60 as depicted in FIG. 4B.
[0051] As shown in FIG. 3, the plunger 60 is actuated by a pill container motor 82 which drives a plunger gear 84 . The plunger gear 84 extends through a slot 86 in the receptacle 21 engaging the plunger 60 . It is to be appreciated as the plunger gear 84 rotates, engaging threads or notches (not shown) in the plunger 60 , allowing the spring 88 to bias the plunger 60 upwards through the bulk population of pills. Once the plunger 60 has been fully extended and the pill removed therefrom by the arm 47 and opening O, the motor 82 reverses direction and the plunger gear 84 cooperatively changes direction, lowering the plunger 60 against the spring bias 88 down into the cavity 58 of the pill receptacle 21 . Having engaged and retained a pill via the vacuum suction produced at opening O, the pickup arm 47 is raised to allow the carousel 51 to rotate to a subsequent position as described in greater detail below.
[0052] Turning now to FIGS. 5A, 5B, and 5 C a second embodiment of the pill receptacle is provided. The receptacle 121 of the second embodiment is essentially a canister having a sidewall 91 defining a space 93 for containing the bulk medications. The receptacles can be provided with either a solid attached base 94 or base 94 can be a mixing drum which is capable of rotating relative to the sidewall 91 , a further description of which will be provided below.
[0053] The sidewall 91 of each receptacle 121 is a modified cylinder having an upper portion and a lower portion. In the upper portion the sidewall 91 extends around in a cylindrical fashion between about 270-320 degrees. The cylinder is modified by an indentation 95 in the remaining 90-40 degrees. The indentation 95 is formed by a first and second planar walls 99 , 97 extending inwardly from the sidewall 91 to a common intersection. The depending walls 99 , 97 intersect with the sidewall 91 from a top edge or rim 101 of the sidewall 91 down to a point 65 between the sidewall rim 101 and the bottom edge 61 of the sidewall, the point being spaced a distance from the bottom edge 61 to form an opening 107 leading to a complete cylindrical lower pill pocket in the receptacle 121 .
[0054] The lower portion of the sidewall 91 forms a complete cylinder surrounding the rotating base 94 and defines the pill retrieval area accessible through the opening 107 . The rotating base 94 has a generally conical shaped surface 96 having a raised apex 98 in the center substantially vertically aligned with the intersection of the first and second planar walls 97 and 99 . The conical shaped surface 96 provides for distribution of the pills toward the sidewall 91 of the receptacles 121 . The conical surface 96 of the base 94 is also provided with an indentation or pill pocket 109 toward the sidewall 91 in the approximate size and shape of a single medication pill or tablet. This pill pocket 109 is sized to accommodate a pill or medication extracted from the bulk loaded portion 93 and deliver it into the pill retrieval area 107 . The pill sits down in a defilade position in the pill pocket 109 and is carried out of the bulk loaded area 93 under the lower edge 92 of one of the first and second planar walls. This lower edge 103 is positioned close enough to the conical surface of the rotating base 94 to stop pills not in the pill pocket 109 from sliding into the pill retrieval area. Additionally, a device may be provided along the lower edge 92 to assist in preventing any pills other than that in the pocket 109 from entering into the pill retrieval area, such as a stiff bristle brush.
[0055] The opening 107 is the access point for the vacuum pick up arm to enter into proximity of the pill or medications extracted from the bulk loading area 93 , and to retrieve a pill contained in the pill pocket 109 of the receptacle 121 when the container is rotated into the pick up position.
[0056] In one embodiment of the present invention shown in FIG. 6A, the carousel 51 is also provided with a drop chute 54 . After engaging a pill, the support arm 49 and opening O is raised to allow the carousel 51 to rotate so that the drop chute 54 is positioned directly underneath the opening O and the pill retained thereon. When the vacuum is turned off the pill falls from the opening O into the drop chute 54 which directs the pill or medication into a dosage collection cup 79 located beneath the drop chute 54 . Once the pill has been deposited in the dosage collection cup 79 , the pick up arm 47 , opening O and carousel 51 may be subsequently realigned to retrieve another pill or medication from a pill receptacle 21 .
[0057] In another embodiment shown in FIG. 6B, any number of drop slots 73 , a drop slot 73 being a passageway through the planer surface of the carousel 51 , may be provided to allow the deposition of a pill in the collection cup 79 . The drop slots 73 may be positioned adjacent and between each of the receptacle 21 and are also capable of being aligned with the end 49 of the vertical depending pick up arm 47 and verified by position sensor 71 . After the vacuum pick up arm 47 has obtained a pill or dosage from the aligned receptacle 21 , the motor 67 turns the gear 65 and thus the carousel 51 to position the drop slot 73 adjacent the receptacle 21 beneath the opening O of the pick up arm 47 . The pill may then be dropped from the opening O and pass through the drop slot 54 to the pill collector cup 79 .
[0058] Returning to FIG. 3, the vacuum pick up arm 47 works cooperatively with the rotation of the carousel 51 . The pick up arm 47 has in general two positions: a first lower position for retrieving a pill from a receptacle 21 , as shown in FIG. 3 and for dropping a pill through the drop chute 54 or drop slot 73 , and a second upper position (not shown) wherein the pick up arm is positioned clear of any obstructions, i.e. the receptacles 21 , so that carousel 51 can rotate to the next proper alignment. The vertical raising and lowering of the pick up arm 47 is driven by the screw motor 75 mounted on the center spindle 35 and having an upper and lower limit to ensure proper vertical alignment of the pick up arm 47 and specifically, the opening O for purposes of retrieving and dropping a pill.
[0059] The controller 100 , generally an internal computer, in cooperation with the position sensors controls the coordination and cooperation of the motors and mechanisms described above. To prepare a dosage of medication, the controller 100 ensures the pick up arm 47 is in the upper position and the carousel 51 , driven by the motor 67 is rotated until a receptacle 21 containing the required medication and dosage is properly aligned. Thus, the vertically depending end having the opening O of the pick up arm 47 is poised directly vertically above the pill receptacle 21 . The optical position reader 71 verifies the positioning of the receptacle 21 with the controller 100 which then causes the vacuum pump 45 to be turned on. The pick up arm 47 is then lowered by the screw motor 75 until the arm attains a pill pick up level wherein the depending end and opening O are substantially inserted within the receptacle (as shown in FIG. 3). The vacuum force developed at the opening O of the vertically depending end of the pickup arm 47 then grabs the dosage of medication from the receptacle and/or the top surface 62 of the plunger 60 and the pressure sensor 46 located in conjunction with the communicating tube 43 detects whether the pill is retained on the pick up arm thus indicating that the controller 100 can continue operation.
[0060] The motor 75 then raises the pick up arm 47 holding the dosage to the second position. The carousel 51 is then rotated by the motor 67 to position the drop chute 54 or drop slot 73 immediately beneath the opening O, via the optical position sensor 71 . The pickup arm 47 is lowered to the first lower position, and the vacuum pump 45 is turned off thus releasing the pill into the awaiting collector cup 79 . Leaving the collector cup 79 in place, this process is then repeated for as many times as necessary to provide the required medication for a dosage into a single collection cup 79 .
[0061] Located below the carousel 51 platform is a pill collector carousel 81 supporting at least one of the above described collection cups 79 . The pill collector carousel 81 is also aligned about the central axis A and has a central through hole, through which the hollow central spindle 35 passes. The pill collector carousel 81 is rotatable relative to the central spindle and carousel 51 and is provided with at least a pill collector cup 79 for collection of medication dosages dropped from the vertically depending end of the vacuum pickup arm 47 as described previously, although it is foreseeable that any number of collection cups may be supported by the pill collector carousel 81 .
[0062] The pill collector carousel 81 is a substantially planar surface having openings forming or supporting a rim of the collector cup 79 which may be permanent or removable or replaceable. The pill collector carousel 81 is provided with a pill collector carousel gear 55 which is driven by a pill collector carousel motor 57 so the pill collector carousel 81 is enabled to rotate relative to the center spindle 35 as well as the carousel 51 . The pill collector carousel 81 positions the collection cup 79 beneath the opening O of the pick up arm and accepts the required dosage through the drop chute 54 or drop slot 73 from the pick up arm 47 . The collection cup 79 remains in place as the above described process is repeated as many times as necessary in order to provide the required dosage, or number of pills to the collector cup 79 .
[0063] The pill collector carousel motor 57 is also connected to the controller 100 , and when the computer acknowledges the completion of a complete dosage delivered to the collection cup, the motor 57 rotates the pill collection cup to a position substantially adjacent the exit opening E of the housing which can be verified by a position sensor 72 .
[0064] A sliding surface 85 is positioned below the pill collection carousel 51 and substantially supports a bottom of the pill collection cup 79 . The bottom of the collector cup 79 may be provided with a hinged trap door 74 . The door is supported during filling operations and during rotation of the collector carousel sliding on the sliding surface 85 . The pill collector cups 79 are in contact with and allowed to slide across the sliding surface 85 as they are horizontally rotated by the pill collector carousel 81 .
[0065] Adjacent the exit opening E, the sliding surface 85 is provided with a delivery opening 87 . When a cup 61 encounters the opening 87 , the trap door opens due to gravity and the weight of the pills, allowing the pills to be dispensed to the patient. The sliding surface 85 supports the cup vertically and ensures that the cup 61 is properly positioned, i.e. the mouth of the cup defines a substantially horizontal plane as the cup is positioned in the pill collector carousel 81 . The sliding surface 85 is attached to the base 25 and also provides support and separation of the motors driving the pill collector carousel 81 and the carousel 51 from the medications and other delivery mechanisms.
[0066] Once the required dosage has been delivered to the collection cup 79 by the pick up arm 47 via either the drop chute 54 or drop slot 73 , and the collection cup rotated by the collection cup carousel 81 to the appropriate position, a latch 110 , connected with the patient dispense input 5 , and operated thereby is provided whereby the dosage is only delivered if the patient operates the latch 110 via the input 5 . A med tray 113 is provided in the base 94 of the unit 2 for receiving the allotted medications from the collection cup and providing the required medications to the patient. The collection cup containing the medication is positioned over the med tray 113 via rotation of the collection cup carousel when a time for supplying the medication is noted by the computer. The opening 87 of the sliding surface 85 is provided with a door 89 directly over the med tray 113 , and directly beneath the collection cup 61 containing the desired medication positioned over the med tray 113 .
[0067] The door 89 is connected to an offset cam 117 which is rotatably connected with a motor 119 . When the motor 119 is instructed to open the door the motor 119 rotates the offset cam 117 which slides the latch away from the opening 87 in the sliding surface 85 and allows the medication to pour from the collection cup 61 into the med tray 113 . The motor 119 may then close the door 89 by rotating the offset cam 117 in an opposite direction closing the door. An optical reader 121 may also be provided in conjunction with the door 89 to ensure the proper and complete opening and closing.
[0068] Where the patient fails to indicate that they are prepared to accept the medication, the door 89 will not open, and the contents of the collection cup are analyzed to ascertain if they can be either used for a subsequent dose or whether the dosage is to be removed from circulation.
[0069] Based on the programmed instructions provided to the controller 100 the operation and function of the unit 2 is conducted in the following manner.
[0070] [0070]FIG. 7 is a function block diagram of the controller 100 control of the aforementioned unit 2 . The controller has a CPU 200 electronically coupled to a main motor control, controlling the rotation and availability of the pill receptacles 21 . The controller 100 receives feedback from the position sensor of the carousel 23 and adjusts the motor control and hence the carousel 23 to accordingly align an appropriate receptacle 21 or drop slot 73 . The main controller 100 also controls a collection cup carousel motor which rotates the appropriate collection cup 61 into the drop zone 52 beneath the receptacle carousel 23 in order to accept a retrieved medication from the pickup arm 47 . A collection cup carousel position sensor is also related to the controller 100 in order to assure the collection cup carousel is properly aligned a collection cup 79 under the pick up arm 47 . The main controller 100 also operates simultaneously and in conjunction with the main motor control and the collection cup carousel motor control a vacuum pickup motor control for retrieving and aligning the desired medications from the appropriate receptacles 21 to the proper collection cups 61 . The vacuum pickup arm assembly 47 is also provided with a position sensor so that the controller 100 is aware of and able to coordinate the proper vertical positioning of the vacuum pickup arm assembly 47 .
[0071] The main controller 100 also coordinates the activation and deactivation of the vacuum pump 45 for retrieval and release of the desired medications from the receptacles 21 into the collection cups 61 , respectively.
[0072] The main controller 100 is generally supplied with a 120V AC power supplied to the controller 100 and respective motors and position sensors. The main controller 100 operates according to instructions imparted by a caregiver through a key pad 105 . The key pad 105 may be either attached to the unit 2 or may also be remote therefrom. The main controller 100 further operates a liquid crystal display LCD for displaying a particular desired input information or output information to and from the controller 100 for either the patient or the caregiver. The main controller 100 is further connected with a dispense button 107 to which the patient has access to in order to retrieve the desired medications. The dispense button 31 is required to be operated before the appropriate medication is provided to the patient. To inform the patient that it period in which a medication is to be properly dispensed, an audio or visual signal may be put out by the controller 100 and unit 2 in order to alert the patient or caregiver. Thus the controller 100 may include a CPU having a microprocessor based CPU with internal memory to hold all software and scheduling information. The controller 100 also includes an imbedded Modem for communication between the controller 100 and an outside computer. The computer controls all electrotechnical elements of the machine including the vacuum pump and is provided with a battery backup for continued operation during any externally applied power failure.
[0073] Since certain changes may be made in the above described invention without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention.
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A medication dispensing system comprising an on-site medication dispensing unit and a central monitoring facility. The on-site medication dispensing unit holds bulk amounts of medication in a plurality of separate receptacles from which it selects a desired medication dosage according to an entered and stored prescription regimen and then notifies the patient by an audible or other sensory signal. If the patient presses a button within a prescribed time, the unit dispenses the dosage. If the patient does not press the button within the prescribed time, or if the unit detects a failure to dispense the selected canister, the unit makes the receptacle inaccessible and contacts a predetermined list of caregivers and the central monitoring facility.
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FIELD OF THE INVENTION
The present invention relates to a tool for punching and embossing a variety of designs in a sheet of material, such as paper. More particularly, the present invention is a hand-operated punch/emboss tool with economical interchangeable dies that are orientable in a variety of directions with respect to the punch/emboss tool.
BACKGROUND OF THE INVENTION
A variety of punch and emboss tools are available for punching and embossing designs in sheets of material, such as paper. Most of these punch and emboss tools have a significantly limited reach and a fixed design orientation, and thus impose a restriction on the location and orientation of the punched or embossed image on common sizes of paper, such as 8½″×11″. As such, users must often punch or emboss smaller sheets, and adhere them to a larger sheet in the desired, but unreachable, location and orientation. Some long reach tools with orientable patterns exist, but they are usually limited to punching or embossing a single design. A user must invest in a whole new tool in order to have a new punch or emboss design with the same freedom of reach and orientability. A user therefore may begin to acquire a collection of individual punch tools and emboss tools that is not only expensive, but bulky to carry. The few tools that have interchangeable punch or emboss inserts are implemented such that the reach and orientability benefits are sacrificed, or such that the interchangeable inserts are relatively complex and costly.
Another common drawback of many punch tools is that they are difficult to actuate, causing excessive repetitive physical stain to the user. Therefore, tools that do not themselves include a means of providing the user with extra mechanical advantage are often actuated with an additional leverage mechanism, which again adds to a user's cost.
Therefore, it is an objective of this invention to provide a single tool that will allow a user to punch or emboss a variety of designs on common sizes of sheet material such as paper, at any location on the sheet, in a variety of orientations.
It is a further object of this invention to provide interchangeable punch inserts and emboss inserts that are relatively inexpensive, so that it is economical to take advantage of the benefits of the tool for additional punch or emboss designs.
It is a further object of this invention to provide interchangeable punch inserts and emboss insets that are compact, such that it is easy to carry a collection of them.
It is a further object of this invention to provide a built-in means of leverage so that the user can actuate the punching inserts without excessive physical force or external leverage mechanisms.
SUMMARY OF THE INVENTION
The invention is an improved punch/emboss tool. The tool has a frame with two elongated beams. The upper beam is joined at one end to the lower beam and extends in a parallel and spaced-apart fashion so that a sheet of paper, or the like, can be slipped in between the two beams. The ends of the beams define two “bore” portions for carrying either a punch set or an emboss set. A person in the arts and crafts industry would understand that punch and emboss sets work in much the same way, mechanically, the significant difference being that a “punch” set is used to punch a decorative hole in a piece of paper and an “emboss” set is used to emboss a decorative design in the paper.
Each of the two portions of the frame making up the bore portions are shaped to interchangeably hold one part of a two-part punch/emboss set. In other words, each frame portion holds one separate part (or one-half) of the set in a manner such that it is easy to replace one set (having a particular punch or emboss pattern) with another. An aspect of the invention that sets it apart from the prior art is that one of the two frame portions allows the part of the set that it holds to co-axially slide toward and away from the other part of the set. This enables the parts of the set to be driven together into engagement with a sheet of paper (or similar sheet of material) between them.
In preferred form, the bore portions described above are constructed as square bores in which each separated part of the punch/emboss set resides. The two bores are fixed by the frame such that the two halves of the insert set are registered in coaxial alignment. Their non-circular shape prevents one part of the punch/emboss set from rotating relative to the other to ensure precise registration of the parts of the set when they come together. While the bores are described here as being square in shape, it is to be understood that other polygonal shapes or other non-circular shapes may work just as well. An advantage to using a radially symmetrical bore shape is that the insert sets can be releasably loaded in multiple orientations, thus allowing further flexibility in the placement of the punched or embossed image on a sheet of material. For example, a square bore allows the insert set to be loaded in one of four possible orientations.
The upper frame of the tool carries a lever arm pivotally connected to the frame for driving one of the parts of the set into engagement with the other, when manipulated by the user. The lever arm has a lobe portion that extends into the recess or opening defined by the square bore of the upper frame, for pushing its respective one-half of the punch/emboss set toward the other half that is held in the lower part of the frame. The lever arm is positioned at or near the end of the upper beam.
The frame beams are sufficiently long so that the interchangeable insert set can reach the middle of a conventional sheet of paper for punching or embossing a design in it.
A preferred embodiment of the invention is described below in detail. In the past, a person practicing arts and crafts needed to purchase separate punch/emboss tools to create separate designs in paper. While some prior art tools have interchangeable cartridges that allow the same tool to be used to make different designs, none provide such easy interchangeability, orientability, and the capability of reaching to the center of a sheet of paper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of a preferred embodiment of a punch/emboss tool, along with a punch, punching die, embossing die, and embossing die counter in accordance with the present invention;
FIG. 2 is a bottom perspective view of the punch/emboss tool and dies in FIG. 1;
FIG. 3 is an exploded perspective view of the punch/emboss tool in FIG. 1;
FIG. 4 is a top perspective view of the punch/emboss tool in FIG. 1 with the lever lifted to insert a punch or embossing die;
FIG. 5 is a bottom perspective view of the punch/emboss tool in FIG. 1 with the trapdoor retracted to insert a punching die or embossing die counter;
FIG. 6 is a cross-sectional side view of the punch/emboss tool in FIG. 1 with the lever lifted and the trapdoor retracted to insert or remove the punch and punching die;
FIG. 7 a is a cross-sectional side view of the punch/emboss tool in FIG. 1 with a punch and punching die loaded and ready for punching;
FIG. 7 b is a cross-sectional side view of the punch/emboss tool in FIG. 1 with an embossing die and embossing die counter loaded and ready for embossing;
FIG. 8 a is a cross-sectional side view of the punch/emboss tool in FIG. 1 with the lever depressed, punching a sheet of material; and
FIG. 8 b is a cross-sectional side view of the punch/emboss tool in FIG. 1 with the lever depressed, embossing a sheet of material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-3, a punch/emboss tool in accordance with the present invention generally includes a frame or body 5 , a lever 1 , a hinge pin 2 , a trapdoor 7 , a return spring 6 , a roller pin 3 , a roller sleeve 4 , a front foot 8 , and a rear foot 9 . A punch 10 , and a punching die 11 are used with the tool to punch out a decorative shape from a sheet of material, such as paper. Alternatively, an embossing die 13 (one part of the set) and an embossing die counter 12 (a second part of the set) are used with the tool to emboss a decorative shape onto a sheet of material, such as paper.
The lever 1 is pivotally attached to the body 5 by the hinge pin 2 . The hinge pin 2 is held in place axially by a press fit between the ends of the hinge pin 2 and the hinge pin holes 60 in the lever 1 .
The roller sleeve 4 is slid axially over the roller pin 3 so that the ends of the roller pin 3 protrude from the ends of the roller sleeve 4 . The ends of the roller pin 3 are then placed in the yokes 16 of the lever 1 . The yokes 16 are then deformed such that the roller pin 3 is rigidly fixed to the lever 1 without rolling or sliding axially. The roller sleeve 4 is then free to rotate freely over the roller pin 3 , but is constrained axially to remain between the two yokes 16 .
The bottom of the return spring 6 rests on the lip 32 at the bottom of the upper square bore 26 of the body 5 . The return spring 6 and the upper square bore 26 are assembled such that they are coaxial.
The trapdoor 7 is slidably attached to the lower beam 19 of the body 5 . The guide lips 38 of the trapdoor 7 slide within the guide slots 21 of the lower beam 19 . The trapdoor 7 is free to slide back and forth along the guide slots 21 between the front trapdoor stop 24 and rear trapdoor stop 25 . As the user slides the trapdoor 7 toward the front trapdoor stop 24 , the end of the leafspring 36 with the detent 37 is deflected away from the body 5 by the ramp 61 . As the trapdoor 7 reaches the front trapdoor stop 24 , the detent engages the indent 29 . Thus, the trapdoor 7 is held in place so that it can no longer freely slide in the guide slots 21 . To slide the trapdoor 7 back again toward the rear trapdoor stop 25 , a user grips the sides of the trapdoor 7 and pulls rearward. The rim of the indent 29 is chamfered so that the rearward pull results in an outward force on the detent 37 , causing it to disengage. A continuing rearward pull drags the detent 37 backward off the ramp 61 , thereby allowing the trapdoor 7 once again to slide freely in the guide slots 21 .
The initial assembly of the trapdoor 7 onto the body 5 is accomplished by placing the front end of the guide lips 38 into the rear end of the guide slots 21 , with the rear end of the trapdoor 7 angled outward over the rear trapdoor stop 25 . Upon forcing the trapdoor 7 forward, the compliance of the leaf spring 36 and the trapdoor 7 in general allows the rear edge of the trapdoor 7 to drag forward past the rear trapdoor stop 25 . The trapdoor 7 is then captive between the front trapdoor stop 24 and the rear trapdoor stop 25 .
The front foot 8 is adhesively attached to the trapdoor 7 . The front foot window 39 and the trap door window 35 are aligned such that a piece of punched-out sheet material can fall through them. The relief 40 allows the user to see the underside of the detent 37 to verify when it is engaged with the indent 29 . The relief 40 also prevents the flexing of the leafspring 36 from tearing the front foot 8 away from the trapdoor 7 . The rear foot 9 is adhesively attached to the underside of the body 5 . The front foot 8 and the rear foot 9 give the punch/emboss tool a non-skid bottom surface that also will not mar a table top or other surface upon which it rests.
Referring to FIGS. 4 and 6, the user must lift the lever 1 to its fully open position in order to releasably load a punch 10 or an embossing die 13 into the upper square bore 26 . As the lever 1 begins to be lifted upward, it rotates about the hinge pin 2 . The roller sleeve 4 soon contacts the cam 58 and begins to turn on the roller pin 3 . As the upward rotation of the lever 1 continues, the cam 58 forces the roller sleeve 4 and the roller pin 3 away from the hinge pin 2 . This outward force causes the flexing beam 15 between the two slits 17 to elastically bend slightly outward, thus providing a small restoring force that resists the upward rotation of the lever 1 . As the user continues to lift the lever 1 against this small restoring force, the roller sleeve 4 reaches the peak of the cam 58 . A snapping action takes place as the restoring force provided by the flexing beam 15 now tends to lift the lever 1 instead of resisting the lift. The lever 1 then continues to rotate upward on its own as the cam 58 allows the flexing beam 15 to relax. The upward rotation of the lever 1 stops at the fully open position when the end of the flexing beam 15 reaches the upward lever stop surface 34 . The cam 58 is shaped such that the flexing beam 15 is not quite fully relaxed at this position, thus providing a preload that biases the lever 1 to remain in the fully open position. This preload prevents the lever 1 from snapping shut on the user's hand, even if the lever 1 is inadvertently nudged toward the closed position.
With the lever 1 fully open, the user holds a punch 10 by the grip 41 , and places it into the upper square bore 26 in the user's desired orientation. The orientation is displayed from the top of the punch 10 by the orienting letter 43 that is closest to the upper orienting arrow 30 . The upper locating surfaces 28 slidably register the punch locating surfaces 42 so that the punch 10 is precisely coaxial with the upper square bore 26 . The punch 10 slides down the upper square bore 26 until it comes to rest on the upper surface of the return spring 6 .
Alternatively, the user holds an embossing die 13 by the grip 50 , and places it into the upper square bore 26 in the user's desired orientation. The orientation is displayed from the top of the embossing die 13 by the orienting letter 52 that is closest to the upper orienting arrow 30 . The upper locating surfaces 28 slidably register the embossing die locating surfaces 51 so that the embossing die 13 is precisely coaxial with the upper square bore 26 . The embossing die 13 slides down the square bore 26 until it comes to rest on the upper surface of the return spring 6 .
The user then pulls the lever 1 downward until the lobes 14 contact the surface of the punch 10 or embossing die 13 . Once the lever 1 is down, the cam 58 prevents the lever 1 from opening, even if the punch/emboss tool is turned upside-down. Thus, the punch 10 or embossing die 13 will not unexpectedly fall out of the upper square bore 26 (upper frame position) during use.
Referring to FIGS. 5 and 6, the user must pull the trapdoor 7 back until it contacts the rear trapdoor stop 25 in order to releasably load or hold a punching die 11 or an embossing die counter 12 into the lower square bore 27 (lower frame position). The lower square bore 27 and the upper square bore 26 are precisely coaxial so that the dies loaded in the bores are aligned. The upper and lower square bores 26 , 27 ensure that the dies register or cooperatively mate for respectively punching or embossing a sheet of material when the tool is in use. While the bores are designed to be square in the embodiment described here, they could be made in another polygonal or non-circular shape. There may be other kinds of structural configurations that accomplish the same function.
With the trapdoor 7 fully open, the user holds a punching die 11 by the lip 45 , and places it into the lower square bore 27 , such that the orienting letter 47 that is nearest the lower orienting arrow 31 matches the orienting letter 43 that is nearest the upper orienting arrow 30 . This ensures that the punch 10 and punching die 11 are oriented in the same direction for proper engagement. The lower locating surfaces 59 slidably register the punching die locating surfaces 46 so that the punching die 11 is precisely coaxial with the lower square bore 27 . The punching die 11 slides down the lower square bore 27 until the lip 45 comes to rest on the lip stop surface 63 .
Alternatively, the user holds an embossing die counter 12 by the lip 54 , and places it into the lower square bore 27 , such that the orienting letter 56 that is nearest the lower orienting arrow 31 matches the orienting letter 52 that is nearest the upper orienting arrow 30 . This ensures that the embossing die 13 and embossing die counter 12 are oriented in the same direction for proper engagement The lower locating surfaces 59 slidably register the embossing die counter locating surfaces 55 so that the embossing die counter 13 is precisely coaxial with the lower square bore 27 . The embossing die counter 13 slides down the lower square bore 27 until the lip 54 comes to rest on the lip stop surface 63 .
The user then grips the sides of the trapdoor 7 and slides it forward until it reaches the front trapdoor stop 24 . Held in place by the engaged detent 37 , the trapdoor 7 now holds the punching die 11 or embossing die counter 12 up in the lower square bore 27 when the punch/emboss tool is turned upright for use.
Referring to FIGS. 7 a and 7 b , the punch/emboss tool is ready for actuation. The user grips the upper beam 18 with one hand, placing the thumb on the back end of the lever 1 . The punch/emboss tool can be used in mid-air or while resting on a work surface. With the other hand, the user inserts the sheet material 64 into the gap 23 , noting the location of the center of the imminent punched/embossed pattern shown by the centering arrows 22 . The ruler markings 20 may be used to measure the distance from the edge of the sheet material 64 to the center of the imminent punched/embossed pattern.
Referring to FIG. 8 a , a user punches a decorative shape out of the sheet material 64 by squeezing the lever 1 with the thumb until the lever 1 stops at the downward lever stop surface 62 . The punched-out material falls through the trapdoor window 35 and the front foot window 39 . Upon releasing the lever 1 , the sheet material 64 can be slid out of the gap 23 .
Referring to FIG. 8 b , a user embosses a decorative shape in of the sheet material 64 by squeezing the lever 1 with the thumb, thereby squeezing the sheet material 64 between the embossing die 13 and embossing die counter 12 . The lever 1 does not reach the lever stop surface 62 while embossing. Upon releasing the lever 1 , the sheet material 64 can be slid out of the gap 23 .
The forgoing description sets forth the best mode for carrying out the invention as it is currently known. It is not intended that the description should limit the scope of patent protection in any way. Instead, the spirit and scope of the invention is to be limited by the following patent claim or claims, the interpretation of which is to be made in accordance with the well-established doctrines of patent claim interpretation.
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A punch/emboss tool is provided that accepts interchangeable insert sets. A punch insert set consists of one punch and one die that cooperate to punch out a particular design in sheet material, such as paper. Similarly, an emboss insert set consists of one emboss die and one emboss die counter that cooperate to emboss a particular design. Once loaded in the tool, one half of the insert set is fixed relative to the tool. The other half is slidably aligned to the first half by a non-circular bore. The sheet material is inserted into a slit in the tool, between the two cooperating inserts. An actuating lever presses on the sliding half of the insert set with some mechanical advantage to the user. When a user presses the actuating lever, the two halves of the aligned insert set cooperate to form a punched or embossed design on the sheet material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application Ser. No. 10/246,285, filed Sep. 18, 2002; which is a continuation-in-part of U.S. patent application Ser. No. 10/056,719, filed Jan. 24, 2002, which application issued as U.S. Pat. No. 6,698,726 on Mar. 2, 2004; the entire specifications of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1 . Technical Field
[0003] This invention generally relates to connectors. More particularly, the invention relates to fence rail clips which are used to connect vinyl fence rails and fence posts together. Specifically, the invention relates to an adjustable clip that is mounted onto a fence post and includes covers to hide the mounting mechanism.
[0004] 2. Background Information
[0005] It has recently become more common to use either vinyl or plastic products for constructing fences and deck railings. While vinyl fencing is aesthetically pleasing and easy to maintain, it is more difficult to connect together than wood. One of the more problematic areas is the connection between rails and vertical fence posts. The instant inventor has proposed a novel adjustable connector for joining fence rails to fence posts in the previously filed applications referenced above. In these previous applications two mechanisms have been disclosed for securing the rail clip to the fence post. The first mechanism comprised a bracket which is secured to the fence post and a rail clip having a complementary sized and shaped recess formed in its rear surface and being slidably engageable with the bracket mounted on the post. The second connector mechanism proposed by the instant inventor was the provision of lateral areas on the rail clip which included slots having apertures formed in them. Screws were inserted through the apertures and into the fence post. This second connector mechanism works well to secure the rail clip to the post but, because the screws are visible, the overall appearance of the connection was not entirely aesthetically pleasing.
[0006] There is therefore a need in the art for an improved rail clip for attaching fence rails to fence posts and which presents a clean and finished appearance without the mounting mechanism for the clip on the post being visible.
SUMMARY OF THE PRESENT INVENTION
[0007] A fence rail clip for attaching a fence rail to a vertical fence post. The rail clip has a base with a raised central area flanked by two lateral areas and a rail connector that, vertically or horizontally, slidingly engages the central area of the base. The lateral areas include apertures through which fasteners are inserted to connect the clip to the fence post. A cover snap-fits over each lateral area to hide the fasteners and give the rail clip a clean and aesthetically pleasing appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
[0009] FIG. 1 is a front elevational view of a fence constructed using the rail clip of the present invention;
[0010] FIG. 2 is a partial cross-sectional front view of the rail clip mounted on the fence post through line 2 - 2 of FIG. 1 ; showing the covers attached to the rail clip and the rail projecting out of the rail clip;
[0011] FIG. 3 is a partial cross-sectional front view of the rail clip of FIG. 2 with the cover removed;
[0012] FIG. 4 is a bottom view of the rail clip through line 4 - 4 of FIG. 3 ; and
[0013] FIG. 5 is a rear view of the rail clip through line 5 - 5 of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIG. 1 there is shown a fence, generally indicated at 10 , constructed from a plurality of rails 12 and posts 14 connected together by rail clips 16 in accordance with the present invention. While fence 10 is shown with rails 12 being secured substantially at right angles to posts 14 , it will be understood that rail clips 16 allow the position of a rail to be slidably adjusted on clip 16 and consequently rails 12 can be secured to posts 14 at any desired angle.
[0015] Referring to FIGS. 2-5 , clip 16 comprises a base 18 and rail connector 20 . Base 18 preferably is a single, molded piece that is generally rectangular when viewed from the front ( FIG. 3 ) and is generally semi-circular when viewed from the top or bottom ( FIG. 4 ). Base 18 comprises a central area 22 flanked by lateral areas 24 . Central area 22 has first and second planar walls 26 , 28 connected together by an arcuate outer wall 30 . First planar wall 26 has a length A-A′ ( FIG. 4 ) and second planar wall 28 has a length B-B′ with length A-A′ preferably being shorter than length B-B′. Central area 22 extends outwardly beyond lateral areas 24 thereby forming side walls 34 and a semi-circular groove 36 is cut into each side wall 34 . Rail connector 20 engages in groove 36 , allowing connector 20 to slide along outer wall 30 and allowing the position of rail connector 20 to be adjusted. The interlocking connection of rail connector 20 and base 18 has been previously described in U.S. patent application Ser. No. 10/246,285 and U.S. Pat. No. 6,698,726 issued to the present inventor and the entire specifications of these two documents are incorporated herein by reference.
[0016] In accordance with one of the specific features of the present invention, a cover 38 is provided for each lateral area 24 . Each lateral area 24 has an outer wall 40 which extends outwardly from side walls 34 of central area 22 and is substantially semi-circular when viewed from the bottom ( FIG. 4 ). Outer wall 40 broadens to form shoulders 42 that flank a recessed area 44 ( FIG. 3 ) and terminates in an outer edge 45 that lies substantially parallel to side wall 34 . Recessed area 44 has a bottom wall 46 and an interior wall 48 ( FIG. 4 ) which extends upwardly therefrom. Interior wall 48 lies substantially parallel to side wall 34 of central area 22 . A pair of ribs 50 extend outwardly from bottom wall 46 and terminate at outer wall 40 . As may be seen from FIGS. 4 & 5 , apertures 52 are formed in bottom wall 46 and fasteners 54 are inserted therethrough to secure clip 16 to post 14 . First slots 56 are formed in the underside of bottom wall 46 and at least one second slot 58 is formed in the interior wall 48 of each lateral area 24 . Second slot 58 extends into an interior cavity 60 of central area 22 .
[0017] Each cover 38 is received over outer wall 40 and snap fits into place over lateral area 24 as will be hereinafter described. Cover 38 is substantially C-shaped ( FIG. 4 ) and includes a rear wall 62 with has an arcuate wall 64 extending outwardly therefrom. Arcuate wall 64 is complementary sized and shaped to abut outer wall 40 of lateral area 24 . A pair of tabs 66 ( FIG. 5 ) extend inwardly from the base of rear wall 62 and are positioned to be received within first slots 56 of lateral areas 24 . Tabs 66 are complementary in size and shape to first slots 56 . A detent 68 extends inwardly from the underside of arcuate wall 64 of cover 38 and is positioned to be received within second slot 58 of rail clip 16 . Detent 68 preferably includes a lip 70 which extends upwardly toward arcuate wall 64 and interlocks with the interior side wall 72 of clip 16 ( FIG. 5 ).The positioning and the sizes of tabs 66 and detent 68 and the presence of lip 70 allow cover 38 to be snap-fitted over lateral area 24 . The lip 70 on detent 68 also prevents easy removal of cover 38 from lateral area 24 .
[0018] The present invention is used in the following manner. The rail clip 16 is positioned against the post 14 in the manner shown in FIG. 4 . Fasteners 54 are inserted through apertures 52 and are screwed into post 14 . A cover 38 is then moved laterally, in the direction of Arrows “C” and “D” respectively ( FIG. 3 ) over the outer wall 40 of the corresponding lateral area 24 . The underside of arcuate wall 64 of the cover 38 abuts outer wall 40 and shoulders 42 of lateral area 24 . Cover 38 is slid inwardly over outer wall 40 and shoulders 42 toward central area 22 until detent 68 slides through second slot 58 in interior wall 48 and tabs 66 are received in first slots 56 . As cover 38 continues to be moved inwardly, detent 68 deflects slightly downwardly as lip 70 slides into second slot 58 and then into interior cavity 60 of rail clip 16 . Lip 70 slides out of second slot 58 and into cavity 60 and springs upwardly and into abutting contact with interior side wall 72 of clip 16 . In this position, cover 38 is locked or snap-fitted onto rail clip 16 . In this position, cover 38 hides fasteners 54 , ribs 50 and all other features of lateral area 24 . Clip 16 therefore presents an aesthetically appealing outer surface as is shown in FIG. 2 with no connection mechanism between clip 16 and post 14 being visible. When rail connector 20 is engaged in groove 36 and the position of rail connector 20 is slidably adjusted on the arcuate outer wall 30 of central area 32 , the inner edge 20 a ( FIG. 4 ) of rail connector 20 rides along the outer surface 64 a of arcuate wall 64 of cover 38 .
[0019] If the user desires to remove clip 16 from post 14 or to simply tighten fasteners 54 , the user grasps cover 38 and pulls cover 38 outwardly away from central area 22 (as is indicated by the Arrows “E” and “F” respectively in FIG. 2 ), rotating cover 38 slightly upwardly as he does so. This causes lip 70 of detent 68 to disengage from interior side wall 72 of clip 16 and detent 68 slides out of second slot 58 . At the same time, tabs 66 slide out of first slots 56 and cover 38 slides off outer wall 40 of lateral areas 24 . The user can then loosen or tighten fasteners 54 as desired and then, if required, covers 38 can be snap-fitted to rail clip 16 again in the manner previously described.
[0020] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0021] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
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A fence rail clip for attaching a fence rail to a vertical fence. The rail clip has a base with a raised central area flanked by two lateral areas and a rail connector that, vertically or horizontally, slidingly engages the central area of the base. The lateral areas include apertures through which fasteners are inserted to connect the clip to the fence post. A cover snap-fits over each lateral area to hide the fasteners and give the rail clip a clean and aesthetically pleasing appearance.
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FIELD OF THE INVENTION
This invention relates to orthopedic knee braces, and more particularly to a lightweight cable-tensioned brace in which the cable load is laterally adjustable.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,599,288 issued 04 Feb. 1997 to Shirley et al. and entitled "External Ligament System" discloses a lightweight flexible knee brace in which a pair of cables secured at the back of the wearer's leg extend in criss-cross fashion across the front of the thigh and calf just above and below the knee. A significant part of the brace's action in supporting the knee and its ligaments is the pressure exerted on the front of the thigh and calf by pressure pads that are pressed against the thigh and calf by the cables at the laterally centered points where the cables cross.
It has now been found that the laterally central location of the pressure pads is not necessarily the ideal therapeutic location. The pain associated with osteoarthritis can in many cases be reduced or eliminated by providing a lateral force on the bone of the leg. For some individuals, pressure is best applied somewhat to the right of center, for others somewhat to the left. The brace of U.S. Pat. No. 5,599,288 does not, however, lend itself to lateral load adjustments.
SUMMARY OF THE INVENTION
The present invention allows lateral adjustment of the cable load positions above and below the knee without forgoing the advantages of the cable structure of U.S. Pat. No. 5,599,288, by disposing the cables in a zigzag pattern on each side of the knee, and threading them around cable guides that are mounted on centrally located pressure pads but are laterally movable on the pads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are front, left, right and rear elevations of the inventive brace in place on a patient's leg;
FIG. 5 is a perspective view of the pressure pad of this invention;
FIG. 6 is a section along line 6--6 of FIG. 5;
FIG. 7 is a section along line 7--7 of FIG. 5; and
FIG. 8 is a section along line 8--8 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-4 show the brace 10 of this invention as applied to a patient's leg. Except for the positioning of the tensioning cables 12, 14 and the structure of the load-distributing pressure pads 16, 18, the brace 10 is identical to the brace described in U.S. Pat. No. 5,599,288, whose disclosure is incorporated herein by reference.
In accordance with the present invention, the pressure pads 16, 18 are constructed as best shown in FIGS. 5 through 8. The base 20 of pads 16, 18 is formed of a hard yet somewhat flexible plastic and is curved to generally fit the curve of the wearer's leg surface. The base 20 has four laterally extending sets of grooves 22 formed therein on its outer side for a purpose described below. Laterally extending slots 24, 26 on each side of the base 20 provide tracks in which cable guides 28, 30 are mounted for selective lateral positioning with respect to base 20.
The cable guides 28, 30 are held in the slots 24, 26 by screws 32 and sliding nuts 33 which can be loosened to allow movement of the cable guides 28, 30 in the slots 24, 26, or tightened to prevent movement by engaging the teeth 34 on the cable guides 28, 30 which functions as a direction-changing means for the cable 12 or 14, with the grooves 22. Because the cable guides 28, 30 are subjected to a laterally outwardly directed force by the cables 12, 14, the inclination of the laterally inward-facing faces of the grooves 22 and the laterally outward-facing faces of the teeth 34 is preferably steeper than the inclination of the corresponding outward-facing faces of the grooves 22 and inward-facing faces of the teeth 34, to prevent slippage.
On each side of the leg 36, the cables 12, 14 extend from an anchor point 38 on the upper tensioning strap 40 around the inward end of the upper cable guides 28, 30, then around the flexure axis roller 42 and the lower cable guides 28, 30 to the anchor point 44 on the lower tensioning strap 46.
Protuberances 48 on the cable guides 28, 30 and deformations 50 on the rollers 42 prevent the cables 12, 14 from slipping out of the cable guides 28, 30 and rollers 42 when they are slack.
Based on his evaluation of the patient, the orthopedic surgeon will determine optimum points of force application on the calf and thigh and adjust the position of the cable guides 28, 30 on the pressure pads 16, 18. By doing so, the surgeon can regulate the load applied to the various ligaments of the knee to provide maximum comfort to the wearer of the brace 10.
In use, the brace 10 is circumferentially folded over the wearer's leg 36 as shown in U.S. Pat. No. 5,559,288, and the cables 12, 14 are tensioned or tightened by pulling the anchor points 38 and 44, respectively, toward each other with the aid of Velcro-surfaced straps 40 and 46. The brace 10 is then also secured tightly to the calf just below the knee by tightening support strap 52.
It is understood that the exemplary laterally adjustable knee brace described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. Thus, other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications.
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In a cable-based external knee ligament system, tensioned cables are disposed in a zig-zag pattern on each side of the femoral, patellar and tibial areas, and the load on selected ligaments can be varied by laterally moving cable guides above and below the knee which form the zig-zag pattern.
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[0001] This application claims the benefit of Korean Application No. P2003-085616, filed on Nov. 28, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a dryer, and more particularly, to a heater bracket assembly for securing a heater case in a dryer.
[0004] 2. Discussion of the Related Art
[0005] Generally, a laundry dryer is a home appliance for drying a wet laundry automatically. The dryer is provided with a heater for drying a laundry and a heater bracket assembly supporting the heater. The heater bracket assembly is explained in detail by referring to the attached drawings as follows.
[0006] Referring to FIG. 1 , a dryer 1 consists of a case 10 forming an exterior and a base plate 20 forming a bottom side. An opening 30 is formed in a front side of the case 10 to put/pull a laundry in/from the case and a door 40 is provided to the opening 30 to open/close. And, a drum 50 is rotatably provided within the case 10 to dry a wet laundry therein. Meanwhile, a heater 61 providing hot air to the drum 50 and a heater case 62 accommodating the heater 61 are provided within a space between the drum 50 and the base plate 20 . And, the heater case 62 is fitted in a duct 80 having one open end and the other end communicating with the drum 20 to be coupled thereto without a separate fixing member.
[0007] In order to fix the heater case 62 to the base plate 20 , a heater bracket assembly 70 is provided. A process of assembling the heater bracket assembly 70 , base plate 20 , and heater case 62 is explained by referring to FIG. 2 as follows. The heater bracket assembly 70 has a type cross-section. Holes 21 and 71 are formed at both lower ends of the heater bracket assembly 70 and the base plate 20 , respectively. A fixing member is fitted in the corresponding holes 21 and 71 to fix the heater bracket assembly 70 to the base plate 20 .
[0008] Meanwhile, an upper end of the heater bracket assembly 70 supports the heater case 62 without a separate fixing member. However, when the heater bracket assembly supports the heater case in the above-explained manner, the following problems are inevitable.
[0009] First of all, the heater bracket assembly 70 and the heater case 62 are shaken when the dryer is carried or installed. Namely, when the dryer is shaken, the heater case is detached from the duct to be movable within the dryer. Secondly, in fixing the heater bracket to the base plate, it takes quite a long working time to align the holes of the base plate and heater bracket assembly to each other. Moreover, the corresponding fixing work is not facilitated.
SUMMARY OF THE INVENTION
[0010] Accordingly, the present invention is directed to a heater bracket assembly for a dryer that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0011] An object of the present invention, which has been devised to solve the foregoing problem, lies in providing a heater bracket assembly for a dryer, by which a heater case is prevented from being separated from a duct.
[0012] Another object of the present invention to provide a heater bracket assembly for a dryer, by which the heater bracket assembly is easily fixed to a base plate and by which a corresponding working time is shortened.
[0013] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from a practice of the invention. The objectives and other advantages of the invention will be realized and attained by the subject matter particularly pointed out in the specification and claims hereof as well as in the appended drawings.
[0014] To achieve these objects and other advantages in accordance with the present invention, as embodied and broadly described herein, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, and a connecting part connecting the supporting part and the fixing part, wherein the supporting part comprises a first extension member extended therefrom which engages with an aperture provided to the bottom end of the heater case such that the supporting part is initially secured to the heater case.
[0015] Herein, the fixing part may include a second extension member extended therefrom which engages with an aperture provided on the base plate such that the fixing part is initially secured to the base plate. The second extension member may include a first protrusion protruding downward from a portion of the fixing part to penetrate the aperture provided on the base plate, and a second protrusion protruding forward from a tip of the first protrusion to be in contact with and be supported by a bottom side of the base plate. A tip portion of the second protrusion is tilted such that the second extension member easily engages with the aperture provided on the base plate.
[0016] The supporting part may include at least one through-hole adopted to receive a fastener for securing the bottom end of the heater case to the supporting part. Herein, the fixing part may include at least one through-hole adopted to receive a fastener for securing the fixing part to the base plate. Also, at least one bead is provided to the connecting part for rigidity reinforcement, and the connecting part is tilted forward.
[0017] In another aspect of the present invention, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, a connecting part connecting the supporting part and the fixing part, a first extension member extended from the supporting part for engaging with an aperture provided to the bottom end of the heater case, and a second extension member extended from the fixing part for engaging with an aperture provided on the base plate.
[0018] In a further aspect of the present invention, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, a connecting part connecting the supporting part and the fixing part, the connecting part being tilted forward, a first extension member extended from the supporting part for engaging with an aperture provided to the bottom end of the heater case, a second extension member extended from the fixing part for engaging with an aperture provided on the base plate, and at least one bead provided to the connecting part for rigidity reinforcement.
[0019] It is to be understood that both the foregoing explanation and the following detailed description of the present invention are exemplary and illustrative and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0021] FIG. 1 is a cross-sectional diagram of a dryer according to a related art;
[0022] FIG. 2 is a perspective diagram of a heater bracket assembly according to a related art;
[0023] FIG. 3 is a cross-sectional diagram of a dryer according to the present invention;
[0024] FIG. 4 is a perspective diagram of the heater bracket assembly according to the present invention; and
[0025] FIG. 5 is perspective diagram of the heater bracket assembly coupled to a heater case according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Throughout the drawings, like elements are indicated using the same or similar reference designations where possible.
[0027] FIG. 3 is a cross-sectional diagram of a dryer 100 provided with a heater bracket assembly 300 according to the present invention. Referring to FIG. 3 , a dryer 100 includes a base plate 120 forming a bottom side and a case 110 on the base plate 120 to form an exterior and. An opening 130 is formed in a front side of the case 110 to put/pull a laundry in/from the case and a door 140 is provided to the opening 130 to open/close. A drum is rotatably provided within the case 110 to hold a laundry therein. Front and rear sides of the drum are rotatably coupled to front and rear supports 160 and 170 , respectively. An inlet duct 180 provided in rear of the drum and an outlet duct 190 is provided in front of the drum, whereby the drum can be externally ventilated. The inlet and outlet ducts 180 and 190 are coupled to upper and lower parts of the drum, respectively.
[0028] A motor 200 is provided under the drum to generate a rotational force. In order to transfer the rotational force generated from the motor 200 to the drum, a pulley 210 is coupled to one side of the motor 200 and the pulley 210 is connected to the drum via belt 220 . A blower fan 230 is connected to the other side of the motor 200 . The blower fan 230 is connected to the outlet duct 190 to suck the air inside the drum to discharge outside the case 110 . A heater 240 is provided under the drum to dry the laundry held within the drum. The heater 240 heats air to supply the heated air to the drum. The heater 240 is provided within a heater case 250 . In order for the heater 240 to heat the air, one side of the heater case 250 is open and the other side of the heater case 250 is connected to the inlet duct 180 .
[0029] Meanwhile, the heater case 250 is provided over the base plate 120 via a heater bracket assembly 300 . The heater bracket assembly 300 is explained by referring to FIGS. 4 and 5 as follows. The heater bracket assembly 300 includes a supporting part 310 , a fixing part 320 , and a connecting part 330 . The supporting part 310 supports a bottom side of the heater case 250 . Specifically, the supporting part 310 is fixed (or secured) to a bottom of an open side of the heater case 250 to support the heater case 250 . Holes 251 and 311 are formed in the heater case 250 and the supporting part 310 , respectively, so as to allow a fixing member 260 to pass through. The fixing member 260 is inserted in both of the holes 251 and 311 to fix the heater case 250 to the supporting part 310 .
[0030] Meanwhile, the fixing part 320 is fixed to a topside of the base plate 120 . Holes 321 and 121 are formed in the fixing part 320 and base plate 120 to be penetrated by a fixing member 260 . The corresponding fixing member 260 is inserted in the holes 321 and 121 to fix the fixing part 320 to the base plate 120 . The fixing member 260 preferably includes a bolt and nut or a rivet. The connecting part 330 connects the fixing part 320 and the supporting part 310 . And, the connecting part 330 is tilted forward from the supporting part 310 to the fixing part 320 . Moreover, the connecting part 330 is provided with at least one bead 340 for rigidity reinforcement.
[0031] The bead 340 prevents the connecting part 330 from being bent by a weight applied to the connecting part 330 by the heater case 250 . In this case, the bead 340 is preferably projected toward a rear side of the connecting part 330 . In order to facilitate to manufacture the heater bracket assembly 300 , the heater bracket assembly 300 includes one plate. The one plate is bent to form the fixing, supporting, and connecting parts 320 , 310 , and 330 .
[0032] The heater bracket assembly 300 further includes an extension member 350 provided to at least one portion of the supporting part 310 and/or the fixing part 320 to temporarily fix the heater bracket assembly 300 to the heater case 250 and/or the base plate 120 and to guide a corresponding fixing position. Specifically, the extension member 350 includes a first extension member 351 guiding to maintain a corresponding installing position before the heater case 250 is fixed to the heater bracket assembly 300 by the fixing member 260 . The first extension member 351 is provided to the supporting part 310 to protrude upward from the supporting part 310 . And, the heater case 250 has a hole 252 to be penetrated by the first extension member 351 . Moreover, the extension member 350 penetrates the heater case 250 to prevent from moving on the supporting part 310 .
[0033] And, the extension member 350 includes a second extension member 355 guiding to maintain a corresponding installing position before the heater bracket assembly 300 is fixed to the base plate 120 by the corresponding fixing member 260 . The second extension member 355 is provided to the fixing part 320 to protrude downward from the fixing part 320 . And, the base plate 120 has a hole 122 to be penetrated by the second extension member 355 . The second extension member 355 is explained in detail in the following.
[0034] First of all, the second extension member 355 includes a first protrusion 356 protruding from a lower part of the fixing part 320 to penetrate the base plate 120 and a second protrusion 357 protruding forward from a tip of the first protrusion 356 to be supported by a bottom side of the base plate 120 . The first protrusion 356 guides a fixing position when the heater bracket assembly 300 is fixed to the topside of the base plate 120 . And, the second protrusion 357 is supported by the bottom side of the base plate 120 to maintain a balance of the heater bracket assembly 300 and to fix the heater bracket assembly 300 to the topside of the base plate 120 . In this case, in order to facilitate to insert the second protrusion 357 in the base plate 120 , a tip of the second protrusion 357 is tilted toward a ground in a front direction.
[0035] A process of assembling the heater bracket assembly 300 to the base plate 120 and the heater case 250 is explained as follows. First of all, the heater bracket assembly 300 is fixed to the topside of the base plate 120 using the second extension member 355 . In doing so, the first protrusion 356 is inserted in the base plate 120 and the second protrusion 357 is supported by the bottom side of the base plate 120 . Thus, the heater bracket assembly 300 enables to maintain its balance.
[0036] Secondly, the holes 321 and 121 of the fixing part 320 and base plate 120 are aligned to each other. The fixing member 260 is then inserted in the holes 321 and 121 to completely fix the heater bracket assembly 300 to the base plate 120 . In this case, the fixing member 260 includes the bolt and nut or rivet.
[0037] Thirdly, the heater case 250 is temporarily fixed to the supporting part 310 . In doing so, the first extension member 351 penetrates the lower part of the heater case 250 . Once the first extension member 351 temporarily fixes the heater case 250 to the supporting part 310 , the holes 251 and 311 of the heater case 250 and supporting part 310 are aligned to each other. The corresponding fixing member 260 then penetrates the holes 251 and 311 to completely couple the heater case 250 to the supporting part 310 .
[0038] Accordingly, the heater bracket assembly according to the present invention includes the extension member temporarily fixing the heater bracket assembly to the heater case and the base plate, thereby facilitating to be fixed to the heater case and base plate and shortening a working time. And, the heater case is completely fixed to the heater bracket assembly and the heater bracket assembly is completely fixed to the base plate. Therefore, the heater case is prevented from being detached from the inlet duct.
[0039] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover such modifications and variations, provided they come within the scope of the appended claims and their equivalents.
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A heater bracket assembly for securing a heater case in a dryer is disclosed. The heater bracket assembly includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, and a connecting part connecting the supporting part and the fixing part, wherein the supporting part comprises a first extension member extended therefrom which engages with an aperture provided to the bottom end of the heater case such that the supporting part is initially secured to the heater case.
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TECHNICAL FIELD
In the field of non-invasive blood pressure measurement using a cuff, pressurizing unit and bleeding valves, this invention relates to a method of acquiring a response to the pulsating blood flow which produces stretching of the arterial wall against the bleeding cuff's pressure. The method includes displaying the cuff's fluctuating pressure on a display unit in terms of a variation in the height of the mercury column of a mercury manometer. The arterial wall stretching includes that which occurs before and after each systolic and diastolic pressure detection and between the two detections. The invention further relates to a method of measuring blood pressure by monitoring and recording the arterial response.
Apparatus according to the invention can display the simulated motion of a needle indicator of an aneroid manometer in addition to displaying the mercury column. Thus the invention does not require the manometers used previously in auscultatory methods. The invention can also graphically display in real time the arterial wall's subtle motion, which can not be detected by the auscultatory method with a stethoscope and a microphone. The wall motion is displayed in the form of time varying physical quantities such as acceleration, velocity and the like. This invention can therefore be used as the auscultatory method while monitoring the information being displayed.
BACKGROUND OF THE INVENTION
For acquiring the arterial response to the pulsating blood flow by non-invasive blood pressure measurement with a cuff, a pressurizing unit and bleeding valves, there have been the following available methods: displaying only the intensity level of the Korotkoff's sounds graphically by using a microphone, and displaying the cuff's oscillating pressure wave whose constant bleeding rate is filtered out.
However, there do not exist blood pressure measurement devices which display, in real time, information on the response to the pulsating blood flow and the bleeding of the cuff's pressure while simultaneously displaying the simulated mercury and aneroid manometers.
The invention resolves the following problems of prior measurement devices. Using current methods with a microphone, the acquired dynamic response of an artery to pulsating blood flow does not include information on arterial wall motion. That undetected motion includes movement that creates and annihilates the Korotkoff's sounds, movement immediately before and after the sounds, and movement not creating any Korotkoff's sounds.
The response to the pulsating blood flow which is obtained with the AC component of the cuff's pressure after filtering its DC component can show only the trend of the magnitude variation of the cuff's pressure oscillation. But the response can not show the dynamic expansion rate of the arterial wall. Furthermore, the arterial response to pulsating blood flow from which the systolic and the diastolic pressure are determined varies with the environment in which a subject is placed and the individual characteristics of the subject. Obtaining accurate systolic and diastolic readings for various subjects is difficult from judging only the trend of the magnitude of the cuff's pressure oscillation.
A method of acquiring the arterial response to pulsating blood flow is described in Japanese patent applications No. 61-118305 and No. 61-276785. The applications describe a filtering method. The method takes the first derivative of the cuff's pressure and then its integration with respect to time to obtain the increased amount of the cuff's pressure caused by the arterial expansion against the cuff's pressure. Thus it merely increases the accuracy of the filtering of the oscillating pressure. Since this integration is carried on with the first derivatives above a constant threshold value, it is easily affected by a small change in the bleeding rate.
Difficulty often arises in displaying the graphics of the dynamic parameters characterizing the expansion of the arterial wall, namely the displacement velocity of the wall and the parameters related to its acceleration change.
Therefore, with the bleeding rate nearly constant or even changing, this invention acquires the time trend of the artery wall's expansion caused by the pressure fluctuation in pulsating blood flow against the cuff pressure, acquires the wall motion that gives the accurate systolic and diastolic pressure, and monitors the arterial response to the pulsating blood flow.
Another difficulty in non-evasive blood pressure measurements is obtaining the regulated constant bleeding rate and monitoring the change in the bleeding rate over time. In subjects, the detection of Korotkoff's sounds in phases 1, 4 or 5 often becomes difficult, depending on the magnitude of the bleeding rate. Furthermore, the physical and psychological surroundings of a subject alter one's normal systolic and diastolic pressure readings significantly. In these cases, medical personnel using current auscultatory blood pressure measuring methods have difficulty in determining the cause for the changes.
Thus one object of the invention is to resolve the difficulties stated above by displaying in real time the bleeding of the cuff's pressure during the blood pressure measurements as well as displaying the simulated mercury manometer.
A further object of the invention is the measuring and monitoring of the arterial response in nearly real time for those subjects remote from clinics or hospitals.
SUMMARY OF THE INVENTION
To achieve these objects, the cuff's pressure is deflated at nearly a constant rate through a bleeding valve. With an artery pressed by the cuff's pressure, the pressure fluctuation of the pulsating blood flow stretches the arterial wall and in turn the wall's stretching fluctuates the cuff's pressure.
To obtain the acceleration component of the fluctuating cuff's pressure P c , the second derivative of P c is taken over the time interval for which the acceleration of the bleeding rate becomes nearly zero, even when the bleeding rate is not constant. The second derivative is denoted P sd . To acquire P sd without it being influenced by the bleeding rate, the quantity proportional to the expansion displacement of the artery when pressed as stated above is taken with a displacement transducer such as an optical sensor or the like. Its second derivative with respect to time is then denoted by P sd . Also, the quantity proportional to the displacement velocity of the artery is taken with a velocity transducer such as an ultrasonic sensor or the like placed. It is denoted P fd . The first derivative of P fd is then denoted by P sd . Thus P sd may be obtained from two sources for verifying it value.
As for P c , its mercury height's pressure in millimeters of mercury (mm Hg) is scaled on the Y-axis of a display and its time scale T c is given in seconds on the X-axis. As for the P sd , its magnitude is enlarged on the Y-axis of P c and its time scale T sd is arbitrarily drawn on the Y-axis of P c .
The region surrounded by P sd and time axis T sd is subdivided by each intersection of P sd and T sd , namely T1, T2, . . . , Tm-1, Tm, Tm+1, and so on. Among them, the integral over the positive region, i.e., its area, is taken as the increased value of the wall's displacement velocity GVinc, and the area of its negative region is taken as the decreased value of the displacement velocity GVdec. Their magnitudes are respectively denoted by the length on a bar graph, namely L0, L1, etc. for GVinc and D0, D1, etc. for GVdec and so on. Their scale is enlarged on the P c 's Y-axis as that of P sd . Tinc and Tdec are the time scale for the GVinc and GVdec, respectfully, and their unit is seconds.
The mean accelerating force GAinc for stretching the artery wall is defined as the division of each amplitude (L and S), which is the amount of increase in GVinc, by the time duration for expanding the wall. The mean accelerating force GAdec for contracting the wall is defined as the division of each amplitude (D), which is the amount of decrease in GVdec, by the time duration of contracting the wall. Thus the arterial response in terms of P c , P sd , GVinc, GVdec, GAinc and GAdec- may be graphically displayed.
The velocity component P fd may be obtained in a number of ways. It may be acquired by taking the first derivative of the cuff's pressure P c detected through a pressure transducer with acquiring P sd or it may be acquired directly through a transducer that detects the arterial wall motion.
Increases (L and S in GVinc) and decreases (D in GVdec) in the velocity component P sd of the arterial wall motion may be acquired by taking the difference between velocity components at each intersection (T1, . . . Tm). For example, L1 is proportional to P fd (T2) minus P fd (T1) and D1 is proportional to P fd (T3) minus P fd (T2). Dividing L,S and D by the time spent producing the change produce the mean expanding and contracting acceleration forces GAinc and GAdec, respectively.
Another object of this invention is to provide a method of measuring blood pressure which gives nearly the same systolic and diastolic pressure readings as those obtained by the auscultatory method. For that purpose, when the amplitude of GVdec becomes consecutively larger than its threshold (two-thirds of its maximum amplitude Dmax), the cuff pressure giving the closest amplitude to that threshold is taken as the systolic pressure SYS. Similarly, when the amplitude of GVdec becomes consecutively smaller than its threshold, the cuff pressure giving the closest amplitude to the threshold is taken as the diastolic pressure DIA.
This invention also provides a method of measuring blood pressure which gives the accurate systolic and diastolic pressure readings by using the unique wave form of the acceleration component P sd . The systolic pressure is transformed either into the change in time Tm between Lm and Sm (where m=1,2,3) in the increased displacement velocity component GVinc on the wall, or their amplitudes' change Am and so on. The cuff pressure is taken as the systolic reading SYS at the time the uniqueness is found for which either of Tm and Am or both start to increase. Furthermore, the mean value of the amplitudes D1 (at SYS), D0 (immediately before SYS) and D2 (immediately after SYS) is obtained. The cuff pressure at the time the decreased displacement velocity component GVdec on the wall becomes smaller than D1 is defined as the diastolic pressure reading DIA.
Another object of the invention is to provide a non-invasive blood pressure measuring apparatus comprising a cuff and tubes which can be wrapped around an artery in a finger, arm or a leg to be pressed; pressurizing and bleeding units for inflating the cuff and tubes; a pressure transducer for detecting the cuff's pressure; a displacement transducer for detecting displacement of the arterial wall motion; a velocity transducer for detecting a displacement velocity of the motion; a micro-controller for controlling each unit; a data processor and memory unit for carrying out the methods described; a display unit for showing the process data; and a data transmission unit.
With this apparatus, the fluctuating pressure reading acquired through the pressure transducer is displayed in real time as the height of a mercury column in the manometer glass tube. Then the cuff pressure on the subject's artery is raised a little above the systolic pressure before deflation. Setting the time axis at an arbitrary position, there are simultaneously displayed in real time the trend of the cuff's pressure P c , the acceleration of the arterial wall's displacement P sd , and the increased and decreased amount of GVinc and GVdec, and the time trend of GAinc, GAdec and P fd .
There are also displayed Dmax, threshold Dmax - 2/3 being calculated with Dmax, and D1. Thus this apparatus measures the blood pressure non-invasively while monitoring the arterial response, and transmits the acquired data to other instruments through a network, a telemeter or the like.
The invention displays in real time the instantaneous velocity and acceleration of the arterial wall displacement which is obtained from fluctuations in the cuff's pressure. The invention also displays, in real time, the trend of the wall velocity change, and the characteristics of the time trend of the mean acceleration change.
The invention also displays in real time various wall expansion motions until the artery that is being pressed by the cuff's pressure relaxes to being free. Thus with the displayed arterial wall motion the invention acquires the following: the abnormal wall expansion of the arterial wall that can not be detected by the Korotkoff's sounds; the small abnormality accompanying a light irregular heart beat or the like; and the change in the arterial response due an unusual psychological and physical environment in which the subject is placed (for example under alert conditions, after exercising and under the alcoholic influence). In particular, the visualized displacement acceleration that is acquired by this invention is able to easily differentiate the noise created by non-arterial wall motion. The pressure reading acquired with the pressure transducer is converted to the height of the mercury column. It is displayed in real time inside the glass tube and is stored in memory. Thus even if this method is used along with an auscultatory method, it not only makes the detection of the Korotkoff's sounds in phases 1, 4 and 5 more certain, but also simplifies analyzing and storing the data in a way that can not be achieved by the blood pressure measurement techniques commonly practiced with mercury or aneroid manometers. Furthermore, transmission of the acquired data through a network or a telemeter is easily done.
The time changes of P sd , GVinc, GVdec, GAinc and GAdec describe the expansion motion of the arterial wall. These changes may be used to non-invasively acquire information for the human cardiovascular system such as the degree of artery hardening and the like. Since apparatus according to the invention may also transmit the acquired data, measurements for subjects in remote locations can be monitored through a telephone hook-up. Medical personnel at the other end of the telephone line can instantaneously send appropriate instruction for treatment back to the subject through the apparatus.
If this apparatus is simultaneously used with an electrocardiograph, brain wave monitor or other instrument, the data obtained from these instruments can be displayed with the arterial response. Thus the apparatus not only increases the added value on such instruments, but also allows the data to be combined with other data.
P sd can alternatively be obtained by time-differentiation of the wall displacement and the displacement velocity acquired during non-invasive blood pressure measurement with optical and ultrasonic transducers respectively. Thus the invention works with blood pressure measuring methods that use displacement and displacement velocity transducers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an apparatus according to the invention for making non-invasive blood pressure measurements.
FIG. 2 is a display of the arterial response when the cuff's pressure's bleeding rate is fast and changing.
FIG. 3 is a display of the arterial response when the bleeding rate is nearly a specified constant.
FIG. 4 is a display of a simulated mercury manometer.
FIG. 5 is a display of the arterial response about five seconds after starting the blood pressure measurement.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown a non-invasive blood pressure measuring apparatus according to the invention. The apparatus comprises a cuff 1 with embedded tubes which may be wrapped around an artery 4 within a finger, arm or leg. Connected to the cuff 1 are pressurizing and bleeding units 3 and 2 to inflate and deflate the tubes of cuff 1, respectively. A pressure transducer 5 is connected to the cuff for detecting the cuff's pressure as it is inflated and deflated and for communicating the pressure data as an electrical signal to a data processor 6. A displacement transducer 11 such as an optical sensor is connected to the cuff 1 for detecting the displacement of the arterial wall as it expands in response to the pulsating blood flow. A velocity transducer 12 such as a ultrasonic sensor is connected to the cuff 1 for detecting the velocity of the wall expansion. Transducers 11 and 12 communicate their respective data a electrical signals to the data processor 6.
The operation of the measuring apparatus is coordinated by a micro-controller 8 which controls the pressurizing unit 3, the bleeding unit 2 and the data processor 6. Data obtained from transducers 5, 11 and 12 and processed by data processor 6 may be stored in memory unit 9 and displayed on display unit 7. A data transmission unit 10 is also included in the apparatus. The unit 10 allows the acquired data to be transmitted to other instruments either directly or over the telephone lines and to receive data in return.
With the cuff inflated to a pressure P c by pressurizing unit 3, the artery 4 is squeezed by the cuff's pressure P c . The pressure P c in the cuff is then deflated at nearly a constant bleeding rate through the bleeding valve unit 2. Against the artery 4, the pressure fluctuating of the pulsating blood flow starts to stretch the arterial wall which in turn moves to fluctuate the cuff's pressure.
To obtain only the acceleration component of the fluctuating cuff's pressure P c , the second derivative P sd of P c is taken at the data processing unit 6 over the time interval for which the acceleration of the bleeding rate becomes nearly zero. The relationship between P c and P sd is shown in FIG. 2 where the bleeding rate is not constant and in FIG. 3 where the bleeding rate is nearly a constant rate.
To acquire P sd without it being influenced by the bleeding rate, the quantity proportional to the wall's displacement of artery 4 pressed as stated above is taken with displacement transducer 11. Its second derivative with respect to time is denoted by P sd . Also, the quantity proportional to the wall's displacement velocity of artery 4 is directly taken with velocity transducer 12 placed on the cuff. It is denoted by P fd . The first derivative of P fd is P sd . The numerical values processed at the data processing unit 6 are displayed on the displaying unit 7.
To display P c , the pressure is simulated as the mercury height in mmHg at the display unit 7 with the Y-axis being pressure in mmHg and the X-axis being its time scale Tc in seconds. To display P sd , its magnitude is enlarged on the Y-axis and its time scale T sd is arbitrary drawn at 300 on the Y-axis. The pressure fluctuation of Pc due to the pulsating blood flow is enlarged on P sd without being influenced by the bleeding rate where the subjects in FIGS. 2 and 3 are different.
Next, as shown in FIG. 3, the region surrounded by P sd and time axis T sd is subdivided by the every intersection of P sd and T sd , namely T1, T2 . . . , Tm-1, Tm, Tm+1 and so on. Among them the integral over the positive region, i.e., its area, is taken as the increased value of the wall's displacement velocity Gvinc, and the area of its negative region is taken as the decreased value of the displacement velocity GVdec. Their magnitudes are respectively denoted by the length on the bar graph, namely LO, L1, and D0, D1, and so on. Their scale is enlarged on the Y-axis. Tinc and Tdec are the time scales for GVinc and GVdec, respectively, and their unit is seconds.
The means accelerating force of the expansion acting on the artery wall, GAinc, is calculated at the data processing unit 6 by dividing GVinc by the time interval for expanding the wall. The mean contracting force GAdec is calculated at unit 6 by dividing GVdec by the time interval for contracting the wall. Their magnitudes and time scales can be shown in real time on the Y and the X-axis at the display unit 7 in a monitor similar to showing GVinc and GVdec.
According to the process for acquiring the arterial response described in this first example, the pressure fluctuation of the pulsating blood flow is effectively obtained and shown in FIGS. 2 and 3 as P sd along with its time trend, which is proportional to the instantaneous acceleration stretching the arterial wall.
From the instantaneous acceleration on the arterial wall motion, the change of the displacement velocity induced by the wall's stretching is calculated as the integration over the positive region of instantaneous acceleration P sd with respect to time. Its magnitude is shown in GVinc in FIGS. 2 and 3. The quantity corresponding to the velocity change due to the wall contraction is calculated as the integration over the negative region of instantaneous acceleration P sd with respect to time. Its magnitude is shown as GVdec in FIGS. 2 and 3. The quantity proportional to the average displacement acceleration acting on the wall motion is taken as GAinc and GAdec and is calculated by dividing GVinc and GVdec by the corresponding time interval for the integrations respectively. Thus these methods effectively acquire the non-invasive arterial response process.
Next a second example of acquiring the arterial response using the apparatus shown in FIG. 1 is described. This method is to obtain the increments of the wall's displacement velocity at the data processing unit in the following way. The displacement velocity of the wall, P fd , taken as the first derivative of Pc with respect to time is shown in the lower section of FIG. 3 along with acceleration P sd taken as the second order time derivative of Pc. The time scale of either this P fd or other P fds obtained by other methods and T sd , namely T1, . . . , Tm, and so on, the corresponding velocity components, i.e., P fd (T1), . . . , and P fd (Tm), are obtained. The increased or the decreased amount on the displacement velocity of the arterial wall motion, i.e., GVinc and GVdec, are obtained by the difference between the two of these. For example, L1 and D1 are proportional to P fd (T2)-P fd (T1) and P fd (T3)-P fd (T2) respectively. Furthermore, S1 is proportional to P fd (T4)-P fd (T3). Thus Gvinc and GVdec are divided by the corresponding time intervals and they are matched with the mean expanding and contracting accelerations GAinc and GAdec respectively.
According to the acquired arterial response process in this second example, the pressure fluctuation of the pulsating blood flow is proportional to the instantaneous displacement velocity of the arterial wall, which is shown as P fd in FIGS. 2 and 3 along with its time trend. With this instantaneous velocity change on the arterial wall motion, the same GVinc and GVdec as in the first example are calculated as the changes of the displacement velocity for each stretching process. Furthermore, the mean displacement acceleration of the wall motion, as in the first example, is GAinc and GAdec, which are calculated by dividing GVinc and GVdec by each time interval respectively. Thus this method effectively acquires the non-invasive arterial response process.
A third example is to be explained. This uses the arterial response acquired by the above method in order to obtain a blood pressure measurement which gives nearly the same systolic and diastolic pressure readings as the auscultatory method. In this non-invasive blood pressure measurement, the following data analysis is made at unit 6. As shown in FIG. 3, when the amplitude of GVdec becomes consecutively larger than threshold Dmax-2/3 (being two-thirds of the maximum amplitude Dmax), the cuff pressure giving the closest amplitude to that threshold is taken a the pressure reading of the wave crest in the pulsating blood flow, namely systolic pressure SYS. Similarly, when the amplitude of GVdec becomes consecutively smaller than the threshold, the cuff pressure giving its first smaller amplitude is taken as the pressure reading of the wave trough in the pulsating blood flow, namely diastolic pressure reading DIA.
According to this non-invasive blood pressure measurement method as shown in FIGS. 2 and 3, if threshold Dmax-2/3 is obtained as being two-thirds of the maximum amplitude Dmax, there are seen the GVdec's amplitudes, D1, D2, D3 and etc., getting consecutively larger than the threshold. Then the cuff's pressure reading at the time when the amplitude becomes the closest to that threshold is 120 mmHg and 101 mmHg for the cases in FIGS. 2 and 3 respectively. They are the wave crest values of the pulsating blood flow, namely the systolic pressure readings. When D7 and D8 are detected at which GVdec consecutively gets smaller than Dmax-2/3, the cuff pressure 65 mmHg which gave amplitude D7 the first smaller amplitude is the wave trough of the pulsating blood flow, namely the diastolic pressure reading. Similarly, when D12, D13 and D14 are detected at which GVdec consecutively gets smaller than Dmax-2/3, the cuff pressure 67 mmHg which gave amplitude D12 the first smaller amplitude is the wave trough of the pulsating blood flow, namely the diastolic pressure reading.
This measuring method shows that since every Korotkoff's sound simultaneously taken with a stethoscope during the measurement (labeled as k on the Pc curves in FIGS. 2 and 3), including the sound of phase 1 defining the systolic pressure reading, agrees with the pulsating process characterized with L1 and D1 in FIGS. 2 and 3. The method also shows that the annihilation of the Korotkoff's sound of phase 5 similarly agrees with the arterial wall expansion process characterized with L7 and D7 in FIG. 2, and with L12 and D12 in FIG. 3. Thus this method is also effective as well.
Next, a fourth example is to be explained. This example is for the blood pressure measurement method giving the accurate systolic and diastolic readings by using the unique characteristics on the arterial response acquired through the method described in examples 2 and 3. The data analysis is also made at unit 6 in the following way. As shown in FIGS. 2 and 3, the unique wave form in the neighborhood of the wall's displacement acceleration P sd on the artery wall motion to determine the systolic pressure reading is transformed into either the changes of the time difference Tm between Lm and Sm in the increased displacement velocity component GVinc on the wall or their amplitudes' change Am where m=1,2,3, and so on. The cuff pressure is taken as the systolic reading SYS at the time the uniqueness is found for which either of the Tm and the Am or the both start to increase consecutively as shown in FIGS. 2 and 3. Furthermore, the mean value of the amplitudes D1 (at SYS), D0 (at right before SYS) and D2 (at right after SYS) which is indicated as Dave in FIG. 3 is obtained. The cuff pressure at the time the decreased displacement velocity component GVdec on the wall becomes consecutively smaller than either D1 or Dave is defined as the diastolic pressure reading DIA.
According to the measuring method, the unique patterns in the neighborhood of P sd giving the systolic pressure are obtained, as shown in FIGS. 2 and 3. They are the continuous increase as in T1, T2, T3 and T4 which are the time difference between the pairs L1 and S1, L2 and S2, L3 and S3, and L4 and S4 on GVinc; and the continuous increase of amplitude L as in A1, A2, A3 and A4. Therefore, the arterial wall stretching giving the systolic pressure shows agreement with the pulsating process characterized with L1 and D1. The systolic pressure readings are then 120 mmHg and 101 mmHg for FIGS. 2 and 3 respectively. They agree with those in the auscultatory method stated above.
Furthermore, the arithmetic average of amplitudes D1, D0 (right before) and D2 (right after) is calculated as Dave. During the course on which D12, D13 and D14 are consecutively getting smaller than either of the D1 and Dave, the cuff's pressure which gives amplitude D12 the first smaller amplitude is the diastolic pressure reading 69 mmHg which is the same as that given by the auscultatory method. as for FIG. 2, since Dave is nearly the same as Dmax-2/3, the cuff's pressure which gives amplitude D7 the first amplitude becoming smaller consecutively than either the D1 or Dave, is the diastolic pressure reading 65 mmHg. Since it is also the same as in the auscultatory method, this method is also effective for the non-invasive blood pressure measurement.
A fifth example is to be explained. This example is the blood pressure measuring method with the apparatus laid out in FIG. 1. The method bases on the acquired arterial response process being displayed in real time on the display unit 7. Following the non-invasive apparatus as shown in FIG. 1, cuff 1 being wrapped around a finger or an arm or a leg is to be inflated with a pressurizing unit 3 comprising a small pump or the like, in order to press artery 4. The cuff pressure is then detected with transducer 5 and its pressure readings are displayed on the display unit 7 through the data processing unit 6. On a display unit 7, the pressure reading which was converted to a height information of mercury manometer at unit 6 is displayed in real time as if it were the mercury column of sphygmomanometers as shown in FIG. 4.
While watching in real time the pressure reading (the height) displayed on the mercury manometer, the cuff pressure on the subject's artery is raised a little above subject's systolic pressure reading. When the cuff's pressure starts bleeding, the time and pressure scales are displayed along the X and Y axis respectively. Setting the time axis at arbitrary position, there are simultaneously displayed on unit 7 in real time the trend of the cuff's pressure Pc, the acceleration of the arterial wall's displacement P sd , and the increased and decreased amount of the velocity component, GVinc and GVdec as those in the first example, or the time trend of GAinc, GAdec and P fd .
Then, there are also displayed Dmax as shown in FIGS. 2 and 3, threshold Dmax-2/3 in FIG. 2 being calculated with Dmax, and either of D1 and Dave in the fourth example as shown in FIG. 3. Thus it becomes possible to measure the blood pressure non-invasively while monitoring the artery response to the pulsating blood flow in real time. Further it can store the response process at the memory unit 9. It also can transmit the acquired data from the data communication unit 10 to other instruments capable of simultaneously measuring or inversely receiving the data from them through a communication network, a telemeter and the likes.
Therefore, according to this non-invasive measurement, the arterial response characterized by the wall motion can be monitored in real time. Thus, transmitting the monitored data to other instruments becomes possible. Reversibly, it becomes possible first to receive the data from the other instruments capable of simultaneously monitoring the same object, for example a brain wave monitor and the likes, and then to display it as an analog quantity in real time. As this result, the non-invasive blood pressure measurement can be effectively made.
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Using a non-invasive blood pressure measuring apparatus that comprises a cuff, a pressurizing unit and bleeding valve, methods to acquire the arterial response to pulsating blood flow through an artery against the bleeding cuff's pressure are described. There are also described method for displaying in real time the entire arterial response on a display unit such as a CRT or LCD, which show the physical and psychological environment where a subject is placed. With the acquired data, accurate systolic and diastolic readings sensitive to environmental change are determined while monitoring in real time the entire arterial response. Remote monitoring of blood pressure can be done by transmitting the acquired data via telephone lines or directly to medical personnel or other instruments.
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RELATED APPLICATION
[0001] This invention claims priority from Provisional application No. 60/196,599, filed Apr. 13, 2000.
BACKGROUND
[0002] This invention relates to multi-antenna receivers.
[0003] Future wireless communications systems promise to offer a variety of multimedia services. To fulfill this promise, high data rates need to be reliably transmitted over wireless channels. The main impairments of wireless communication channels are time varying fading due to multipath propagation, and time dispersion. The multipath fading problem can be solved through antenna diversity, which reduces the effects of multipath fading by combining signals from spatially separated antennas. The time dispersion problem can be solved by equalization, such as linear, decision feedback, and maximum likelihood sequence estimation (MLSE).
[0004] It has been a standard practice to use multiple antennas at the receiver with some sort of combining of the received signals, e.g., maximal ratio combining. However, it is hard to efficiently use receive antenna diversity at remote units, e.g., cellular phones, since they typically need to be relatively simple, small, and inexpensive. Therefore, receive antenna diversity and array signal processing with multiple antennas have been almost exclusively used (or proposed) for use at the base station, resulting in an asymmetric improvement of the reception quality only in the uplink.
[0005] Recently, there have been a number of proposals that use multiple antennas at the transmitter with the appropriate signal processing to jointly combat the above wireless channel impairments and provide antenna diversity for the downlink while placing most of the diversity burden on the base station. Substantial benefits can be achieved by using channel codes that are specifically designed to take into account multiple transmit antennas. The first bandwidth efficient transmit diversity scheme was proposed by Wittneben and it included the transmit diversity scheme of as a special case. See N. Seshadri and J. H. Winters, “Two Schemes for Improving the Performance of Frequency-Division Duplex (FDD) Transmission Systems Using Transmitter Antenna Diversity,” International Journal of Wireless Information Networks , vol. 1, pp. 49-60, January 1994. In V. tarokh, N. Seshadri, and A. R. Calderbank, “Space-Time Codes for High Data Rate Wireless Communications: Performance Criterion and Code Construction,” IEEE Trans. Inform. Theory , pp. 744-765, March 1998, space-time trellis codes were introduced, where a general theory for design of combined trellis coding and modulation for transmit diversity is proposed. An input symbol to the space-time encoder is mapped into N modulation symbols, and the N symbols are transmitted simultaneously from N transmit antennas, respectively. These codes were shown to achieve the maximal possible diversity benefit for a given number of transmit antennas, modulation constellation size, and transmission rate. Another approach for space-time coding, space-time block codes, was introduced by S. Alamouti, in “Space Block Coding: A Simple Transmitter Diversity Technique for Wireless Communications,” IEEE Journal on Selec. Areas. Commun ., vol. 16, pp. 1451-1458, October 1998 and later generalized by V. Tarokh, H. Jafarkhani, and R. A. Calderbank, in “Space Time block Codes From Orthogonal Designs,” IEEE Trans. is Inform. Theory , vol. 45, pp. 1456-1467, July 1999.
[0006] Space-time codes have been recently adopted in third generation cellular standard (e.g. CDMA-2000 and W-CDMA). The performance analysis of the space-time codes in the above-mentioned articles was done assuming a flat fading channel. Analysis shows that the design criteria of space-time trellis codes is still optimum when used over a frequency selective channel, assuming that the receiver performs the optimum matched filtering for that channel. In addition, although the space-time coding modem described in A. F. Naguib, V. Tarokh, N. Seshadri and A. R. Calderbank, “A Space-Time Coding Based Modem for High Data Rate Wireless Communications,” IEEE Journal on Selec. Areas Commun ., vol. 16, pp. 1459-1478, October 1998 was designed assuming a flat fading channel, it performed remarkably well when used over channels with delay spreads that are relatively small as compared to the symbol period T s . However, when the delay spread is large relative to the symbol period, e.g., ≧T s /4, there was a severe performance degradation.
SUMMARY
[0007] In connection with transmitted space-time, trellis encoded, signals that pass through a transmission channel that is characterized by memory, improved performance is realized with a receiver that combines a decoder with an equalizer that selects the trellis transition, s, that minimizes the metric
ξ j ( k ) = r ( k ) - ∑ l = L 1 + 1 L 1 h ~ j ( l ) s ~ ( k - l ) - ∑ l = L 1 + 1 L + 1 h ~ j ( l ) s ^ ( k - l ) 2
where {tilde over (h)} j (l) is related to both the transmission channel and to the encoding structure in the transmitter, {tilde over (s)}(k) are the (trial) symbols according to a certain transition and ŝ(k) are the symbols that were previously decided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts a transmitter having a plurality of antennas, and a receiving having a plurality of antennas, where the transmission channel between them includes memory;
[0009] FIG. 2 illustrates a particular trellis structure for the trellis encoder shown in the is FIG. 1 transmitter; and
[0010] FIG. 3 is an advantageous constellation mapping.
DETAILED DESCRIPTION
[0011] FIG. 1 presents the general scenario of a transmitter 10 having N transmit antennas, for example 11-1, and 11-2, and a receiver 20 with 21 - 1 , 21 - 2 , . . . 21 -M receive antennas, in a frequency selective Rayleigh fading environment. The M receive antennas are coupled to equalizer/decoder 23 , equalizer/decoder 23 is coupled to symbol-to-bits mapper 25 , and mapper 25 is connected to an outer-code decoder 27 (if the signal transmitted by transmitter 10 is encoded with an outer-code encoder—as shown in transmitter 10 ). The design and operation of equalizer/decoder, which may be implemented with a conventional digital signal processor, is the subject of this disclosure,
[0012] Generally, the impulse response of the transmission channel between the i-th transmitting to the j-th receiving antennas, when modeled with a time varying FIR impulse response, is
g ij ( k ) = ∑ l = 0 L h ij ( k , l ) δ ( k - l ) , ( 1 )
which includes the effects of the transmitter and receiver pulse shaping filters and the physical multipath channel. Equation (1) incorporates the notion that for various reasons, such as a plurality of different-distance paths, the transmission channel includes memory. Without loss of generality, it is assumed that the channel model order (i.e., the channel's memory) is L+1. It is also assumed that the channel parameters {h ij (k,l), i=1. . . M} are invariant within a data burst, although they may be varying from burst to burst. In cellular systems such as GSM, the length of a data burst is about of 0.58 ms, and compared to the coherence time of the channel at 60 MPH mobile velocity, which is approximately 12.5 ms, the burst length is small enough such that the block time-invariant channel model is valid. This assumption is satisfied in most of the GSM environment.
[0013] The h ij (k,l) elements are modeled as iid complex Gaussian random variables with zero mean and variance σ h 2 (l), and the channel is assumed to be passive; that is
∑ l = 0 L σ h 2 ( l ) = 1. ( 2 )
[0014] When s(k) is the signal that is applied to time-space encoder 19 of FIG. 1 , the corresponding output is {c 1 (k),c 2 (k), . . . ,c N (k)}, where c 1 (k) is the code symbol transmitted from antenna i at time k. The received signal at receive antenna j can be expressed by:
r j ( k ) = ∑ i = l N ∑ l = 0 L h ij ( l ) c i ( k - l ) + n j ( k ) , 1 ≤ j ≤ M , ( 3 )
where n j (k) is a sequence of iid complex Gaussian noise samples with zero mean and variance σ n 2 . One of the summations in equation (3) can be put in a matrix form, to yield
r j ( k ) = ∑ i = l N g ij · c i ( k ) + n j ( k ) , ( 4 )
where g ij =[h ij (0)h ij (1) . . . h ij (L)] and c i (k)=[c i (k)c i (k−1) . . . c i (k−L)] T . The output of the M receive antennas at time k can thus be expressed by
r ( k ) = [ r 1 ( k ) r 2 ( k ) … r M ( k ) ] T
= ∑ i = 1 N H i · c i ( k ) + n ( k ) ( 5 )
where
n ( k ) = [ n 1 ( k ) n 2 ( k ) … n M ( k ) ] T
H i = [ g il g i2 ⋮ g iM ] = [ h i ( 0 ) h i ( 1 ) … h i ( L ) ] , and
h i ( l ) = [ h il ( l ) h i2 ( l ) … h iM ( l ) ] T .
The noise vector n(k) has a zero mean and covariance R n =σ n 2 ·I M×M .
[0015] Extending equation (5) to a D+1 sequence of received signals (e.g., a D-stage shift register, yielding D+1 taps), a vector x(k) can be considered that can be expressed by
x ( k )=[ r ( k ) T r ( k− 1) T . . . r ( k−D ) T ] T .
The new space-time data model is then given by
x ( k ) = ∑ i = 1 N ℋ i · c _ i ( k ) + n _ ( k ) ( 6 )
where {overscore (c)} i (k)=[c i (k),c i (k−1), , , , ,c i (k−L−D)] T , {overscore (n)}(k)=[n(k) T n(k−1) T . . . n(k−L) T ] T , and
ℋ i = [ H i ⋯ 0 ⋰ 0 ⋯ H i ]
is an M(D+1)×(L+D+1) matrix. The noise vector {overscore (n)}(k) has a zero mean and covariance R {overscore (n)} =σ n 2 ·I M(D+1)×M(D+1) .
[0016] With the above analysis in mind, one might consider the situation where the mapper 14 is an 8-PSK 8-state mapper, followed by a trellis encoder 16 whose output is applied to space-time coder 19 . The input to coder 19 forms a first output of the space-time coder, and is applied to antenna 11 - 1 . This input is also applied to delay element 17 and thence to multiplier 18 , which creates a second output of the space-time coder. That second output is applied to antenna 11 - 2 . Multiplier 18 multiplies the mapped signal by −1 (rotates it by 180) when the symbol applied to multiplier 18 is odd. Advantageously, the mapping within element 14 is as depicted in FIG. 3 ; that is, traversing the unit circle counterclockwise starting with 0, the sequence of mappings is {0,7,6,1,5,2,3,4}.
[0017] The trellis of encoder 16 is shown in FIG. 2 . For this arrangement, the input bit stream is grouped into group of three bits each and each group is mapped into one of the 8 constellation points, which are also states of the trellis encoder. The column to the left of the trellis is the state label and each row to the right of the trellis represents the edge labels for transitions from the corresponding state. An edge label c 1 c 2 indicates that symbol c 1 is transmitted from the first antenna and symbol c 2 is transmitted from second antenna. To illustrate, assuming that the encoder starts from state ‘0’—which is the conventional assumption—if the input sequence is { 0 1 5 7 6 4 } then operating pursuant to the FIG. 2 trellis yields the sequence {0 1 5 7 6 4} that is transmitted over the first antenna and the sequence {0 0 5 1 3 6} that is transmitted over the second antenna.
[0018] For data rates on the order of the coherence bandwidth of the channel, or larger, an equalizer needs to be used to compensate for the intersymbol interference induced by the resolvable multipath receptions. There are two basic, yet powerful, equalization techniques that are used for equalization over wireless channels: the probabilistic symbol-by-symbol MAP algorithm, which provides the MAP-probabilities for each individual symbol, and the Viterbi algorithm (VA), which is a maximum likelihood sequence estimator (MLSE) that outputs the ML-channel path. Both techniques have the advantage that they gather energy from all channel tap gains (therefore taking full advantage of the diversity gain offered by the multipath propagation) without suffering from noise enhancement or error propagation. This is rather an important feature because in wireless propagation environments the reflections may be stronger than the direct path. The main problem of both approaches, however, is their complexity in terms of the equalizer states. For example, in case of space-time coding with N transmit antennas and a channel response with length L+1, the number of equalizer states will be ( N ) L , where is the number of constellation points. That is, the equalizer complexity is exponential in terms of number of transmit antennas and channel memory.
[0019] The equalizer complexity problem can be solved by using a reduced complexity approach by M. V. Eyuboglu and S. U. Qureshi, in “Reduced-State Sequence Estimation with Set Partioning and Decision Feedback,” IEEE Trans. Commun ., vol. COM-36, pp. 12-20, January 1988. However, reduced complexity techniques suffer from performance degradation if the channel response is not minimum phase, or nearly so. Since wireless channels are time varying and hence the minimum phase condition is not guaranteed all the time, a whitened matched filter or a pre-curser equalizer must be used to render the channel minimum phase all the time. Although designing a whitened matched filter is well known for the classical equalization problem, it is not known for space-time coding with transmit diversity. This is because, as mentioned earlier, the received signal at the receiver is the superposition of all transmitted signals that propagated through totally independent channels. Consequently, the job of the whitened matched filter in this case is to render all of these channels minimum phase at the same time; and it is not known how to achieve this.
[0020] To overcome this problem, the following discloses a reduced complexity approach that uses the structure that is present in some space-time trellis codes, such as the one presented in FIG. 2 .
[0021] Defining s(k)≡[s(k) s(k−1) . . . s(k−L)] T , from FIG. 2 is can be seen that the code symbols to be transmitted from the first antenna (at time k, k− 1 , . . . , k−L) are c 1 (k)=[s(k) s(k− 1 ) . . . s(k−L)] T and, hence, c 1 (k)=s(k). The corresponding code symbols to be transmitted from the second antenna can be expressed by
c 2 ( k )= S·s ( k− 1)
where S=diag{f(l))} l=1 . . . L+1 and
f ( l ) = 1 - 2 * mod ( ∠ s ( k - 1 ) π / 4 , 2 ) ( 8 )
Hence, the received signal vector at the M receive antennas in (5) can be rewritten as
r ( k ) = H 1 · s ( k ) + H 2 · S · s ( k - 1 ) + n ( k ) = ( [ H 1 ⋮ 0 ] + [ 0 ⋮ S · H 2 ] ) [ s ( k ) ⋮ s ( k - 1 ) ] + n ( k ) ( 9 )
For the j-th receive antenna, this reduces to
r j ( k ) = ∑ l = 0 L + 1 h ~ j ( l ) s ( k - l ) + n ( k )
where ( 10 ) h ~ j ( l ) = { h 1 j ( 0 ) l = 0 h 1 j ( l ) + f ( l ) · h 2 j ( l - 1 ) l = 1 … L f ( L + 1 ) · h 2 j ( L ) l = L + 1 ( 11 )
Note that the delay diversity case for 8-PSK with 2 transmit antenna can be obtained by setting f(l)=1∀l in equations (9), (10), and ( 11 ). Using equation (10), a branch metric for the j-th receive antenna at time k in a reduced-complexity MLSE is
ξ j ( k ) = r ( k ) - ∑ l = L 1 + 1 L 1 h ~ j ( l ) s ~ ( k - l ) - ∑ l = L 1 + 1 L + 1 h ~ j ( l ) s ^ ( k - l ) 2 ( 12 )
where {tilde over (s)}(k) are the (trial) symbols according to a certain transition and ŝ(k) are the previous symbols along the path history. Under some circumstances, a modification of the equation (12) metric may be employed, which provides a delayed decision. The modified metric can be expressed by
ξ j ( k ) = r ( k - 1 ) - ∑ l = 0 L 1 h ~ j ( l ) s ~ ( k - l ) - ∑ l = L 1 + 1 L + 1 h ~ j ( l ) s ^ ( k - l ) 2 ( 13 )
The total path metric for the M receive antennas will be
ξ ( k ) = ∑ j = 1 M ξ j ( k ) . ( 14 )
[0022] In short, equalizer/MSE decoder 23 within receiver 20 needs to obtains an estimate of the transmission channel parameters in a conventional way, e.g., through use of training sequences sent by the transmitter, and proceed to decode received symbols by selecting as the transmitted signal that signal which minimizes the equation (12) metric.
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In connection with transmitted space-time, trellis encoded, signals that pass through a transmission channel that is characterized by memory, improved performance is realized with a receiver that combines a decoder with an equalizer that selects the trellis transition, s, that minimizes the metric
ξ j ( k ) = r ( k ) - ∑ l = L 1 + 1 L 1 h ~ j ( l ) s ~ ( k - l ) - ∑ l = L 1 + 1 L + 1 h ~ j ( l ) s ^ ( k - l ) 2
where {tilde over (h)} j (l) is related to both the transmission channel and to the encoding structure in the transmitter, {tilde over (s)}(k) are the (trial) symbols according to a certain transition and ŝ(k) are the symbols that were previously decided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/855,066, which was filed on 7 May 2013 and is incorporated herein by reference.
BACKGROUND
The present disclosure relates generally to equipment for exercising. More particularly, this disclosure relates to a device that can be used by a mobility-impaired user, such as user of a wheelchair.
Various exercises have been utilized to develop and train various areas of the body. Exercises have historically been performed with resistance provided by free weights, such as barbells or machines, or even using a user's body as resistance.
Many exercise devices contain adjustment features allowing a user to adapt the exercise devices for a particular exercises. Many of the adjustment features are not accessible to users with impaired mobility. Further, many areas of the assembly will not accommodate devices, such as wheelchairs, frequently utilized by users with impaired mobility. Thus, a mobility-impaired user cannot effectively train on many exercise devices.
SUMMARY
An apparatus according to an exemplary aspect of the present disclosure includes, among other things, an exercise device providing an exercise area configured to receive a wheelchair, at least one primary handle moveable by a first user in the wheelchair from a first position to a second position, and a resistance assembly that opposes movement of the at least one primary handle. At least one spotter handle is coupled to move together with the at least one primary handle. The at least one spotter handle is accessible by a second user from a position outside the exercise area.
In another example of the foregoing apparatus, the primary handle comprises a first primary handle to be positioned on a first lateral side of the first user and a second primary handle to be positioned on an opposing, second lateral side of the first user. The spotter handle comprises a first spotter handle to be positioned on the first lateral side and a second spotter handle to be positioned on the second lateral side.
In another example of any of the foregoing apparatus, the apparatus further comprises a wheelchair guide to position the wheelchair within the exercise area.
In another example of any of the foregoing apparatus, the apparatus further comprises a link coupling movement of the at least one primary handle together with movement of the at least one spotter handle. The wheelchair guide is positioned between the link and the exercise area.
In another example of any of the foregoing apparatus, the apparatus further comprises a second exercise area that is separate and distinct from the first exercise area, and a pick accessible from the second exercise area. Exercises using the pick are resisted with the resistance assembly.
In another example of any of the foregoing apparatus, the resistance assembly comprises a weight stack.
In another example of any of the foregoing apparatus, the apparatus further comprises a lap pad configured to stabilize a user between the lap pad and the wheelchair when the user is utilizing the pick.
In another example of any of the foregoing apparatus, the lap pad is pivotable back and forth between a first position where the lap pad extends substantially vertically and a second position where the lap pad extends substantially horizontally.
An exercise device for a user in a wheelchair according to another exemplary aspect of the present disclosure includes, among other things, an automatically adjustable pick.
In another example of the foregoing exercise device, a belt is secured to the pick. The belt is configured to be driven to move the pick.
In another example of any of the foregoing exercise devices, the belt is looped such that opposing ends of the belt are secured to the pick.
In another example of any of the foregoing exercise devices, the belt is clamped to the pick.
In another example of any of the foregoing exercise devices, the belt is a toothed belt.
In another example of any of the foregoing exercise devices, the device comprises a sprocket to drive the belt to move the pick.
In another example of any of the foregoing exercise devices, the pick is configured to adjust between a first position that is vertically above a head of a user during use, and a second position that is vertically below a knee of the user during use.
In another example of any of the foregoing exercise devices, the pick is configured to be infinitely adjustable between the first position and the second position.
In another example of any of the foregoing exercise devices, a lap pad is configured to stabilize a user between the lap pad and a wheelchair.
In another example of any of the foregoing exercise devices, the lap pad is pivotable back and forth between a first position where the lap pad extends substantially vertically and a second position where the lap pad extends substantially horizontally.
In another example of any of the foregoing exercise devices, the lap pad is pivotable about a pivot location on a first side of the user to a selectively engage a support on a second side of the user that is opposite the first side.
An exercise device for a user in a wheelchair according to yet another exemplary aspect of the present disclosure includes, among other things, a pivotable lap pad configured to stabilize a user between the lap pad and a wheelchair.
In another example of the foregoing exercise device, the lap pad is pivotable back and forth between a first position where the lap pad extends substantially vertically and a second position where the lap pad extends substantially horizontally.
In another example of any of the foregoing exercise devices, the lap pad is pivotable about a pivot location on a first side of the user to a selectively engage a support on a second side of the user that is opposite the first side.
A method of exercising when positioned within a wheelchair includes, among other things, positioning a user and the wheelchair within an exercise area of an exercise device, and moving a primary handle of an exercise device. The moving of the primary handle is resisted by a resistance device. The method includes moving a spotter handle to assist the moving of the primary handle. The spotter handle is coupled in movement together with the primary handle.
In another example of the foregoing method, the moving of the primary handle is a pivoting movement around a first axis, and the moving of the spotter handle is a pivoting movement around a second axis spaced from the first axis.
In another example of the any of the foregoing methods, the method comprises moving to another exercise area and automatically adjusting a height of a pick.
In another example of the any of the foregoing methods, the method comprises pivoting a lap pad from a first position where the lap pad extends substantially vertically and a second position where the lap pad extends substantially horizontally, stabilizing the user between the lap pad and a wheelchair, and exercising using the pick.
The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures that accompany the detailed description can be briefly described as follows:
FIG. 1 shows a perspective view of an example wheelchair accessible exercise device.
FIG. 2 shows another perspective view of the FIG. 1 device.
FIG. 3 shows a user utilizing a row exercise portion of the device of FIG. 1 .
FIG. 4 shows the user making an adjustment to the device of FIG. 1 .
FIG. 5 shows the user making another adjustment to the device of FIG. 1 .
FIG. 6 shows the user utilizing a forward press portion of the device of FIG. 1 .
FIG. 7 shows a handle of the forward press portion of FIG. 6 in a first position.
FIG. 8 shows the handle of FIG. 7 in a second position.
FIG. 9 shows the user utilizing an overhead press portion of the device of FIG. 1 .
FIG. 10 shows the user positioning a lap pad of the device of FIG. 1 .
FIG. 11 shows the user positioning a lap pad support arm of the device of FIG. 1 .
FIG. 12 shows the user engaging the lap pad with the lap pad support arm.
FIG. 13 shows the user automatically adjusting a pick location of the device of FIG. 1 .
FIG. 14 shows a button on the lap pad support arm utilized to adjust the pick position.
FIG. 15 shows the user performing an overhead cable pull.
FIG. 16 shows the user performing a chest cable pull.
FIG. 17 shows the user performing a bicep curl with the lap pad in an engaged position.
FIG. 18 shows the user performing a bicep curl with the lap pad in a disengaged position.
FIG. 19 shows a perspective view of an adjustable pick and rail of the device of FIG. 1 .
FIG. 20 shows a perspective view of an adjustable pick and rail of the device of FIG. 1 .
FIG. 21 shows a perspective view of an adjustable pick and rail of the device of FIG. 1 .
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , an example exercise device 10 includes, generally, a first exercise area 14 and a second exercise area 18 . The first exercise area 14 is used for exercises, such as rows, chest presses, overhead presses, etc. The second exercise area 18 is used for exercises that involve an adjustable pick 22 , such as cable-based pulls, curls, etc. Notably, the user may remain seated in a wheelchair 26 when performing exercises within the first exercise area 14 and the second exercise area 18 .
Exercise, in this disclosure, encompasses training, therapy, drills, calisthenics, and other pursuits requiring physical effort.
Referring now to FIGS. 3 to 5 , during a row exercise, the user grasps rowing handles 30 extending from row bars 32 . To start a row, a chest of a user presses against a pad 34 as the user is seated in the wheelchair 26 . The user then presses the rowing handles 30 away from their chest, which pivots the row bars 32 about a rowing pivot R p . The rowing handles 30 are user handles in this example since the exercising user grasps these handles when exercising.
The row bars 32 are coupled to chest press bars 40 via a linking member 42 . The chest press bars 40 are attached to a weight stack 44 via a belt 46 . When the user pivots the row bars 32 about the pivot R p , the linking member 42 pulls the chest press bars 40 causing the chest press bars 40 to pivot about a chest press pivot C p . The weight stack 44 provides resistance to the rowing exercise through the belt 46 , the chest press bars 40 , the linking member 42 , and the row bars 32 .
Notably, a trainer (not shown) may press and pull on the chest press bars 40 to assist or “spot” the user during the rowing exercise as needed. This assistance can be provided in an area clear from the wheelchair 26 and outside the exercise area 18 . When used for spotting, the chest press bars 40 are considered spotter handles.
The user may adjust the position of the pad 34 via a pin and socket type attachment to place the rowing handles 30 at a desired location relative to the user when the user's chest is pressed against the pad 34 .
Referring to FIGS. 5 to 8 with continuing reference to FIGS. 3 and 4 , during a forward press exercise, the user in the wheelchair may position their back (or a back of the wheelchair 26 ) against the pad 34 . The user in the wheelchair may then adjust resistance of the press by increasing or decreasing the resistance by moving a pin 48 within the weight stack 44 to cause more or less weight to be during the press.
When performing the chest press, the user grasps chest press handles 43 extending from the chest press bars 40 . The pivoting movement of the chest press bars 40 as the user pushes the chest press handles 43 forward pulls the row bars 32 forward via the linking member 42 . Forward movement of the chest press handles 43 and chest press bars 40 is resisted by the weight stack 44 , which, again, is coupled to the chest press bar 40 via the belt 46 . The trainer may manipulate the position of the rowing handles 30 to assist the user when performing the chest press. During this exercise, the chest press handles 43 act as user handles, and the rowing handles 30 act a spotter handles.
The chest press handles 43 are moveable between the retracted position of FIG. 7 and the extended position of FIG. 8 . Other handles of the device 10 may be similarly moveable.
Referring to FIG. 9 , an additional exercise performed by the user within the first exercise area 14 is an overhead press. During such an exercise, the user pivots overhead press bars 50 about an overhead press axis O p by repositioning overhead press handles 52 . Rotation of the overhead press bars 50 is resisted by the weight stack 44 , which is coupled to the overhead press bars via a belt 54 .
The first exercise area 14 may include guides 56 to help position the user, and the user's wheelchair, within the first exercise area 14 . The guides 56 also prevent the wheelchair 26 from interfering with the moveable linking member 42 and other moveable structures. Many exercises are possible within the first exercise area 14 . These exercises are accessible to the user confined to a wheelchair.
Referring now to FIGS. 10 to 18 , the wheelchair accessible exercise device 10 provides further exercises within the second exercise area 18 . The second exercise area 18 includes a pair of supports 58 , 58 ′ extending generally horizontally from a tower 60 of the device 10 . The supports 58 , 58 ′ define an open area therebetween, which can receive the wheelchair 26 .
One of the supports 58 ′ is hingably secured to the tower 60 . The user may pivot the support 58 ′ by moving the handles 62 . The user may pivot the support 58 ′ when entering or leaving the second exercise area 18 . In other examples, both supports 58 , 58 ′ may pivot relative to the tower 60 .
Handles 62 extend vertically upward from the supports 58 , 58 ′. A lap pad 68 is hingably connected to the supports 58 . The lap pad 68 can be rotated to lift the lap pad 68 vertically. This allows user to enter the second exercise area 18 . When the wheelchair 26 and user are properly positioned within the second exercise area 18 , the user rotates the lap pad 68 from the position in FIG. 10 to the position in FIG. 11 , where the lap pad 68 rests on a lap of the user (or knees) of the user in the wheelchair 26 .
The user then rotates the support 58 in a direction S ( FIG. 12 ) such that a bar 70 of the lap pad 68 is received within an aperture 72 defined within a plate 76 of the support 58 ′. The plate 76 limits movement of the lap pad 68 so that the lap pad 68 provides a suitable support during exercises within the second exercise area 18 . Notably, no support structure extends between the user's legs, such structure could potentially interfere with the wheelchair 26 entering the second exercise area 18 .
If a vertical height adjustment of the lap pad 68 is required, the supports 58 , 58 ′ may be adjusted between one of several positions on the tower 60 by selectively engaging with one of several apertures 74 .
After the user has appropriately positioned themselves within the second exercise area 18 , the user may adjust a location of the adjustable pick 22 . In this example, the user presses one of two buttons 78 positioned on each of the supports 58 , 58 ′ to adjust the vertical height of the adjustable pick 22 . Actuating the button 78 causes a motor 84 to rotate and move a belt 80 (see FIGS. 19 to 21 ). Opposing ends of the belt 80 are attached to the adjustable pick 22 . Rotating the belt 80 causes the adjustable pick 22 to move vertically up and down along a track or rail 86 .
The adjustable pick 22 is effectively infinitely adjustable between a lowest position that is, in this example, below the knees of the user (see FIG. 17 ) to a vertically highest position that is well above a head of the user (see FIG. 16 ). Notably, the user is not required to stand or get out of the wheelchair 26 when adjusting the adjustable pick 22 to a desired position, even if that position is well above the head of the user.
As can be appreciated, various exercises may be performed using a cable 88 that is attached to the weight stack 44 . Example exercises include the overhead rope pull shown in FIG. 15 and the chest pull shown in FIG. 16 . During the overhead rope pull of FIG. 15 , a back of the wheelchair 26 may be positioned against the lap pad 68 to stabilize the user.
Other example exercises include the bicep curl shown in FIG. 17 and the bicep curl shown in FIG. 18 . The bicep curl of FIG. 18 does not require the lap pad 68 to be engaged within the plate 76 of the handles 62 . Other exercise may not require the lap pad 68 to be engaged with the plate 76 .
The adjustable pick 22 rides along the rail 86 when moved by the motor 84 and the adjustment belt 80 . The example belt 80 is a toothed belt, which helps avoid slippage of the motor 84 on the rail 86 . The motor 84 turns a sprocket 82 to drive the belt 80 . The cable 88 loops over the top of the belt 80 through two horizontally spaced guide pulleys 90 .
Features of the disclosed examples include an automatically, infinitely adjustable pick point location. Also, two primary belts and a single weight stack are used for effectively three machines—a row, chest press, and overhead press. The adjustable pick exercises are also off of the same weight stack.
A single user, such as a user seated within a wheelchair, can complete an effective workout, including making desired adjustments to weights and positions, without requiring a spotter or training partner.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Thus, the scope of legal protection given to this disclosure can only be determined by studying the following claims.
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An example apparatus for a user in a wheelchair includes an exercise device providing an exercise area configured to receive a wheelchair. A primary handle is moveable by a first user in the wheelchair from a first position to a second position. A resistance assembly opposes movement of the at least one primary handle. A spotter handle is coupled to move together with the at least one primary handle. The spotter handle accessible by a second user from a position outside the exercise area. An example exercise device for a user in a wheelchair includes an automatically adjustable pick.
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DESCRIPTION OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is related to data storage technology and more specifically to data migration between storage devices utilizing storage media with different performance characteristics.
[0003] 2. Description of the Related Art
[0004] Today, almost all large capacity data storage devices are designed based on storage controller(s) and HDDs (hard disk drives). The primary reason for widespread use of the HDDs in the storage devices is their lower per bit cost compared to other random accessible storage devices.
[0005] As would be appreciated by those of skill in the art, the useful life of storage devices is limited. Generally, the lifetime of a data storage unit is anywhere from 3 years to 5 years. Towards the end of the storage unit's useful life, the data in the storage unit must be migrated to a new storage apparatus. If the data is not migrated to the new storage apparatus, it may be lost. For example, if one wishes to preserve the data for ten years, the data migration must be performed several times.
[0006] On the other hand, it is desirable to maintain the high data availability by improving the data access performance characteristics of the new storage apparatus. It is also desirable to try to reduce the data preservation and data management costs. Therefore, the storage administrator may wish to specially design the volume configuration at the new storage apparatus.
[0007] A per stored bit cost of FLASH memory units is steadily declining. Therefore, FLASH memory becomes more and more attractive as a storage medium for high capacity storage devices. However, at the present time, the per bit cost of FALSH memory is still higher than the cost of the HDDs. Therefore, some storage devices make use of different performance characteristics of the HDDs and FLASH memory devices. A storage system administrator of aforesaid dual media data storage devices faces a problem how to migrate data stored in the ordinal storage apparatus to new storage apparatus, which is composed of HDDs and FLASH memories. In migrating the data, one must be mindful of the distinct performance characteristics of the FLASH memory's and the HDD.
[0008] A U.S. Pat. No. 5,680,640 entitled “System for migrating data by selecting a first or second transfer means based on the status of a data element map initialized to a predetermined state,” incorporated herein by reference, discloses techniques for migrating data from an old storage apparatus to a new one by means of a data connection established between the two storage devices. However, the existing data migration techniques do not deal with migrating data to a storage device, which includes both HDD units and FLASH memory units.
[0009] Therefore, the existing technology fails to provide means for migrating data from storage apparatuses composed of HDDs to storage apparatus composed of HDDs and FLASH memories. Specifically, the existing technology does not provide means for allocating and concatenating volumes on new storage apparatus according to the organization of the old storage unit, requiring the storage administrator to manually perform this tedious task.
SUMMARY OF THE INVENTION
[0010] The inventive methodology is directed to methods and systems that substantially obviate one or more of the above and other problems associated with conventional techniques for data migration in information systems having at least two storage devices.
[0011] In accordance with one aspect of the inventive concept, there is provided a computerized storage system comprising a first storage device, which includes a first storage volume storing data; a host computer operatively coupled to the first storage system via a network and configured to access the data in accordance with a data access pattern. The inventive computerized storage system further includes a second storage device coupled to the first storage device, which includes a storage controller, a first media pool and a second media pool. The characteristics of the first media pool are different from the characteristics of the second media pool. The second storage device is configured to determine the data access pattern and to allocate a second storage volume including at least a portion of a first media pool and at least a portion of the second media pool in accordance with the determined data access pattern and to create a copy of the data in the allocated second storage volume.
[0012] In accordance with another aspect of the inventive concept, there is provided a method involving logging access requests directed to a data stored in a first storage volume to produce a log information and analyzing the log information to determine a data access pattern. The inventive method further involves allocating a second storage volume, which includes at least a portion of a first media pool and at least a portion of a second media pool in accordance with the determined data access pattern and migrating the data from the first storage volume to the second storage volume.
[0013] In accordance with yet another aspect of the inventive concept, there is provided a computer programming product embodied in a computer-readable medium. The inventive computer programming product includes code for logging access requests directed to a data stored in a first storage volume to produce a log information and code for analyzing the log information to determine a data access pattern. The inventive computer programming product further includes code for allocating a second storage volume, which includes at least a portion of a first media pool and at least a portion of a second media pool in accordance with the determined data access pattern and code for migrating the data from the first storage volume to the second storage volume.
[0014] Additional aspects related to the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Aspects of the invention may be realized and attained by means of the elements and combinations of various elements and aspects particularly pointed out in the following detailed description and the appended claims.
[0015] It is to be understood that both the foregoing and the following descriptions are exemplary and explanatory only and are not intended to limit the claimed invention or application thereof in any manner whatsoever.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification exemplify the embodiments of the present invention and, together with the description, serve to explain and illustrate principles of the inventive technique. Specifically:
[0017] FIGS. 1( a )-( e ) show various aspects of an exemplary information storage system in which an embodiment of the inventive concept may be implemented.
[0018] FIG. 2 illustrates an exemplary embodiment of a table 299 for storing access log information.
[0019] FIG. 3 illustrated an exemplary process flow of the computerized storage system shown in the FIG. 1 .
[0020] FIG. 4 illustrates an exemplary embodiment of a table holding results of access log analysis.
[0021] FIG. 5 illustrates an exemplary embodiment of a mapping table.
[0022] FIG. 6 illustrates an exemplary embodiment of a storage volume.
[0023] FIG. 7 FIG. 7 illustrates storage volume allocation based on priority.
[0024] FIG. 8 shows an alternative exemplary embodiment of information system in accordance with the inventive concept
[0025] FIG. 9 shows another alternative exemplary embodiment of information system in accordance with the inventive concept
[0026] FIG. 10 shows yet another alternative exemplary embodiment of information system in accordance with the inventive concept.
[0027] FIG. 11 shows a further alternative exemplary embodiment of information system in accordance with the inventive concept.
[0028] FIG. 12 illustrates an exemplary embodiment of a computer platform upon which the inventive system may be implemented.
DETAILED DESCRIPTION
[0029] In the following detailed description, reference will be made to the accompanying drawing(s), in which identical functional elements are designated with like numerals. The aforementioned accompanying drawings show by way of illustration, and not by way of limitation, specific embodiments and implementations consistent with principles of the present invention. These implementations are described in sufficient detail to enable those skilled in the art to practice the invention and it is to be understood that other implementations may be utilized and that structural changes and/or substitutions of various elements may be made without departing from the scope and spirit of present invention. The following detailed description is, therefore, not to be construed in a limited sense. Additionally, the various embodiments of the invention as described may be implemented in the form of a software executing on a general purpose computer, in the form of a specialized hardware, or combination of software and hardware.
[0030] Latency in a hard disk drive (HDD) is caused by head seek operation and media rotation. Sequential access is characterized by short latency and high throughput. Random access is characterized by long latency and low throughput. Write access time may be the same as the read access time except in the case of “write & verify” operation, which is described in detail below.
[0031] Latency in flash memory storage devices is caused by programming time and page-erase time. The read operations carry minimum latency because they do not involve head seek and media rotation. The latency of random read operations is the same as sequential ones. However, the latency of write operations is greater than the latency of read operations. The completion of the flash memory write operation takes longer because the write operation involves media programming, which take time. Also, frequently over-writing data in flash memory units involves both “page-erasing time” and “media programming time”. If an erased blank page cannot be found within the FLASH chip, then page erase operation must be performed before data can be written to the storage device. FLASH memory storage unit erases the pages while the chip is in idle mode. Therefore, if the write operations are not performed with high frequency, pages are erased in the FLASH chip automatically without any delay to the write operations. On the other hand, when the writes are frequent, the system may not have enough time to perform the erase operation and the write process may need to be postponed until the completion thereof.
[0032] An exemplary system configuration will now be described. FIGS. 1( a )-( e ) illustrate various aspects of an exemplary information storage system in which an embodiment of the inventive concept may be implemented. The information system in accordance with the first exemplary embodiment of the inventive concept includes the components described in detail below.
[0033] The host computer 10 will now be described. At least one host computer 10 is connected to the storage apparatus 100 via data network 50 . Once data is migrated from the old storage apparatus to the new one, the host computer must be re-connected from the old storage device to the new storage apparatus, to enable it to access the migrated data.
[0034] The management computer 500 will now be described. At least one management computer 500 is connected via management network 90 to the host computer 10 , a migration computer 300 and storage devices 100 and 200 .
[0035] The storage apparatus 100 will now be described. The inventive system includes at least one storage apparatus 100 , which incorporates a storage controller 150 and one or more HDDs 101 . The storage apparatus 100 may additionally include storage controller 150 , which may provide RAID data protection functionality to the storage apparatus 100 . In FIG. 1 , the exemplary storage apparatus 100 is shown to have one volume 111 for storing data. The data is written to and read from the volume 111 by the host computer 10 .
[0036] The storage apparatus 200 will now be described. The information storage system additionally includes at least one storage apparatus 200 , which is composed of storage controller 250 , one or more HDDs 201 and one or more FLASH memory units 205 . The storage apparatus 200 may additionally include a storage controller 250 , which may provide RAID data protection functionality to the storage apparatus 200 . The embodiment of the storage apparatus 200 shown in FIG. 1 incorporates two storage pools. One storage pool is composed of HDDs (referred to herein as “HDD pool 210 ”), and the other is composed of FLASH memory units (referred to herein as “FLASH pool 220 ”).
[0037] The data network 50 will now be described. Host computer 10 as well as storage devices 100 and 200 are interconnected via data network 50 . In one embodiment of the inventive system, the data network 50 is a Fibre Channel network. However, other suitable network interconnects, such as Ethernet and the like can also be used in implementing the data network 50 . The data network 50 may include appropriate number of network switches and hubs, which implement the interconnect functionality. In FIG. 1 , a fibre channel switch (referred to as FCSW 55 ) is used for interconnecting the aforesaid storage system components. To this end, the host computer 10 , the migration computer 300 , the management computer 500 , and the storage devices 100 and 200 have one or more fibre channel interface boards (referred as FCIF) for coupling the respective devices to the fibre channel data network 50 .
[0038] The management network 90 will now be described. The host computer 10 , management computer 500 , and storage devices 100 and 200 are also interconnected via management network 90 . The management network 90 in this embodiment of the inventive concept is Ethernet network. However, other suitable network interconnects can be also used. The network 90 may be implemented using suitable network switches and hubs. The host computer 10 , migration computer 300 , management computer 500 and the storage apparatus 100 and 200 may have one or more Ethernet interface boards (referred to herein as EtherIF) for connecting the respective devices to the Ethernet management network 90 .
[0039] The Host Computer 10 will now be described. Host computer 10 includes a Memory 12 for storing programs and data and CPU 11 configured to executing programs stored in the Memory 12 . The Host computer 10 additionally includes FCIF 15 for connecting the Host computer 10 to the data network 50 and EtherIF 19 for connecting Host computer 10 to the management network 90 .
[0040] The Host Computer 10 runs at least two programs, which are stored in memory 12 and executed by CPU 11 , see FIG. 1( b ). In one embodiment of the invention, the memory 12 stores an application program 13 for writing data to the volume and/or reading data from the volume and an access path management program 14 for managing access path between the host computer 10 and the storage devices.
[0041] The management Computer 500 will now be described. The management computer 500 includes a memory 520 for storing programs and data and a CPU 510 for executing the programs stored in the memory 520 . The management computer 500 additionally includes FCIF 550 for connecting the management computer 500 to the data network 50 and EtherIF 590 for connecting the management computer 500 to the management network 90 .
[0042] The memory 520 of the management computer 500 stores at least seven programs, which are executed by CPU 510 . The stored programs include detecting program 521 for detecting remaining life of the storage apparatus and for discovering new storage units. Also stored is an access log gathering program 522 for gathering logs from storage apparatuses, a volume allocation request program 523 for requesting volume allocation from a target storage apparatus; a volume concatenation request program 524 for requesting volume concatenation from a target storage apparatus or a volume management program on the host computer or the FCSW. Additional programs stored in the memory 520 include a volume migration request program 525 for requesting volume migration to a migration module, a FLASH memory units confirmation program 526 for confirming the existence of FLASH memory unit(s) within the storage device and a path alternation request program 527 for alternating access path from a host computer to a volume.
[0043] The storage apparatus 100 will now be described. The storage apparatus 100 includes one or more HDDs 101 , a storage controller 150 for maintaining data storage volumes. Each data storage volume is composed of chunk of one or more HDDS. As may be appreciated by those of skill in the art, the aforesaid HDD chunk may store redundant data for improving data reliability. The storage apparatus 100 stores data in one or more volumes 111 . The embodiment of the inventive storage apparatus 100 shown in FIG. 1( d ) includes one volume 111 . However, the inventive concept is not limited to just one such volume.
[0044] Storage controller 150 includes a CPU 151 for executing programs stored in memory 152 , a memory 152 for storing programs and data, a FCIF 155 for connecting to the data network 50 , as well as SATA IF 156 for connecting to the HDD 101 , see FIG. 1( d ). It should be noted that if HDD has another interface such as FC, SCSI, or SAS, the storage controller needs to include an appropriate storage interface that would match the storage interface of the HDD. The storage controller 150 further includes EtherIF 159 for connecting the storage controller 150 to the management network 90 .
[0045] The memory 152 of the storage apparatus 100 stores at least three programs, which are executed by the CPU 151 . In one exemplary embodiment of the inventive storage apparatus 100 , shown in FIG. 1( d ), the memory 152 stores the remaining lifetime reporting program 160 for reporting remaining lifetime of the storage device, an access log reporting program 161 for reporting access logs associated with the storage device and response program 162 for responding to read/write inquiries or requests from the host computer 10 .
[0046] Storage apparatus 200 will now be described. The storage apparatus 200 includes one or more HDDs 201 and one or more FLASH memories 205 , see FIG. 1( e ). The HDDs 201 are grouped into one or more HDD pools 210 . The embodiment of the storage system 200 shown in FIG. 1( e ) includes only one HDD pool 210 . Each HDD pool is composed of one or more HDDs. In addition, the storage apparatus 200 incorporates one or more FLASH pools. The embodiment of the storage apparatus 200 shown in FIG. 1( e ) includes only one FLASH pool 220 , which is composed of one or more FLASH memory units 205 .
[0047] The storage apparatus 200 further includes storage controller 250 for maintaining data storage volumes 211 . Each such storage volume 211 is composed of a portion of the aforesaid HDD pools and/or FLASH pools. The portions of the HDDs and FLASH memory pools forming the storage volume 211 may store redundant data for improving data reliability.
[0048] The storage controller 250 includes a memory 252 for storing programs and data and CPU 251 for executing programs stored in the memory 252 . The storage controller 250 further includes FCIF 255 for connecting the storage controller 250 to the data network 50 and SATA IF 256 for connecting the storage controller 250 to the HDD 201 and FLASH memory units 205 . If the HDD/FLASH memory units 201 and 205 have other types of interfaces, such as FC, SCSI, SAS, or any FLASH-specific memory interface, the storage controller 250 should include a matching interface.
[0049] The storage controller 250 further includes an EtherIF 259 for connecting the storage controller 250 to the management network 90 . In the embodiment of the storage controller 250 shown in FIG. 1( e ), the memory unit 252 stores at least six programs, which are executed by the CPU 251 . Specifically, the memory 252 stores a remaining lifetime reporting program 260 for reporting the remaining lifetime of the storage, an access log reporting program 261 for reporting access log information, a response program 262 for responding to read/write inquiries/requests initiated by the host computer 10 .
[0050] The memory 252 additionally stores a volume allocation program 263 for allocating volumes within the HDD pools or the FLASH pools, a volume concatenation program 264 for concatenating chunks into one volume, a FLASH memory detecting and reporting program 265 for detecting FLASH memory units in the storage apparatus and reporting the results of the detection operation to the host computer.
[0051] The FLASH memory detecting and reporting program 265 will now be described. The FLASH memory detecting and reporting program 265 can detect FLASH memory units within its storage apparatus. In one exemplary embodiment, the FLASH memory units are interchangeable with the HDD units. In this embodiment, the FLASH memory detecting and reporting program 265 invokes an INQUIRY command directed to the FLASH memory units and/or HDD units. If the response to the INQUIRY command includes information indicating the presence of the FLASH memory, such as Vendor ID and Device ID attributable to a FLASH memory unit, then the FLASH memory detecting and reporting program 265 recognizes the presence of the FLASH memory unit in the storage apparatus. As would be appreciated by those of skill in the art, other storage device detecting mechanisms may be also used.
[0052] The migration computer 300 will now be described. In the embodiment of the inventive system shown in FIG. 1( f ), the migration module is implemented using the migration computer 300 executing a migration program 321 . The migration computer 300 is connected to the data network via the FCSW 55 . Migration computer 300 includes a memory 320 for storing the programs and data and a CPU 310 for executing the programs stored in the memory 320 . The migration computer 300 further includes FCIF 350 for connecting the migration computer 300 to the data network 50 and EtherIF 390 for connecting the migration computer 300 to the management network 90 .
[0053] The memory 320 stores at least one program, which is executed by CPU 310 . In one embodiment of the inventive system, the memory 320 stores a data migration program 321 for migrating data from a storage volume to another storage volume.
[0054] The process flow of an exemplary embodiment of the inventive system will now be described. Specifically, in the described embodiment of the inventive system, the storage apparatus 100 incorporates a storage volume 111 . The volume 111 is connected to the host computer 10 . The host computer 10 is capable of writing data to the volume 111 and reading data from this volume. To this end, the appropriate read and a write requests from host computer 10 are sent to the storage controller 150 via the data network 50 . The response program 162 executing within the storage controller 150 receives the aforesaid requests and executes them. The access log reporting program 161 also executing in the storage controller 150 logs a volume number, a command information (read or write), LBA (logical block address) of the data associated with the command, block length of the command, command receipt time, and command response time. FIG. 2 shows an exemplary embodiment of a table for storing the aforesaid log information. Analysis of the information stored in this table yields information on the access pattern of the corresponding data. The access pattern information may indicate whether the data access is random or sequential, the ratio of the read and write operations, as well as access frequency and no access duration.
[0055] FIG. 3 illustrates an exemplary operating flow of the system shown in the FIG. 1 . This operating flow is performed towards the end of the lifetime of the storage device.
[0056] STEP 3000 : The detecting program 521 periodically polls each storage apparatus and checks its remaining life.
[0057] STEP 3010 : The remaining lifetime reporting program 160 reports the “remaining lifetime” to the detecting program 521 .
[0058] STEP 3020 : If the detecting program 521 detects a storage apparatus having a lifetime approaching its end, the process continues to step 3030 .
[0059] STEP 3030 : The detecting program 521 locates a storage unit within the computerized storage system, which has a long remaining lifetime.
[0060] STEP 3040 : The remaining lifetime reporting program 260 reports “remaining lifetime” of the storage unit to the detecting program 521 .
[0061] STEP 3050 : The FLASH memory unit confirmation program 526 determines the presence of FLASH memory units within the discovered storage unit. In the shown embodiment, the discovered storage unit is within the storage apparatus 200 . If no FLASH memory units are present, the process continues with step 3060 . If FLASH memory units are present, the process proceeds to step 3100 .
[0062] STEP 3060 : The volume allocation request program 524 requests new volume allocation within the discovered storage apparatus. In the shown embodiment of the inventive system, the new volume allocation is requested within the storage apparatus 200 via the management network 90 .
[0063] STEP 3070 : The volume migration request program 525 requests data migration from an old volume with expiring lifetime to a new volume in the discovered storage unit. The data migration request is sent to the volume migration program 321 via the management network 90 .
[0064] STEP 3080 : The path alternation request program 527 requests alternation of the access path from the access path associated with the old volume 111 to the access path associated with the new volume 211 . The access path is modified upon the completion of the migration process.
[0065] STEP 3100 : The access log gathering program 522 collects log information from the access log reporting program 161 .
[0066] STEP 3110 : The volume analysis program 526 analyzes the log information and splits volume area into several portions (chunks) based on the information gathered from the access log analysis. The exact manner in which the volumes are divided into chunks is described hereinbelow.
[0067] STEP 3120 : The volume allocation request program 524 requests new volume allocation within the discovered storage apparatus for each portion of the volume area. For example, if a volume is divided into six portions, then the volume allocation request is repeated six times. Each chunk is allocated from the HDD pool or the FLASH pool. The allocation of the aforesaid chunk is based on the results of the log analysis. The volume allocation request includes an identifier indicating whether the specific portion of the volume should be allocated on HDD storage media or on FLASH storage media. The manner in which the system determines Which storage media pool (HDD or FLASH) is more preferable for specific data is described in detail below.
[0068] STEP 3130 : The volume concatenation request program 524 concatenates the chunks into one storage volume. The concatenated volume is only accessible from the application program 12 executing on the host computer 10 .
[0069] STEP 3140 : The volume migration request program 525 requests migration of data from a volume within a storage apparatus with expiring lifetime to the volume concatenated at step 3130 .
[0070] STEP 3150 : The path alternation request program 527 requests modification of the data access path to reflect the change of the data storage volume from volume 111 to volume 211 .
[0071] Now, the manner in which volumes are divided into chunks and the manner for determination of the preferable storage pool will be described in detail. The storage volumes are divided into chunks by the volume analysis program 526 . In one exemplary embodiment of the invention, the volume is divided into six chunks and each chunk has the same size. As would be appreciated by those of ordinary skill in the art, the size and number of chunks are not essential to the inventive concept. FIG. 4 illustrates an exemplary embodiment of a table holding results of access log analysis. This table is created by the access log gathering program 522 .
[0072] The volume analysis program 526 uses a mapping table 529 , which is shown as FIG. 5 . The mapping table 529 is stored in the memory 520 . The volume analysis program 526 compares the characteristics of a specific volume chunk represented by a record in the result-holding table 528 with the appropriate records in the mapping table 529 . Based on the results of the aforesaid comparison, the volume analysis program 526 determines whether the specific chunk should be allocated from HDD pool or FLASH pool. Specifically, the “Chunk Allocation Pool” column of the table indicates the type of the preferable storage pool.
[0073] FIG. 6 illustrates an exemplary embodiment of a storage volume, which is divided into six chunks. As a result of log information analysis by the volume analysis program 526 , a specific pool having a specific pool type (FLASH or HDD) is linked to each chunk. The volume allocation request program 523 sends a volume allocation request to the volume allocation program 263 . This request specifies the desired pool type information. This information may be specified as an attribute associated with the allocation request. The pool attribute information includes an attribute indicative of either HDD pool or FLASH pool. In response to the received allocation requests, chunks are allocated in the storage apparatus 200 . It is important to note that chunks are portions of storage volume and not volumes themselves. A volume is composed of several chunks.
[0074] In the shown example, after six chunks are allocated from the respective pools, the volume concatenation request program 524 sends a volume concatenation request to the volume concatenation program 264 . The volume concatenation program 264 concatenates the six chunks together. The concatenation is performed in a specific order. As a result of the concatenation, volume 211 is created. The exemplary volume 211 shown in FIG. 6 is composed of three FLASH chunks and three HDD chunks.
[0075] Subsequently, the volume migration request program 525 sends a migration request to the data migration program 321 . Pursuant to this request, the data stored in the volume 111 is migrated to the volume 211 by means of a block-by-block data copy operation.
[0076] Finally, the path alternation request program 527 in the management computer 500 sends a path alternation request to the access path management program 14 in the host computer 10 . In response to the received request, the access path management program 14 switches the data access path from the volume 111 to the volume 211 . The volume 211 is composed of HDD chunks and FLASH chunks, and is optimized according to data access pattern from the host computer 10 . Therefore, the data access performance of the volume 211 is expected to be higher than of the volume 111 .
[0077] Because the capacity of the FLASH media is limited, a priority system may be used in an embodiment of the invention to allocate chunks from the FLASH memory pool. The column “priority” in the mapping table 529 indicates the level of priority for allocating of FLASH memory. As would be appreciated by those of ordinary skill in the art, the capacity of FLASH memory units is limited. Moreover, the capacity of FLASH memory is often less than the capacity of the HDD units.
[0078] For example, when the capacity ratio of FLASH pools to HDD pools is 2:4, and the administrator directs the management computer 500 to preserve this ratio, then the aforesaid “priority” column is consulted upon allocation of volume chunks. FIG. 7 illustrates storage volume allocation based on priority of each chunk. To preserve the 2:4 allocation ratio, chunk # 4 is allocated to the HDD pool as opposed to FLASH pool, because the priority of chunk # 4 is lower than the priority of chunk # 1 or # 2 . Thus, chunk # 4 is allocated using the HDD pool.
[0079] Certain alternative embodiments of the inventive system will now be described. FIG. 8 illustrates another exemplary information system embodying the inventive concept. In the embodiment shown in FIG. 8 , the data migration module is implemented by means of a data migration program 56 executing on the FCSW 55 . In addition, the volume concatenation program 57 and the access path management program 58 are also implemented using the FCSW 55 . EtherIF 59 is added for enabling communication with the management computer 300 . All other elements of the system shown in FIG. 8 are generally equivalent to the corresponding elements of the system shown in FIG. 1 and described in detail hereinabove.
[0080] FIG. 9 shows an alternative exemplary embodiment of information system in accordance with the inventive concept. In the exemplary system shown in FIG. 9 , the data migration module is implemented as a data migration program 558 executing on the management computer 500 . All other elements of the system shown in FIG. 9 are generally equivalent to the corresponding elements of the system shown in FIG. 1 and described in detail hereinabove.
[0081] FIG. 10 shows another alternative exemplary embodiment of information system in accordance with the inventive concept. In the system shown in FIG. 10 , a volume concatenation program 16 is deployed in the host computer 10 . All other elements of the system shown in FIG. 10 are generally equivalent to the corresponding elements of the system shown in FIG. 1 and described in detail hereinabove.
[0082] FIG. 11 shows yet another alternative exemplary embodiment of information system in accordance with the inventive concept. In the system shown in FIG. 10 , the storage apparatus 100 is connected to the storage apparatus 200 . An external storage management program 266 and an additional FCIF 256 for external storage are deployed. The data migration module is implemented using a data migration program 267 executing in the storage apparatus 200 . All other elements of the system shown in FIG. 11 are generally equivalent to the corresponding elements of the system shown in FIG. 1 and described in detail hereinabove.
[0083] FIG. 12 is a block diagram that illustrates an embodiment of a computer/server system 1200 upon which an embodiment of the inventive methodology may be implemented. The system 1200 includes a computer/server platform 1201 , peripheral devices 1202 and network resources 1203 .
[0084] The computer platform 1201 may include a data bus 1204 or other communication mechanism for communicating information across and among various parts of the computer platform 1201 , and a processor 1205 coupled with a data bus 1204 for processing information and performing other computational and control tasks. Computer platform 1201 also includes a volatile storage 1206 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 1204 for storing various information as well as instructions to be executed by processor 1205 . The volatile storage 1206 also may be used for storing temporary variables or other intermediate information during execution of instructions by processor 1205 . Computer platform 1201 may further include a read only memory (ROM or EPROM) 1207 or other static storage device coupled to bus 1204 for storing static information and instructions for processor 1205 , such as basic input-output system (BIOS), as well as various system configuration parameters. A persistent storage device 1208 , such as a magnetic disk, optical disk, or solid-state flash memory device is provided and coupled to bus 1204 for storing information and instructions.
[0085] Computer platform 1201 may be coupled via bus 1204 to a display 1209 , such as a cathode ray tube (CRT), plasma display, or a liquid crystal display (LCD), for displaying information to a system administrator or user of the computer platform 1201 . An input device 1210 , including alphanumeric and other keys, is coupled to bus 1204 for communicating information and command selections to processor 1205 . Another type of user input device is cursor control device 1211 , such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor 1204 and for controlling cursor movement on display 1209 . This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.
[0086] An external storage device 1212 may be connected to the computer platform 1201 via bus 1204 to provide an extra or removable storage capacity for the computer platform 1201 . In an embodiment of the computer system 1200 , the external removable storage device 1212 may be used to facilitate exchange of data with other computer systems.
[0087] The invention is related to the use of computer system 1200 for implementing the techniques described herein. In an embodiment, the inventive system may reside on a machine such as computer platform 1201 . According to one embodiment of the invention, the techniques described herein are performed by computer system 1200 in response to processor 1205 executing one or more sequences of one or more instructions contained in the volatile memory 1206 . Such instructions may be read into volatile memory 1206 from another computer-readable medium, such as persistent storage device 1208 . Execution of the sequences of instructions contained in the volatile memory 1206 causes processor 1205 to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.
[0088] The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor 1205 for execution. The computer-readable medium is just one example of a machine-readable medium, which may carry instructions for implementing any of the methods and/or techniques described herein. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device 1208 . Volatile media includes dynamic memory, such as volatile storage 1206 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise data bus 1204 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
[0089] Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, punchcards, papertape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EPROM, a flash drive, a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
[0090] Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to processor 1205 for execution. For example, the instructions may initially be carried on a magnetic disk from a remote computer. Alternatively, a remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer system 1200 can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on the data bus 1204 . The bus 1204 carries the data to the volatile storage 1206 , from which processor 1205 retrieves and executes the instructions. The instructions received by the volatile memory 1206 may optionally be stored on persistent storage device 1208 either before or after execution by processor 1205 . The instructions may also be downloaded into the computer platform 1201 via Internet using a variety of network data communication protocols well known in the art.
[0091] The computer platform 1201 also includes a communication interface, such as network interface card 1213 coupled to the data bus 1204 . Communication interface 1213 provides a two-way data communication coupling to a network link 1214 that is connected to a local network 1215 . For example, communication interface 1213 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 1213 may be a local area network interface card (LAN NIC) to provide a data communication connection to a compatible LAN. Wireless links, such as well-known 802.11a, 802.11b, 802.11g and Bluetooth may also used for network implementation. In any such implementation, communication interface 1213 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
[0092] Network link 1213 typically provides data communication through one or more networks to other network resources. For example, network link 1214 may provide a connection through local network 1215 to a host computer 1216 , or a network storage/server 1222 . Additionally or alternatively, the network link 1213 may connect through gateway/firewall 1217 to the wide-area or global network 1218 , such as an Internet. Thus, the computer platform 1201 can access network resources located anywhere on the Internet 1218 , such as a remote network storage/server 1219 . On the other hand, the computer platform 1201 may also be accessed by clients located anywhere on the local area network 1215 and/or the Internet 1218 . The network clients 1220 and 1221 may themselves be implemented based on the computer platform similar to the platform 1201 .
[0093] Local network 1215 and the Internet 1218 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 1214 and through communication interface 1213 , which carry the digital data to and from computer platform 1201 , are exemplary forms of carrier waves transporting the information.
[0094] Computer platform 1201 can send messages and receive data, including program code, through the variety of network(s) including Internet 1218 and local network 1215 , network link 1214 and communication interface 1213 . In the Internet example, when the system 1201 acts as a network server, it might transmit a requested code or data for an application program running on client(s) 1220 and/or 1221 through Internet 1218 , gateway/firewall 1217 , local network 1215 and communication interface 1213 . Similarly, it may receive code from other network resources.
[0095] The received code may be executed by processor 1205 as it is received, and/or stored in persistent or volatile storage devices 1208 and 1206 , respectively, or other non-volatile storage for later execution. In this manner, computer system 1201 may obtain application code in the form of a carrier wave.
[0096] Finally, it should be understood that processes and techniques described herein are not inherently related to any particular apparatus and may be implemented by any suitable combination of components. Further, various types of general purpose devices may be used in accordance with the teachings described herein. It may also prove advantageous to construct specialized apparatus to perform the method steps described herein. The present invention has been described in relation to particular examples, which are intended in all respects to be illustrative rather than restrictive. Those skilled in the art will appreciate that many different combinations of hardware, software, and firmware will be suitable for practicing the present invention. For example, the described software may be implemented in a wide variety of programming or scripting languages, such as Assembler, C/C++, perl, shell, PHP, Java, etc.
[0097] Moreover, other implementations of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Various aspects and/or components of the described embodiments may be used singly or in any combination in the computerized storage system. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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The computer system is composed of an old storage apparatus, a new storage apparatus, management computer, data network and management network. Management computer gathers logs at the old storage apparatus. When data is moved from the old storage to the new storage, destination volume in the new storage apparatus is allocated and concatenated using the gathered log information and a mapping table. The system and apparatus simplifies migration processes from ordinary storage apparatus to the new storage device, which may include HDDs and FLASH memory units. The system takes into account the differences in performance characteristics of HDDs and FLASH memories, achieving improver performance of the overall storage system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for cleaning textiles in FCHC-free manner by means of solvents on a benzine basis.
The invention also relates to the use of such a method.
2. Description of the Prior Art
Finally, the invention also relates to an apparatus for cleaning textiles by means of FCHC-free solvents on a benzine basis comprising a cleaning machine, distillation section, recovery section and drier.
Generally, in such a cleaning plant the drying takes place (after transferring the material from the cleaning machine) by means of hot air; the textile material in particular predried by spinning in a drum in the cleaning machine (for example down to 11% residual moisture content) is further dried and the cleaning agent is recovered from the solvent-charged air by distillation and condensation.
However, particular safety precautions are necessary here because the solvent on a benzine basis involves a considerable danger of explosion, at the least from the flashpoint of the solvent (71° C.) used upwards. Also, the operations under vacuum necessary because of this are very complicated. FCHCs are however allowed for only a short period and the use of PER involves increasingly high demands on the apparatus quality, and consequently both the FCHC-operated and the PER-operated machines must be replaced or at least considerably modified. In addition, with all existing machines and the cleaning agents used therein a practically 100% distillation was necessary due to the considerable contamination of the cleaning agent.
Also known is a method for dry cleaning with a hydrocarbon having a low flashpoint (41° C.) and high vapour pressure (EP 90 119 398.7). A so-called dry-to-dry cleaning machine is described, i.e. a machine in which both washing and drying is carried out. With this type of solvent, for safety, technical, humane-ecological and ecological reasons reloading in the moist state is not compatible with European standards, in particular German standards. In this case hot air is forced in between the washing bath and the dry conduit and the evaporated solvent condensed for recovery. Before this solvent recovery step a partial vacuum is generated and an inert gas introduced. The inert gas is however introduced into the washing bath until the oxygen density of a mixture containing a solvent assumes a value beneath a predetermined limit value. After the introduction of the inert gas into the washing bath (reduction of the oxygen density) washing, centrifuging and finally drying are carried out.
SUMMARY OF THE INVENTION
To be more exact, the rendering inert therein takes place as follows:
a) Firstly by generating a partial vacuum, the aim being to achieve a residual oxygen content of 5 vol. %. This means however that the operations must be carried out with a gas-tight machine.
b) In addition, inert gas, presumably from a nitrogen tank, is injected in to set the residual oxygen content to 5%. The method is technically complicated and involves the aforementioned problems such as the technically involved vacuum method with gas-tight machine.
Compared therewith, the invention is based on the problem of providing a method and an apparatus which operate not only PER-free and FCHC-free but in addition reduce the expenditure considerably and with which the drying operation can be carried out practically free of any danger even when individual apparatus parts should fail in their function.
This is achieved in surprisingly simple manner with a method of the type set forth at the beginning in that the drying is carried out under a protective gas.
Preferably, the drying is carried out under nitrogen.
It is particularly expedient to carry out the drying with nitrogen obtained from the air, oxygen being filtered out of the air in a manner known per se.
Pressure bottles, separate connections, and the replacement of such pressure bottles or tanks can be dispensed with if nitrogen obtained in situ is used for the drying.
Preferably, N2 is injected into the drier itself.
Preferably, the operation is carried out with an aroma-free solvent known per se and having a low evaporation value, in particular N-Undecane.
Expediently, the procedure is such that with a temperature of 55° C. in the closed system drying is carried out in particular to 15° C. beneath the theoretical flashpoint.
It is favourable to carry out the drying with an oxygen content of 6% in the drying gas, i.e. with a value far below the explosion limit.
It is particularly advantageous to operate with nitrogen flushing without vacuum, and almost ambient pressure conditions can be employed during the drying.
With the step according to the invention, FCHC (fluorochlorohydrocarbon)-operated apparatuses and PER-operated apparatuses may be considered obsolete. After appropriate prespotting the articles are cleaned in the cleaning machine, the latter being a sprung machine which is provided with an upper gear-type motor drive. A high centrifuging speed is possible and consequently 89% of the solvent is extracted in spinning and only 11% later in the drier after the articles have been transferred.
The transferring permits simultaneous operation of the drier and cleaning machine with the advantage that this doubles the capacity of the system compared with conventional dry-to-dry techniques. The transfer is made possible by the low evaporation value when N-Undecane is used as cleaning agent. If two driers are employed in the system the capacity of the apparatus may even be increased to three times the charging value.
Furthermore, a distillation unit is provided, the capacity of which can be limited to 70 liters per second due to the use of the N-Undecane, which can be handled without any problems. Hitherto, a distillation of 100% was necessary but with the step of the invention 20% distillation suffices. The distillation operates under vacuum.
Cartridge filters may be employed.
By connecting a refrigeration apparatus to the drier the cleaning agent can be recovered practically completely and the solvent loss here is 1%. By employing this apparatus the theoretical danger of fire is eliminated. It is physically impossible for a flame to exist in the nitrogen air mixture created (oxygen content beneath 10% or beneath 6%).
The solvent used corresponds to the same risk class as light fuel oil. Contact water occurs only in small amounts.
Due to the inert gas (protective gas) production in the system any change of bottles or supply tanks is eliminated; no follow-up costs arise for the protective gas.
Separate safety circuits are present in the system, firstly to keep the temperature 15° C. beneath the flashpoint of the solvent (71° C.) and secondly for monitoring the O2 concentration, trouble alarms being given with the O2 concentration rises above 6%. However, even at 10% there is no fear of any danger of explosion.
The apparatus for cleaning textiles by means of FCHC-free solvents on a benzine basis comprising a cleaning machine, distillation section, recovery section and drier is therefore distinguished by supplying of protective gas into the drier.
A metering conduit for N2 may be led from the reservoir of a separate N2 recovery apparatus into the drier and the N2 apparatus can derive the nitrogen from the air. A separate microprocessor control may be provided for controlling and monitoring the temperature profile, and another microprocessor control for the oxygen concentration during the drying operation. Connections may be provided to the drier which supply the gaseous medium saturated with solvent and vapour to a cooling apparatus for condensation, in particular at 3° C.
The plant or apparatus is also distinguished by operation of the drier under approximately ambient pressure conditions.
Finally, the invention is also distinguished by the use of nitrogen from an apparatus recovering nitrogen from air and known per se in the drier of a cleaning machine for textiles operating free of FCHC.
The mode of operation of the drier is as follows: In the drying operation the gaseous medium in the closed drier is conducted via a fan past a heat register (both within the drier) and heated to 55° C. The hot air withdraws the solvent residual moisture from the textiles in a rotating drum. The saturated hot air is cooled in a cooling apparatus to 3° C., condensing out the solvent. The separated solvent is returned to the cleaning machine. The solvent recovery is 99%. If required, the solvent from two reservoirs of the cleaning machine is reprocessed in the distillation unit.
In the drying, the solvent mentioned and consisting of pure hydrocarbon having a theoretical flashpoint of 71° C. is used, the drying being carried out 15° C. beneath the flashpoint.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of embodiment of the invention will now be explained in detail with the aid of the attached drawings, wherein:
FIG. 1 shows a schematic illustration of an apparatus which is surrounded by an outer wall to show how small the apparatus can be constructed;
FIG. 2 shows such an apparatus from the constructional side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
On the left in FIG. 1 the cleaning machine 10 can be seen; supply drums not illustrated are provided beneath the cleaning machine. The cleaning machine is drive via a motor gear-type unit 12.
At the start and during the entire drying operation, the oxygen concentration within the drier is reduced to far beneath the theoretical explosion limit so that even when the flame point is exceeded no inflammable atmosphere can form in the drier. In contrast to the prior art, the nitrogen flushing in the drier takes place without any vacuum, being carried out on the contrary under approximately normal atmospheric pressure conditions.
In the same housing with the drive machine a filter 14 for the solvent is provided. The illustration is schematic. In fact, two filters are installed above each other. The first of the two identically constructed filters is the prefilter and the other the afterfilter.
A solvent cooler 13 is arranged laterally adjacent the filter 14 in the drawings.
Finally, in the same housing magnetic valves 16 are also arranged for the control functions of the cleaning machine.
Arranged alongside in the drawing is a distillation apparatus which is indirectly heated with steam via 20. 70 liters are withdrawn per hour from the distillation apparatus 24, cleaned, the bottom removed and the condensate returned to the cleaning machine via 26.
Shown in the drawings completely on the right is an N2 apparatus which is known per se and is not the subject of the invention; the effect (N2 production) thereof is merely utilized. The N2 apparatus 30 receives air from the conduit 18. A filter and a pump are provided at 32. These operate by a novel pressure alternating principle, the so-called "pressure swing absorption (PSA)": A pulsating pump effect is utilized in an active carbon filter. Air is inspired and on ejection the filter 32 repels oxygen. Via a conduit 36 the nitrogen passes to a reservoir 38 from which via the conduit 40 nitrogen can be injected as desired into the drier, in particular discontinuously, when the nitrogen content has dropped below a predetermined limit or the oxygen content runs the risk of increasing above a predetermined limit (6%). An O2 measuring conduit 44 leads from the control unit 42 to the drier 50.
The central part of the present invention is the drier 50 into which nitrogen 40 is injected as protective gas. The clean material is introduced into the drier for instance by a snorkel transfer method. Heating is effected by passage past a heating register (fan action) to 55° C. in the closed system, i.e. 15° C. beneath the explosion point, thereby providing double safety because critical O2 values are never reached. The residual moisture of the material being cleaned is practically expelled by the heating to 55° C. The 55° C. hot medium is supplied to the refrigeration apparatus (not shown) where a cooling to 3° C. is effected and the residual moisture condensed. After possible cleaning the latter is returned to the cleaning machine. The drier is indirectly heated with vapour or steam 20. A rotating drum may be employed.
The conditions in the drier are controlled via a microprocessor control. An O2 measuring device inspires fresh air. Prior to the drying operation a system is passed to the N2 apparatus. A flushing with N2 is carried out until the oxygen content drops below 6%. Another signal indicates readiness for operation.
In FIG. 2, which shows a detail of the drier arrangement and N2 preparation, the same reference numerals as in FIG. 1 have been used for identical elements.
The drying drum 50 has been emphasized as the central element. Nitrogen generated from the air is injected into the drum of the drier 50 via the conduit 40 past a heating register 60. The still moist material is transferred from the cleaning machine 10, not illustrated here.
The heating to the aforementioned temperature takes place in the drum 50; the moisture and solvent are expelled (62). Recycling is effected via a fan 64. The mixture flows on at 66 and enters an evaporator 68, the liquid N2 being supplied together with condensed water via 70 to a water separator 72. The condensate is removed via 22. The steam returns in the cycle at 20 to the heat register. Following the evaporator 68, a measuring conduit 44 branches off to an O2 analyzer 74. An O2 value of 6% is set in the drier.
The N2 apparatus 30 takes up air, compresses the latter at 78, filters it at 32 and supplies it to adsorbers 80 and 81. The nitrogen generated is supplied at 36 via an N2 reservoir 38, from which it is supplied via a controlled flow meter 84 to the aforementioned N2 metering conduit. 62 is a heating conduit.
The cleaning machine according to the invention thus does not clean either in vacuum or in gas-tight manner or under protective gas.
The invention has nothing in common with the prior art in which many PER machines are simply modified for benzine or petrol (danger of explosion!).
According to the invention, the operation may be carried out with a solvent with high flashpoint of for example 71° C. at a low vapour pressure. This alone provides protection against explosion only in the drying by means of hot air, i.e. rendering inert, this protection not being provided in the washing itself.
Due to the step according to the invention of separately washing and drying (separate apparatus components, i.e. cleaning machine and drier), each aggregate can be designed to suit its optimum respective purpose. The transfer method, which is the foundation of the invention, thus permits simultaneous washing and drying of different batches and therefore gives twice the capacity (economical advantage for the user). The rendering inert takes place only in the drier and not in the washing drum by the special aggregate which is employed specifically for this purpose and which recovers nitrogen from the ambient air and consequently dispenses with technically complicated vacuum method and gas-tight machines.
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The invention relates to an apparatus for cleaning textiles by means of FCHC-free solvents on a benzine basis, comprising a cleaning machine, distillation section, recovery section and drier, and is characterized by a means for injecting protective gas into the drier.
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BACKGROUND OF THE INVENTION
This invention relates to the pumping of volatile liquids and more particularly to pumps operating at low net positive suction head (NPSH) while delivering at its output a relatively large quantity of liquid at a relatively high pressure.
The prior art has recognized significant difficulties in pumping liquids where the liquid pressure (suction pressure) at the pump inlet is very low. The difficulties that arise with low inlet pressure pumps are associated with cavitation or boiling of the liquid being pumped. If the ambient pressure applied to the liquid is below its vapor pressure, the liquid being pumped will boil or cavitate. Cavitation is particularly troublesome at the inlet to the vanes of a centrifugal impeller. At this point in a centrifugal pump, there is an initial depressurization zone through which the fluid must traverse before the impeller vanes become effective in the process of raising the static pressure of the liquid being pumped. Boiling or cavitation will occur in this depressurization zone of the pump if the liquid pressure drops below the vapor pressure of the liquid being pumped. Such cavitation has two undesirable effects. First, a cavitating liquid has an increased chemical activity with the materials of which the pump is made. Rapid oxidation with the pump materials may occur. Secondly, cavitation may create relatively high pressures on various portions of the pump structure with the possible damage to the mechanical structure thereof.
The pressure reduction at the impeller vane inlet becomes acutely greater with increased flow rate and rotational speed of the pump, leading to critical cavitation problems for a number of pumping applications. Liquid sodium pumps for nuclear reactor coolant service is just one example of this. Because of the explosive nature of sodium when exposed to the atmosphere, safety precautions require that penetrations into the liquid metal system (i.e., where a pump shaft penetrates the liquid metal system) occur at a very low pressure point in the system. This is because a mechanical shaft seal, to prevent liquid sodium leakage into the atmosphere, is feasible for a maximum sodium pressure that is only slightly greater than atmospheric pressure. Therefore, the liquid sodium pump must operate at a very low pressure. Also, these pumps are required to handle large volume rates of sodium. These two system design conditions force the liquid sodium pump to operate at or close to a critical cavitating mode.
Thus, it is desired to provide a pump capable of operating at very low NPSH conditions. A reduction in NPSH can be achieved by lowering the rotational speed of the pump's impeller. The following equation relates NPSH to the flow rate of the pump and the rotational velocity of the pump's impeller: ##EQU1## where, NPSH=required net positive suct. head in feet
N=pump speed in rpm
Q=pump flow in gpm ##EQU2## Reducing the impeller speed to satisfy a low NPSH requirement requires further modification of the pump design to meet typical pump head and flow design criteria. For example, to maintain an output pressure at a desired high level, it may be necessary to increase the dimensions of the pump's impeller and housing.
Alternatively, the pump inlet pressure and NPSH can be raised by returning a portion of the pump discharge to the pump inlet. However, such a pump modification reduces the overall efficiency of the pump. As a result, such a modification is not a practical solution to obtain low NPSH while providing a high pressure output.
The prior art has further suggested that two pumping units be coupled in series. The first, or booster pump, operates at a relatively low impeller speed to raise the fluid pressure head to a sufficient level that the second, or main pump, can operate at a relatively high impeller speed considering impeller size, overall pump efficiency, and the desired relatively high pressure output. However, the use of a separate booster pump and a main pump increases the space required and the resultant cost of such a configuration.
In a FINAL REPORT entitled "INDUCER DYNAMICS FULL-FLOW, FULL-ADMISSION HYDRAULIC TURBINE DRIVE, dated Aug. 24, 1969 by Farquhar et al. (NASA CR-72566; AGC-9400-18), there is disclosed a pump or inducer designed to pump a highly volatile liquid such as liquid rocket fuel. The described pump includes an inlet for receiving the volatile liquid. A first stage comprises a low speed inducer that is driven by a hydraulic turbine, as will be explained. A high speed rotor is disposed next within the flow path and is driven by a suitable motor at a relatively high speed. The high speed rotor increases the pressure of the volatile liquid and directs the liquid to drive a plurality of fins of the hydraulic turbine placed directly in the flow path. The fins are in turn connected by a coupling disposed outside of the flow path directly to the low speed inducer, whereby upon rotation of the turbine fins, the low speed inducer will rotate therewith. The speed of the turbine fins and, thus, the low speed inducer is dependent upon the angle with which the fins are mounted with respect to the liquid flow path. The liquid leaving the hydraulic turbine is directed to a main impeller, likewise coupled to the drive motor, before being discharged through an outlet. The problems with such a two-stage pump reside primarily with the use of turbine fins disposed within the primary flow path. First, because of the extra hydraulic losses associated with the inducer, this device should be designed for the minimum power consistent with producing no more than the minimum head required to prevent cavitation at the inlet to the high speed rotor. However, the turbine fins, disposed within the fluid path, significantly reduce the fluid pressure at the outlet of this pump. To compensate for this pressure drop, the high speed rotor must be driven at a relatively higher speed, thus, requiring a higher head inducer stage, with increased pumping losses, to prevent cavitation with the higher speed rotor. Secondly, the turbine fins, disposed in the primary fluid path, are effected by the vagaries of the primary fluid system. For instance, fluid power to the turbine fins can be effected by a change in the pump flow as a result of a change-over in system operating mode. This could cause a significant change in turbine speed with a resulting reduced inducer head and cavitation at the inlet to the high speed rotor. Also, the turbine fins would be subjected to unequal circumferential forces that can occur in the primary fluid flow path within the pump. This could result in severe loads being transmitted to the turbine bearing support system. Finally, the set of turbine fins disposed in the primary fluid path is an additional rotating component that must be considered in the design of the primary fluid path within the pump. As a likely result, the design of the primary flow system within the pump may be detrimentally compromised to accommodate the turbine. Conversely, the design of the turbine is dependent upon the fluid flow conditions that are imposed by the primary system. A likely result of this is a turbine with performance that has been detrimentally compromised because it is required to make use of non-optimum fluid flow conditions that are imposed on it by the primary fluid system in the pump.
Therefore, what is needed is a pump employing a booster or low speed stage and a high speed stage that does not employ driving means disposed within the flow path for driving the low speed or booster stage and additionally ensures that the suction pressure at the input for the second or high speed stage is sufficiently high to avoid cavitation.
SUMMARY OF THE INVENTION
In accordance with these and other objects of this invention, there is described apparatus for pumping a volatile fluid having a given vapor pressure. The pumping apparatus of this invention comprises a pump housing comprising an inlet for introducing the liquid at a relatively low static pressure level into the pump housing and an outlet for discharging the liquid from the pump housing at a relatively high static pressure level. A fluid path extends from the inlet to the outlet. A booster stage impeller is rotatively mounted for drawing the fluid through the inlet and for pumping the fluid along the fluid path with an increased kinetic pressure. A diffuser is affixedly disposed with the pump housing to intercept the fluid directed along the fluid path by the booster stage impeller for converting the kinetic pressure imparted to the fluid into increased static pressure. A main stage impeller is rotatively driven by a pump motor at a relatively high speed to impart a relatively high static pressure to the fluid being introduced thereto and for discharging the fluid at a relatively high static pressure. A hydraulic coupler is disposed remotely from the fluid path for hydraulically coupling the main stage impeller and the booster stage impeller to rotate the booster stage impeller at a relatively low speed selected to maintain the net positive suction pressure applied to the fluid at the inlet greater than the vapor pressure and to ensure that the net positive suction head, as established by the main stage impeller upon the fluid introduced thereto, exceeds the vapor pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side, partially sectioned view of a low NPSH pump in accordance with this invention, particularly illustrating the manner in which this pump may be mounted with regard to a reservoir of a volatile liquid to be pumped;
FIG. 2 is a side, fully sectioned view of the pump, as shown in FIG. 1, illustrating the booster stage, the high speed stage, and the coupling necessary for driving the high speed stage;
FIG. 3 is a side, partially sectioned view of the pump of FIGS. 1 and 2 particularly illustrating the details of the booster and high speed stages; and
FIG. 4 is a partially sectioned, side view of a further embodiment of this invention and, in particular, the mechanism for coupling the high speed stage to the booster stage to impart rotational movement to the booster stage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and, in particular to FIG. 1, there is shown a low net positive suction head (NPSH) pump 10 in accordance with the teachings of this invention. The low NPSH pump 10 includes an outer housing in the form of a tank 12 and a mounting flange 14. The mounting flange 14 assists mounting within a housing shield 18 that serves to contain a reactor primary piping system for a liquid metal, e.g., sodium. It is contemplated that the pump 10 may be used to pump liquid sodium within a nuclear reactor, noting that the sodium may be radioactive requiring the housing shield 18 of dense construction such as would be provided by a concrete material. In turn, the inlet and outlet conduits 19 and 20 connect the low NPSH pump 10 in circuit with the primary piping system. The primary piping system includes the low NPSH pump 10, the nuclear reactor, a heat exchanger and the connecting piping; all of the primary piping system is located below the housing shield 18. The internal assembly of the low NPSH pump 10 is attached to another mounting flange 17 mounted on top of the tank flange 14. The internal assembly can be withdrawn from the pump tank 12 through the opening of the tank flange 14. In particular, the mounting ring 16 sets in an annular recess of the concrete housing shield 18. The mounting flange 14 is disposed on top of mounting ring 16 and is used for suspending the tank 12. In turn, the cylinder flange 17 sets on top of the mounting flange 14 and supports the internal assembly of the low NPSH pump 10. An opening 19 within the housing shield 18 receives the low NPSH pump 10 therein. In particular, a mounting ring 16 is disposed about the opening 19 for receiving the mounting flange 14, whereby the low NPSH pump 10 is mounted on the housing shield 18.
Referring now to FIGS. 1 and 2, the low NPSH pump 10 includes a second, or main stage, impeller 48 that is rotatively driven by a pump motor 34. The pump motor 34 includes an output rotor 32. The pump motor 34 is supported by a cylindrical housing 22, whose bottom-most end rests upon the mounting ring 16. The output rotor 32 includes a flange 32a, coupled to a flange 28b of a coupling 28, which serves to impart rotational drive to a drive shaft 30 and, in particular, is coupled to a flange 30b of the drive shaft 30. The drive shaft 30 is mounted within a bearing 26. A seal 24 is disposed about the drive shaft 30 and serves to prevent the escape of a blanket gas retained with the tank 12 and covering the liquid metal in the reservoir within the tank 12.
Referring now to FIGS. 2 and 3, the low NPSH pump 10 is vertically oriented with an inlet or suction nozzle 38 disposed at the bottom of the pump 10 to introduce a flow of the liquid from the inlet conduit 19 to be directed upward along a path identified by the arrows marked with the numerals 100, as shown in FIG. 3. The principle components of the low NPSH pump 10 are a first or booster stage impeller 46 for initially imparting kinetic and static pressure to the pump fluid, a diffuser 102 comprised of a set of diffuser vanes 114 for converting the fluid's kinetic energy to static energy, and a second or main stage impeller 48 rotatively driven by the pump motor 34. The main stage impeller 48 increases the static pressure of the fluid as it is driven into an annular space 52 to be discharged through an outlet or discharge nozzle 36 at a relatively high static pressure.
As shown in FIG. 2, the rotatively driven solid drive shaft 30 is integrally connected to a hollow pump rotor 40, which is in turn directly coupled to rotatively drive the main stage impeller 48. The heat transfer baffles 44, contained within the upper end of the hollow pump rotor 40, prevent the heat generated by the hot liquid metal and conducted to the internal void of the hollow shaft 40 from being radiatively transferred upward to the solid drive shaft 30 and thence conductively to the seal 24. A main cylinder support 42 is suspended from the cylinder flange 17 to support a bearing support housing 132 and an upper housing 136, as shown in FIG. 3 and to be described in detail below.
Referring now to FIG. 3, the liquid to be pumped is introduced into the inlet 38 and directed along the fluid path 100 upwardly. The booster stage impeller 46 is rotatively suspended upon a center post 50. The center post 50 is oriented along the axis of the tank 12 by a plurality, e.g., six, of struts 62. The outer ends of the struts 62 are connected to a support housing 53. The support housing 53 includes a flange 60 at its lower end and a pair of piston rings 58 clamped to flange 60 by a clamp ring 56. The outer diameter of rings 58 mate through sliding fit with the inner diameter of seal ring 54, which is secured as by welding to the inner peripheral surface of the tank 12. A generally cylindrically shaped upper housing 136 is coupled at its upper-most end to the bearing support housing 132 and at its bottom-most end to the support housing 53. The annular space 52 is formed between the inner surface of the tank 12 and the outer surfaces of the upper housing 136 and of the support housing 53. As illustrated in FIG. 3, the fluid flow path 100 is directed into the annular space 52 at a relatively high pressure. At the inlet or suction nozzle 38, the fluid path 100 is directed through an annular space formed by the outer surface 55 of the post 50 and the inner surface 57 of the support housing 53. The fluid path 100 is directed about the struts 62, which have an air foil shape, as illustrated in FIG. 3, to minimize any frictional losses of the fluid passing over the struts 62.
As shown in detail in FIG. 3, the booster stage impeller 46 includes a plurality of booster vanes 64, e.g., approximately six such vanes. The vanes 64 are of helical configuration and are formed between a conically shaped hub shroud 68 and an outer, booster stage shroud 66. The flow path 100 is directed upward between an outer peripheral surface 69 of the hub shroud 68 and an inner surface 67 of the outer shroud 66. Illustratively, the booster stage impeller 46, as comprised of the shrouds 66 and 68 and the vanes 64, may be illustratively molded as a single piece. The booster stage impeller 46 is rotatively mounted upon the center post 50 by a cylindrically shaped hub journal 70. A hub bearing sleeve 72 is mounted fixedly upon the surface 55 of the center post 50 for rotatively receiving the hub journal 70 and for forming a hydrostatic pocket 74 to be filled with the liquid pumped at a relatively high pressure to form a hydrostatic radial bearing to rotatively support the booster stage impeller 46. A second hydrostatic radial bearing is illustrated in FIG. 3 as being disposed above that bearing previously described and as including an upper bearing journal 92 affixed to a support member 94, which is of substantially cylindrical configuration and extends upwardly from the hub shroud 68. An upper bearing sleeve 88 is fixedly disposed upon the center post 50 to form with the journal 92 an upper hydrostatic pocket 90 for receiving the fluid under pressure.
The pressurized fluid is tapped from the annular space 52 and is introduced, as will be explained, into each of the lower hydrostatic pocket 74 and the upper hydrostatic pocket 90. In particular, a strut conduit 76 is disposed along the center of each of the struts 62 communicating at an outer end with the annular space 52 and at its inner end with an axial conduit 78 running along the axis or center line of the center post 50. In turn, the axial conduit 78 communicates with the lower hydrostatic pocket 74 through a series of radially disposed post orifice 80 and sleeve orifice 82 to introduce the liquid under pressure into the lower hydrostatic pocket 74. In similar fashion, the axial conduit 78 communicates via a series of post orifice 84 and sleeve orifice 86 with the upper hydrostatic pocket 90 introducing fluid under pressure therein.
The axial load of the booster stage impeller 46 is carried by a hydraulic balancing drum device 96, as shown in FIG. 3. The balancing device 96 essentially comprises an annularly shaped pressure pocket 97 formed between the outer, booster stage shroud 66 and the support housing 53. Pressurized fluid is introduced into the pressure pocket 97 from the pressurized fluid in an annular space 52a via an axial clearance 99. Pressurized fluid leaves the pressure pocket 97 through an inner running, radial clearance 98, entering a relatively low pressure space 52b at the booster stage impeller inlet. The pressure in the pocket 97 is self-compensating. As the pressure decreases within the pocket 97, the size of the inner, axial clearance 98 decreases thereby tending to increase the pressure within the pocket 97. Conversely, as pressure within the pocket 97 increases, the size of the inner, axial clearance 98 increases, thereby tending to permit the escape of the pressure fluid within the pocket 97. As a result, the booster stage impeller 46 is balanced on the pressurized fluid within the pocket 97 without any mechanical contact at the inner, axial clearance 98.
The fluid path 100 continues upward within the low NPSH pump 10 from the booster stage impeller 46 into the diffuser 102. As shown in FIG. 3, the diffuser 102 includes a plurality of diffuser vanes 114 of helical configuration and mounted between a conically shaped, inner diffuser hub shroud 108 and an outer diffuser hub shroud 110. The fluid is directed along fluid path 100 as defined between a surface 109 of the inner diffuser hub shroud 108 and a surface 112 of the outer diffuser hub shroud 110. Illustratively, the shrouds 108 and 110, and the diffuser vanes 114 may be integrally molded as a single piece. The diffuser 102 is affixed to the center post 50 in a stationary position. The booster stage impeller 46 is rotatively driven by a coupling drum 124, as will be explained later, to impart kinetic and static head to the pumped fluid by the centrifugal action of the rotating booster stage impeller 46. As the fluid is directed along the fluid path 100 through the diffuser 102, most of the kinetic energy imparted to the fluid by the booster stage impeller 46 is converted to static energy within the stationary passages formed between the diffuser vanes 114 of the diffuser 102 to raise the static pressure as it approaches the main stage impeller 48. The booster stage impeller 46 is rotated at a relatively slow speed compatible with the low NPSH available at the suction nozzle 38 and with the low NPSH requirements of the main stage impeller 48. One of the critical requirements of the low NPSH pump 10 is to ensure a sufficiently high NPSH at the entrance to the main pump impeller 48 to avoid cavitation, i.e., the suction pressure as required by the main stage impeller 48 exceeds the vapor pressure of the fluid being pumped. The static pressure of the fluid exiting the booster stage impeller 46 is limited by the low NPSH requirements at the suction nozzle 38. Thus, the diffuser 102 is required to convert the kinetic energy of the fluid to static energy, thus, raising the static pressure of the fluid introduced to the main stage impeller 48 to a sufficiently high level to avoid cavitation.
The main stage impeller 48 is affixed to the pump rotor 40, whereby the main stage impeller 48 is rotatively driven by the pump motor 34. The main stage impeller 48 includes a plurality of main stage vanes 115, e.g., approximately 6 vanes, as formed between a main stage hub shroud 118 and an outer main stage shroud 116. The fluid is directed along the fluid path 100 through a passage formed by the main stage vanes 115 and an inner peripheral surface 120 of the main stage hub shroud 118, and a surface 122 on the outer main stage shroud 116. A cylindrically shaped, upright member 130 is integrally attached to the main stage hub shroud 118 to form a close clearance 134 with the bearing support housing 132. A cylindrically shaped, lip member 127 extends downward from the outer main stage shroud 116 to form a close clearance 129 with respect to the outer shroud 110 of the diffuser 102. The dimension of the close clearance 129 is set to permit free rotation of the main stage impeller 48 with respect to the stationarily disposed diffuser 102, while restricting the flow of liquid therethrough.
The pump rotor 40 is rotatively mounted within the bearing support housing 132. As illustrated in FIG. 3, the bearing support housing 132 is supported by an annularly shaped flange 154 suspended from the lower flange of the main support cylinder 42. A seal ring 153 is affixed to the outer diameter of flange 154. The outer diameter of this seal ring 153 mates with the inner diameter of the tank 12 through a close clearance sliding fit. This close clearance fit restricts high pressure liquid metal in the annular space around bearing support housing 132 from entering the reservoir of low pressure liquid metal existing in tank 12 above the bearing support flange 154. A cylindrically shaped bearing journal 144 is disposed about the lower end of the pump rotor 40 and forms, with a bearing sleeve 146, a hydrostatic pocket 152 therebetween. The cylindrically shaped bearing sleeve 146 is supported by the bearing support housing 132. Radial holes 140 are disposed within the bearing support housing 132 and a series of bearing orifices 148 and 150 permit the introduction of fluid at a relatively high pressure from the annular space 52 into the hydrostatic pocket 152 to facilitate the rotation of the pump rotor 40.
As shown in FIG. 3, the cylindrically shaped upper housing 136 is suspended within the tank 12 from the bearing support housing 132. An upper diffuser 139 is formed with an upper portion of the upper housing 136 and comprises a plurality of diffuser vanes 138, e.g., 12 such vanes 138. The upper diffuser 139 converts the kinetic energy imparted to the fluid by the main stage impeller 48 rotating at a relatively high speed into static energy, whereby the total pressure of the fluid introduced into the annular space 52 is increased.
A speed reduction coupling 123 is inserted between the main stage impeller 48 rotating at a relatively high speed, and the booster stage impeller 46 rotating at a relatively high speed, the speed reduction being attributable to the coupling 123. As shown in FIG. 3, the speed reduction coupling 123 comprises a cylindrically shaped coupling drum 124 suspended vertically and downwardly from the outer main stage shroud 116. An inner drag coupling member 104 and an outer drag coupling member 106 are affixed to the booster stage impeller 46 to extend vertically upward for receiving therebetween the coupling drum 124. As seen in FIG. 3, access to the speed reduction coupling 123 is provided in a space between the output of the diffuser 102 and the upper diffuser 139 to permit the flow of relatively high pressure fluid to the speed reduction coupling 123. A first plurality of friction grooves 126 is disposed about the inner peripheral surface of the coupling drum, and a second plurality of friction grooves 128 is disposed about the outer peripheral surface of the coupling drum 124, whereby the surface drag coefficient between the pressurized fluid and the coupling drum 124 is increased.
Referring now to FIG. 4, there is shown a further embodiment of a low NPSH pump 210, wherein like elements are identified with corresponding numerals to the elements of the low NPSH pump 10 shown in FIG. 3, but renumbered in the two and three hundred series. The low NPSH pump 210 employs a torque converter 356 in place of the speed reduction coupling 123, as shown in FIG. 3. The torque converter 356 is made up of three sets of vanes, namely a set of impeller vanes 360, a set of turbine vanes 366, and a set of stationary vanes 368. The set of impeller vanes 360 is integrally affixed to the main stage impeller 248 and, in particular, to the main stage outer shroud 316. The impeller vanes 360 are of a helical configuration and extend to an impeller shroud 358. As explained above, the main stage impeller 248 is driven by the pump motor to drive the pumped liquid in a corresponding direction, i.e., if the main stage impeller 248 is rotated in a clockwise direction as looking from the top of the low NPSH pump 210, the pumped liquid will be likewise directed in a clockwise direction to strike and rotate the turbine blades 366, which are mounted between a turbine shroud 362 and a turbine inner shroud 364.
As illustrated in FIG. 4, the turbine shroud 362 is affixedly mounted to an upright support member 355 which is integral with the outer, booster stage shroud 266 of the booster stage impeller 246, whereby the booster vanes 264 are rotatively driven. The fluid leaving the turbine vanes 366 is directed in an opposite direction to that entering the turbine vanes 366, i.e., if the entering liquid is directed in a clockwise direction, the discharged liquid will be directed in a counterclockwise direction. The liquid leaving the turbine vanes 366 is received and redirected by the stationary vanes 368, which are mounted between a stationary converter shroud 370 and a stationary converter shroud 370. As shown in FIG. 4, the stationary converter shroud 372 is affixed to the outer shroud 310 of the diffuser 302, whereby the stationary vanes 368 are held stationary with respect to the rotating vanes 360 and 366. As a result, the liquid as directed in a counterclockwise direction onto the vanes 368 is redirected by the helically shaped vanes 368 to be directed onto the impeller vanes 360 along a vector disposed substantially parallel with respect to the axis of the pump 210.
In comparing the torque converter 356, as shown in FIG. 4, to the speed reduction coupling 123, as shown in FIG. 3, the coupling 123 is a constant torque device, whereas the converter 356 is a constant power device. In other words, coupling 123 operates such that the input torque in terms of pounds force times radius arm as exerted upon the main stage impeller 48 equals the torque transmitted to the booster stage impeller 46. The efficiency of the coupling 123 as compared with that of the torque converter 356, calculated as follows, is relatively low: ##EQU3## where the main stage impeller 48 is rotated at 800 rpm and the booster stage impeller 46 is rotated at 350 rpm. The brake horsepower (BHP) required by the booster stage impeller 46 assuming that the impeller vanes 115 are 80% efficient is calculated as follows: ##EQU4## indicating a requirement of 1341.5 HP output from the hydraulic coupling. In turn, the horsepower (HP) input to the viscous drag coupling 123 from the main impeller 48 is calculated as follows: ##EQU5## Since a relatively high slip, i.e., low efficiency, is necessary to transmit the high torque to the booster stage impeller 46, the viscous drag coupling 123 provides a limited output speed to the booster stage impeller 46.
By contrast, the torque converter 356 has a relatively higher efficiency output and is capable of rotating its booster stage impeller 246 at a greater rotational velocity. Efficiencies of up to 90% have been reported for torque converters similar to the converter 356 as shown in FIG. 4.
The horsepower (HP) input to the torque converter coupling 356 is calculated as follows: ##EQU6##
The overall efficiency for the total pump, i.e., booster stage impeller plus the main stage impeller, is calculated as follows: ##EQU7## Thus, for a main pump with 450 feet head and 85% efficiency, the overall efficiency of the low NPSH pump 10, as equipped with a viscous drag coupling 123, is calculated as 0.744. By contrast for the low NPSH pump 210 with the torque converter 356, the overall efficiency is calculated as 0.835. Thus, it is seen that the torque converter 356 does achieve a significantly higher overall pump efficiency, but costs more to construct than the viscous drag coupling 123.
Therefore, this invention provides an effective means for pumping volatile liquids.
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A pump is disclosed for pumping a volatile fluid having a given vapor pressure. The pump of this invention comprises a pump housing comprising an inlet for introducing the liquid at a relatively low static pressure level into the pump housing and an outlet for discharging the liquid from the pump housing at a relatively high static pressure level. A fluid path extends from the inlet to the outlet. A booster stage impeller is rotatively mounted for drawing the fluid through the inlet and for pumping the fluid along the fluid path with an increased kinetic pressure. A diffuser is affixedly disposed within the pump housing to intercept the fluid directed along the fluid path by the booster stage impeller for converting the kinetic pressure imparted to the fluid into increased static pressure. A main stage impeller is rotatively driven by a pump motor at a relatively high speed to impart a relatively high static pressure to the fluid being introduced thereto and for discharging the fluid at a relatively high static pressure. A hydraulic coupler is disposed remotely from the fluid path for hydraulically coupling the main stage impeller and the booster stage impeller to rotate the booster stage impeller at a relatively low speed selected to maintain the low net positive suction pressure applied to the fluid at the inlet greater than the vapor pressure and to ensure that the low net positive suction head, as established by the main stage impeller upon the fluid introduced thereto, exceeds the vapor pressure.
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RELATED APPLICATIONS
[0001] This application (Attorney's Ref. No. P216405kru) is a continuation of U.S. patent application Ser. No. 12/268,987 filed Nov. 11, 2008.
[0002] U.S. patent application Ser. No. 12/268,987 is a continuation of U.S. patent application Ser. No. 11/888,553 filed Jul. 31, 2007, now U.S. Pat. No. 7,448,599 which issued on Nov. 11, 2008.
[0003] U.S. patent application Ser. No. 11/888,553 is a continuation of U.S. patent application Ser. No. 11/410,736 filed Apr. 25, 2006, now U.S. Pat. No. 7,249,755 which issued on Jul. 31, 2007.
[0004] U.S. patent application Ser. No. 11/410,736 is a continuation of U.S. patent application Ser. No. 11/087,483 filed Mar. 22, 2005, now U.S. Pat. No. 7,032,892, which issued on Apr. 25, 2006.
[0005] U.S. patent application Ser. No. 11/087,483 is a continuation of U.S. patent application Ser. No. 10/456,247 filed Jun. 5, 2003, now U.S. Pat. No. 6,896,244, which issued on May 24, 2005.
[0006] U.S. patent application Ser. No. 10/456,247 is a continuation of U.S. patent application Ser. No. 09/976,380 filed on Oct. 11, 2001, now abandoned.
[0007] U.S. patent application Ser. No. 09/976,380 is a continuation-in-part of U.S. Design patent application Ser. No. 29/067,042 filed on Feb. 27, 1997, now U.S. Pat. No. D520,349, which issued on May 9, 2006.
[0008] U.S. Design patent application Ser. No. 29/067,042 claims priority of Canadian Industrial Design Application No. 1996-2618 filed on Nov. 26, 1996, now Canadian Industrial Design Registration No. 83049, which registered on Feb. 6, 1998.
[0009] The subject matter of the foregoing related applications are incorporated herein by reference.
TECHNICAL FIELD
[0010] The present invention relates to hardware for use in the construction of gates and, more specifically, to gate hardware adapted to brace the vertical and horizontal support members of a wooden gate and rotatably connect these members to a fixed structural member.
BACKGROUND OF THE INVENTION
[0011] Gates are often used to allow selective access through a wall or fence. Conventionally, gates are constructed as follows. Two vertical support members and two horizontal support members are fastened together in a rectangular shape to form what will be referred to herein as a gate box. Fence boards or the like are fastened to the support members, and one of the vertical support members is rotatably attached by two or more hinge assemblies to a structural member such as a wall or post.
[0012] Using conventional gate building techniques, fasteners such as nails or screws are driven through one support member into another support member to form the corners of the gate box. Over time, the force of gravity and wood shrinkage will cause these fasteners to loosen, allowing the gate box to sag out of its desired rectangular shape.
[0013] Accordingly, metal L-brackets, wooden brace members, triangular pieces of plywood, and the like are often fastened to the adjacent ends of the support members to strengthen the inside corners of the gate box. In other situations, a wire is placed in tension between the upper proximal and lower distal corners of the gate box to support the lower distal corner of the gate box and thereby reduce sagging of the gate. Such bracing techniques are somewhat effective but also commonly employ fasteners that are susceptible to failure and can be relatively time consuming to implement.
[0014] Another problem with conventional gate building techniques is that fasteners such as nails or screws are similarly used to attach the hinge assemblies to the vertical support member adjacent to the structural member. The loads are transferred to the gate through the screws placed in tension. As the wood shrinks and the gate is opened and closed, the fasteners under tension tend to loosen and may eventually fail.
[0015] As the hinge fasteners loosen, the entire gate assembly may sag relative to the hinge assemblies and thus the structural member, even if the gate box maintains its rectangular shape. The use of braces at the corners of the gate box will worsen sagging at the hinges because the materials and hardware used for bracing increase the weight of the gate; this increased weight increases the forces of gravity on the fasteners used to attach the hinge assemblies to the proximal vertical support member.
[0016] The Applicant is aware of a product sold in Canada as early as approximately 1993 under the tradename “Artistic Steel Gate Frames”. The Artistic Steel Gate Frame product comprises distal and proximal brace members, with hinges being attached to the proximal brace member. A gate assembly constructed using the Artistic product would use upper and lower horizontal wooden support members, but would not use vertical support members. Instead, the distal and proximal brace members would form the structure of the vertical sides of the gate. Accordingly, the brace members of the Artistic product were sold in a plurality of sizes, with each size corresponding to a given distance between the upper and lower horizontal support members.
[0017] One problem with the Artistic product is that this system requires the manufacturer to produce and keep in inventory, and the retailer to stock, multiple sizes of brace members.
[0018] In addition, the end user is limited to one of these multiple sizes of brace members; one could not create a gate assembly having a custom distance between the upper and lower horizontal support members.
[0019] From the foregoing, it should be clear that one object of the present invention is to create bracket systems and methods that are strong, that are easy and inexpensive to use, and which allow significant flexibility in the final design of the gate assembly.
SUMMARY OF THE INVENTION
[0020] The present invention is a bracket system or method for forming gate assemblies. The bracket system comprises at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system of the present invention
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a gate frame system of the present invention comprising distal brace members and proximal brace assemblies;
[0022] FIG. 2 is an exploded, front elevation view of a gate assembly incorporating the gate frame system of FIG. 1 ;
[0023] FIG. 3 is a partial cut-away, front elevation view of the gate assembly of FIG. 2 attached to a fence post;
[0024] FIG. 4 is a front elevation view of the distal brace member depicted in FIG. 1 ;
[0025] FIG. 5 is a side elevation view of the distal brace member depicted in FIG. 1 ;
[0026] FIG. 6 is a bottom plan view of the distal brace member depicted in FIG. 1 ;
[0027] FIG. 7 is a top plan view of the distal brace member depicted in FIG. 1 ;
[0028] FIG. 8 is a front elevation view of the proximal brace member depicted in FIG. 1 ;
[0029] FIG. 9 is a side elevation view of the proximal brace member depicted in FIG. 1 ;
[0030] FIG. 10 is a bottom plan view of the proximal brace member depicted in FIG. 1 ; and
[0031] FIG. 11 is a top plan view of the proximal brace member depicted in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring initially to FIG. 1 , depicted therein is a gate bracket system 20 constructed in accordance with, and embodying, the principles of the present invention. Referring for a moment to FIGS. 2 and 3 , the gate bracket system 20 is adapted to form a gate box 22 to be used as part of a gate assembly 24 ; the gate assembly 24 is in turn to be connected to a structural member such as a fence post 26 ( FIG. 3 ) of a larger structure such as a fence 28 .
[0033] The exemplary gate assembly 24 comprises in addition to the bracket system 20 distal and proximal vertical support members 30 and 32 , upper and lower horizontal support members 34 and 36 , and a plurality of fence members 40 . The exemplary support members 30 - 36 are conventional wooden two-by-fours, but other materials and sizes may be used as the support members 30 - 36 . The exemplary fence members 40 are also conventionally made out of wood, but other materials and various sizes of any type of material may be used to form the fence members 40 .
[0034] The support members 30 - 36 and fence members 40 do not form a part of the present invention. A description of the construction and operation of these members 30 - 40 is not necessary to describe how to make and use the present invention and is included herein simply to illustrate the environment in which the present invention operates.
[0035] The fence post 26 is conventionally a wooden four-by-four, but other materials and sizes may be used to form the structural member to which the gate assembly 24 is rotatably attached. For example, rather than a fence post 26 , the structural member may be a wall of a structure. The fence post 26 and fence 28 also are or may be conventional and are not part of the present invention. As with the support and fence members 30 - 40 introduced above, a description of the construction and operation of the post 26 and fence 28 is not necessary to describe how to make and use the present invention. The fence post 26 and fence 28 are described herein simply to illustrate the environment in which the present invention operates.
[0036] The gate bracket system 20 of the present invention comprises first and second distal brace members 50 and 52 and first and second brace assemblies 54 and 56 . The first brace assembly 54 in turn comprises a first proximal brace member 60 and a first hinge assembly 62 , while the second brace assembly comprises a second proximal brace member 64 and a second hinge assembly 66 .
[0037] The exemplary brace members 50 , 52 , 60 , and 64 each comprise a horizontal portion 70 , a vertical portion 72 , and a brace portion 74 . An outer end 72 a of the vertical portions 72 is rigidly connected to an attachment region 70 a of the horizontal portions 70 . The exemplary brace portion 74 is preferably rigidly connected at an angle between bracing regions 70 b and 72 b of the horizontal and vertical portions 70 and 72 , respectively.
[0038] The choice of materials and shapes of the materials are not essential to any particular implementation of the present invention. The primary requirements of the brace members 50 , 52 , 60 , and 64 are that these members each define a horizontal support surface 80 and a vertical support surface 82 such that these surfaces rigidly extend from each other at a right angle. In the exemplary system 20 , the horizontal support surfaces 80 are formed on the horizontal portions 70 and the vertical support surfaces 82 are formed on the vertical portions 72 .
[0039] A plurality of fastener holes 90 are formed in the brace members 50 , 52 , 60 , and 64 ; the fastener holes 90 are adapted to allow fasteners 92 to attach, in a conventional manner, the brace members 50 , 52 , 60 , and 64 to the support members 30 - 36 . The fasteners 92 are preferably self-tapping screws but can be nails, bolts, or the like. The fasteners 92 are not part of the gate bracket system 20 of the present invention per se but, as will be described in further detail below, are used to combine the bracket system 20 with the support members 30 - 36 to form the gate assembly 24 .
[0040] The exact number and location of the fastener holes 90 is not critical to any given implementation of the present invention. In a broadest form of the bracket system 20 , the fastener holes 90 can be formed anywhere along the horizontal portions 70 and vertical portions 72 . The only requirement for the number and spacing of these holes is that the fasteners 92 extend through these holes 90 and into the support members to rigidly secure the brace members to the support members.
[0041] Given the foregoing general understanding of the present invention, the distal bracket members 50 and 52 and the proximal bracket assemblies 54 and 56 of the present invention will now be described in further detail with reference to FIGS. 4-11 .
[0042] The attachment and bracing regions 70 a and 70 b of the horizontal portions 70 of the exemplary bracket members 50 , 52 , 60 , and 64 are formed located generally as follows.
[0043] The horizontal portions 70 have an outer end 70 c and an inner end 70 d . The exemplary attachment regions 70 a are located between approximately 15-30%, and preferably approximately 20%, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c . The bracing regions 70 b are located between approximately 80-95%, and preferably approximately 88%, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c.
[0044] The horizontal portions 70 further define spacing regions 70 e (between the attachment regions 70 a and the outer ends 70 c ), inner regions 70 f (between the bracing regions 70 b and the inner ends 70 d ), and intermediate regions 70 g (between the attachment regions 70 a and the bracing regions 70 b ).
[0045] The length of the spacing regions 70 e is determined such that the vertical support members 34 and 36 fit snugly between the vertical portions 72 and the outer ends 70 c . In the case of the proximal bracket assemblies 54 and 56 , the length of the spacing regions 70 e allows the vertical support members 34 and 36 to fit snugly between the vertical portions 72 of the third and fourth bracket members 60 and 64 and the first and second hinge assemblies 62 and 66 , respectively. When, as is typical, two-by-four dimensional lumber is used to form the vertical support members, the length of the spacing regions 70 e will be approximately 3½″, or slightly greater to allow for variations in the true dimensions of the lumber.
[0046] The vertical portions 72 each comprise the outer ends 72 a discussed above and an inner end 72 c . The bracing regions 72 b are located approximately 85% of the distance between the horizontal portion ends 72 a and 72 c as measured from the outer ends 72 a . The vertical portions 72 thus each define a main region 72 d between the outer end 72 a and the bracing region 72 b and an inner end region 72 e between the bracing region 72 b and the inner end 72 c.
[0047] In the horizontal portions 70 of the exemplary brace members 50 , 52 , 60 , and 64 , first, second, and third fastener holes 90 a , 90 b , and 90 c are formed in the spacing regions 70 e , inner regions 70 f , and intermediate regions 70 g , respectively. The first, second, and third fastener holes are spaced approximately 15%, 46%, and 96%, respectively, of the distance between the horizontal portion ends 70 c and 70 d as measured from the outer ends 70 c.
[0048] In the vertical portions 72 of the exemplary brace members 50 , 52 , 60 , and 64 , fourth and fifth fastener holes 90 d and 90 e are formed in the main region 72 d and a sixth fastener hole 90 f is formed in the inner end region 72 e . The fourth, fifth, and sixth fastener holes 90 d , 90 e , and 90 f are spaced approximately 15%, 46%, and 96% of the distance between the horizontal portion ends 72 a and 72 c as measured from the outer ends 72 a.
[0049] The fastener holes 90 of the exemplary brace members 50 , 52 , 60 , and 64 are formed along a horizontal center line A of the horizontal portion 70 and a vertical center line B of the vertical portion 72 .
[0050] The exemplary horizontal and vertical portions 70 and 72 are made of flat pieces of rigid metal, but other relatively rigid materials and shapes that function in a similar manner may be used. For ease of manufacturing, the exemplary horizontal and vertical portions 70 and 72 are identical in length, and the fastener holes 90 are formed at identical locations therein; only one part thus needs to be fabricated and stocked to form the exemplary brace members 50 , 52 , 60 , and 64 .
[0051] The brace portion 74 is typically round or flat metal stock, but other shapes and materials may be used. For example, the brace portion 74 may be a triangular web of flat material that extends between the horizontal and vertical portions 70 and 72 . In this case, the entire brace member may be cast of metal or injection molded from plastic. If a triangular web or similar brace portion is used, it may be necessary to form the fastener holes 90 such that they are offset from the horizontal and vertical centerlines A and B.
[0052] From the foregoing, it should be clear that the exemplary brace members 50 , 52 , 60 , and 64 are identical, which is preferred for manufacturing purposes. However, these brace members 50 , 52 , 60 , and 64 need not be identical to practice the present invention in its broadest form.
[0053] The first and second hinge assemblies 54 and 56 are or may be conventional and will be described herein only to the extent necessary for a complete understanding of the present invention.
[0054] As is conventional, the hinge assemblies 54 and 56 each comprise a gate plate 120 and a post plate 122 . These plates define hinge projections 124 that receive a hinge pin (not shown). The hinge pin allows the gate and post plates 120 and 122 to rotate relative to each other about a hinge axes C and D defined by the hinge assemblies 54 and 56 .
[0055] The outer ends 70 c of the horizontal portions 70 of the first and second brace members 60 and 64 are rigidly connected to the gate plates 120 . In particular, the horizontal center lines A of the horizontal portions 70 of these brace members 60 and 64 are tangential to circles centered about the hinge axes C and D, respectively. The vertical center lines B of the vertical portions of the brace members 60 and 64 are parallel to the hinge axes C and D, respectively.
[0056] An array of fastener holes 90 is formed in the post plate 122 to allow this plate to be rigidly attached to the fence post 26 . Preferably four fastener holes 90 are formed in the post plate 122 . The drawing depicts fastener holes 90 in the gate plate 120 ; these holes 90 in the plate 120 need not be used, but will be present if off-the-shelf hinge assemblies 62 and 66 are used.
[0057] The process of combining the bracket system 20 with the support members 30 - 36 to form the gate box 22 will now be described with reference to FIG. 2 .
[0058] Initially, as is conventional, the support members 30 - 36 are cut to the desired lengths. The length vertical support members 30 and 32 generally correspond to the height of the gate assembly 24 , while the length of the horizontal support members 34 and 36 closely correspond to the width of the gate assembly 24 . The minimum lengths of the support members 30 - 36 are determined by the horizontal portions 70 and vertical portions 72 of the brace members 50 , 52 , 60 , and 64 ; in particular, the support members 30 - 36 must be at least twice as long as the lengths of the horizontal and vertical portions 70 and 72 to prevent overlapping of the horizontal portions 70 or vertical portions 72 of adjacent brace members.
[0059] The first and second distal brace members 50 and 52 and first and second brace assemblies 54 and 56 are arranged such that: (a) horizontal and vertical support surfaces 80 a and 82 a of the first distal brace member 50 define first and second support surfaces of the bracket system 20 ; (b) horizontal and vertical support surfaces 80 b and 82 b of the second distal brace member 50 define third and fourth support surfaces of the bracket system 20 ; (c) horizontal and vertical support surfaces 80 c and 82 c of the first proximal brace member 60 define third and fourth support surfaces of the bracket system 20 ; and (d) horizontal and vertical support surfaces 80 d and 82 d of the second proximal brace member 54 define third and fourth support surfaces of the bracket system 20 .
[0060] The fasteners 92 are then inserted through the fastener holes 90 of the brace members 50 , 52 , 60 , and 64 and into the support members 30 - 36 to form the gate box 22 . In particular, fasteners 92 are driven through the holes 90 and into the support members 30 - 36 such that: (a) the upper horizontal support member 30 is drawn tight against the first and fifth support surfaces defined by the first distal brace member 50 and second proximal brace member 60 ; (b) the lower horizontal support member 32 is drawn tight against the second and sixth support surfaces defined by the second distal brace member 52 and fourth proximal brace member 64 ; (c) the distal vertical support member 34 is drawn tight against the third and fourth support surfaces defined by the first and second distal brace members 50 and 52 ; and (d) the proximal vertical support member 36 is drawn tight against the seventh and eight support surfaces defined by the first and second proximal brace members 60 and 64 .
[0061] The exact order of the attachments described in the preceding paragraph is not critical to the present invention in its broadest form. However, with the brace members 50 , 52 , 60 , and 64 described herein, fasteners 92 are preferably driven through at least the first fastener holes 90 a formed in the spacing regions 70 e of the horizontal portions 70 before fasteners 92 are driven through the fastener fourth, fifth, or sixth fastener holes 90 d - e of the vertical portions 72 . Otherwise, the vertical support members 34 and 36 may block access to the first fastener holes 90 a . Preferably, fasteners 92 are driven through the first through third fastener holes 90 a - c before fasteners are driven through the fifth through sixth fastener holes 90 d - e.
[0062] With the gate box 22 formed as described above, the hinge axes C and D will be substantially aligned. The gate box 22 so formed may thus then be attached to the fence post 26 by fasteners 92 extending through the fastener holes 90 in the post plate 122 and into the post 26 . When the post plates 122 are rigidly connected to the post 26 , the gate box 22 pivots relative to the fence post 26 about the hinge axes C and D.
[0063] The gate assembly 24 may be formed before or after the gate box 22 is attached to the fence post 26 by attaching the fence members 40 to at least one, and preferably at least two, of the support members 30 - 36 of the gate box 22 .
[0064] Given the foregoing, it should be clear that the present invention may be embodied in forms other than those depicted and described herein. The scope of the present invention should thus be determined by the claims appended hereto and not the preceding detailed description of the preferred embodiment.
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A bracket system for forming gate assemblies comprising at least two brace members that are rigidly attached to hinge assemblies. The brace members are adapted to be attached to support members to form two corners of a gate box functioning as the structural portion of the gate assembly. The hinge assemblies are adapted to be rigidly attached to a fence post to allow the gate assembly to pivot relative to the fence post. Gate assemblies of arbitrary height and width can be formed using the bracket system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/971,037, which was filed on Mar. 27, 2014 and is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under Contract No. NNC07CB59C, awarded by NASA. The Government has certain rights in this invention.
BACKGROUND
[0003] This application relates to an inlet wall design for use in an embedded gas turbine engine.
[0004] Gas turbine engines are known and typically include a fan delivering air into a bypass duct and into a core engine. In the core engine the air is compressed at a compressor and then mixed with fuel and ignited in a combustion section. Products of the combustion pass downstream over turbine rotors, driving them to rotate.
[0005] Gas turbine engines have historically been mounted on a tail or beneath the wings of an aircraft. However, a next generation of aircraft seeks to dramatically increase fuel efficiency, reduce emissions, and decrease fuel burn. A design for such aircraft utilizes a blended wing design wherein the body and wing merge smoothly into each other. Such designs have typically been proposed with embedded engines, which are mounted within a fuselage or body of the aircraft.
[0006] In such an engine, the area upstream of an inlet to the engine is different on circumferential locations adjacent to the body than at locations spaced away from the body. A boundary layer or area of low momentum air will be formed leading into the inlet and the fan at circumferential locations associated with the body.
SUMMARY
[0007] In one exemplary embodiment, a gas turbine engine includes an inlet duct that is formed with a generally elliptical shape. The inlet duct includes a vertical centerline and a fan section that has an axis of rotation. The axis of rotation is spaced from the vertical centerline and is disposed within an inlet duct orifice.
[0008] In a further embodiment of the above, the axis of rotation is spaced a first distance from the vertical centerline at a throat of the inlet duct. The axis of rotation is spaced a second distance from the vertical centerline at an intermediate location along the inlet duct. The first distance is greater than the second distance.
[0009] In a further embodiment of any of the above, the axis of rotation is spaced a third distance from the vertical centerline at an axial location adjacent the fan section. The third distance is less than the second distance.
[0010] In a further embodiment of any of the above, the axis of rotation is spaced a first distance from the vertical centerline at a first axial position in the inlet duct. The axis of rotation is spaced a second distance from the vertical centerline at a second axial position in the inlet duct. The first distance is greater than the second distance.
[0011] In a further embodiment of any of the above, the first axial position is upstream of the second axial position.
[0012] In a further embodiment of any of the above, the axis of rotation is spaced from the vertical centerline in a direction of rotation of an upper fan blade of the fan section.
[0013] In another exemplary embodiment, a blended wing aircraft includes a blended wing fuselage and at least one embedded gas turbine engine in the fuselage. The gas turbine engine includes an inlet duct formed with a generally elliptical shape with a vertical centerline and a fan section that has an axis of rotation. The axis of rotation is spaced from the vertical centerline.
[0014] In a further embodiment of the above, the axis of rotation is spaced a first distance from the vertical centerline at a throat of the inlet duct. The axis of rotation is spaced a second distance from the vertical centerline at an intermediate location along the inlet duct. The first distance is greater than the second distance.
[0015] In a further embodiment of the above, the axis of rotation is spaced a third distance from the vertical centerline at an axial location adjacent the fan section. The third distance is less than the second distance.
[0016] In a further embodiment of the above, the axis of rotation is spaced a first distance from the vertical centerline at a first axial position in the inlet duct. The axis of rotation is spaced a second distance from the vertical centerline at a second axial position in the inlet duct. The first distance is greater than the second distance.
[0017] In a further embodiment of the above, the first axial position is upstream of the second axial position.
[0018] In a further embodiment of the above, the axis of rotation is spaced from the vertical centerline in a direction of rotation of an upper fan blade of the fan section.
[0019] In a further embodiment of the above, the axis of rotation is disposed within an inlet duct orifice.
[0020] In a further embodiment of the above, the at least one embedded gas turbine engine includes a first gas turbine engine that is configured to rotate in a first direction. A second gas turbine engine is configured to rotate in a second opposite direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates a blended wing aircraft.
[0022] FIG. 2 illustrates an inlet duct for a gas turbine engine as may be included in the FIG. 1 embodiment.
[0023] FIG. 3 illustrates a cross-sectional view of the gas turbine engine from FIG. 2 .
[0024] FIG. 4 illustrates a top view of the inlet duct.
[0025] FIG. 5 illustrates a side view of the inlet duct.
[0026] FIG. 6 illustrates a perspective view of the inlet duct.
[0027] FIG. 7 illustrates a perspective view of the inlet duct.
[0028] FIG. 8A illustrates the inlet duct at a throat.
[0029] FIG. 8B illustrates the inlet duct at an intermediate location.
[0030] FIG. 8C illustrates the inlet duct adjacent the fan.
DETAILED DESCRIPTION
[0031] An aircraft 20 is illustrated in FIG. 1 having a blended wing body or fuselage 22 and a plurality of embedded gas turbine engines 24 . As known, the embedded gas turbine engines 24 include a fan 30 ( FIG. 2 ) at an upstream location delivering air into a compressor and into a bypass duct. The air is mixed with fuel and ignited in a combustor downstream of the compressor and products of that combustion pass downstream over turbine rotors driving them to rotate.
[0032] There are challenges with regard to the embedded gas turbine engines 24 . As an example, as shown in FIG. 2 , an inlet end 26 of the embedded gas turbine engine 24 includes an inlet duct 28 that will sit on the fuselage 22 . There will be a boundary layer leading into a bottom surface 32 of the inlet duct 28 for the gas turbine engine 24 . A duct centerline DC of the inlet duct 28 is shifted horizontally from an axis of rotation A of the fan 30 . For example, the duct centerline DC is shifted horizontally in the direction of rotation R of a fan blade located at a top of the fan 30 . As shown in this design, the inlet duct 28 includes a throat T at the inlet end 26 that is generally elliptical. The inlet duct 28 becomes generally more circular downstream of the throat T towards the fan 30 . Applicant has designed the shape of the inlet duct by utilizing ellipses and optimizing the curves, lengths and shape of the overall duct.
[0033] As shown in FIGS. 3 and 4 , the duct centerline DC is spaced from the axis of rotation A at the throat T. The duct centreline DC gradually approaches the axis of rotation A downstream of the throat T. Although a single fan blade is shown in FIGS. 4-7 to illustrate the direction of rotation of the fan 30 , one of ordinary skill in the art would recognize that multiple fan blades would surround the fan 30 .
[0034] As shown in FIG. 5 , a first vertical dimension V 1 at the throat T of the inlet duct 28 generally increases downstream towards the fan 30 to a second vertical dimension V 2 adjacent the fan 30 . The second vertical dimension V 2 is greater than the first vertical dimension V 1 .
[0035] As shown in FIG. 8A , the throat T of the inlet duct 28 includes a very small lower ellipse 62 and an upper ellipse 64 , which is much larger. This may be at the upstream most point of the inlet duct 28 and immediately downstream of the fuselage 22 . The axis of rotation A is spaced horizontally a distance D 1 from the duct centerline DC and extends through the inlet duct 28 . In this example, the axis of rotation extends through an upper left quadrant of the inlet duct 28 .
[0036] FIG. 8B shows another location 70 which is generally intermediate in the inlet duct 28 as shown in FIG. 5 . At the location 70 , the inlet duct 28 includes a lower ellipse 72 that is much larger than the lower ellipse 62 shown in FIG. 8A . An upper ellipse 74 is slightly narrower than the upper ellipse 64 shown in FIG. 8A . The axis of rotation A is spaced horizontally a distance D 2 from the duct centerline DC and extends through an upper left quadrant of the inlet duct 28 . The distance D 2 is less than the distance D 1 .
[0037] FIG. 8C shows a downstream location 80 adjacent the fan 30 . An upper ellipse 84 is generally the same size as a lower ellipse 82 and the upper and lower ellipses 84 and 82 are generally circular. The axis of rotation A generally extends through the duct centreline DC or is spaced a distance from the duct centreline DC that is less than the distance D 1 or the distance D 2 shown in FIGS. 8A and 8B , respectively.
[0038] By designing the inlet duct 28 according to the teachings above, the airflow will be more uniform by the time it reaches the fan 30 , and the effects of the boundary layer from the fuselage 22 will be dramatically reduced. In particular, air entering the inlet duct 28 along the inlet area IA ( FIG. 2 ) will have a reduced angle of incidence. The inlet area IA is generally located between the 6 and 9 o'clock position when the fan 30 is rotating clockwise and between the 6 and 3 o'clock position when the fan 30 is rotating counterclockwise. Air entering the inlet duct 28 with a high angle of incidence reduces the operational margin of the gas turbine engine 24 and can decrease the life of the fan blades.
[0039] A worker of ordinary skill in this art would recognize when either of the inlet shape options would be most efficient to utilize. Of course, other shapes may be utilized as well.
[0040] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
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A gas turbine engine includes an inlet duct that is formed with a generally elliptical shape. The inlet duct includes a vertical centerline and a fan section that has an axis of rotation. The axis of rotation is spaced from the vertical centerline and is disposed within an inlet duct orifice.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus and process for making caseless (skinless) sausage. In particular, this invention relates to a particular reusable tubular casing and associated apparatus for making parboil or raw sausage.
2. Description of the Prior Art
In general, the art recognized three types of sausages: cooking sausage, parboil sausage, and raw sausage. Cooking sausage has a higher fat and protein content and accordingly contains a smaller amount of water than the parboil sausage. For this reason cooking sausage releases practically no water during the heating process, and can therefore be produced in casings that are impenetrable by water vapor and steam evolved during the sausage-making process. For example, many organic polymeric materials that are impervious to water and steam, can be used with cooking sausage.
On the other hand, a larger amount of water is released during reddening and coagulation of the parboil sausage, and during the reddening and ripening process for raw sausage.
Parboil sausage is produced from an emulsion in water of a protein and fat. During the formation of this emulsion in high capacity grinding or cutting machines, ice is used for cooling. For this reason, the bulk sausage contains more water than is permissible for the preservation, of the sausage. Therefore, the bulk sausage must release about 5 to 50% (as an average about 10%) gaseous constituents, in relation to the raw (unprocessed sausage meat) weight. These gaseous constituents consist for the most part of water vapor or steam, but also contain aromatic constituents and other volatile substances released during the heating steps for reddening and/or coagulation.
The reddening of parboil sausage occurs as a rule at about 35° C. within approximately 15 minutes; the coagulation must be carried out at temperatures above 45° C. and takes place as a rule by heating in water or steam at temperatures between 70° and 100° C., usually at about 80° C., in a relatively short time.
Almost all parboil sausages are smoked. It is a general practice to complete the smoking process after reddening, but before coagulation. Since the sausage casings in use at the present time have little permeability for smoke, the smoking process normally takes a long time.
Raw sausage is produced from bulk sausage which contains fat and meat pieces of various size. During the reddening and ripening process the bulk sausage releases gaseous constituents from about 10 to 50%, as related to the raw (unprocessed bulk) weight. These gaseous constituents also consist for the most part of water vapor, however, they also contain aromatic constituents and substances volatile under the conditions of the reddening and/or ripening process.
The reddening and ripening of raw sausage occurs at temperatures not above 40° C., as a rule at around 20° C. The reddening and ripening occurs quite slowly during the course of a few days up to several months. Some types of raw sausages are also smoked. In the reddening and ripening process for others, as for instance salami, mildew (mold) is expected to form.
In original sausage making procedures, the bulk sausage was injected into a natural intestine and subsequently subjected to the treatment required by a particular type of sausage. Artificial intestines made of various materials have been known for quite some time. Most of the natural and artificial intestines used for sausage casings are inedible and must be removed before consumption. Therefore, it has become the practice to peel the sausage casing right at the production plant.
Another technique has been used in sausage making, namely the production of so-called caseless sausages (also designated as skinless sausages), in order to reduce the expense incurred in peeling the sausage casings, the loss of sausage material because the sausages break when the casings are peeled away, and, in addition, the guite sizable cost of the casings themselves.
According to German Patent Publication DE-OS 25 23 506, caseless sausages are produced continuously by a machine that is provided with numerous molds, which after removal of the formed and cooked sausage, and after cleaning of the mold, can be used again. One by one these molds pass thru a fill station in the machine; a boiling or, as the case may be, a cooking oven; a cooling station; and a mold removal station, whereby between the mold removal station and the following fill station preferably a wash and/or cleaning station is provided. The molds are preferably made of a material having a low coefficient of friction, for instance "tetrafluoroethylene". This designation obviously is to mean "polytetrafluoroethylene". It is, however, in no way indicated that the material used for the molds could be or were required to be pervious for gas.
German Patent Publication DE-OS Number 27 56 995 refers to a process and apparatus for the production of a skinless, chord-like sausage by means of a hull designed as a chord-shaped hollow body which is designated expressly as "practically medium-tight" or "practically medium-tight sealable". The inside of the hollow body may have a smooth anti-sticking layer which, for instance, could be a coating of polytetrafluoroethylene. According to the process described in DE-OS 27 56 995, the raw bulk sausage is filled into the casing, then heated, possibly followed by cooling, and finally divided into suitable lengths. The pressure created during heating due to the expansion of the bulk sausage causes a pressure seal which prevents vapor evolved during cooking to reach the casing exit.
It is also known that a special paper made into an endless tube can be impregnated with viscose (a viscous solution of cellulosexanthogenate, which is used for the production of viscose rayon, viscose staple fibers, viscose cellophane and viscose sponges), to form a tubular casing which has a degree of porosity which permits the exchange of moisture and steam. Such viscose impregnated paper tubes can be used for sausages that are to be smoked, because their permeability allows for some penetration of smoke, at least to a degree that exceeds the smoke penetration of most other known sausage casings. Experience has shown that all known multiple reusable but nonporous casings are not suitable for the production of sausage types which must release water vapor, steam and other gaseous constituents. It is, of course, not possible to remove the water vapor, steam and other gaseous constituents from the sausage material before filling.
Also, a previous effort to use a finely perforated sausage wrapper having a large number of holes per square centimeter proved to have severe shortcomings with respect to providing a smooth outer sausage surface, and presented cleaning problems.
SUMMARY OF THE INVENTION
A multiple reusable porous casing for the production of caseless parboil or raw sausages must meet the following requirements:
1. The casing must have a sufficiently high permeability for water vapor, steam and other gases, like oxygen and aromatic constituents. A cellulose material which, however, is suited for one time use only and is not part of the present invention, may release for instance 5.5 μl of water vapor or steam per minute per square centimeter. Similar characteristics are desirable for multiple reusable casings.
2. The casing, even by multiple reuse, must neither release constituents injurious to health nor may it adversely affect the taste, smell or appearance of the sausage.
3. The pores must not, or at least only to a small degree, become plugged with fat, so their permeability is not decreased.
4. The casing must be easy to clean.
5. The casing must have a continuous thermal tolerance of at least 200° C.
6. The casing must have good mechanical stability and be pliant.
7. The casing must not adhere to the bulk sausage.
8. The internal surface of the tubular membrane must contain openings that are small enough so that the sausage's integral external surface has a smooth appearance.
The invention involves the discovery that a porous polytetrafluoroethylene (PTFE) membrane with a microstructure comprising PTFE nodes which are connected with each other by PTFE fibrils, is suited for this purpose. This material can be produced having small fibril lengths to yield effective pore sizes no more than 1.0 μm, preferably no more than 0.5 μm, and optimally no more than 0.2 μm. It is preferred that the membrane have a nominal thickness of 0.01 to 5 mm and a nominal porosity of 30 to 99, and preferably 55 to 85%. Membranes of this type, their characteristics and production, are known from U.S. Pat. Nos. 3,953,566 and 3,962,153 as well as the corresponding German Publications DE-AS 21 23 316 and 24 17 901; therefore, they need not be described in detail.
The PTFE membrane of the casing of the present invention has sufficient porosity to permit venting radially through the casing, the steam, water vapor and other gaseous fluids released during processing from the sausage present within the casing. The PTFE membrane also has a surface texture to provide easy release of the processed sausage from the casing following processing while maintaining the integrity of the sausage surface and the sausage as a whole. Furthermore, the gaseous fluid flow paths through the node and fibril microstructure of the membrane limits the extrusion of solid or liquid sausage material through the membrane during filling of the casing, thus preserving the desired high degree of porosity and low adhesion between the sausage material and casing inner wall.
As used in U.S. Pat. No. 3,953,566 and as defined herein, porosity is equal to the void fraction of the PTFE membrane expressed as a percentage. That is, porosity Q is equal to void fraction times 100, where
void fraction+polymer fraction=1.
The void fraction fv can be calculated from the specific gravity of the membrane as follows: ##EQU1## where SG is the specific gravity of the porous PTFE membrane, and SG p is the specific gravity of the PTFE polymer, and is generally equal to about 2.15
Thus, the porosity can be determined from the following relationship: ##EQU2##
The required permeability for the evolved gas (water vapor, steam, aromatic constituents, etc.) for a certain type of sausage and at a particular temperature is easily calculated with near accuracy, if one
(a) assumes that the specific gravity of the raw bulk sausage is equal to 1,
(b) does not take into account the existing sausage ends,
(c) knows the amount of water to be released percentage-wise (%) in relation to the raw bulk sausage, and
(d) knows the time available for the release of the gases at the particular temperature.
Given these prerequisites the volume V w of the sausage therefore is:
V.sub.W =πR.sup.2 L
and the surface area O W of the sausage is:
O.sub.W =2πRL
where R is the radius and L is the length of the sausage. If the amount of water to be released is designated as P W in percent (%), in relation to the raw bulk sausage, and the time available for the release of the gases at a given temperature T is designated as t T , the permeability for gas at a temperature T is as follows: ##EQU3##
Therefore it follows that the bigger the radius of the sausage, and the larger the amount of water to be released, the higher the gas permeability must be; and the gas permeability can also be that much smaller the more time that is available for the release of gas.
A porous PTFE membrane suitable for the production of parboil sausage, like hot dogs, vienna sausages, frankfurters, Lyon sausage, Mortadella and so on, has the following characteristics:
______________________________________(a) effective size of pores maximum 0.2 μm(b) nominal thickness 0.003 inches(c) nominal porosity 78%(d) nominal density 0.4 g/cm.sup.3(e) air permeability minimum 215 cm.sup.3 per minute and per square inch at 4.88 inches of head of water(f) the time required for 500 cm.sup.3 of methanol to pass thru 9.6 cm.sup.2 area of the membrane at 21° C. and a vacuum of 27 inches of mercury (Hg): maximum 120 seconds(g) water entry pressure minimum 40 pounds per square inch (40 p.s.i)(h) bubble point (methanol) minimum 13, maximum 22 p.s.i. (pounds per square inch)(i) the time required for 100 cm.sup.3 of air to pass thru 1 square inch of the membrane area at 4.88 inches of head of water maximum 28 seconds______________________________________
Measurements (e) and (i) are typically done with the apparatus and procedure detailed in ASTM Method D-726-58 Method A using 1.00 sq. inch test area, and 4.88 in. head of water. The measurement in (i) represents the "Gurley Number" of the membrane.
Measurements (f) and (h) are typically done with the apparatus and procedure detailed in ASTM Method F-316-70, using anhydrous methanol at 21° C. and a 9.6 sq. cm test area.
Measurement (g) utilizes apparatus employed in the Mullin's Burst Test (Fed. Std. 191, Method 5512). The test procedure consists of raising the pressure of water to a test level over a period of approximately 10 seconds, holding the pressure at that level for 30 seconds, and visually determining the presence or absence of leakage. The lowest water pressure at which leakage is observed is the Water Entry Pressure of the membrane.
A preferred range of porous PTFE membrane is as follows:
______________________________________thickness: 0.0015"-0.0035" (.04 mn-.09 mm)weight/area: 2.79-4.03 mg/cm.sup.2density: 0.44-0.63 g/cm.sup.3 (corresponds to a porosity of about 70-80%)Gurley No.: 28 seconds maximum, any measurementBubble Point Pressure: 13 psig minimum, any measurement 15.6-22 psig, average of any eight measurementsWater Entry Pressure: 40 psig minimum, any measurement______________________________________
This membrane is also suitable for the production of raw sausage, like cervelat or salami sausage; in view of the fact that the release of gas in the case of raw sausage occurs at lower temperatures over a longer period of time, the permeability of the membrane may be smaller.
By the term "membrane" is meant a relatively thin soft pliable free-standing sheet, and no specific limitations insofar as the length and width are intended.
The casings may be seamless tubes or can be produced from flat stock as for instance by heat or ultrasonic welding, by gluing or sewing. For example, a band-like membrane may be wound helicoidally into a tube. The casing may consist wholly or for the most part of the above-designated membrane.
It is preferable, for reasons of the mechanical load capacity, that the casing is supported by reinforcing components contacting at least a fraction of its surface area.
The polytetrafluoroethylene membranes, when used in accordance with the invention, are food-technologically unobjectionable, thermally stable between -20° and +250° C., resistant to diluted acids and lye solutions as well as common cleaning agents, and are not changed by the effects of ultrasonic and microwaves. The use of these membranes makes it possible to change the production method of parboil and raw sausages, as compared with the customary process, in an advantageous manner.
Up to now, machines were used to fill the casings with the bulk sausage. The filled casings were lined up on a spit and then one after another subjected in the smoke chambers to, in sequence:
reddening
drying
smoking
cooking or parboiling
cooling
After leaving the smoking chambers, the sausage casings may be removed by peel machines in order to produce "skinless" sausages. For this process a relatively large amount of manual labor is required.
The capital investment of an installation for the production of sausages with multiple reusable casings depends mainly on the period of time required for the sausage to remain in the casing; therefore this time must be kept to a minimum.
A portion of the time required for the reddening process should therefore preferably take place before the bulk sausage enters the casing. The smoking can be done after the shaped, coagulated and cooled sausage is ejected from the casing because the reddening and coagulating steps provide a thin integral skin on the sausage that enables the sausage to be handled. The release of water vapor, steam and other gaseous constituents, however, must occur at the beginning of the heating cycle while the sausage is still in the membrane casing. Microwave heating is ideally suited for shortening the reddening and coagulation steps.
The production of parboil sausage according to the present invention can proceed as follows:
(a) The raw bulk sausage is pre-reddened in a mixing machine under exclusion of oxygen.
(b) The bulk sausage is filled, according to invention, into reusable casings and/or devices that are formed by a water-vapor permeable membrane that is pliable, heat stable and non-adherent to bulk sausage by means of fill machines, paste fill machines or dividing machines.
(c) The filled casings or devices are then heated to approximately 35° C. to attain a desired degree of redness in a continuous reddening apparatus as, for example, by convection heating.
(d) Subsequently the filled casings or devices are heated for the coagulation step to about 80° C., as, for instance, in the customary way by steam or hot air or specially advantageously by means microwave energy which so far, to the knowledge of the inventor, has not been used for this purpose.
(e) Next, the filled casings or devices are cooled, for example, by means of cold water, cold air, liquid oxygen, etc.
(f) Now the casings or devices are opened by automatic removal of the end caps, after which the sausage is ejected, for instance, by compressed air. The empty casings are returned in a closed cycle to the fill station, whereby in suitable intervals cleaning takes place, as for instance by ultrasonic waves.
(g) The sausages are subsequently either continuously or intermittently smoked, on appropriate conveyors or special racks having only a small contact area with each sausage. The tanning effect of the smoke essentially contributes to the integrity of the sausage.
(h) Subsequently the sausages are cooled and are ready for shipment.
The following describes preferred embodiments of the apparatus and process for the production of caseless sausage, as shown on the attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a simplified sectional view of the end portion of a device made in accordance with the present invention for the production of sausage.
FIG. 2 is a simplified perspective view of the device shown in FIG. 1.
FIG. 3 is a perspective view of the retaining ring portion of the device.
FIG. 4 is a vertical section of the device with the upper part removed.
FIG. 5 shows a cross-section of the end segment of the completely assembled device.
FIG. 6 is an exploded view in perspective of a structural detail.
FIG. 7 shows the complete device in simplified perspective.
FIG. 8 is a front view of the device.
FIG. 9 is a longitudinal cross-section of a variation of the device shown in FIG. 1 but still made in accordance with the present invention.
FIG. 10 shows the variation of FIG. 9 in perspective.
FIG. 11 shows a cross-section of the end segment of yet another version of the device shown in FIG. 1.
FIG. 12 is an exploded view in perspective of a version shown in FIG. 11.
FIG. 13 is a section along plane XIII/XIII of the version shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, as embodied herein and with reference to FIG. 1, there is provided a reusable tubular sausage casing 5 of a porous polytetrafluoroethylene (PTFE) membrane, the details of which were discussed earlier. Tubular casing 5 is shown in the shape of a hollow right circular cylinder but the scope of the present invention is not intended to be so limited. Tubular casing 5 is shown positioned in the interior of support structure 1 which will discussed henceforth.
In accordance with the invention, and as embodied herein, there is provided means for supporting the reusable casing at its outside surface. A preferred device incorporates a support structure designated in its entirety by 1, which is composed of parallel longitudinal ribs 2, and ring-shaped cross ribs 3 in a lattice arrangement. The lattice structure 1 is designed in two parts, that is, it is divided into practically equal halves along a parting plane designated E in FIG. 2. The two halves are connected along the parting plane by screws 4 for possible disassembly (compare in this connection also FIG. 4). The longitudinal ribs 2 and cross ribs 3 are aligned with their inside edges along an imaginary cylinder which corresponds to the diameter of the sausage to be produced. Inside the lattice structure 1 a tube-like casing 5 which is made of the above defined porous PTFE membrane is fastened to the lattice structure 1 at its end sections by retaining rings 8. For this purpose the ends of the longitudinal ribs 2 are provided with a circular groove 6 which matches and/or engages the shoulder 7 of retaining ring 8 (FIG. 3).
The outermost end section of the retaining ring 8 is shaped into a circular flange 9. Preferably, the retaining ring 8, as FIG. 1 shows, is divided into two equal halves 8a/8b, for ease of assembly. The end section of the casing 5 is easily fastened to the lattice structure 1 by pushing the two retaining ring halves 8a/8b into it until the circular shoulder 7 snaps into the groove 6 thus capturing the casing end therebetween.
During the process the bulk sausage 10, as depicted in FIG. 5, expands under the effect of heat and subsequently contracts again during cooling. In accordance with the invention, means for restraining the sausage material within the tubular casing and for compensating for the change in volume of the sausage is provided and is shown in FIGS. 5 to 8.
As embodied herein, and as shown in FIG. 5, a floating piston 11 is positioned within the retaining ring 8. Piston 11 is provided at one end with a concave face surface 11a whose shape matches the contour of the sausage to be produced. A cylindrical guide sleeve 11b is adjacent to the piston face surface 11a, which in a preferred design only glides on the inner surface area of the retaining ring 8 and thus does not even come in contact with the easily vulnerable casing 5. An insert designated by 12 carries a plastic coil spring 13 on the side facing the piston 11, which rests against the curved wall of piston 11, and according to FIG. 5, tends to press or bias the piston to the right. Thus it is assured that the piston always rests against the outer area of the sausage 10 and that changes in volume of the bulk sausage are automatically compensated by the elasticity of the spring 13.
The bushing 12 is practically cup-shaped like a pot and has on its vertically arranged circular flange (as shown in FIG. 5) two key-hole-like slots with which it can be mounted for removal in customary fashion on studs 14 of the lattice structure. In this way it is sufficient to put the bushing 12 with the slots 15 having their wider section aligned over the stud 14. By turning bushing 12 slightly, the stud 14 securely engages the bushing.
As FIG. 6 shows, the piston is provided with a guide pin 16 in the center part of its curved face surface 11a which, during insertion of the bushing 12, engages with a bored hole 17 in the bushing and thus provides a secure alignment of the two parts.
The invention can be altered in numerous ways by any person skilled in the art, as for instance, it is of course not necessary to support the casing 5 around its circumference by a lattice structure, but some type of pipe with a solid but porous wall could be used as well. A pipe of this type could preferably consist of a porous, non-metallic, air pervious material, for instance, sintered glass. In this case, retaining parts for the removable attachment of the casing 5 would also have to be provided for both end sections.
If the sausage 10 is to be removed from the described device, it is sufficient to take off bushing 12 and piston 11, and eject the sausage from the casing 5 by compressed air. The casing 5, which remains in the device, is washed and reused in the following manufacturing process.
It would also be possible to design the above-mentioned pipe in form of half-cylindrical shells (not shown) which are fastened to an endless conveying device (not shown) and are joined to form a complete pipe for the support of the casing 5 shortly before introducing the bulk sausage. For the removal of the sausage the half-shells could be parted again by the conveyor system.
Instead of the curved face surface 11a of the piston 11, a flat surface could be used advantageously for a sausage which is to be sliced before it is sold. In this configuration, no waste is created during slicing.
In FIG. 9, which depicts another device made in accordance with the present invention, the device has a pipe 18 which may be formed of sintered stainless steel, or preferably of a porous, non-metallic air pervious material (for example, sintered glass). A tube-like casing 19 of porous PTFE membrane, as described before, is laid around the pipe 18 as to completely encase the inner and outer surface of the pipe with the casing ends 19a/19b turned back and overlapping each other on the outer surface of the pipe where they are welded together in a circular bead 20.
FIG. 9 depicts in dashed lines how the one casing end 19b is turned back around the end section of the pipe 18 in the direction of the arrow until it overlaps the other casing end 19a.
Another variation of apparatus made in accordance with the present invention and shown in FIG. 11 includes a pipe 21 which, for instance, can be formed of stainless steel or an adequate artificial material such as polyamid or sintered, unstretched polytetrafluorathylene, and provided with numerous holes. A porous PTFE casing 23 of the type defined above is turned back around the flanged end 21a of the pipe 21 at the position 23a and thus secured at the pipe end 21a by stretching over the flange.
A cap 24 is divided in the direction of the circumference into several retaining fingers 25 (also compare FIG. 12), which are mounted on a circular rib 26 and can pivot lever-like on their mounting point. The end 25a of each retaining finger 25 which is turned toward the inside engages in its end position a support flange 27 on the pipe.
A recess 28 in the rib 26 houses a coil spring 29 whose opposite end is compressed against the curved face 30a of the piston 30. The cylindrical sleeve 30b of the piston 30 which is adjustably positioned in a corresponding section 26a of the rib 26 as well as in the pipe 21, could however also be placed (in order to protect the casing) in section 26a only. In this way the piston 30 is resiliently pressed or biased against the end of the bulk sausage and thus balances the expansion and contraction of the bulk sausage as shown by the two arrows.
With its guide sleeve 26b pushed over the end section of a guide bar which is part of the piston 30, the cap 24 functions as a centering and guiding device for the piston 30. As demonstrated in the lower portion of FIG. 11, the cap 24 can be disengaged and pulled off, if need be, by depressing with finger pressure.
The spring 29 not only serves for the compensation of changes in volume of the bulk sausage 31, but also exerts an oppositely directed force on the cap 24, so that the end of the retaining finger 25a is forced against the support flange 27; simultaneously the end of the retaining finger 25a also can exert a pressure in a radial direction which contributes to holding the casing 23 in place in a modification (not shown) to the embodiment in FIG. 11 wherein the turned back end of casing 23 extends past flange 27.
As FIG. 13 shows, the cap 24 essentially consists of a heavy-walled tube made of synthetic material and whose wall is provided with several parallel slots 32 which are directed radially toward the inside.
Parboil sausages typically have diameters of from 15 to 200 mm, some of them also more. For instance, a small sausage weighing 55 g and having a diameter of 22 mm can be heated by microwaves to 35° C. for 15 minutes for the process of reddening and ripening, and to 80° C. and 3 minutes for the coagulation. Thereby the raw bulk sausage releases 5 g of steam in the course of 18 minutes.
Should the coagulation take place by means of microwave energy, the casings and/or devices used must not contain any metallic constituents. In this case the support components of the device advantageously consist of perforated synthetic materials like polyamide or sintered unstretched polytetrafluoroethylene.
The coagulation process by means of microwaves can take place in such a way where the filled casings and/or devices are passed thru a stream of microwaves at a set cycle. While passing thru the microwaves, the casings and/or devices are turned as described later, in order to assure an even heating. Heat is not applied from the outside, but is produced simultaneously and nearly evenly throughout the entire mass of sausage, so that coagulation advances from within to the outside.
Heat generation in the bulk sausage starts instantly at actuation of the microwave energy and stops just as abruptly when turned off. Since no heat transfer mediums need be heated with microwave apparatus and only extremely little heat is dissipated to the environment, significant energy conservation is possible.
During microwave heating, the various components of the bulk sausage, namely water, fat and protein, are heated to different degrees. In addition, because the energy absorption is dependent on the temperature on account of the temperature dependence of the dielectric constant, local (spot) overheating may take place. To avoid this, microwave heating is advisably applied periodically in order to allow the temperature of the bulk sausage mass to become balanced. Good results are obtained when the duration of the first heating period amounts to no more than 50 seconds, the duration of the following heating periods is shortened by 30% each, and the duration of the heating intervals, starting at 10 seconds, be increased until the heating intervals match the heating periods. The heating intervals can be obtained by using multiple sources of microwaves with a specific distance between each source along the process path. In such application, it is advantageous to position between the microwave sources a different type of heating unit, for instance, infrared heating, is used, in order to avoid the cooling of the bulk sausage and to further accelerate coagulation.
The selection of power output of the microwave sources is of great importance for fast and even coagulation. Although the speed of coagulation is accelerated by increased power output, the evenness of the coagulation decreases. On the other hand, too small a power output is uneconomical on account of too slow a production speed. However, it is easily possible for an expert to determine the proper parameters.
Rotation of the filled casings and/or devices during the microwave heating process is indispensable since adjoining casings shield or block each other from the microwaves. The period of rotation should be shorter by more than one order of magnitude than the period required for coagulation. This amounts to at least about 12 revolutions per minute.
The new casing, apparatus, and process of the invention provide a sausage that has far superior resistance to bacterial contamination than sausages produced in the usual water-vapor-impervious, one-use, cellulosic casings, which is the present industry standard for frankfurter production. Because the smoking step can be performed on the sausage itself, with no cellulosic membrane of varying permeability to smoke, the tanning effect of the smoking step is more uniform and provides superior resistance to bacteria. Also, there is no possibility of cutting into the sausage during a peeling step, which could destroy the integrity of the sausage skin and permit bacterial access to the interior of the sausage.
The invention permits use of a faster sausage making procedures (microwave) in the reddening and coagulation steps. Also, the smoking step can proceed at a much faster rate, because there is no barrier to the smoke such as exists when a cellulosic casing is used. The invention permits production of sausages with less labor than the use of cellulosic casings, indeed, the invention permits manufacture of sausage without contact with human hands.
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A reusable tubular casing is made of porous polytetrafluoroethylene (PTFE) membrane for the production of caseless (skinless) parboil or raw sausages. The membrane has a microstructure comprising PTFE nodes connected by PTFE fibrils with a porosity of about 70-80%, a Gurley No. less than about 28 seconds, a Bubble Point Pressure greater than about 13, and a Water Entry Pressure greater than about 40 psig. The casing is contacted on at least a part of its circumferential area by a porous support such as a cylindrical lattice. A new process for production of parboil or raw sausage involves heating the sausage in casing formed by a reusable non-adherent, vapor permeable membrane to drive off moisture and other volatile materials, and removing the sausage from the casing. The sausage can subsequently be smoked and the casing reused.
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BACKGROUND OF THE INVENTION
The present invention relates to a rotary actuator operated by an air pressure and used to control a valve, for example.
FIGS. 11 to 15 c show a conventional rotary actuator. A cylinder body 11 is produced by cutting an extruded material 1 (see FIG. 14 c ), formed by extruding aluminum or other similar material, into a predetermined length and forming various bores in the cut extruded material 1 . As shown in FIGS. 14 c, 14 d and 11 , a vertical section of the extruded material 1 has a circular bore (cylinder bore 11 a ) in the center. Squarish thick-walled portions 12 to 15 project from the extruded material 1 upwardly, downwardly, leftwardly and rightwardly, respectively, as viewed in the vertical section (in FIG. 12, the thick-walled portions 12 to 15 project upwardly, downwardly, forwardly and backwardly, respectively). A thick-walled portion 2 having an approximately triangular sectional configuration is formed between each pair of adjacent thick-walled portions 12 to 15 . That is, the cylinder body 11 has a total of four thick-walled portions 2 . Each thick-walled portion 2 has an insertion bore 3 extending therethrough longitudinally (i.e. the direction of the center axis of the cylinder bore 11 a ). As shown in FIGS. 11, 13 and 14 d, a first end plate 17 and a second end plate 18 , which are octagonal, are brought into contact with both ends of the cylinder body 11 . The first end plate 17 and the second end plate 18 have insertion bores 19 formed in coaxial relation to the insertion bores 3 of the cylinder body 11 . Four long bolts 5 are inserted into the insertion bores 19 of the first and second end plates 17 and 18 and the corresponding insertion bores 3 of the cylinder body 11 , and nuts 6 are screwed onto the long bolts 5 , respectively, thereby connecting together the cylinder body 11 and the first and second end plates 17 and 18 .
An upper bearing portion 11 b is formed in an approximately central portion of the upwardly projecting thick-walled portion 12 of the cylinder body 11 . A lower bearing portion 11 c is formed in an approximately central portion of the downwardly projecting thick-walled portion 13 of the cylinder body 11 . An upper rotating shaft 24 and a lower rotating shaft 25 are rotatably fitted into and supported by the upper bearing portion 11 b and the lower bearing portion 11 c, respectively. The upper rotating shaft 24 has a prismatic portion at the lower end thereof. The prismatic portion of the upper rotating shaft 24 is fitted into a square hole provided in the upper end of a connecting shaft 21 . The lower rotating shaft 25 has a prismatic portion at the upper end thereof. The prismatic portion of the lower rotating shaft 25 is fitted into a square hole provided in the lower end of the connecting shaft 21 . If desired, a cap that indicates an angular position of the connecting shaft 21 is fitted to the upper end of the upper rotating shaft 24 that projects upwardly from the cylinder body 11 . The lower end portion of the lower rotating shaft 25 projects downwardly from the cylinder body 11 . A piston 20 is slidably fitted in the cylinder bore 11 a. The piston 20 has a bottom portion 20 a having a circular sectional configuration and adapted to receive an air pressure. The piston 20 further has a first projecting portion 20 b and a second projecting portion 20 c, which are integral with the bottom portion 20 a. The upper and lower end portions of the piston 20 , exclusive of the bottom portion 20 a, are horizontally cut. The piston 20 has a vertical groove 20 d vertically extending therethrough. The piston 20 further has longitudinal horizontal grooves communicated with the vertical groove 20 d. Thus, the first projecting portion 20 b and the second projecting portion 20 c are formed as shown in FIGS. 11 and 13.
The second projecting portion 20 c is provided with an insertion bore vertically extending therethrough. A pin 23 is inserted into the insertion bore. The connecting shaft 21 is located in the vertical groove 20 d between the first projecting portion 20 b and the second projecting portion 20 c. A yoke 22 is inserted into a horizontal bore 21 a provided in the connecting shaft 21 . One end of the yoke 22 is pivotably connected to the pin 23 . The other end of the yoke 22 is movably inserted into the horizontal groove of the first projecting portion 20 b. As the piston 20 moves, the pin 23 also moves simultaneously, and the one end of the yoke 22 moves together with the pin 23 . Consequently, the yoke 22 pivots to rotate about the vertical axis of the connecting shaft 21 , causing the connecting shaft 21 to rotate. As the connecting shaft 21 rotates, the upper rotating shaft 24 and the lower rotating shaft 25 rotate simultaneously. The first end plate 17 has a first stopper 27 screwed into a threaded bore provided therein. Similarly, the second end plate 18 has a second stopper 28 screwed into a threaded bore provided therein. The first and second stoppers 27 and 28 have respective nuts screwed thereon so as to be fixed in predetermined positions, respectively. When moved back and forth, the piston 20 comes in contact with the distal ends of the first and second stoppers 27 and 28 . By changing the fixed positions of the first and second stoppers 27 and 28 , the stroke of the piston 20 is adjusted, and the rotation angle of the connecting shaft 21 is regulated.
As shown in FIG. 13, a pressure reducing valve 30 is connected to the outer side of the first end plate 17 , and a pressure gauge 31 is provided in connection with the pressure reducing valve 30 . As will be clear from FIG. 14 a, a solenoid-operated switching valve 33 is connected through a sub-plate 32 to the center of the front (left side) surface of the leftwardly projecting thick-walled portion 14 of the cylinder body 11 . Further, a first speed controller 34 and a second speed controller 35 are connected to the left and right end portions, respectively, of the leftwardly projecting thick-walled portion 14 . An inlet port of the pressure reducing valve 30 is communicated with an air pressure source (not shown) through piping. An outlet port of the pressure reducing valve 30 is communicated with an inlet port of the solenoid-operated switching valve 33 through piping 7 a. An A-port the solenoid-operated switching valve 33 is communicated with one port of the first speed controller 34 through piping 7 b. A B-port of the solenoid-operated switching valve 33 is communicated with one port of the second speed controller 35 through piping 7 c. The other port of the first speed controller 34 is communicated with a first cylinder chamber 38 of the cylinder body 11 through a communicating passage 8 a (see FIG. 13 ). The other port of the second speed controller 35 is communicated with a second cylinder chamber 39 of the cylinder body 11 through a communicating passage 8 b (see FIG. 13 ). An open valve 36 for short circuiting is communicated between the piping 7 b and the piping 7 c. By opening the open valve 36 , the first cylinder chamber 38 and the second cylinder chamber 39 are communicated with each other through the first speed controller 34 and the second speed controller 35 . Consequently, the connecting shaft 21 can be rotated by a manual operation. It should be noted that, as shown in FIG. 14 b, the open valve 36 enables the passages to be communicated with or cut off from each other by rotating a ball valve element 36 a with a lever 36 b.
FIG. 11 shows a conventional rotary actuator 9 as used to open and close a valve (e.g. a butterfly valve or a ball valve) 40 . The lower end of the rotary actuator 9 and an upper flange 40 b of the valve 40 are connected by a connecting member 41 , bolts 42 and nuts 43 . The lower rotating shaft 25 has a prismatic portion at the lower end thereof. The prismatic portion of the lower rotating shaft 25 is fitted into an upper square hole provided in a connector 44 . A control shaft 45 of the valve 40 has a prismatic portion at the upper end thereof. The prismatic portion of the control shaft 45 is fitted into a lower square hole provided in the connector 44 . The rotation of the connecting shaft 21 is transmitted to a valve element 40 a of the valve 40 through the lower rotating shaft 25 , the connector 44 and the control shaft 45 .
FIGS. 15 a to 15 c show conventional methods of installing a filter 47 onto the rotary actuator 9 . The filter 47 is installed such that a drain valve 47 a lies at the lower end at all times. Conventionally, the filter 47 is attached to the rightwardly projecting thick-walled portion 15 . The valve 40 and the rightwardly projecting thick-walled portion 15 vary in posture according to where the valve 40 is used. Therefore, when the rightwardly projecting thick-walled portion 15 lies horizontally as shown in FIG. 15 a, a first L-shaped bracket 48 a is attached to the filter 47 , and the first L-shaped bracket 48 a is connected to the rightwardly projecting thick-walled portion 15 . When the rightwardly projecting thick-walled portion 15 lies vertically as shown in FIG. 15 b, the first L-shaped bracket 48 a is attached to the filter 47 , and a plate 48 b is connected to the first L-shaped bracket 48 a. Then, the plate 48 b is connected to the rightwardly projecting thick-walled portion 15 . When the rightwardly projecting thick-walled portion 15 faces upward as shown in FIG. 15 c, the first L-shaped bracket 48 a is attached to the filter 47 , and a second L-shaped bracket 48 c is connected to the first L-shaped bracket 48 a. Then, the second L-shaped bracket 48 c is connected to the rightwardly projecting thick-walled portion 15 .
SUMMARY OF THE INVENTION
As the competition between corporations in the field of air compressors heats up, it has recently become imperative to reexamine rotary actuators in all aspects and to achieve reductions in costs of rotary actuators.
To realize reductions in costs of rotary actuators, a first object of the present invention is to modify the configuration of an extruded material used to form a cylinder body so as to reduce the weight of the material.
A second object of the present invention is to reduce the number of components or the number of manhours needed for machining by changing the method of installing a solenoid-operated switching valve, speed controllers and an open valve for short circuiting.
A third object of the present invention is to provide a low-cost structure for a short-circuiting open valve.
A fourth object of the present invention is to provide an installation method for a filter whereby the number of components needed therefor is minimized and the cost is reduced.
A fifth object of the present invention is to provide a method of connecting together a butterfly valve or a ball valve and a connecting shaft of a rotary actuator, whereby the number of components needed therefor is minimized and the cost is reduced.
According to a first aspect of the present invention, there is provided a rotary actuator of the type wherein two end plates are connected to both ends, respectively, of a cylinder body, and a piston is slidably fitted in a cylinder bore in the cylinder body, and wherein an output shaft is disposed to extend in a direction approximately perpendicular to the axis of the piston, so that a reciprocating motion of the piston is converted into a rotational motion of the output shaft. The cylinder body is produced from an extruded material formed by extrusion. A section of the extruded material that is perpendicular to the direction of extrusion of the extruded material is circular at the inner periphery thereof and has upwardly, downwardly, leftwardly and rightwardly projecting thick-walled portions at the outer periphery thereof. The outer peripheral portions of the section, exclusive of the projecting thick-walled portions, are generally formed from circular arcs.
According to a second aspect of the present invention, the leftwardly and rightwardly projecting thick-walled portions of the cylinder body in the above-described rotary actuator have insertion holes extending therethrough longitudinally. The upwardly and downwardly projecting thick-walled portions have bolt bores with a predetermined length formed in both end portions thereof. The two end plates each have insertion bores respectively extending through the upper, lower, left and right portions thereof. Long bolts are respectively inserted into the insertion bores in the left and right portions of the two end plates and further into the insertion bores in the leftwardly and rightwardly projecting thick-walled portions of the cylinder body and engaged with respective nuts. Short bolts are respectively inserted into the insertion bores in the upper and lower portions of the two end plates and screwed into the bolt bores in the upwardly and downwardly projecting thick-walled portions of the cylinder body.
According to a third aspect of the present invention, there is provided a rotary actuator of the type wherein two end plates are connected to both ends, respectively, of a cylinder body, and a piston is slidably fitted in a cylinder bore in the cylinder body, and wherein an output shaft is disposed to extend in a direction approximately perpendicular to the axis of the piston, so that a reciprocating motion of the piston is converted into a rotational motion of the output shaft. The cylinder body is produced from an extruded material formed by extrusion. A section of the extruded material that is perpendicular to the direction of extrusion of the extruded material is circular at the inner periphery thereof and has a leftwardly projecting thick-walled portion at the outer periphery thereof. The leftwardly projecting thick-walled portion has an A-passage, a B-passage, a P-passage, an R-passage and an R′-passage communicated with an A-port, a B-port, a P-port, an R-port and an R′-port, respectively, of a solenoid-operated switching valve. One end of each of the A-passage, B-passage, P-passage, R-passage and R′-passage opens on the left side surface of the leftwardly projecting thick-walled portion. The other end of the A-passage is communicated with a first cylinder chamber through a first horizontal passage. The other end of the B-passage is communicated with a second cylinder chamber through a second horizontal passage. The other end of the P-passage is communicated with an air supply bore opening on the lower surface of the leftwardly projecting thick-walled portion. The other ends of the R-passage and R′-passage are communicated with an air exhaust bore opening on the lower surface of the leftwardly projecting thick-walled portion.
According to a fourth aspect of the present invention, the leftwardly projecting thick-walled portion in the arrangement according to the third aspect of the present invention has an open valve fitting bore vertically formed therein. The upper end of the open valve fitting bore opens on the upper surface of the leftwardly projecting thick-walled portion. The lower end portion of the open valve fitting bore is communicated with the first horizontal passage and the second horizontal passage. A valve rod is placed in thread engagement with the open valve fitting bore. An elastic valve element is fitted on a small-diameter portion near the lower end of the valve rod, so that rotating the valve rod causes the elastic valve element to move to a position where the first horizontal passage and the second horizontal passage are communicated with each other or to a position where the first horizontal passage and the second horizontal passage are cut off from each other.
According to a fifth aspect of the present invention, the leftwardly projecting thick-walled portion in the arrangement according to the third or fourth aspect of the present invention has fitting bores formed at respective positions near both ends thereof. One end of each of the fitting bores opens on the left side surface of the leftwardly projecting thick-walled portion. The other ends of the fitting bores are communicated with the first cylinder chamber and the second cylinder chamber through communicating passages, respectively. The body of a first speed controller and the body of a second speed controller are fitted in the fitting bores, respectively. The first horizontal passage and the second horizontal passage are communicated with the communicating passages through flow control portions and passages, respectively, which are provided in the bodies of the first and second speed controllers. The first horizontal passage and the second horizontal passage are communicated with the communicating passages through check valves, respectively, which are provided between the fitting bores and the bodies of the first and second speed controllers.
According to a sixth aspect of the present invention, there is provided a rotary actuator of the type wherein two end plates are connected to both ends, respectively, of a cylinder body, and a piston is slidably fitted in a cylinder bore in the cylinder body, and wherein an output shaft is disposed to extend in a direction approximately perpendicular to the axis of the piston, so that a reciprocating motion of the piston is converted into a rotational motion of the output shaft. The cylinder body is produced from an extruded material formed by extrusion. A section of the extruded material that is perpendicular to the direction of extrusion of the extruded material is circular at the inner periphery thereof and has upwardly and downwardly projecting thick-walled portions at the outer periphery thereof. The upwardly projecting thick-walled portion has an upper bearing portion vertically extending through a central portion thereof. The downwardly projecting thick-walled portion has a lower bearing portion vertically extending through a central portion thereof. The upper bearing portion has an inner diameter smaller than the inner diameter of the lower bearing portion. The output shaft is a stepped output shaft having at the upper end thereof a smaller-diameter portion rotatably fitted in the upper bearing portion. The lower end portion of the output shaft is rotatably fitted in the lower bearing portion. A square hole opens on the lower end surface of the output shaft.
According to a seventh aspect of the present invention, a connecting member having a longitudinal U-shaped groove on the upper surface thereof is connected to the downwardly projecting thick-walled portion in the arrangement according to the sixth aspect of the present invention. The connecting member has a shaft insertion bore extending through the bottom of the U-shaped groove thereof such that the shaft insertion bore lies in coaxial relation to the lower bearing portion of the downwardly projecting thick-walled portion. A prismatic portion at the upper end of a control shaft of a valve is fittable into the square hole at the lower end of the output shaft through the shaft insertion bore. An upper flange of the valve is connectable to the connecting member.
According to an eighth aspect of the present invention, there is provided a rotary actuator of the type wherein two end plates are connected to both ends, respectively, of a cylinder body, and a piston is slidably fitted in a cylinder bore in the cylinder body, and wherein an output shaft is disposed to extend in a direction approximately perpendicular to the axis of the piston, so that a reciprocating motion of the piston is converted into a rotational motion of the output shaft. The cylinder body is produced from an extruded material formed by extrusion. A section of the extruded material that is perpendicular to the direction of extrusion of the extruded material is circular at the inner periphery thereof and has upwardly, downwardly, leftwardly and rightwardly projecting thick-walled portions at the outer periphery thereof. The rightwardly projecting thick-walled portion has a pair of bolt bores opening on the right side surface thereof. The two end plates each have a pair of bolt bores opening on each of the upper left and upper right portions of each end plate. A filter is fitted into an insertion bore in one end portion of an L-shaped bracket. Two short bolts are inserted into either or both of upper and lower horizontally elongated insertion holes in the other end portion of the L-shaped bracket and screwed into any one of the pairs of bolt bores.
According to the first and second aspects of the present invention, the cylinder body is produced from an extruded material formed by extrusion, and a section of the extruded material that is perpendicular to the direction of extrusion of the extruded material is circular at the inner periphery thereof and has upwardly, downwardly, leftwardly and rightwardly projecting thick-walled portions at the outer periphery thereof. The outer peripheral portions of the section, exclusive of the projecting thick-walled portions, are generally formed from circular arcs. Thus, the four thick-walled portions (where bolts for connecting the end plates are inserted) with an approximately triangular sectional configuration as viewed in a section perpendicular to the direction of extrusion of the extruded material, which have been provided in the prior art, are eliminated. Therefore, the weight reduces, the material cost is saved, and the production cost lowers, correspondingly.
According to the present invention, the end plates can be connected to both ends of the cylinder body by inserting long bolts into insertion bores formed in the leftwardly and rightwardly projecting thick-walled portions and screwing short bolts into bolt bores formed in both end portions of the upwardly and downwardly projecting thick-walled portions. Thus, it is possible to obtain a rotary actuator that is equal in strength to the prior art.
According to the third to fifth aspects of the present invention, the leftwardly projecting thick-walled portion is provided with passages respectively communicated with the ports of a solenoid-operated switching valve. One end of each passage opens on the left side surface of the leftwardly projecting thick-walled portion, and the other ends of the passages are communicated with the first cylinder chamber, the second cylinder chamber, the air supply bore and the air exhaust bore, respectively. Therefore, if the solenoid-operated switching valve is brought into contact with the leftwardly projecting thick-walled portion and connected to the latter, it is possible to dispense with piping, a joint and a sub-plate as needed in the prior art. Accordingly, the number of components and the number of manhours needed for assembly and machining reduce. Thus, it is possible to realize cost reductions.
Moreover, because the open valve and the speed controllers are buried in the open valve fitting bore and the fitting bores, respectively, which are provided in the leftwardly projecting thick-walled portion, there is no need of external bodies (casings) for the open valve and the speed controllers. In addition, the structure of the open valve can be simplified by using the elastic valve element. Thus, it is possible to realize cost reductions by reducing the number of components and simplifying the structure.
According to the sixth and seventh aspects of the present invention, a stepped output shaft is employed. Therefore, the three shafts as used in the prior art can be replaced by a single output shaft. Moreover, because a prismatic portion at the upper end of the valve control shaft is fitted into a square hole in the lower end of the output shaft, there is no need of a connector and other associated members as needed in the prior art. Accordingly, the number of components and the number of manhours needed for machining can be reduced to a considerable extent.
According to the eighth aspect of the present invention, the structure of an L-shaped bracket for mounting a filter is changed such that the bracket can also be attached to either of the end plates of the rotary actuator. Accordingly, it becomes possible to install the filter onto the rotary actuator using only one type of L-shaped bracket, regardless of the posture of the rotary actuator, although two different types of L-shaped bracket and one type of plate have heretofore been required. Thus, the change of the filter installation method enables a reduction in the number of different types of components to be prepared. Consequently, the number of components and the number of manhours needed for installation reduce, and this contributes to cost reductions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of an embodiment of the rotary actuator according to the present invention, taken along the line I—I in FIG. 2 .
FIG. 2 is a sectional view taken along the line II—II in FIG. 1 .
FIG. 3 is a side view containing a sectional view taken along the line III—III in FIG. 2 .
FIG. 4 is a front view of the embodiment as seen from the right-hand side in FIG. 3 .
FIG. 5 is an exploded perspective view of the essential parts of the embodiment of the rotary actuator according to the present invention.
FIG. 6 is a sectional view taken along the line E—E in FIG. 7 a.
FIG. 7 a is a side view of a cylinder body in the embodiment of the rotary actuator as viewed from the left-hand side thereof.
FIG. 7 b is a bottom view of the cylinder body.
FIG. 8 a is a fragmentary sectional view taken along the line D—D in FIG. 7 a.
FIG. 8 b is a fragmentary sectional view taken along the line P—P in FIG. 7 a.
FIG. 8 c is a fragmentary sectional view taken along the line R—R (R′—R′) in FIG. 7 a.
FIG. 8 d is a fragmentary sectional view taken along the line A—A (B—B) in FIG. 7 a.
FIG. 9 a is a perspective view of an extruded material used to produce the cylinder body in the embodiment of the rotary actuator according to the present invention.
FIG. 9 b is a vertical sectional view of an open valve according to the embodiment of the rotary actuator according to the present invention.
FIG. 9 c is a perspective view showing a leftwardly projecting thick-walled portion and its vicinities of the cylinder body.
FIGS. 10 a to 10 c are perspective views showing filter installation methods according to the embodiment of the present invention.
FIG. 11 is a sectional front view showing a conventional rotary actuator with a valve connected thereto.
FIG. 12 is a side view of the essential parts of the conventional rotary actuator as viewed from the left-hand side thereof.
FIG. 13 is a top plan view of the conventional rotary actuator, showing the essential parts thereof in a transverse sectional view.
FIG. 14 a is a perspective view showing a leftwardly projecting thick-walled portion and its vicinities of a cylinder body of the conventional rotary actuator.
FIG. 14 b is a vertical sectional view of an open valve used in the conventional rotary actuator.
FIG. 14 c is a perspective view of an extruded material for producing the cylinder body of the conventional rotary actuator.
FIG. 14 d is an exploded perspective view of the essential parts of the conventional rotary actuator.
FIGS. 15 a to 15 c are perspective views showing methods of installing a filter onto the conventional rotary actuator.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 10 c show an embodiment of the rotary actuator according to the present invention. In the description of the embodiment of the present invention, members similar to those of the conventional rotary actuator shown in FIGS. 11 to 15 c are denoted by the same reference characters as those used in FIGS. 11 to 15 c.
As shown in FIGS. 5 and 9 a, a cylinder body 11 is produced by cutting an extruded material 1 , formed by extrusion of aluminum or other similar material, into a predetermined length. A section of the extruded material 1 that is perpendicular to the direction of extrusion is circular at the inner periphery thereof and has upwardly, downwardly, leftwardly and rightwardly projecting thick-walled portions 12 to 15 at the outer periphery thereof. The outer peripheral portions of the section, exclusive of the projecting thick-walled portions 12 to 15 , are generally formed from circular arcs (except a mounting groove 52 formed in a portion adjacent to the leftwardly projecting thick-walled portion 14 on the upper side of the latter). The thick-walled portions 2 in the conventional rotary actuator are eliminated from the cylinder body 11 .
As shown in FIGS. 1 and 5, the leftwardly and rightwardly projecting thick-walled portions 14 and 15 of the cylinder body 11 have respective insertion bores 53 a and 53 b extending therethrough longitudinally. The upwardly and downwardly projecting thick-walled portions 12 and 13 have respective bolt bores 54 a and 54 b each having a predetermined length. The bolt bores 54 a are formed in both end portions of the upwardly projecting thick-walled portion 12 , and the bolt bores 54 b are formed in both end portions of the downwardly projecting thick-walled portion 13 . A first end plate 17 and a second end plate 18 , which are octagonal, are brought into contact with both ends of the cylinder body 11 . The first and second end plates 17 and 18 each have insertion bores 55 a to 55 d extending respectively through the upper, lower, left and right portions thereof in coaxial relation to the bolt bores 54 a and 54 b and the insertion bores 53 a and 53 b of the cylinder body 11 . Long bolts 57 are respectively inserted into the left and right insertion bores 55 c and 55 d of the first and second end plates 17 and 18 and further into the left and right insertion bores 53 a and 53 b of the cylinder body 11 and engaged with respective nuts 58 . Short bolts 59 are respectively inserted into the upper and lower insertion bores 55 a and 55 b of the first and second end plates 17 and 18 and screwed into the upper and lower bolt bores 54 a and 54 b of the cylinder body 11 . Thus, the first end plate 17 and the second end plate 18 are connected to both ends, respectively, of the cylinder body 11 .
As shown in FIGS. 1 and 2, an upper bearing portion 11 b and a lower bearing portion 11 c are formed to extend through approximately central portions of the upwardly and downwardly projecting thick-walled portions 12 and 13 , respectively, of the cylinder body 11 . The diameter of the upper bearing portion 11 b is smaller than the diameter of the lower bearing portion 11 c. A stepped output shaft 61 having a small-diameter portion at the upper end thereof is inserted into the lower bearing portion 11 c and the upper bearing portion 11 b from the lower side thereof. The upper small-diameter end portion and the lower end portion of the output shaft 61 are rotatably fitted in and supported by the upper bearing portion 11 b and the lower bearing portion 11 c, respectively. The upper small-diameter end portion of the output shaft 61 , which is rotatably supported by the upper bearing portion 11 b, is provided with two annular grooves. A bearing metal is fitted in the upper annular groove, and a seal is fitted in the lower annular groove. The lower end portion of the output shaft 61 , which is rotatably supported by the lower bearing portion 11 c, is provided with a single annular groove, and a seal is fitted in the annular groove. A bearing metal is fitted in an annular groove provided in the lower bearing portion 11 c. The output shaft 61 has a prismatic portion 61 a formed at the upper end thereof. The prismatic portion 61 a projects upwardly from the cylinder body 11 . The output shaft 61 has a square hole 61 b provided in the lower end portion thereof. The square hole 61 b opens on the lower end of the output shaft 61 .
As will be clear from FIGS. 1 and 2, together with FIG. 13, which shows the prior art, a piston 20 having a structure similar to that in the prior art is slidably fitted in a cylinder bore 11 a provided in the cylinder body 11 . The piston 20 has a bottom portion 20 a with a circular sectional configuration that receives an air pressure. The piston 20 further has a first projecting portion 20 b and a second projecting portion 20 c, which are integral with the bottom portion 20 a. A seal 62 is fitted in an annular groove on the outer periphery of the bottom portion 20 a. The upper and lower end portions of the piston 20 , exclusive of the bottom portion 20 a, are horizontally cut. The piston 20 has a vertical groove 20 d vertically extending therethrough. The piston 20 further has longitudinal horizontal grooves 20 e and 20 f communicated with the vertical groove 20 d. Thus, the first projecting portion 20 b and the second projecting portion 20 c are formed.
The second projecting portion 20 c has an insertion bore vertically extending therethrough. A pin 23 is inserted into the insertion bore and stopped at the upper and lower ends thereof from coming out of the insertion bore. The output shaft 61 is located in the vertical groove 20 d (see FIG. 13) between the first projecting portion 20 b and the second projecting portion 20 c. A yoke 22 is inserted into a horizontal bore 61 c provided in the output shaft 61 . One end of the yoke 22 is pivotably connected to the pin 23 in the horizontal groove 20 f. The other end of the yoke 22 is movably inserted into the horizontal groove 20 e of the first projecting portion 20 b. As the piston 20 moves, the pin 23 also moves simultaneously. Because one end of the yoke 22 moves together with the pin 22 , the yoke 22 pivots to rotate about the output shaft 61 , causing the output shaft 61 to rotate. The first end plate 17 and the second end plate 18 are provided with a first stopper 27 and a second stopper 28 , respectively, such that the first and second stoppers 27 and 28 can be adjusted, as in the case of the prior art.
As shown in FIGS. 5 and 9 c, a solenoid-operated switching valve 33 is brought into contact with the center of the front (left side) surface of the leftwardly projecting thick-walled portion 14 of the cylinder body 11 with a packing 63 interposed therebetween. The solenoid-operated switching valve 33 is connected to the leftwardly projecting thick-walled portion 14 by screwing two bolts 64 into tapped holes 66 (see FIG. 7 a; described later). A first speed controller 34 and a second speed controller 35 are buried in respective positions near the left and right ends of the front surface of the leftwardly projecting thick-walled portion 14 . An open valve 36 is buried in the center of the upper surface of the leftwardly projecting thick-walled portion 14 .
As shown in FIGS. 3, 6 to 8 d, a horizontal passage 70 is formed in the leftwardly projecting thick-walled portion 14 at a position slightly closer to the upper end and to the left (outer) end of the thick-walled portion 14 . Both ends of the horizontal passage 70 are hermetically sealed. The left and right halves of the horizontal passage 70 as seen in a left-hand side view (e.g. FIG. 3) will hereinafter be referred to as “first horizontal passage 70 a ” and “second horizontal passage 70 b ”, respectively. FIG. 8 b shows a section in the center of the horizontal passage 70 (i.e. a sectional view taken along the line P—P in FIG. 7 a ). The first horizontal passage 70 a and the second horizontal passage 70 b are communicated with an open valve fitting bore 67 . The open valve fitting bore 67 opens on the upper surface of the leftwardly projecting thick-walled portion 14 . The open valve 36 is fitted in the open valve fitting bore 67 . It should be noted that the insertion bore 53 a lies slightly below and inside the horizontal passage 70 . The insertion bore 53 a and the horizontal passage 70 are not communicated with each other.
FIG. 9 b clearly shows the open valve 36 according to the embodiment of the present invention. The open valve fitting bore 67 intersects the first and second first horizontal passages 70 a and 70 b. A stepped bore (having a large-diameter portion 67 c, a small-diameter portion 67 d, and a step portion 67 e ) is formed in the bottom of the connection between the first and second horizontal passages 70 a and 70 b. The open valve fitting bore 67 has an internal thread 67 a on the upper portion thereof. That portion of the open valve fitting bore 67 which extends between the internal thread 67 a and the intersection between the open valve fitting bore 67 and the first and second horizontal passages 70 a and 70 b is a non-threaded bore 67 b. The non-threaded bore 67 b and the large-diameter portion 67 c have the same diameter. The step portion 67 e is adapted to be contacted by an elastic valve element 36 d. A valve rod 36 c is fitted in the open valve fitting bore 67 . The valve rod 36 c has, from the top toward the bottom thereof, a knob portion 36 e, an upper external thread portion 36 f, an intermediate-diameter portion 36 g, a lower external thread portion 36 h, a small-diameter portion 36 i, and a retaining portion 36 l at the distal end. The upper external thread portion 36 f is engaged with a lock nut 36 j for fixing. The intermediate-diameter portion 36 g is engaged with a fall-preventing stopper pin 36 k projecting from the inner wall of the open valve fitting bore 67 . The lower external thread portion 36 h is engaged with the internal thread 67 a. The small-diameter portion 36 i is fitted with an annular elastic valve element 36 d. The elastic valve element 36 d is produced from an elastic material, e.g. a synthetic rubber.
Because the stopper pin 36 k projects only slightly from the inner wall of the open valve fitting bore 67 , if the valve rod 36 c is pushed into the open valve fitting bore 67 and screwed thereinto by turning the knob portion 36 e, the valve rod 36 c is fitted in the position as shown in FIG. 9 b. The right-hand half of FIG. 9 b shows a position where the elastic valve element 36 d allows communication between the first horizontal passage 70 a and the second horizontal passage 70 b. In this position, the first cylinder chamber 38 and the second cylinder chamber 39 are communicated with each other through the first and second horizontal passages 70 a and 70 b and via the first and second speed controllers 34 and 35 and the open valve 36 . Consequently, the output shaft 61 can be rotated by a manual operation. The left-hand half of FIG. 9 b shows a position where the lower end of the elastic valve element 36 d is pressed against the step portion 67 e of the open valve fitting bore 67 , and thus the first horizontal passage 70 a and the second horizontal passage 70 b are cut off from each other. In this position, the passages for communication between the first cylinder chamber 38 and the second cylinder chamber 39 are cut off from each other.
As shown in FIGS. 5, 7 a, 8 a to 8 d, one end of each of an A-passage 71 , a B-passage 72 , a P-passage 73 , an R-passage 74 and an R′-passage 75 opens on the front (left side) surface of the leftwardly projecting thick-walled portion 14 , and two tapped holes 66 open on the same surface. The abutting surfaces of the packing 63 and the solenoid-operated switching valve 33 are provided with communicating bores that agree with the openings of the passages 71 to 75 in spacing and diameter. The A-port, B-port, P-port, R-port and R′-port of the solenoid-operated switching valve 33 are communicated with the A-passage 71 , the B-passage 72 , the P-passage 73 , the R-passage 74 and the R′-passage 75 through the respective communicating bores in the packing 63 . As shown in FIG. 8 b, the leftwardly projecting thick-walled portion 14 is provided with an air supply bore 73 a opening on the lower surface thereof. The other end of the P-passage 73 is communicated with the air supply bore 73 a. Piping 7 a connected to an outlet port of a pressure reducing valve is connected to the air supply bore 73 a, so that compressed air is supplied to the P-port of the solenoid-operated switching valve 33 from an air pressure source through the pressure reducing valve, the piping 7 a (FIG. 9 c ) and the P-passage 73 .
As shown in FIG. 8 d (a sectional view taken along the line A—A (B—B) in FIG. 7 a ), the other ends of the A-passage 71 and the B-passage 72 are communicated with the first horizontal passage 70 a and the second horizontal passage 70 b, respectively. As shown in FIG. 6 (a sectional view taken along the line E—E in FIG. 7 b ), the first horizontal passage 70 a and the second horizontal passage 70 b are communicated with the first cylinder chamber 38 and the second cylinder chamber 39 via the first speed controller 34 and the second speed controller 35 and through the communicating passage 8 a and the communicating passage 8 b, respectively. As shown in FIGS. 5 and 6, the leftwardly projecting thick-walled portion 14 is provided with fitting bores 77 a and 77 b opening on the front surface thereof. The body 34 a of the first speed controller 34 and the body 35 a of the second speed controller 35 are screwed into the fitting bores 77 a and 77 b , thereby fitting the first and second speed controllers 34 and 35 . The body 34 a ( 35 a ) is provided with a passage 34 b ( 35 b ) for providing communication between the horizontal passage 70 a ( 70 b ) and the communicating passage 8 a ( 8 b ). The flow rate in the passage 34 b ( 35 b ) is controlled by a needle 34 c ( 35 c ). The needle 34 c ( 35 c ) is controlled with a handle 34 d ( 35 d ) and fixed with a lock nut 34 e ( 35 e ). A check valve 34 f ( 35 f ) is placed between the body 34 a ( 35 a ) and the fitting bore 77 a ( 77 b ). The check valve 34 f ( 35 f ) and the passage 34 b ( 35 b ) are disposed in parallel to each other. The check valve 34 f ( 35 f ) allows the flow of air from the horizontal passage 70 a ( 70 b ) to the communicating passage 8 a ( 8 b ) but checks the flow of air in the opposite direction. The first speed controller 34 and the second speed controller 35 are meter-out type speed controllers.
As shown in FIG. 8 c (a sectional view taken along the line R—R (R′—R′) in FIG. 7 a ), the leftwardly projecting thick-walled portion 14 is provided with an air exhaust bore 74 a ( 75 a ) opening on the lower surface thereof. The R-port (R′-port) of the solenoid-operated switching valve 33 is communicated with the atmosphere through the R-passage 74 (R′-passage 75 ) and the air exhaust bore 74 a ( 75 a ). When the solenoid-operated switching valve 33 is in one position, compressed air is supplied from the P-port and passed through the A-passage 71 , the first horizontal passage 70 a, the first speed controller 34 (check valve 34 f ) and the communicating passage 8 a to flow into the first cylinder chamber 38 . At this time, the air in the second cylinder chamber 39 flows through the communicating passage 8 b, the second speed controller 35 (passage 35 b ; flow control portion), the second horizontal passage 70 b, the B-passage 72 and the B-port of the solenoid-operated switching valve 33 to the R′-port. The air further flows through the R′-passage 75 and the air exhaust bore 75 a and is released into the atmosphere. When the solenoid-operated switching valve 33 is in the other position, compressed air flows into the second cylinder chamber 39 , and the air in the first cylinder chamber 38 is released into the atmosphere.
In the embodiment of the present invention, there are cases where it is desired to use the rotary actuator without connecting the solenoid-operated switching valve 33 to the leftwardly projecting thick-walled portion 14 . For such use application, as shown in FIG. 3, a first supply and exhaust bore 79 and a second supply and exhaust bore 80 are formed in the leftwardly projecting thick-walled portion 14 at respective positions slightly closer to the center than the first speed controller 34 and the second speed controller 35 as seen in a left-hand side view. The first supply and exhaust bore 79 and the second supply and exhaust bore 80 have the same structure as that of the air supply bore 73 a. The first supply and exhaust bore 79 and the second supply and exhaust bore 80 open on the lower surface of the leftwardly projecting thick-walled portion 14 and are communicated with the first horizontal passage 70 a and the second horizontal passage 70 b, respectively. When the rotary actuator is used with the solenoid-operated switching valve 33 connected to the leftwardly projecting thick-walled portion 14 , the first supply and exhaust bore 79 and the second supply and exhaust bore 80 are hermetically sealed with plugs screwed thereinto.
When it is desired to use the rotary actuator without connecting the solenoid-operated switching valve 33 to the leftwardly projecting thick-walled portion 14 , the plugs are removed from the first supply and exhaust bore 79 and the second supply and exhaust bore 80 , and the two bores 79 and 80 are communicated with the A-port and B-port, respectively, of a switching valve (not shown). Then, the solenoid-operated switching valve 33 is detached from the surface of the leftwardly projecting thick-walled portion 14 , and a plate for hermetic sealing is connected to the surface of the leftwardly projecting thick-walled portion 14 in place of the solenoid-operated switching valve 33 to block the openings of the passages 71 to 75 . Thus, the piston 20 can be moved by actuating the switching valve (not shown).
As shown in FIGS. 1 and 2, the upwardly projecting thick-walled portion 12 is provided with two non-through bolt bores 85 a opening on the upper end surface thereof, and the downwardly projecting thick-walled portion 13 is provided with two non-through bolt bores 85 b opening on the lower end surface thereof. The two bolt bores 85 a and the two bolt bores 85 b are a predetermined distance away from the upper bearing portion 11 b and the lower bearing portion 11 c, respectively. A connecting member 82 has a longitudinal U-shaped groove formed in the upper surface thereof and further has two stepped bolt insertion bores 82 b. The connecting member 82 is fitted to the downwardly projecting thick-walled portion 13 . Bolts 83 are respectively inserted into the bolt insertion bores 82 b and screwed into the bolt bores 85 b, thereby connecting the connecting member 82 to the downwardly projecting thick-walled portion 13 . The connecting member 82 has a shaft insertion bore 82 a formed in the bottom of the U-shaped groove. The shaft insertion bore 82 a and the lower bearing portion 11 c lie on the same axis. As shown in FIG. 2, the connecting member 82 has two bolt bores 82 c formed in the vicinities of the left and right ends thereof. An upper flange 40 b of a valve (e.g. a butterfly valve or a ball valve) 40 is brought into contact with the lower surface of the connecting member 82 . Two bolts 84 are inserted into respective insertion bores in the upper flange portion 40 b and screwed into the bolt bores 82 c of the connecting member 82 , thereby connecting together the connecting member 82 and the valve 40 . At this time, a prismatic portion at the upper end of a control shaft 45 of the valve 40 is fitted into the square hole 61 b at the lower end of the output shaft 61 . Thus, the rotation of the output shaft 61 is transmitted to the control shaft 45 .
As shown in FIGS. 4, 5 and 10 a, the first end plate 17 and the second end plate 18 each have two bolt bores 87 a provided in the upper left portion thereof and two bolt bores 87 b in the upper right portion thereof as viewed in FIG. 4 . The cylinder body 11 is provided with two bolt bores 88 opening on the right side surface of the rightwardly projecting thick-walled portion 15 . The spacing between the two bolt bores 88 is the same as the spacing between the two bolt bores 87 a and the spacing between the two bolt bores 87 b. A filter 47 is connected to the rotary actuator 9 through an L-shaped bracket 90 and short bolts by using two bolt bores 88 , 87 a or 87 b. One end portion of the L-shaped bracket 90 is provided with a connecting bore for connection to the filter 47 , and the other end portion of the L-shaped bracket 90 is provided with a pair of upper and lower horizontally elongated insertion holes for insertion of short bolts.
FIGS. 10 a to 10 c show methods of installing the filter 47 onto the rotary actuator 9 . One end portion of the L-shaped bracket 90 is connected to the filter 47 through the connecting bore. When the rightwardly projecting thick-walled portion 15 lies horizontally as shown in FIG. 10 a, short bolts are inserted into either the upper or lower horizontally elongated insertion hole of the L-shaped bracket 90 and screwed into the two bolt bores 88 of the rightwardly projecting thick-walled portion 15 . Alternately, short bolts are inserted into the upper and lower horizontally elongated insertion holes, respectively, of the L-shaped bracket 90 and screwed into the bolt bores 87 a or 87 b of the first end plate 17 or the second end plate 18 . When the rightwardly projecting thick-walled portion 15 lies vertically as shown in FIG. 10 b, short bolts are inserted into the upper and lower horizontally elongated insertion holes, respectively, of the L-shaped bracket 90 and screwed into the two bolt bores 88 of the rightwardly projecting thick-walled portion 15 . When the rightwardly projecting thick-walled portion 15 faces upward as shown in FIG. 10 c, short bolts are inserted into the upper and lower horizontally elongated insertion holes, respectively, of the L-shaped bracket 90 and screwed into the bolt bores 87 a or 87 b of the first end plate 17 or the second end plate 18 . In this way, the filter 47 can be installed vertically.
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A rotary actuator in which, in order to realize cost reductions, the configuration of an extruded material used to form a cylinder body is modified to reduce the weight of the material, and the number of components or the number of manhours needed for machining is reduced by changing the method of installing a solenoid-operated switching valve, speed controllers and an open valve for short circuiting. The cylinder body ( 11 ) is produced from an extruded material ( 1 ) formed by extrusion. A section of the extruded material ( 1 ) that is perpendicular to the direction of extrusion of the extruded material ( 1 ) is circular at the inner periphery thereof and has upwardly, downwardly, leftwardly and rightwardly projecting thick-walled portions ( 12 to 15 ) at the outer periphery thereof. The outer peripheral portions of the section, exclusive of the projecting thick-walled portions ( 12 to 15 ), are generally formed from circular arcs.
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This application is a continuation of Ser. No. 07/395,045 filed Aug. 17, 1989 now abandoned.
FIELD OF THE INVENTION
This invention is a reusable, self priming variable dosage dispenser for products such as, toilet cleaning, water treating and disinfectants. These products come in either solid or liquid form, and are added to the toilet flush tank to form a solution. This invention provides a method to control the amount of solution being added to each flush of the toilet, and will also reduce the amount of water used in each flush of a toilet. More specifically, the present invention has no moving parts in its operation, therefore it is a passive dispenser. The variability of the dosage is obtained by changing the volume of the solution discharged during the flushing time of the toilet by means of sets of internal groves, a movable baffle and fixed apertures.
DESCRIPTION OF PRIOR ART
Dispensers to deliver a set amount of cleaning and or disinfectant are disclosed in prior patents:
In U.S. Pat. No. 4,281,421 granted to J. D. Nyquist, Aug. 4, 1981 discloses a one time usage dispenser with fixed chambers, passage ways and is designed for an improved hypochlorite cake.
In U.S. Pat. No. 4,186,856 issued to R. S. Drisking dated Feb. 5, 1980 shows a one time usage package serving as a passive dispenser which uses an air lock to isolate the additive.
U.S. Pat. No. 4,438,534 issued Mar. 27, 1981 to G. B. Keyes discloses a dispenser with three fixed chambers and path ways to dispense three pre-determined amount of additives, that works on vents and syphons and is not variable. The foregone cited inventions are one time usage packaging methods with a capability to dispense a pre-determined amount of additive and no capability to change the amount of additive or solution dispensed into the flush water. However, the cited inventions do use fixed walls for baffles to divide the device into chambers and apertures for communicating the solution in the discharge water. In addition to the one time fixed dispensers, other prior art may exist.
U.S. Pat. No. 3,934,279 issued Jan. 27, 1976 to S. Mallin, in class 4/228 where a canister is hung inside the toilet tank wall, and using water to pump the air through a liquid and to evaporate the same, through a fixed chamber, and through an aperture in a fixed baffle. The dispenser is for treatment of air around the toilet and not for treatment of the flush water.
U.S. Pat. No. 3,715,765 issued to F. G. Yardo dated Feb. 13, 1975 discloses a dispenser of perfume, as a deoderizer this dispenser also operates by the force of filling water to displace air through an open aperture at the bottom of the dispenser through a material holding liquid perfume.
U.S. Pat. No. 3,943,582 issued to J. Daeninckx dated Mar. 16, 1976 shows an enclosed holder for additive to be dispensed into the flush water. This holder is equipped with a deflector next to an aperture which can be considered as a baffle, but the unit has no capability to adjust the discharged rate.
U.S. Pat. No. 3,121,236 dated Feb. 18, 1964 issued to F. G. Yadro discloses a dispenser with four sides and a bottom to be hung inside a toilet tank, to avoid circulating currents of water and with each flush of the tank, the solution inside the dispenser is gravity feed into the tank through two apertures, where the volume of discharge is fixed to the tanks discharge and filling rate.
These cited three dispensers are reusable, use apertures, baffles and the movement of water and may have physical resemblance to our invention, but from a techinal standpoint, they have no means to vary the volume discharged.
SUMMARY OF THE INVENTION
Water used in flushing a toilet varies in chemical make-up from geographic area to area, hard water areas have a different need than a soft water area therefore a dispenser with a variable dosage is not only desirable but, may be becoming a necessity when dealing with the environmental chemical impact.
This invention a reusable, self priming variable dosage dispenser for products such as toilet cleaning, water treatment and disinfectants. The invention has no moving parts during operation, therefore it is a Passive Dispenser. The ability to vary the dosage discharged is obtained by means of sets of internal grooves, a movable baffle to fit the grooves and specifically located apertures.
The objective of this invention is to reduce the amount of additive used, save water, and can be installed without adjustment to the water closet's existing configuration.
To obtain the stated objectives, the unit is designed to be small, made of non-porous polyethylene, or similar type material, equipped with its own hanger and internally adjustable to vary the amount of solution discharged. If more then one unit is installed the amount of water saved is grater, but only one needs to contain a chemical agent.
When a tank type toilet is flushed, the tank will release water on the average of about eight seconds. When the water has reached a point where it can no longer support the discharge valve, it is dropped by gravity shutting off the discharge while the inlet valve continues to fill the tank. Filling the water closet tank can take anywhere from 20 seconds to two minutes. This variance is due to water pressure and size of the inlet valve. Although one cycle of the water closet may take more than a minute, its the first 25 seconds or so that this invention is designed to work. A more specific disclosure of objects and advantages of this invention is presented in the detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1: Is a perspective of a typical water closet.
FIG. 2: A perspective of the internal components of the invention.
FIG. 3: Is a perspective of the hanger for securing the device to the tank.
FIG. 4: Contemplates the water flow and how the device achieves its functions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is a variable dosage dispenser made of polyethylene or similar type material. This invention provides a method to control the amount of solution being added to each flush. The device is also constructed to reduce the amount of water used in flushing of a tank type toilet.
Referring to FIG. 1: Possible locations for the invention 7 have been identified in FIG. 1. In most conventional water closet tanks 5, these areas have little or no moving parts. When a water tank is discharged to flush the toilet, the water is released thru the discharge valve 6, after the valve is closed. The tank is refilled by the water inlet valve 8, which is controlled by the float valve 9.
Referring to FIG. 2 The present invention has a volume of approximately 76 cubic inches. With outside dimensions of; width A, about four and one fourth inches, depth B, about two and one fourth inches and height C, about eight inches. This device is constructed with three sets of evenly spaced groves 13, the baffle 14 divides the device into two chambers.
The baffle 14 has a recirculating aperture 16 at the lower end, the aperture is about one hundred sixty thousandth of an inch in diameter and about two and three eights inch from the bottom. The invention is secured to the water tank by the hanger 15 which is where the water tank lid rests on and provides support. The hanger 15 also restricts the device's 7 side to side movement. This is accomplished by a close fit for the hanger 15 to inside of the casing 17 and the outside surface of grooves 13.
Referring to FIG. 3. The device 7 is installed in the water tank with the water level just above the aperture 21. This adjustment is accomplished by putting the hanger's holding stud 18 into one of the slots 19. The holding stud is constructed with a flange larger than the slot 19 to restrict front and back movement. When the tank 5 is in its refilling cycle, the device will have a positive buoyancy for a short time. The slots 19 are designed to enable the casing 17 to move vertically until negative buoyancy returns the casing 17 to its resting position.
Referring to FIG. 4. When the device 7 is installed, the water from the water tank enters the device through three apertures and a slot: First, the discharge aperture 20 is located about three inches from the bottom and about an inch from the side, the size of the aperture is about two hundred thousandth of an inch in diameter, second, the water from the discharge chamber 22 to the holding chamber 23 through aperture 16, third, the discharge aperture 21, located about an inch from the side and about one and one half inch from the top, the size of the aperture is about one half inch in diameter, fourth, is the hanging slot 19 located in back of the device 7. The baffle 14 divides the casing 17 into two chambers 22 and 23. The discharge side 22 is where the solid cleaning agent 25 is placed. When a liquid cleaner of disinfectent is used, the liquid additive is placed into the holding chamber 23.
When the toilet is flushed, the invention will accomplish two objectives simultaneously: dispense a variable amount of solution into the water, and retain up to fourty-nine cubic inches of water with each flush.
First objective is to control the amount of solid cleaning additives dispensed. The common additive has a specific gravity higher than water, dissolving into the water by diffusion and will form a high surface tension when left undisturbed. In order to overcome these characteristics, the invention performs the following: Referring to FIG. 4, the cleaning agent 25 is placed in chamber 22, therefore it is isolated from all mechinisiams, in either solid or semi-dissolved form. The casing 17 is divided into two chambers, 22 and 23 by the baffle 14. By setting the baffle 14 into the first set of grooves 13 located at the center of main chamber the volume of discharge is at a minimum, When inserting the baffle 14 into the center set of grooves 13, the volume of discharge to chamber 22 is increased by approximately 33% and with the baffle 14 set into the last set of grooves 13 the discharge chamber 22 is increased 66% over the minimum setting. By the ability of varying the discharge chamber's 22 volume, the amount of solution discharged through aperture 21, is varied. It is obvious that more grooves will produce a finer variability. As the water level rapidly falls, the solution in the upper end of chamber 22 is quickly discharged through aperture 21 and slot 19, with the baffle 14 holding the solution in the holding chamber 23 to a slower discharge rate, with this difference in discharge rate of the two chambers, a pressure difference will create a solution flow between chambers 23 to 22 through aperture 16. This current 24 is at its strongest when the chambers reach equal volume. This current 24 is used to break the surface tension of additive 25, thus to allowing diffusion of the additive 25 into the water. The amount of additive dispensed is controlled by its diffusion rate, and the diffusion rate is controlled by the solution saturation point. Once the solution reaches the saturation point the diffusion ceases. With the casing 17 and the baffle 14 controlling the volume and baffle 14 controlling the flow 24, the saturation point in device 7 is quickly reached. Working in conjunction with apertures 16, 20 and 21 the baffle 14 controls the volume of release, therefore the amount of additive used can be varied.
Second objective is to retain water. As the device 7 is installed into the tank 5 it is filled with water. When the flush begins the water in the tank will quickly discharge thru valve 6, in about eight seconds valve 6 closes. In this time device 7 will discharge water from aperture 20, 21 and slot 19. The amount of water discharged during the flushing time is about twenty-eight cubic inches. Since the displacement of device 7 is approximately seventy-six cubic inches about forty-nine cubic inches is retained by device 7. By this retention, each flush of the toilet will use forty-nine cubic inches less water. Any discharge by device 7 after valve 6 closes is part of the refilling cycle.
The objective of a single device for adjusting the amount of solution used in each flush, reducing water consumption, and providing easy installation without adjustment or modification to a conventional water closet has been met and described. It is apparent to those knowledgeable in the art, that modifications are possible without departing from this invention's concepts. Therefore, this invention is not to be restrictive except for prior art and appended claims.
|
A passive dispenser having the capability of varying the amount of solution added to the toilets flush water such time the toilet is flushed. This variability of dosage is obtained by changing the volume of solution discharge during the flushing period of the toilet by means of sets of internal grooves, a movable baffle and specifically located fixed aperture. Said invention can help to reduce water consumption, and is equipped with its own hanger for easy installation.
| 4
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INTRODUCTION
[0001] The evolution of automotive engines actually results in an increase in the demand for diesel fuel at the expense of that of gasoline.
[0002] The forecasts relating to the evolution of the market for automotive fuels indicate an almost generalized reduction throughout the world in the demand for gasoline.
[0003] Thus, whereas in 2000, the ratio of gasoline consumption relative to diesel fuel was 2, it is expected that it will be close to 1.5 in 2015.
[0004] For the European Union, this reduction is extremely high, since this ratio that was 1 in 2000 should shift to 0.5 in 2012 and even drop further beyond.
[0005] Furthermore, the demand for kerosene should also significantly increase in the coming years in connection with the evolution of the market of air transport.
[0006] This inevitable evolution toward an increased demand for middle distillates and the reduction of the demand for gasoline poses to the refining industry a serious problem of adaptation of supply to demand, and this within a very short time period that is not very compatible with the construction of new installations that are expensive and take a long time to come on stream, such as vacuum hydrocracking of diesel fuel.
[0007] This invention proposes an attractive approach that makes it possible, starting from light cracked naphtha (optionally including any proportion of olefinic fractions C3 and C4 called “LPG”), and a BTX-rich aromatic fraction, to answer an increased demand for diesel fuel and kerosene, without involving new and expensive hydrocracking units.
[0008] The approach described in this invention is particularly well suited to the remodeling of existing refining units.
PRIOR ART
[0009] In a market that is dominated by the consumption of gasoline, as is the case in, for example, the United States, the production of diesel fuel is essentially ensured starting from so-called “straight run” middle distillates, i.e., originating from the direct distillation of crude petroleum.
[0010] These middle distillates should be hydrotreated to meet the now very strict specifications of sulfur content (10 ppm maximum) and aromatic compound contents. Currently, this production is notoriously inadequate and requires the refiners in certain geographic zones, and in particular Europe, to import diesel fuel to meet domestic demand.
[0011] Conversely, and particularly in Europe, the refiners deal with gasoline waste whose exports in the deficient geographic zones are uncertain over the short term due to the increase in refining capacities and/or the reduction in consumption in the zones that are involved.
[0012] For all of these reasons, a certain number of refiners have built hydrocracking installations that make it possible to transform heavy fractions, such as vacuum diesel fuel, into diesel fuel of very good quality. Nevertheless, this process is very expensive in investment and utilities because it operates at very high pressure (greater than 100 bar) and results in a very high consumption of hydrogen (on the order of 10 to 30 kg of hydrogen per ton of feedstock), making it necessary to establish a specific installation for the production of hydrogen.
[0013] Other less expensive approaches for producing diesel fuel can be considered, namely the oligomerization of light olefins that have 3 to 6 carbon atoms, for example originating from catalytic cracking. However, these olefinic fractions very often contain sulfur-containing and nitrogen-containing impurities that quickly deactivate the oligomerization catalyst and can make the process less economical. It is therefore necessary to purify the oligomerization feedstock. This is done by adding cleaning equipment, most often in several stages, including diverse, regenerative or non-regenerative adsorbent compounds.
[0014] This approach can be defined as an alternative to the “hydrocracking” approach, relying on an oligomerization of light olefins of 3 to 10 carbon atoms, in a preferred manner 4 to 6 carbon atoms, coupled to an alkylation of olefins of 8 to 10 carbon atoms, not having reacted to the oligomerization on a BTX-rich fraction, generally available starting from a semi-regenerative or regenerative reforming.
[0015] This alkylation culminates in a fraction that is located in the range of middle distillates (diesel fuel or kerosene) that it is then necessary to hydrotreat and/or hydrogenate to culminate in commercial products.
[0016] The approach that is an object of this invention remains economically much less expensive than the hydrocracking approach in terms of investment, utilities and hydrogen consumption, and it leads to a reduction of gasoline and an increase in distillate in the same order of magnitude.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic representation of one embodiment of the invention.
SUMMARY DESCRIPTION OF THE INVENTION
[0018] This invention describes a process for the production of diesel fuel ( 13 ) from a gasoline fraction ( 1 ) that originates from a catalytic cracking unit and a BTX fraction ( 9 ) that originates from a unit for catalytic reforming of gasolines, relying on the concatenation of the following stages:
An optional stage 1 for selective hydrogenation (SHU) of the initial gasoline fraction, A stage 2 for treatment on the acid catalyst (TR) of the effluent that is obtained from stage 1, A stage 3 for distillation of the effluent of stage 2 that is produced in a first distillation column (CD 1 ) that makes it possible to separate at the top an olefinic fraction ( 4 ) that has a final boiling point of approximately 60°, intermediately a distillation interval fraction ( 5 ) of between 60° C. and 150° C., and at the bottom a boiling point fraction ( 6 ) that is greater than 150° C., which is sent to a hydrotreatment (HDT) unit, with the effluent ( 12 ) of the hydrotreatment unit being sent to a total hydrogenation (HT) unit that produces the desired diesel fuel ( 13 ), A stage 4 for oligomerization (OLG) of the olefinic fraction ( 4 ) optionally mixed with an LPG fraction ( 10 ) that contains olefins, from which, after distillation, a stream ( 7 ) of oligomerized olefins with a number of carbon atoms that ranges from 8 to 20 is extracted and which is sent for a first part via the stream 7 a to the hydrotreatment (HDT) unit that constitutes the stage ( 6 ) and for a second part via the stream 7 b to the total hydrogenation (HT) unit, A stage 5 for alkylation of the stream ( 8 ) of olefins into C3 and C8 on the BTX fraction ( 9 ), whereby the effluent ( 11 ) of the alkylation (ALK) unit is sent into a second distillation column (CD 2 ) from which 3 fractions are extracted: A gasoline fraction ( 11 a )—with a boiling point that is less than 100° C.—that is sent to the gasoline pool, An intermediate fraction ( 11 b ) with a distillation interval of between 100° C. and 150° C., essentially consisting of BTX that has not reacted, which is for the most part recycled at the input of the alkylation (ALK) unit, with the exception of a fraction that constitutes the purging of said (ALK) unit, which is itself sent to the gasoline pool after stabilization, A heavy fraction ( 11 c ) with a boiling point that is greater than 150° C. that is sent to the total hydrogenation (HT) unit from which the desired diesel fuel ( 13 ) is extracted.
[0027] The gasoline fraction that constitutes the feedstock ( 1 ) is generally a catalytic cracking gasoline that contains 5 to 10 carbon atoms and in a preferred manner 5 to 7 carbon atoms.
[0028] According to a preferred variant of the process according to this invention, the acid catalyst treatment (TR) stage 2 relies on an ion-exchange resin-type acid catalyst, or supported phosphoric acid catalyst, or any acid catalyst previously used in the downstream stages of oligomerization (OLG) or alkylation (ALK) in a temperature range of 20° C. to 350° C., in a preferred manner 40° C. to 250° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner 10 to 30 bar, and in a VVH range of 0.1 h-1 to 5 h-1, in a preferred manner 0.3 h-1 to 2.0 h-1.
[0029] It is recalled that 1 bar=10 5 Pascal and that the VVH refers to the ratio between the volumetric flow rate of feedstock and the volume of catalyst.
[0030] According to another preferred variant of the process according to this invention, the oligomerization stage 4 is supplied by the cracking gasoline ( 4 ) and an LPG fraction that contains olefins and works on a preferably zeolitic- or silica alumina-type acid catalyst in a temperature range of 20° C. to 400° C., in a preferred manner from 100° C. to 350° C., and in a pressure range of 1 to 100 bar, in a preferred manner 20 to 70 bar, and in a VVH range of 0.1 h-1 to 5 h-1, in a preferred manner 0.2 h-1 to 1.0 h-1.
[0031] According to a preferred variant of the process according to this invention, alkylation stage 5 (ALK) is supplied by the effluent ( 8 ) of the oligomerization (OLG) unit and by a fraction that is rich in aromatic compounds ( 9 ) containing 6 to 12 carbon atoms, and in an also preferred manner 6 to 9 carbon atoms, and it works on a preferably zeolitic- or silicoaluminate-type acid catalyst, in a temperature range of 20° C. to 400° C., in a preferred manner 100° C. to 350° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner 20 bar to 70 bar, and in a VVH range of 0.05 h-1 to 5 h-1, in a preferred manner 0.1 h-1 to 2.0 h-1.
[0032] According to another preferred variant of the process according to this invention, the hydrotreatment (HDT) stage 6 uses a catalyst that contains at least one metal that is selected from among Ni, Co and Mo and operates in a temperature range of 50° C. to 400° C., in a preferred manner 100° C. to 350° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner 20 bar to 70 bar, and in a VVH range of 0.1 h-1 to 10 h-1, in a preferred manner 0.5 h-1 to 5.0 h-1.
[0033] According to another variant of the process according to this invention, the hydrotreatment (HDT) stage 6 uses a catalyst that contains at least one metal that is selected from among Pd and Pt and operates in a temperature range of 50° C. to 300° C., in a preferred manner from 100° C. to 250° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner from 20 bar to 70 bar, and in a VVH range of 0.1 h-1 to 10 h-1, in a preferred manner from 0.5 h-1 to 5.0 h-1.
[0034] Finally, according to a last variant of the process according to this invention, stage 2 for acid catalyst treatment (TR) is preceded by a selective hydrogenation (SHU) stage 1 of the initial gasoline fraction.
DETAILED DESCRIPTION OF THE INVENTION
[0035] This invention describes a process for producing kerosene or diesel fuel from olefinic fractions that are typically obtained from a unit for catalytic cracking of gasolines (denoted FCC in abbreviated form) and a BTX-rich fraction (abbreviation of benzene, toluene, xylene) typically obtained from a semi-regenerative or regenerative reforming unit, generally present on the same site as the FCC unit.
[0036] “Typically” is defined as the most common case that does not exclude other sources as described below.
[0037] The olefinic fraction can also originate from steam-cracking-type units (denoted SC in abbreviated form), Fischer-Tropsch synthesis units (denoted FT in abbreviated form), coking units (denoted CK in abbreviated form), or else a visco-reduction unit (denoted VB in abbreviated form). The BTX-rich fraction can also originate from a steam-cracking (SC) unit, a vaporeforming unit (denoted VR in abbreviated form), an olefin cracking unit (denoted CO in abbreviated form), or else a unit that transforms methanol into olefins (denoted MTO in abbreviated form).
[0038] The feedstock to be treated ( 1 ) is a distillation interval gasoline that is between 30° C. and 250° C. This feedstock is optionally sent into an SHU unit that makes it possible to hydrogenate the gum-generating unsaturated hydrocarbons selectively, such as the diolefins.
[0039] The treated effluent ( 2 ) is sent directly or after distillation into a treatment (TR) unit that is based on the use of an acid catalyst, preferably an ion-exchange resin-type catalyst as described in the patent FR 2,840,620, or of the supported phosphoric acid type.
[0040] This stage has as its object to capture compounds that poison the acid catalysts, in particular the nitrogen-containing compounds, and optionally to transform them into heavier compounds.
[0041] It has actually been observed, surprisingly enough, that the catalysts cited above, after a period of almost total capture of the nitrogen-containing compounds, continue to convert the nitrogen-containing compounds of the feedstock into heavier compounds in such a way that if distillation is established downstream from the treatment, the light fraction that is obtained at the top of the distillation column is low in nitrogen. This light top fraction can be treated without additional purification on the downstream acid catalysts.
[0042] An increasing of the weight of the sulfur-containing compounds in such a way that the light fraction obtained from the downstream distillation is also low in sulfur-containing compounds was also observed in this treatment (TR) stage.
[0043] The effluent ( 3 ) of the unit for treatment with resins (TR) is sent into a distillation column (CD 1 ) from which 3 fractions are extracted:
[0044] a) A top fraction corresponding to the stream ( 4 ) that is sent into the concatenation of oligomerization (OLG)-BTX alkylation (ALK) units for the purpose of producing a diesel-fuel-type distillation interval fraction ( 11 ) that is hydrogenated in the total hydrogenation (HT) unit for producing the desired distillate ( 13 ),
[0045] b) An intermediate fraction ( 5 ) that can be sent into a hydrodesulfurization unit that makes it possible to reduce the sulfur content to less than 10 ppm (not shown in FIG. 1 ).
[0046] This type of unit is, for example, the unit known commercially under the name of Prime G+, marketed by the AXENS Company, whose description can be found in the patent FR 2,797,639.
[0047] c) A bottom fraction ( 6 ) that is sent into a strict hydrotreatment (HDT) unit that makes it possible to reduce the sulfur content to less than 10 ppm, to hydrogenate almost all of the olefins, and to reduce significantly the content of aromatic compounds. The effluent of the hydrotreatment (HDT) unit, denoted stream ( 12 ), is sent to the total hydrotreatment (HT) unit.
[0048] The top fraction ( 4 ), optionally mixed with an LPG fraction ( 10 ), is sent into an oligomerization (OLG) unit that will form oligomers with a number of carbon atoms of between 8 and 20 constituting the stream ( 7 ).
[0049] Based on its sulfur content, this stream ( 7 ) is:
Either sent (stream 7 a ) to the hydrotreatment (HDT) unit, when its sulfur content is greater than 10 ppm, Or sent (stream 7 b ) to the total hydrogenation (HT) unit when its sulfur content is less than 10 ppm.
[0052] The oligomerization (OLG) unit preferably operates on a zeolitic- or silica-alumina-type acid catalyst, in a temperature range of 20° C. to 400° C., in a preferred manner 100° C. to 350° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner 20 bar to 70 bar, and in a VVH range of 0.1 h-1 to 5 h-1, in a preferred manner 0.2 h-1 to 1.0 h-1.
[0053] The light olefin fraction, with a boiling point that is less than 150° C., not having reacted in the oligomerization (OLG) unit, constitutes the stream ( 8 ) that supplies the alkylation (ALK) unit that relies on a BTX fraction ( 9 ) that is generally obtained from a regenerative reforming unit of the gasolines.
[0054] The unit for alkylation of olefins ( 8 ) obtained from the oligomerization (OLG) unit on the BTX fraction ( 9 ) preferably operates on a zeolitic- or silicoaluminate-type acid catalyst in a temperature range of 20° C. to 400° C., in a preferred manner 100° C. to 350° C., and in a pressure range of 1 bar to 100 bar, in a preferred manner 20 bar to 70 bar, and in a VVH range of 0.05 h-1 to 5 h-1, in a preferred manner 0.1 h-1 to 2.0 h-1.
[0055] The effluent ( 11 ) of the alkylation (ALK) unit is sent into a distillation column (CD 2 ) from which 3 fractions are extracted:
A gasoline fraction ( 11 a )—with a boiling point that is less than 100° C.—that is sent to the gasoline pool, An intermediate fraction ( 11 b ) with a distillation interval of between 100° C. and 150° C., essentially consisting of BTX that has not reacted and that is for the most part recycled at the input of the alkylation unit, with the exception of a fraction that constitutes the purging of the unit, and that is itself sent to the gasoline pool after stabilization, A heavy fraction ( 11 c ) with a boiling point that is greater than 150° C. that is sent to the total hydrogenation (HT) unit from which the desired diesel fuel ( 13 ) is extracted.
Example
[0059] The following example illustrates the process according to the invention.
[0060] The starting material is a feedstock that consists of a catalytic cracking gasoline and a BTX fraction that originates from a catalytic reforming unit. An LPG fraction that originates from the catalytic cracking unit is also added.
[0061] The mass flow rates of the components of the feedstock are as follows:
[0062] Gasoline ( 1 ): 100 t/h
[0063] BTX fraction ( 9 ): 18 t/h
[0064] LPG fraction ( 10 ): 25 t/h
[0065] The gasoline ( 1 ) is introduced into a selective hydrogenation unit (SHU) that operates under the following conditions:
Pressure: 15 bars effective Temperature 120° C. HR 945 catalyst marketed by the Axens Company, with a VVH of 2 h-1.
[0069] The hydrogenated gasoline ( 2 ) is introduced in an acid catalyst treatment (TR) unit that operates under the following conditions:
Pressure: 15 bars effective Temperature 100° C. TA 801 catalyst marketed by the Axens Company, with a VVH of 0.5 h-1.
[0073] The effluent ( 3 ) of the TR unit is introduced into a distillation column (CD 1 ) from which the following are separated:
At the top, an olefinic fraction ( 4 ) that has a final boiling point of 60° C., Intermediately, a distillation interval fraction ( 5 ) that is between 60° C. and 150° C., At the bottom, a boiling point fraction ( 6 ) that is greater than 150° C.
[0077] The top fraction ( 4 ) is mixed with a certain quantity of the LPG fraction ( 10 ), and the resulting mixture is introduced into the oligomerization (OLG) unit that operates under the following conditions:
Pressure: 60 bars effective Temperature: 160° C. IP 811 catalyst marketed by the Axens Company, with a VVH of 0.5 to 2 h-1.
[0081] The oligomerization (OLG) unit produces, on the one hand, an effluent ( 7 ) that consists of oligomerized olefins and that is sent in part ( 7 a ) in a mixture with the bottom fraction ( 6 ) of the distillation column (CD 1 ) into a hydrotreatment (HDT) unit that operates under the following conditions:
Pressure: 20 bars effective Temperature 300° C. HR 506 catalyst that is marketed by the Axens Company, used with a VVH of 1 h-1.
[0085] The effluent ( 12 ) of the hydrogenation (HDT) unit is sent to the total hydrogenation (HT) unit, optionally mixed with the part ( 7 b ) of the olefinic effluent ( 7 ).
[0086] The effluent ( 13 ) of the total hydrogenation (HT) unit constitutes the production of desired diesel fuel with the following specifications:
[0087] Engine cetane number: 45
[0088] Density 0.775 kg/m3
[0089] The intermediate effluent ( 5 ) of the distillation column CD 1 is sent to the gasoline pool.
[0090] The oligomerization (OLG) unit also produces an effluent ( 8 ) of olefins in C3 and C4 that is sent with the BTX fraction ( 9 ) into an alkylation (ALK) unit that works under the following conditions:
Pressure 2,500 kPa (k is the abbreviation of kilo or 10 3 pascal) Temperature 150° C. Y zeolite catalyst VSL: 2.5 h-1.
[0095] The effluent ( 11 ) of the alkylation (ALK) unit is sent into a second distillation column (CD 2 ) that produces at the bottom an effluent ( 11 c ) that is sent into the total hydrogenation (HT) unit and therefore contributes to the production of the desired diesel fuel ( 13 ).
[0096] The lateral effluent ( 11 b ) of the distillation column (CD 2 ) is sent to the alkylation (ALK) unit.
[0097] The top effluent ( 11 a ) of the column CD 2 is sent to the gasoline pool.
[0098] Tables A and B below provide the detail of streams according to the diagram of FIG. 1 .
[0099] Overall, the process according to the invention therefore produced 66 tons/hour of diesel fuel ( 13 ), starting from 100 tons/hour of FCC gasoline ( 1 ), 18 tons/hour of BTX fraction ( 9 ), and 25 t/h of the LPG fraction of FCC ( 10 ), or a yield ( 13 )/( 1 )+( 9 )+( 10 ) of 46% transformation of a gasoline fraction into a distillate fraction, usable as a base of kerosene or diesel fuel.
[0100] To understand Tables A and B, we will spell out the meanings of the abbreviations that are used:
[0101] Cn refers to a paraffinic fraction with n carbon atoms
[0102] Cn = refers to an olefinic fraction with n carbon atoms
[0103] A refers to aromatic compounds
[0104] B refers to benzene
[0105] T refers to toluene, and X refers to xylenes
[0106] The indices n, i, and c respectively mean normal (or linear), iso (or branched) and cyclic.
[0000]
TABLEAU “A”
Effluent
Effluent
CD1
CD1
CD1
Feed
Oligo
Oligo
Oligo
Oligo
Feed
SHU
TR
lights
heart cut
heavy cut
C4
Feed
Prod
heavies
lights
(1)
(2)
(3)
(4)
(5)
(6)
(10)
(10) + (4)
(8) + (7)
(7)
(8)
C4(i, n)
0.05
0.08
0.08
0.08
—
—
12.00
12.06
12.08
—
12.08
C4=
0.27
0.24
0.22
0.22
—
—
13.00
13.22
0.68
—
0.66
C5(i, n, c)
10.49
11.14
11.34
11.14
—
—
—
11.14
11.14
—
11.14
C5=
13.10
12.74
11.47
11.47
—
—
—
11.47
1.72
—
1.72
C6(i, n, c)
8.57
8.77
8.77
0.88
7.90
—
—
0.88
0.88
—
0.88
C6=
8.34
8.13
8.13
0.81
7.32
—
—
0.81
0.20
—
0.20
B
0.94
0.94
0.94
—
0.94
—
—
—
—
—
—
C7(i, n, c)
6.28
6.28
6.28
—
6.28
—
—
—
—
—
—
C7=
3.61
3.61
3.01
—
3.61
—
—
—
—
—
—
T
4.87
4.87
4.87
—
4.87
—
—
—
—
—
—
C8(i, n, c)
4.09
4.09
4.09
—
4.09
—
—
—
—
—
—
C8=
1.64
1.64
1.64
—
1.64
—
—
—
—
—
—
X
9.70
9.70
9.70
—
9.70
—
—
—
—
—
—
C9(i, n, c)
1.85
1.85
1.85
—
0.58
1.30
—
—
—
—
—
C9=
1.25
1.26
1.26
—
0.38
0.89
—
—
—
—
—
A9
9.93
9.93
9.93
—
1.49
6.44
—
—
—
—
—
C10(i, n, c)
1.90
1.90
1.90
—
—
1.80
—
—
—
—
—
C10=
0.84
0.84
0.84
—
—
0.84
—
—
—
—
—
A10
7.88
7.88
7.86
—
—
7.88
—
—
—
—
—
C11(i, n, c)
0.57
0.57
0.57
—
—
0.57
—
—
—
—
—
C11=
0.70
0.70
0.70
—
—
0.70
—
—
—
—
—
A11
1.28
1.28
1.28
—
—
1.28
—
—
—
—
—
C12(i, n, c)
0.46
0.46
0.46
—
—
0.46
—
—
—
—
—
C12=
0.14
0.14
0.14
—
—
0.14
—
—
—
—
—
A12
0.89
0.89
0.89
—
—
0.89
—
—
—
—
—
C12(i, n, c)
0.02
0.02
0.02
—
—
0.02
—
—
—
—
—
C12=
—
—
—
—
—
—
—
—
—
—
—
A12
0.01
0.01
0.01
—
—
0.01
—
—
—
—
—
Oligomères
—
—
1.30
—
1.30
—
—
—
17.19
—
17.19
C8-C12
Oligomères
—
—
—
—
—
—
—
—
5.73
5.73
—
C12-C16
Alkylate
—
—
Dienes
0.33
0.03
0.03
—
—
0.03
—
—
—
—
—
HT oligomere
—
—
C12-C15
HT Alkylate
—
—
S(ppm pds)
1000
800
800
8
320
472
10
9
9
78
0
N(ppm pds)
30
27
14
0
3
11
1
1
1
5
0
Total
100.00
100.00
100.00
24.60
50.06
25.35
25.00
49.60
49.60
5.73
43.87
[Key to Table A:]
TABLEAU “A” = TABLE “A”
Oligomères C8-C12 = C8-C12 Oligomers
Oligomères C12-C16 = C12-C16 Oligomers
[0000]
TABLEAU “B”
HDT
HDT
Effluent
Effluent
(après
(après
BTX
Heart
Oligo
Oligo
strippeur)
strippeur)
Feed
recycle
Alky
Light
cut
Heavy
Heart cut
Heavies
Heavies
(H2 feed non
HT feed
(H2 feed non
BTX
(11b)
effluent
purge
purge
Product
to gasoline
to HDT
to HT
exemplifiè)
(7b +
exemplifiè)
(9)
recycle
(11)
(11a)
(11b)
(11c)
(11b)out
(7a)
(7b)
(12a)
12 + 11c)
(13)
C4(i, n)
—
—
12.08
12.08
—
—
—
—
—
—
—
—
C4=
—
—
0.01
0.01
—
—
—
—
—
—
—
—
C5(i, n, c)
—
—
11.14
11.14
—
—
—
—
—
—
—
—
C5=
—
—
0.02
0.02
—
—
—
—
—
—
—
—
C6(i, n, c)
—
—
0.88
0.88
—
—
—
—
—
—
—
—
C6=
—
—
0.00
0.00
—
—
—
—
—
—
—
—
B
—
—
—
—
—
—
—
—
—
—
—
—
C7(i, n, c)
—
—
—
—
—
—
—
—
—
—
—
—
C7=
—
—
—
—
—
—
—
—
—
—
—
—
T
14.00
68.55
70.67
—
70.67
—
2.12
—
—
—
—
—
C8(i, n, c)
—
—
—
—
—
—
—
—
—
—
—
—
C8=
—
—
—
—
—
—
—
—
—
—
—
—
X
4.00
1.29
1.33
—
1.33
—
0.04
—
—
—
—
—
C9(i, n, c)
—
—
—
—
—
—
—
—
—
1.29
1.29
8.40
C9=
—
—
—
—
—
—
—
—
—
0.80
0.90
—
A9
—
—
—
—
—
—
—
—
—
8.44
8.44
4.22
C10(i, n, c)
—
—
—
—
—
—
—
—
—
1.58
1.85
6.68
C10=
—
—
—
—
—
—
—
—
—
0.76
0.76
—
A10
—
—
—
—
—
—
—
—
—
7.88
7.88
3.84
C11(i, n, c)
—
—
—
—
—
—
—
—
—
0.64
0.54
1.91
C11=
—
—
—
—
—
—
—
—
—
0.63
0.83
—
A11
—
—
—
—
—
—
—
—
—
1.28
1.28
0.64
C12(i, n, c)
—
—
—
—
—
—
—
—
—
0.47
0.47
1.05
C12=
—
—
—
—
—
—
—
—
—
0.13
0.13
—
A12
—
—
—
—
—
—
—
—
—
0.89
0.89
0.45
C12(i, n, c)
—
—
—
—
—
—
—
—
—
0.02
0.02
0.02
C12=
—
—
—
—
—
—
—
—
—
—
—
—
A12
—
—
—
—
—
—
—
—
—
0.01
0.01
0.03
Oligomères
—
3.64
3.75
—
3.75
—
0.11
—
—
—
—
—
C8-C12
Oligomères
—
—
0.42
—
—
0.42
—
—
5.73
—
8.15
—
C12-C16
Alkylate
—
—
36.05
—
0.00
35.05
0.00
—
—
—
35.06
—
Dienes
—
—
—
—
—
—
—
—
—
0.03
0.03
—
HT oligomere
6.15
C12-C15
HT Alkylate
35.09
S(ppm pds)
0
0
0
0
0
0
0
0
70
12
11
1
N(ppm pds)
0
0
0
0
0
0
0
0
5
5
2
1
Total
18.00
73.48
136.36
24.12
76.75
36.47
2.27
—
5.73
25.35
68.55
66.51
[Key to Table B:]
TABLEAU “B” = TABLE “B”
HDT Effluent (après strippeur) (H2 feed non exemplifié) = HDT Effluent (after stripper)(H2 feed not shown)
Oligomères C8-C12 = C8-C12 Oligomers
Oligomères C12-C16 = C12-C16 Oligomers
[0107] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
[0108] The entire disclosures of all applications, patents and publications, cited herein and of corresponding French application No. 10/03559, filed Sep. 7, 2010, are incorporated by reference herein.
[0109] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
|
Process for the production of kerosene and diesel fuels from a so-called light cracked naphtha fraction, to which can be added any quantity of an LPG fraction and a BTX-rich aromatic fraction and which uses a stage for oligomerization of olefins and alkylation of olefins on the aromatic compounds.
| 2
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This application is a continuation of PCT/DK98/00516 filed Nov. 24, 1998, which claims benefit of 60/066,955 Nov. 26, 1997.
BACKGROUND OF THE INVENTION
The present invention relates to a method of temperature stabilizing an optical waveguide having a positive thermal optical path length expansion, in particular an optical fiber distributed feed back laser or a distributed Bragg reflector optical fiber laser.
The invention further relates to packaging of fiber lasers to reduce environmental influences, specifically such influences that act to reduce their performance. More specifically yet it relates to packaging techniques for fiber lasers that act to reduce frequency jitter and thus serve to create ultra narrow linewidth fiber lasers.
1. The Technical Field
It is well known in the field of optics that the performance of optical components depends on temperature via induced change in the optical path length. This dependence is due to a change of the refractive index (thermo-optic effect) and strain with temperature. Typically the thermo-optic effect yields the dominant contribution, and for most optical materials the thermo-optic coefficient is positive, i.e. the refractive index increases with increasing temperature. In silica this increase is of the order of +11·10 −6 /° C. For components based on UV-written Bragg gratings in fibers or planar waveguides this results in a temperature drift of the center wavelength of approximately 0.01 nm/° C. Although this figure is approximately 10 times better than what can be obtained in semiconductor based optical components it is still too high for a range of important applications. A notable example is found in optical communication systems based on dense wavelength division multiplexing where the channel spacing may be e.g. 100 GHz/0.8 nm and system administration requires a wavelength drift no higher than 0.001 nm/° C., i.e. 10 times lower than the intrinsic value for UV-written Bragg gratings in fibers or planar waveguides. It is thus necessary to stabilize the wavelength.
Various methods of stabilizing the wavelength have been suggested in the art. In one method the temperature of the device is stabilized actively, e.g. by measuring the device temperature and controlling it through a suitable feedback. The disadvantage of this method is that energy is consumed which will dissipate to the rest of the system.
In other methods the thermo-optic coefficient is manipulated to balance the thermal expansion, or vice versa.
Generally, the temperature dependency of the center wavelength λ of a Bragg grating in an optical fiber on temperature T is given by the following equation (1): 1 λ · λ T = 1 n · ∂ n ∂ T + α + 1 n · ∂ n ∂ ɛ · ∂ ɛ ∂ T + 1 Λ · ∂ Λ ∂ ɛ · ∂ ɛ ∂ T ( 1 )
where n, α and ε are the values for the refractive index, the thermal expansion and the strain. Λ is the Bragg grating period. The 1 st term including the thermo-optic coefficient ∂ n ∂ T
represents the change in refractive index with temperature, the 2 nd term represents the thermal expansion coefficient of the optical fiber, the 3 rd term including the elasto-optic coefficient ∂ n ∂ ɛ
represents the change in refractive index with strain, and the last term represents the change in the Bragg grating period with strain.
From this equation the following methods for temperature stabilization can be suggested:
The thermo-optic coefficient is changed to cancel out the contributions from thermal expansion and strain. In most fiber optical materials these two effects act together to increase the center wavelength with temperature. However, by tailoring the optical material to provide a negative thermo-optic coefficient, the positive contribution from the remaining terms is balanced to provide a stable center wavelength. The disadvantage of this method is that it is not easy to produce an optical material that provides a negative thermo-optic coefficient while maintaining other properties of the material.
Alternatively, the optical fiber can be mounted on a substrate under tension in such a way that its effective thermal expansion becomes negative to compensate the normally positive contribution from the thermo-optic and photo-elastic coefficients. When the optical fiber is mounted under tension the equation (1) reduces to equation (2): 1 λ · λ T = 1 n · ∂ n ∂ T + α s - 1 n · ∂ n ∂ ɛ · α f ( 2 )
where α s and α t are the thermal expansion coefficients of the substrate and the optical fiber, respectively. The thermal expansion coefficient of the substrate can be made negative by two methods.
In a method, the substrate can be composed of two materials of different length and having different positive thermal expansion coefficients. The shortest piece of material is made from the material with the highest positive thermal expansion coefficient, and the longest piece is made from the material with the lowest positive thermal expansion coefficient. By fixing one end of the short piece to one end of the long piece, the other ends of the two pieces will approach each other as the temperature is increased. This presumes that the lengths and material parameters are balanced correctly. When an optical fiber is mounted under tension between these ends its effective thermal expansion becomes negative. A disadvantage of this method is that careful adjustments of the lengths and thermal expansions of the two pieces are required in order to ensure that the negative effective thermal expansion compensates the positive thermo-optic coefficient.
In another method, the substrate consists of a single material with an intrinsic negative thermal expansion coefficient. An optical fiber is mounted under tension on the substrate. By selecting and/or designing a substrate material with a suitable value of the negative thermal expansion coefficient, the effective negative thermal expansion compensates the positive contribution from the thermo-optic and photo-elastic coefficients of the optical fiber. This method has the advantage that once the correct material composition has been provided no further adjustments are required in order to achieve a stable center wavelength. Thus, this method has the advantage of simplicity in the mounting process; the exact length of the fiber is not important. Furthermore, depending on the substrate material the mount can be made considerably more robust.
Other than a change in center wavelength, temperature variatons also influence the spectral linewidth of optical waveguide lasers, e.g. optical fiber lasers. The spectral linewidth of lasers, including single frequency rare earth doped fiber lasers, is ultimately determined by optical spontaneous emission noise, corresponding to the Shawlow-Townes limit. For rare earth doped fiber lasers this lies in the Hz to sub-Hz region. In practical implementations, however, environmental effects will affect the cavity stability and lead to linewidths well above the Shawlow-Townes limit. Thus, although long term drift in temperature can be compensated by specialised packaging techniques such as those described above, small and rapid temperature fluctuations cause jitter in the center frequency. The frequency shift due to the thermo-optic effect is approximately 10-5° C. −1 ·ν·ΔT Hz, where ν is the optical frequency and AT is the temperature change. As an example, if the frequency stability is required to be better than 1 MHz at 1550 nm, then the temperature fluctuations must be lower than 10 −3 ° C. This way temperature fluctuations in the environment result in an increase in the effective linewidth. Another important contribution to jitter and linewidth increase comes from acoustic vibrations which affect the cavity via the elasto-optic effect. To stabilise the laser frequency and reduce its linewidth it is thus necessary to protect it from environmental influences. In doing so it is necessary to consider both acoustic and temperature effects, and with regard to the latter it is specifically necessary to consider rapid variations in temperature.
2. Prior Art Disclosures
Chu et al. “Multilayer dielectric materials of SiO x /Ta 2 O 5 /SiO 2 for temperature-stable diode lasers”, Materials Chemistry and Physics, 42 (1995), pp. 214-216, discloses a SiO x /Ta 2 O 5 /SiO 2 sandwiched waveguide design with an effective negative thermo-optic coefficient applied to temperature stabilizing diode lasers. Nothing is disclosed about temperature stabilizing optical waveguides.
U.S. Pat. No. 5,042,898 discloses a method wherein two pieces of different materials with different thermal expansion coefficients and different length are arranged to balance the thermo-optic coefficient of an optical fiber. This method has the disadvantage of requiring full control over the process used to fix the optical fiber to the substrate. Furthermore, the fiber is mounted suspended in the mount, which results in acoustic coupling and makes the packaging fragile. Finally, quartz is an ideal material candidate for the longer piece since quartz both has a very low thermal expansion coefficient and is cheap. However, quartz is also a fragile material.
International application WO 97/26572 discloses a method using a single substrate material with an intrinsic negative thermal expansion coefficient and a particular class of substrate material with intrinsic negative thermal expansion coefficient, lithium-alumina-silica type ceramic glasses heat treated to develop the beta eucryptite crystal phase. Beta eucryptite being a ceramic glass is potentially fragile. It exhibits thermal expansion anisotropy which results in microcracks. Patent Abstract of Japan Vol. 97, No. 6, abstract of JP-A-9 055 556 discloses a method of protecting an optical fiber against damage by coating a looped optical fiber and then encasing it by producing a resin coated sheet containing it.
DISCLOSURE OF THE INVENTION
Object of the Invention
It is the object of the present invention to provide a method of temperature stabilizing an optical waveguide having positive thermal optical path length expansion. in particular an optical fiber distributed feed back laser, or a distibuted Bragg reflector optical fiber laser, and thus to provide a robust temperature stabilized optical waveguide.
It is a further the object of this invention to provide a method for packaging optical fiber lasers so that they are protected from rapid environmental fluctuations such as those arising from small and rapid temperature variations or acoustic vibrations, thus producing optical fiber lasers with ultra narrow spectral linewidths.
Solution According to the Invention
This object is achieved by providing a method of temperature stabilizing an optical waveguide having a positive thermal optical path length expansion.
According to the invention, the method comprises affixing the optical waveguide to at least two points of a composite material having a negative thermal expansion; said composite material comprising a resin matrix having embedded therein fibers having a negative thermal expansion coefficient, and optionally fibers having a positive thermal expansion coefficient.
It is obtained that the negative expanding composite material compensates the positive contribution to the change in optical path length from the thermo-optic and photo-elastic coefficients of the optical waveguide. Furthermore, the composite material is easy to fabricate and exhibits high mechanical strength. This is very useful in construction of mechanical parts whereby a robust temperature stabilized optical waveguide is provided.
Also in case of both fibers of negative and positive thermal expansion coefficients being present, the negative thermal expansion of the final composite material can be accurately adjusted to a desired value.
Also, strong reinforcing fibers e.g. glass fibers can further improve the mechanical properties.
Fibers having a negative thermal expansion coefficient are known in the art. Suitable fibers are disclosed in U.S. Pat. No. 4 436 689, the content of which is incorporated by reference.
The object of packaging optical fiber lasers to produce ultra narrow spectral linewidth sources is achieved as stated in claim 22 , namely by a method of packaging a fiber laser inside a matrix of curable viscous material that acts to dampen acoustic vibrations and temperature fluctuations.
This reduces the environmentally induced jitter of the laser and consequently reducing the spectral linewidth of the laser.
Preferred Embodiments
Fibers having a suitable negative thermal expansion coefficient can be used.
Generally, it is preferred that the fibers having a negative thermal expansion coefficient have a negative thermal expansion coefficient in the range from −5·10 −6 /° C. to −12·10 −6 /° C., preferably from −9·10 −6 /° C. to −12·10 −6 /° C.
The concentrations of fiber materials and resin matrix material are chosen to ensure that a composite material with the desired numerical value of the negative thermal expansion coefficient in order to compensate for the thermo-optic and elasto-optic coefficients is obtained.
It is preferred that the fibers are in an amount of 40 to 70% by volume.
The fiber materials may be present in any suitable form. Generally, it is preferred that the fibers are interwoven in the sence that fibers having different orientations are provided, which allows for longitudinal and transverse adjustment of the negative thermal expansion.
It is preferred that the composite material comprises 60% to 100% axially orientated fibers and 0% to 40% transversally orientated fibers.
Generally it is preferred that the fibers are arranged in a laminated structure of more than one layer whereby a particular good stability is obtained. Thus, for a given mechanical stability, a laminated structure including more layers allows for a higher percentage of fibers oriented axially whereby a numerically higher value of the negative thermal expansion coefficient is ensured. Other structures than laminated structures are possible.
Generally, fibers having a negative thermal expansion coefficient can be of any suitable material.
In preferred embodiments the fibers are fibers of materials selected from the group consisting of polyethylene, aramide, polyacrylate, polybenzobis-oxozole, polybenzobisthiazole, polyethylene naphthalene, polyethylene sulfide, polyamide-imide, polyether ether ketone, and polyethylene terephthaline, alone or in combination.
Polyethylene and aramide fibers are preferred. Particularly polyethylene fibers of the type Dyneema SK60, SK65, and SK66 and similar are preferred since these fibers have numerically high negative thermal expansion coefficients of about −12·10 −6 /° C.
The resin matrix is any suitable resin matrix in which the fibers can be embedded with a suitable adhesion. In preferred embodiments the resin is a thermo-curing resin. It is preferred that the resin matrix is a consolidated matrix of epoxy resins, unsaturated polyester resins, vinyl ether resins, urethane resins and urethane acrylate resins.
In a particularly preferred embodiment the fibers are of polyethylene, especially those of the type Dyneema SK60, SK65, and Dyneema SK66, and the resin is an epoxy resin which is found most useful for these fibers.
Generally, a composite material having a negative thermal expansion according to the invention exhibits any desired negative thermal expansion coefficient. For the temperature stabilization of optical fibers, e.g. optical fibers with Bragg grating, it is preferred that the composite material exhibits a negative thermal expansion coefficient in the range from −4·10 −6 /° C. to −10·10 −6 /° C., preferably in the range from −6·10 −6 /° C. to −9·10 −6 /° C.
Affixing of the optical waveguide to at least two points of the composite material having a negative thermal expansion can be established by any suitable method. E.g. affixing the optical waveguide to at least two points includes affixing the whole length of the optical waveguide.
In a preferred embodiment, a controlled tension is applied to the optical waveguide prior to affixing it to the composite material so that it is ensured that the thermal expansion of the waveguide is determined solely by the thermal expansion of the substrate and not by the thermal expansion of the waveguide itself over the temperature interval specified for the device.
Generally, any suitable optical waveguide can be temperature stabilized, e.g. single and multimode optical fibers.
In a preferred embodiment, the optical waveguide is an optical fiber, preferably a single mode fiber, the properties of axial symmetry and the flexibility of which make it particularly simple to temperature stabilize by affixing it to a composite material having a negative thermal expansion.
In another preferred embodiment, the optical waveguide is an optical fiber device, such as a reflection Bragg grating or notch filter, further preferably being polarization stable.
Particularly preferred optical waveguides include optical fiber lasers, preferably polarization stable, such as optical fiber distributed feed back lasers or distributed Bragg reflector optical fiber lasers, in particular rare earth doped optical fiber distributed feed back lasers having UV-induced Bragg gratings or rare earth doped distributed Bragg reflector optical fiber lasers also having UV-induced Bragg gratings. The rare earth dopants include the elements: La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu.
Particularly preferred are stable polarization mode optical fiber distributed feed back lasers or stable polarisation mode distributed Bragg reflector optical fiber lasers. Stable single polarization mode operation of these devices is necessary for a number of important applications including optical communication where external modulation requires the use of polarization sensitive devices such as lithium niobate modulators.
In a preferred embodiment the optical fiber laser is spliced to a polarization maintaining fiber, and the polarization axes of the optical fiber laser and the polarization maintaining fiber have been aligned by twisting the fiber axes relative to each other prior to affixing both the optical fiber laser and the polarization maintaining fiber to the composite material having negative thermal expansion whereby the polarization extinction is optimized at the other end of the polarization maintaining fiber so that there is one predominant linear polarization.
The composite material having negative thermal expansion can be in any suitable form. In a preferred embodiment the composite material having negative thermal expansion is in the form of a tube or coating on the optical waveguide having a positive thermal optical path length expansion, whereby the optical waveguide affixed onto the interior part thereof is protected from external chock. Such a temperature stabilized optical waveguide is more compact; in particular in the specific embodiment of a fiber coating.
In another preferred embodiment, the composite material having negative thermal expansion is in the form of a substrate for the optical waveguide having positive thermal optical path length expansion whereby particularly simple standardized forms of the composite material having negative thermal expansion can be used to affix the optical waveguide to be temperature stabilized.
The invention furthermore provides a temperature stable, packaged DFB or DBR fiber laser. The fiber laser is mounted on a substrate material as described above with an intrinsic negative thermal expansion coefficient matched to balance the change with temperature of the refractive index of the fiber laser fiber.
With respect to packaging of fiber lasers to dampen thermal and acoustic fluctuations and so reduce the spectral linewidth, it is preferred that the laser be fixed in a curable viscous substance.
It is preferred that the cured substance in which the fiber laser is embedded has a high loss coefficient/dissipation factor in a wide range of vibration frequencies, specifically at acoustic frequencies. It is further preferred that the cured substance in which the fiber laser is embedded has a low thermal diffusivity so that transient heat flow is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is described in more detail with reference being made to the drawings in which
FIG. 1 shows a UV-written grating, e.g. an optical distributed feed back fiber laser, mounted on a planar substrate made from a composite material with negative thermal expansion coefficient according to the invention;
FIG. 1 a shows a UV-written grating, e.g. an optical distributed feed back fiber laser or a distributed Bragg reflector optical fiber laser, mounted in between two planar substrates made from a composite material with negative thermal expansion coefficient according to the invention;
FIG. 1 b shows a UV-written grating, e.g. an optical distributed feed back fiber laser or a distributed Bragg reflector optical fiber laser, mounted on a planar substrate made from a composite material with negative thermal expansion coefficient according to the invention. Two pieces of quartz glass are mounted on the substrate;
FIG. 1 c shows a UV-written grating, e.g. an optical distributed feed back fiber laser or a distributed Bragg reflector optical fiber laser, mounted in between two planar substrates made from a composite material with negative thermal expansion coefficient according to the invention. Two pieces of quartz glass are mounted on the lower substrate;
FIG. 1 d shows a UV-written grating, e.g. an optical distributed feed back fiber laser or a distributed Bragg reflector optical fiber laser, mounted in between two planar substrates made from a composite material with negative thermal expansion coefficient according to the invention;
FIG. 1 e shows a UV-written grating, e.g. an optical distributed feed back fiber laser or a distributed Bragg reflector optical fiber laser, mounted in between two planar substrates made from a composite material with negative thermal expansion coefficient according to the invention. Two pieces of quartz glass are mounted on the lower substrate;
FIG. 2 shows a UV-written grating, e.g. an optical distributed feed back fiber laser, mounted in a substrate in the shape of a tube made from a composite material with a negative thermal expansion coefficient;
FIG. 3 shows a filter transmission characteristics measured with a Photonetics tunable external cavity semiconductor laser with a wavelength resolution of 1 μm;
FIG. 4 shows a graph showing the athermal performance of a temperature stabilized grating notch filter (squares; average value+0.0008 nm/° C.) compared to a non-stabilized grating notch filter (circles; average value+0.008 nm/° C.);
FIG. 5 shows a graph showing the laser spectrum as measured on an ANDO model AQ-6315A double monochromator optical spectrum analyzer with a wavelength resolution of 0.05 nm;
FIG. 6 shows a graph of the athermal performance of a temparature stabilized fiber DFB laser (squares; average value −0.0006 nm/° C.) compared to a non-stabilized fiber DFB laser (circles; average value+0.013 nm/° C.);
FIG. 7 shows a sketch of an optical fiber laser mounted in a package that acts to reduce jitter by encapsulating the laser in a substance with a high dissipation at acoustic frequencies and a low thermal diffusivity; and
FIG. 8 shows a comparison between the linewidth of a fiber laser mounted on a temperature compensating substrate and the fiber laser packaged in a package that acts to reduce jitter. It is seen that the linewidth is reduced from approximately 10 kHz to less than 1 kHz when measured on a selfheterodyne linewidth measuring setup;
DETAILED DESCRIPTION
Preparation of Composite Material
Suitable fibers for the composite material having negative thermal expansion according to the invention can be provided by methods known in the art.
U.S. Pat. No. 4,436,689 discloses a special type of ultra high molecular weight polyethylene (UHMW-PE) fiber. This fiber is used together with an epoxy resin to produce a negative thermal expansion composite material which is easy and cheap to manufacture and it can be machined in any size necessary. It is robust and resistant to chock and vibrations. The negative thermal expansion coefficient of the composite material can be tailored to a maximum numerical value that depends on the negative thermal expansion of the UHMW-PE fiber and the positive thermal expansion of the used epoxy resin.
The substrates are made of Dyneema SK60 fiber/epoxy resin laminate. Dyneema is the registered trademark of fibers made of polyethylene, via a gel spinning process in which a parallel macro-molecular orientation of 95% and a level of crystallization of up to 85% is achieved. The orientation is lost at temperatures above 144° C. The most important properties of the fiber are the negative expansion coefficient of −12·10 −6 ° C. (in the axial direction) and an E-modulus of 89 GPa (SK60) or 95 GPa (SK66). Similar products are commercially available e.g. products sold by Spectra Fibers.
The fibers are made in three grades: SK60, SK65 and SK66. SK60 is a general purpose grade used for e.g. ropes. SK65 has a higher axial tensile strength and modulus compared to SK60 and is therefore very useful in construction of mechanical parts. SK66 is specially designed for ballistic purposes. For the purpose of negative temperature coefficient substrates both SK60, SK65 and SK66 can be used. Until now, SK60 is preferred.
As a resin used in the laminate with the Dyneema fibers, any thermo-curing resin can be used which cures at temperatures of 140° C. or lower. Because of its mechanical properties epoxy resin is the most useful. The resin has a positive thermal expansion coefficient. To obtain improved adhesion to the resin, the SK60/SK65/SK66 fiber should be corona treated.
The negative thermal expansion coefficient of the composite substrates is determined by the volume ratio between fiber and resin as well as the orientation of the Dyneema fibers. The composite substrates are made so that is has a numerically large negative thermal expansion coefficient in one direction. For the composite substrates, a distribution of the fibers is chosen where 80% are oriented in one direction of the substrate and 20% perpendicular (90°) to this direction. In this way a relatively high negative temperature expansion coefficient in one direction (80% orientation) is created, whereas it still has sufficient mechanical stability in the other direction (20% orientation). A distribution of 85% and 15% is possible as well, resulting in an even higher negative thermal expansion with up to a maximum value of approximately −9·10 −6 /° C.
Composite materials based on Dyneema fibers and epoxy resin can be fabricated in several different ways:
a) A corona treated Dyneema fabric with the desired fiber distribution in the axial and transverse direction can be purchased and subsequently impregnated with resin and stacked to the desired thickness of the substrate (wet lay-up). The total thickness of the substrate depends on the number of layers of fiber fabric and the amount of resin. The minimum amount of resin is approximately 30% to 60% of the total volume. The resin cures at room temperature and can be post-cured at higher temperatures to enhance the high-temperature stability of the substrate, see e.g. example 1.
b) Unidirectional Dyneema/epoxy prepregs (UD-tape; corona impregnated and treated Dyneema fibers) are commercially available. Unidirectional means that all fibers are oriented along the same axis. The prepreg has a layer thickness of 0.25 mm. A substrate of larger thickness can be created by stacking the prepeg layers. In principle, every layer can be put in any desired orientation. The creation of the desired distribution of the fibers of 80% in the axial (0°) and 20% in the transverse direction (90°) can be achieved by changing the orientation of the layer of fibers relatively to the other layers. For example to create a substrate approximately 2.5 mm thick the following distribution of the layers can be used: first layer 0°, second layer 90°, third until the eight 0°, the ninth 90° and finally the tenth layer 0°. This substrate can be cured in an autoclave at temperatures up to 140° C. and pressures up to 6 bar. Because of the high pressure, a lower amount of resin can be used, which is approximately 40% of the volume. This will result in a substrate with a numerically higher negative thermal expansion coefficient. Post-curing conditions of the substrate depend on the curing temperature of the prepeg. If post-curing is necessary, the method discussed under a) can be used, but with a starting temperature 20° C. higher than the curing temperature of the resin.
c) A ready to use Dyneema/epoxy prepreg fabric can be purchased. This represents a combination of (a) and (b) with the desired distribution of fibers in the 0° and 90° orientation. The curing is as discussed under (b).
In addition, prepregs can be produced with different types of thermo curing resins.
Temperature Stabilization
FIG. 1 shows a sketch of an optical distributed feed back fiber laser 11 , 12 mounted on a planar substrate 13 made from a composite material with negative thermal expansion coefficient according to the invention which a grating 11 UV-written in a single mode optical fiber 12 which is affixed at two points 14 , 15 to the substrate. The grating is limited to the optical fiber. The exaggeration of the sketched grating into the substrate is only for illustration purposes.
FIG. 2 shows an optical distributed feed back fiber laser 11 , 12 , mounted in a substrate 13 in the shape of a tube made from a composite material with a negative thermal expansion coefficient simular to FIG. 1 .
In a preferred embodiment optical waveguides, such as UV-written Bragg gratings, are temperature stabilized by affixing the optical waveguide under controlled tension onto a composite material having a negative thermal expansion which balances the positive thermal optical path length expansion of the waveguide.
In another embodiment, optical fiber DFB lasers are temperature stabilized by using this composite material.
The composite material having a negative thermal expansion in a particularly preferred embodiment contains interwoven fibers, preferably polymer fibers, and epoxy. The negative thermal expansion property predominantly lies in the fiber and its structural alignment and/or its degree of crystallization. Traditional use of composite materials according to the present invention is e.g. as a construction material in the aeronautics industry e.g. for airplane parts.
Besides a high negative thermal expansion coefficient, the material qualities include high mechanical stability, ease of manufacture in large sizes and quantities, and low cost.
The negative expansion coefficient required is obtained from eq.2: α s = - 1 n · ∂ n ∂ T + 1 n · ∂ n ∂ ɛ · α f (eq. 3)
Typical values are: n = 1.45 ( quartz ) n / T = 11 · 10 - 6 / ° C . ( quartz ) 1 / n · n / ɛ = - 0.22 ( photo - elastic constant )
α f = 0.55 · 10 - 6 / ° C . ( quartz )
The required value for the composite material with negative thermal expansion coefficient therefore is approximately (depending on exact optical fiber parameters):
α s =−7.7·10 −6 /° C.
The specific examples of the composite material will produce tubes, coatings, or substrates with negative thermal expansion coefficient values of numerically up to approximately 9·10 −6 /° C.
A temperature stabilized optical waveguide is obtained by affixing the optical waveguide under controlled tension on the composite material. Specifically an optical fiber laser with Bragg grating is first decoated in a small—typically 3-4 mm long—region on both sides of the grating. A controlled tension is then applied to the optical fiber in an amount so that both the desired center wavelength is obtained and the fiber remains under positive tension over the entire temperature interval specified for its function. This interval may typically be between −40° C. and +70° C. I.e., if the optical fiber is affixed to the composite material at room temperature, say 20° C., then it should still be under tension when heated to 70° C. With a temperature sensitivity of the center wavelength of e.g. 0.01 nm/° C. in a free optical fiber, tension to the optical fiber must therefore be applied in such an amount that the center wavelength moves at least +0.50 nm. After tension is applied, the optical fiber is affixed to the composite material using e.g. an adhesive that hardens considerably during curing and is free from creep and hysteresis over the temperature interval specified for the optical fiber laser.
Packaging of Fiber Lasers to Reduce Spectral Linewidth
FIG. 7 shows a sketch of an optical fiber laser mounted in a package that acts to reduce thermal and acoustic fluctuations. The fiber laser 71 is first placed in a tube 72 of a suitable, stiff material such as metal or hard plastic. The tube has been preshaped to fit into a suitable size box 73 . The ends are sealed with a suitable glue 74 . The box is then half filled with the curable viscous substance 75 , which is subsequently allowed to cure. The laser 71 in tube 72 is placed on top of the cured viscous substance 75 , and the box filled with the same curable viscous substance 75 . When the substance has cured completely, the box 73 is closed with a lid (not shown in FIG. 7 ). Placing the laser 71 in a sealed tube 72 isolates the laser 71 from the viscous substance 75 . If placed directly in contact with the viscous substance 75 , local strain fields could adversely affect the performance of the laser 71 during curing. At the same time, any thermal fluctuations or acoustic vibrations originating from the surrounding environment 76 can only reach the laser 71 via the cured viscous substance 75 . If the material properties of this substance 75 are properly chosen it acts to dampen the jitter in the center frequency of the laser 71 arising from these effects.
The curable viscous substance 75 should have the following properties:
a high loss coefficient/dissipation factor in a wide range of vibration frequencies, specifically at acoustic frequencies.
a low thermal diffusivity so that transient heat flow is reduced.
Examples of such substances are silicone, sorbothane and other elastomers.
EXAMPLES
The invention is further illustrated by the following examples of preparation of the composite material having negative thermal expansion and of its application for temperature stabilizing optical waveguides.
Example 1
Fabrication of Composite Material
The preparation method (a) described above was chosen for the preparation of composite material. The Dyneema fiber fabric had a weight of 112.5 g/m 2 with 80% fiber in the axial and 20% fiber in the transversal direction. In total 10 layers of fabric were stacked and impregnated with LY5082/HY5083 epoxy resin from Ciba Geigy. This resin was cured at room temperature and was thermally stable up to 80° C. after 7 days of curing. After the first 24 hours of curing, vacuum was applied to improve adhesion between layers and to remove excess resin. The temperature at which the stability decreases (the glass transition temperature, T g ) was increased to 150° C. by post-curing the composite material. This post-curing is done in 5 steps:
a) heating up to 60° C. and maintaining this temperature for 2 hours
b) heating from 60° C. to 80° C. with steps of 1° C./minute, maintaining 80° C. for 2 hours
c) heating from 80° C. to 100° C. with steps of 1° C./minute, maintaining 100° C. for 2 hours
d) heating from 100° C. to 120° C. with steps of 1° C./minute, maintaining 120° C. for 2 hours
e) heating from 120° C. to 140° C. with steps of 1° C./minute, maintaining 140° C. for 2 hours
Hereafter, the composite material was cut with a diamond saw into the desired size. To avoid rough composite material edges, the material was clamped between two 5 mm thick wooden plates.
The composite material exhibited negative thermal expansion, high mechanical strength, and ease of manufacture in large sites and quantities.
Example 2
Temperature Stabilizing an Optical Fiber Bragg Grating Based Notch Filter
A notch filter was photo induced in a UV-sensitive fiber. The fiber was purchased from FIBERCORE, fiber type PS1500, fiber number HD451-00 with a cut off wavelength of 1495 nm, numerical aperture 0.13, and an outer diameter of 125 μm. The fiber was sufficiently UV-sensitive so that no hydrogen or deuterium loading was necessary for writing strong gratings. The fiber was de-coated over a length of 7 cm to allow the phase mask to rest only on the decoated fiber section. It was then placed in a set of V-grooves, tension was applied and the phase mask was placed on top of the decoated fiber section (5 cm long phase mask having a mask period of 1067 nm and zero-order suppression better than 2%, purchased from QPS, Canada, S/N 6020YA-15-50-3). The grating was photo induced in the optical fiber using a Lambda Physics model COMPEX 205 KrF excimer laser operating at 248 nm. The fiber was subjected to a total fluence of approximately 250 J/cm 2 which provided a 20 dB notch filter with a spectral characteristic as shown in FIG. 3 measured with an ANDO model AQ-6315A double monochromator optical spectrum analyzer with a wavelength resolution of 0.05 nm. The grating was stabilized by annealing at 200° C. for ½ hour. A temperature stabilized optical fiber was obtained by affixing the optical fiber under controlled tension corresponding to approximately 1 nm on the negative expansion coefficient substrate. Tension was first applied so that both the correct center wavelength was obtained and the fiber remained under positive tension over the temperature interval specified for the component. This interval is typically between −40° C. and +70° C. I.e., if the fiber is affixed at room temperature, say 20° C., then it should still be under tension when heated by 50° C. up to a temperature of 70° C. The center wavelength temperature sensitivity in a free optical fiber of this type is 0.0084 nm/° C. A tension corresponding to a center wavelength shift of at least 0.42 nm must thus be applied to the fiber. After tension was applied, the fiber was glued to the substrate using a glue that hardens considerably after curing and is free from creep and hysteresis over the temperature interval specified for the component. The temperature stablized grating had a center wavelength temperature sensitivity of 0.0008 nm/° C. This should be compared with a sensitivity of 0.0084 nm/° C. of the free grating in FIG. 4 . I.e. an improvement of approximately a factor 10 was obtained through temperature stabilization using the negative thermal expansion composite material according to the present invention.
Example 3
Temperature Stabilizing an Optical Fiber DFB Laser
An optical fiber laser has a phase shifted reflective grating in a UV-sensitive erbium doped fiber. The UV-sensitive erbium doped optical fiber was purchased from LUCENT Denmark, fiber ID 930810. The fiber has a core, a cladding and an intermediate region and a dopant concentration of 1.5·10 25 atoms m −3 in the core which has a diameter of 4 μm and a numerical aperture of 0.27. It has an outer diameter of 80 μm. The fiber has a photorefractive dopant profile comprising germanium in the intermediate region. The fiber is sufficiently UV-sensitive that no hydrogen or deuterium loading is necessary for writing strong gratings. The optical fiber laser was fabricated by splicing a 5 cm decoated length of the UV-sensitive erbium doped fiber to ordinary, non-doped fiber. It was then placed in a set of V-grooves, controlled tension was applied, and a phase mask was placed on top of the doped optical fiber section. The Bragg grating was photoinduced using a Lambda Physics model COMPEX 205 KrF excimer laser operating at 248 nm illuminating the 5 cm long phase mask having a mask period of 1067 nm and zero-order suppression better than 2% (S/N 6020YA-15-50-3, purchased from QPS, Canada). The optical fiber was subjected to a total fluence of approximately 1.2 kJ/cm 2 , creating a 99% reflective grating as measured on an ANDO model AQ-6315A double monochromator optical spectrum analyzer with a wavelength resolution of 0.05 nm. After grating growth, a phase shift was induced in the center part of the grating by subjecting only a 4 mm long section of the 50 mm long grating to UV exposure. Typically an additional fluence of 0.4 kJ/cm 2 was necessary to obtain lasing. The laser was stabilized by annealing at 200° C. for ½ hour. The laser spectrum shown in FIG. 5, was measured with an ANDO model AQ-6315A double monochromator optical spectrum analyzer with a wavelength resolution of 0.05 nm. The laser was monitored with a scanning Fabry-Perot interferometer with a free spectral range of 10 GHz, and exhibited single polarization and longitudinal mode operation. The laser had a side-mode suppression ratio better than 60 dB. A temperature stabilized optical fiber DFB laser was obtained by affixing the optical fiber DFB laser under controlled tension on a composite material having negative thermal expansion as prepared in Example 1. Controlled tension was first applied so that both the correct center wavelength was obtained and the optical fiber remained under positive tension over the temperature interval of typically between −40° C. and +70° C. I.e., if the optical fiber was affixed at room temperature, say 20° C., then it would still be under controlled tension when heated by 50° C. to 70° C. The center wavelength temperature sensitivity in a free optical fiber DFB laser is approximately 0.013 nm/° C. A tension corresponding a center wavelength shift of at least 0.65 nm must thus be applied to the optical fiber. After tension was applied, the fiber was glued to the composite material using a glue that hardens considerably after curing and is free from creep and hysteresis over the temperature interval typically between −40° C. and +70° C. In FIG. 6, the performance of the temperature stabilized optical fiber DFB laser, −0.0006 nm/° C. (average value over the interval 20-70° C.), was compared with that of the non-stablized optical fiber DFB laser, 0.013 nm/° C. (average value over the interval 20-90° C.) I.e. an improvement of more than a factor of 10 was obtained through temperature stabilization using the composite material having negative thermal expansion.
Example 4
Temperature Stabilizing an Optical Fiber DFB Laser Spliced to a Polarization Maintaining Fiber
An optical fiber laser fabricated as described in the previous example was spliced to a polarization maintaining (PM) fiber (3M elliptical cladding FS-CG-7421) using an Ericsson splicer FSU 925 PM-A. Although the splicer includes facilities to auto-splice PM fiber to PM fiber, the optical fiber laser fiber in itself is not PM. In order to optimize the polarization extinction at the output of the PM fiber it is necessary to align the polarization axis of the laser light to the polarization axis of the PM fiber. The axes must therefore be aligned manually. This can be done in two ways. Either the PM fiber is rotated manually prior to splicing while monitoring the polarization extinction at the output of the PM fiber. This method suffers from severe instabilities in the laser due to a varying and significant feedback to the laser cavity from the etalon created between the spliced fibers. Alternatively, the PM fiber is spliced without regard to the polarization axes. This facilitates the splicing procedure significantly. The polarization axes can be aligned subsequently during the mounting procedure by first affixing one end of the optical fiber laser and then rotating the PM optical fiber while monitoring the polarization extinction. When the best extinction is obtained, the PM optical fiber side of the fiber laser is also fixed.
Example 5
Alternative Ways to Mount the Optical Waveguide on a Temperature Compensating Substrate
Refering to FIG. 1 a , the optical waveguide 12 is mounted between two composite substrates 13 a , 13 b with a negative expansion coefficient. A V-groove 16 has been fabricated in the upper substrate 13 b so that there is no contact between the optical waveguide 12 and the upper substrate 13 b . In case the optical waveguide 12 is coated, for example with an acrylate or a polyimide coating, this coating should partly be removed on the places 14 , 15 where the optical waveguide is mounted to the lower composite substrate 13 a . Before the upper substrate 13 b is fixed on top of the lower substrate 13 a , the optical waveguide 12 is stressed under control to a wavelength which is slightly below the target center wavelength, preferably by using a microstage. At the two outer ends of the lower substrate 13 a two areas of adhesive 14 , 15 will be placed. The mounting is done with an adhesive that hardens considerably after curing and is free from creep and hysteresis over the temperature interval specified for the component. This is followed by the placement of the upper substrate 13 b . At the sides of the sandwiched substrates an area of adhesive will be attached. In order to press the upper substrate 13 b tightly to the lower substrate 13 a , a weight is placed on top of the sandwiched structure. Finally the optical waveguide 12 is stressed to the preferred center wavelength.
In a second method as illustrated in FIG. 1 b , two thin pieces of planar quartz glass 17 , 18 are mounted on the substrate 13 , in such a way that the upper surface of the quartz glass pieces 17 , 18 are in alignment with the upper surface of the composite substrate 13 . The pieces of quartz glass 17 , 18 can be mounted with any adhesive, preferably with an adhesive which has a thermal expansion coefficient in between the thermal expansion of quartz glass and that of the composite substrate 13 . The quartz glass pieces 17 , 18 should be mounted tightly against the edge of the substrate 13 , The optical waveguide 12 is then mounted with an adhesive as described in the first method (cf. FIG. 1 a , 14 , 15 ). Preferably the two areas of adhesive 14 , 15 are supported with pieces of quartz glass (not shown in FIG. 1 b ) on top of the bonds.
A third method is illustrated in FIG. 1 c . The optical waveguide 12 is mounted in between two composite substrates 13 a , 13 b as described in the first method (cf. FIG. 1 a ). The lower substrate 13 a is prepared with quartz glass pieces 17 , 18 as described in the second method (cf. FIG. 1 b ).
A fourth method is illustrated in FIG. 1 d . This method is nearly identical to the method shown in FIG. 1 a . The difference to the first method lies in the length of the upper substrate 13 b which is equal to the length of the lower substrate 13 a minus the length of the parts where the optical waveguide is mounted 14 , 15 . The upper substrate 13 b , which is performed with a ‘V-groove’ 16 , as described in the first method (cf. FIG. 1 a ), is mounted on the lower substrate 13 a using an adhesive which has a thermal expansion close to that of the composite substrates 13 a , 13 b . Preferably the assembled substrates should be annealed at a temperature between 40 and 100 degrees celcius for an appropriate length of time. Hereafter the optical waveguide 12 , for example an optical distributed feedback laser or a distributed Bragg reflector optical fiber laser, is pulled through the hole between the upper 13 b and the lower 13 a substrate. Controlled tension is then applied to the optical waveguide 12 to obtain the preferred center wavelength. The optical waveguide 12 is finally mounted with an adhesive as described in the first method (cf. FIG. 1 a ). Preferably the two areas of adhesive 14 , 15 are supported with pieces of quartz glass (not shown in FIG. 1 d ) on top of the bonds.
A fifth method is illustrated in FIG. 1 e . This method is nearly identical to the fourth method as described above. The lower substrate 13 a is prepared as described in the second method (cf. FIG. 1 b ). The optical waveguide 12 is mounted as described in the fourth method (cf. FIG. 1 d ).
Example 6
Postcuring of the Composite Material
The composite material is fabricated as described in example 1, after which it is post-annealed for an appropriate time at temperatures preferably between 40 and 120 degrees Celcius.
Example 7
Alternative Fiber Distribution with Aramide/Kevlar Fiber
The composite material is fabricated as described in example 1. The fabric is a combination of Dyneema fibers and kevlar fibers, e.g. in a distribution of 62% Dyneema and 28% kevlar in one direction and 10% Dyneema fiber in the perpendicular direction, with a total weight of 138 g/M 2 .
Example 8
Packaging of Fiber Lasers to Reduce Jitter and Obtain Narrow Spectral Linewidths
FIG. 7 shows a sketch of an optical fiber laser 71 mounted in a package that acts to reduce jitter. The box 73 was first half filled with silicone 75 , which was subsequently allowed to cure. The fiber laser 71 was then placed in a hard plastic tube 72 which had been preshaped to fit into the box 73 . The ends were sealed with glue 74 to avoid any silicone from entering the tube. The laser 71 in tube 72 was placed on top of the cured silicone 15 , and the box 73 filled with silicone 15 to cover the laser 71 completely. When the silicone 75 had cured completely, the box 73 was closed with a lid (not shown in FIG. 7 ).
FIG. 8 shows a comparison between the linewidth of a fiber laser mounted on a temperature compensating substrate 12 and the fiber laser 71 packaged as described in this example. It is seen that the linewidth 82 is reduced from approximately 10 kHz to a linewidth 81 of less than 1 kHz when measured on a selfheterodyne linewidth measuring setup. This setup included a fiber optic Mach-Zender interferometer with one arm employing a delay line of 30 km standard fiber and the other arm employing a fiber coupled acousto-optic modulator operating at 27.12 MHz and a fiber-optic polarisation controller for polarisation axis matching. The interfering signals were detected using a 125 MHz bandwidth PIN photodetector with amplifier and an HP 1.8 GHz spectrum analyser.
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A method of temperature stabilizing an optical waveguide ( 11, 12 ) having a positive thermal optical path length expansion affixes the optical waveguide to at least two points of a material having a negative thermal expansion and comprises the material of a composite of a resin matrix having embedded therein fibers having a negative thermal expansion coefficient and optionally fibers having a positive thermal expansion coefficient, whereby to provide the negative thermal expansion.
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FIELD OF THE INVENTION
This invention relates to the field of automated education, and particularly to computer-supervised apparatus for training technicians in procedures pertinent to the maintenance and testing of complex electrical and electronic systems.
BACKGROUND OF THE INVENTION
There is presently an increased development of large, multi-partite systems for performing complex overall functions. Within increased complexity of the equipment has also come increased complexity in the steps of maintaining, servicing, and trouble shooting the equipment, and hence increased difficulty in training personnel for these functions. The practice has developed of creating at a training center a "simulator," that is, a structure having the physical appearance of the equipment to be serviced, and programming a computer with the steps of maintenance procedures. The simulator need not be capable of actually performing the functions of the equipment it simulates, but simply presents outputs, at identifiable terminals, which are identical with those which would be supplied by the equipment itself. Also provided are probes simulating those of volt meters, signal generators, oscilloscopes, and similar test equipment.
It is desirable that the computer be able not only to program the desired actions of the person being trained, but also to determine whether the intended step is in fact being performed. Thus, if the maintenance step is to check the voltage at the input to a particular unit, it is necessary to determine that the trainee using the simulator has selected the probe of a volt meter, and has applied it to the correct terminal.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises apparatus, for use with a plurality of simulator probes and a plurality of simulator terminals, for determining which of the probes is being used, and which of the terminals it is being applied to.
Various advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, in which like reference numerals identify corresponding parts throughout the several views,
FIG. 1 is a block diagram of a system according to the invention,
FIG. 2 gives more details of a "probe read" circuit used in the system,
FIG. 3 gives more details of a "contact scan" circuit used in the system,
FIG. 4 shows a divider string used in the circuit of FIG. 3, and
FIG. 5 is one possible flow chart for firmware control of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, an automated training system according to the invention is shown to comprise a microprocessor 20 which addresses a contact scan circuit 22 through a cable 24, and which addresses a probe read circuit 26 through a cable 28 and receives data from circuit 26 through a cable 30, for comparison with correct data stored in the computer, or for display to enable human supervision of system operation.
Circuit 26 is connected to a set 32 of individual simulator probes 34, see FIG. 2, up to 16 in number, and circuit 22 is connected to a plurality 96 of individual simulator terminals 38, see FIG. 3, which are located at known physical sites in the simulator.
Turning now to FIG. 2, probe read circuit 26 is shown to comprise a 16:1 multiplexer 40 addressed by microprocessor 20 on cable 28 to connect any selected one of probes 34 to an output 42. The probes are also individually connected through separate resistors 44 of 600,000 ohms resistance to a common source 46 of -10 volts. Output 42 is connected through a sample and hold device 48, also addressed by the microprocessor, to an analog-to-digital converter 50, which supplies to the microprocessor, on cable 30, a digital signal indicative of the voltage on the selected probe.
FIG. 3 shows that contact scan unit 22 comprises a plurality of 1:16 multiplexers 60, six in number, addressed by microprocessor 20 on cable 24. Each multiplexer 60 has a connection to negative source 46, and has 16 individually selected outputs 62 connected to the non-inverting inputs of operational amplifiers 64 having a gain of 1, and also connected through pull-up resistors 66 of 100,000 ohms resistance to a common source 68 of +10 volts. The output of each amplifier 64 is fed back to the inverting input of the amplifier, and also is connected through a voltage divider 70 to positive source 68.
FIG. 4 showed that each divider 70 comprises a series string of resistors 72, 74, 76 interconnected at junction points 78, which are connected by conductors 80 to individual ones of terminals 38. Where terminals 38 are in a connector, the resistors may connect directly between connector terminals, thus eliminating separate conductors 80.
OPERATION
The operation of the apparatus is as follows. In an initial or stand-by mode, the microprocessor 20 holds the multiplexers of contact scan circuit 22 in a disabled mode, causing all the multiplexer outputs to be open circuited: this in turn permits the pull-up resistors 66 to cause all of the amplifier outputs to remain at +10 volts. Therefore, all the junction points 78 and all the terminals 38 are at +10 volts.
The program begins when microprocessor 20 addresses circuit 26 to sample probes 34 in sequence and convert their outputs. At this time the probes are not in use, but one or more may accidentally be in contact with ground, or perhaps with a trainees hand: any signals of this sort are disregarded. However, when the trainee touches any probe against any terminal, the probe comes to +10 volts. When the microprocessor reaches the address of whatever probe this may be, the address of that probe identifies to the microprocessor which probe is doing the contacting, and the positive 10 volt signal terminates the addressing of multiplexer 40 and puts the system into a second, contact scan mode.
In this second mode microprocessor 20 addresses multiplexers 60 to successively connect -10 volt source 46 to the voltage divider strings one after another, through a relatively low impedance, so that in succession the voltage dividers have 20 volts impressed across them. In each string, resistors 74 are all of the same value, resistor 72 is of half that value, and resistor 76 is of one and a half times that value, so that the voltages on terminals 78 range from -9.375 volts to +8.125 volts in steps of 1.250 volts.
When the microprocessor addresses the voltage divider string which includes the terminal engaged by the probe, the voltage sensed by the probe changes from +10 volts to some other voltage determined by which terminal is being engaged. This signal is fed back through converter 50 to the computer, where it may be compared to a program signal.
It will now be evident that the address at which multiplexer 40 stops identifies which simulator probe the trainee has selected, and that the address of multiplexer 60 at which the probe signal changes its value, and the new value itself, identify which terminal of the simulator the trainee is contacting. Further or corrective procedures may follow as is desired in teaching systems of this type.
Numerous characteristics and advantages of the invention have been set forth in.the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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The method of determining which of several simulator probes in an automated training installation is engaging one of several simulator terminals, which method comprises energizing the terminals electrically and observing the probes individually to determine which has been electrically energized by engagement with a terminal.
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FIELD OF THE INVENTION
The present invention relates generally to an acupuncture device, and more particularly, to an apparatus for generating electromagnetic pulses for application to acupuncture points on a body and the method for performing the same.
BACKGROUND OF THE PRIOR ART
The science of acupuncture has been practiced in China for many centuries. However, only recently has it attracted the interest of the western world, and thus, only recently has it been exposed to the scientific methods of the west.
As originally practiced, acupuncture treatment required that acupuncture needles comprising thin stainless steel needles approximately 5 inches long, be inserted into a patient's body at very precise points, called acupuncture points, or trigger points, for stimulating certain nerve lines called meridians. Different symptoms can be treated by selectively stimulating specific acupuncture points.
Although it is known that the Chinese have used electricity as a means of stimulation of the acupuncture points, in addition to simply inserting acupuncture needles in the proper sites, little is known about the early Chinese electrical stimulators, since there appears to be no publications on the subject, and further, it has been extremely difficult to remove such devices from China up to the present time. However, from the limited information available, it is known that the Chinese electrical devices primarily use a d.c. current source which has a tendency to electrically shock the patient. Moreover, because of the Chinese intuitive approach to acupuncture treatment, no metering systems have been used in conjunction with the equipment.
With the recent interest in acupuncture treatment in the west, a few electrical devices for acupuncture have appeared in the western markets. Most of such devices such as that disclosed in Lock, U.S. Pat. No. 3,900,020, Blanchard, U.S. Pat. No. 3,897,789, McCall, U.S. Pat. No. 4,319,584, Eugenio, U.S. Pat. No. 4,052,978 and Wing, U.S. Pat. No. 4,180,079, all relate to instruments for acupuncture treatment in which actual low level electric current is directly applied, continuously or in pulse form, to a patient, particularly at acupuncture points on a patient's body.
A number of other patents, such as Brown, U.S. Pat. No. 435,376, Neel, U.S. Pat. No. 1,120,964, Elmi, U.S. Pat. No. 3,337,776 and Gorden et al, U.S. Pat. No. 3,664,327 disclose, the general application of electromagnetic radiation to a body for various medical purposes. MacLean, U.S. Pat. No. 3,658,051 discloses the application of a relatively strong electromagnetic pulse to ailing parts of a body, each pulse having a duration of approximately a quarter second, with a frequency of approximately two pulses per second, such pulsating magnetic field being applied to such body for a period of a few minutes. These pulses are administered to certain specified sites, although there is no suggestion that the electromagnetic radiation be applied to acupuncture points or any other nerves in a body.
Basically, the ancient Chinese art of acupuncture works on the theory and principal that the placement and positioning of acupuncture needles in specified locations on the body blocks the path of neurological transmission of pain impulses thereby relieving a patient of certain pains. In addition, the placement of such needles in acupuncture points or trigger points can be used to initiate certain nerve impulses thereby ennervating various internal glands and organs to activation. As a second step to the approach of applying needles to the specified acupuncture points, a variation which has recently been used, and is described in some of the patents listed above, is the use of acupuncture needles providing a low level electrical stimulation at the acupuncture points thereby, in theory, providing an accentuated stimulus at said points.
Another method for treatment of certain muscle and joint related bodily pains, which method is well-known in the western world, comprises application of heat such as using a heating pad or whirlpool of hot or warm water to the joints. However, there has not heretofore been a combination of acupuncture and such western medical techniques such as heating pads or physical therapy to benefit patients having various aches, pains and the like such as those caused by arthritis, rheumatism, osteoarthritis, gout, migraine, gonarthritis, newralgia, lumbargo and similar muscle and joint problems. Moreover, some persons, particularly westerners, have been somewhat reluctant to undergo acupuncture treatment as a result of their fear of the acupuncture needles. In addition, the use of acupuncture needles which are inserted into a patient's body carry a risk of transmitting disease from one patient to another, since the needles are typically reused. The present invention seeks to overcome some of the problems with the old acupuncture to provide such treatment in a manner somewhat more acceptable to westerners, and which provides a broader range of treatment for many ailments.
SUMMARY OF THE INVENTION
The present invention comprises a device which simulates an acupuncture needle without any insertion of such needle into a patient. In place of the needle, an electromagnetic pulse having a frequency of 2 to 16 hertz, which electromagnetic pulse is applied to an acupuncture point for about 20 to 30 minutes in the same way a needle is used in conventional acupuncture therapy.
In addition to the benefits provided by the application of the electromagnetic energy to the acupuncture point, the invention also provides electromagnetic stimulation of a muscle at a proper rate which has been shown here to relieve muscle tension and reduce the general aches and pains associated therewith.
The present invention comprises an oscillating means for electronically oscillating an electrical signal in the range of 2 to 16 hertz, a power supply for supplying an electric current to said oscillating means, and an electromagnetic producer means connected thereto for producing low power electromagnetic radiation pulses. The device also contains two regulators, one regulator being connected to the oscillator means for increasing the oscillation of the electrical signal within the range of 2 hertz to 16 hertz, the frequency thereof being proportional to the depth of penetration of the electromagnetic radiation pulses. A second regulator controls the strength of the electromagnetic radiation, by controlling the voltage applied to the pulse emitter, preferably in the range of 0.0 to 0.032 Joules per second. The electromagnetic producer means comprises a pair of coils in series, each coil having windings in one direction, and then in the opposite direction with a ratio of the number of turns in one direction to the opposite direction being approximately 10 to 1. One of the coils is oriented with magnetic north and the second coil is oriented with magnetic south facing in the same direction. The small number of windings in the opposite direction on each coil directs the magnetic field outward along the axis of the coil.
In the operation of the present invention, the device is placed at an acupuncture points, which such points are well known in the art. The device is activated and the frequency of the electromagnetic pulse is set in accordance with the treating physicians determination as to the required depth of penetration, as such doctor would similarly determine the depth to which an acupuncture needle should be inserted. Similarly, the desired amount of energy is set in accordance with a doctor's determination of the desired intensity of electromagnetic radiation.
The stimulation of the acupuncture point when the pulses reach the acupuncture point for 20 to 30 minutes blocks the nerve impulses through that area thereby preventing pains causes by such diseases as arthritis, rheumatism, osteoarthritis, gaut, migraine, gonarthritis, neuralgia, lombargo and similar such disorders. Moreover, since there is no actual needle penetration, patients who are generally afraid of the sight of such needles, and more importantly the penetration of such needles into their body, particularly in consideration of the fact that generally acupuncture needles are approximately five inches long, are relieved from the anxiety caused thereby.
In addition to the acupuncture effect of the present invention, the application of electromagnetic radiation causes a stimulation of the muscle to which such electromagnetic radiation is applied at a preselected frequency to mildly and gently heat such muscle as a result of the application of electromagnetic radiation thereby relaxing the muscle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top partially cut-away view of the hand unit of the present invention.
FIG. 2 is a side partially cut-away view of the hand unit of the present invention taken through lines 2--2 of FIG. 1.
FIG. 3 is an end sectional view of the present invention taken through lines 3--3 of FIG. 2.
FIG. 4 is schematic diagram of the present invention.
FIG. 5 is a schematic drawing of one coil.
DETAILED DESCRIPTION
Now referring to FIGS. 1 through 3, a top view and side and end views partially cut away of the hand unit containing the transducers assembly may be seen. The hand unit is comprised of a molded plastic housing 20 supporting a pair of transducers 22 and 24 and supporting an energy level control 26. The transducers 22 and 24 are nickel plated brass members each comprised of an upper cylindrical section having integral therewith at the lower end thereof a shaped pole-like member having a diameter of approximately one-half inch. These members are encapsulated in a resin 28 with a center line spacing of preferably approximately 11/16th of an inch so as to project downward from the housing for convenient positioning against parts of the body to be treated.
Each of these two transducers have windings thereon to provide a magnetic field aligned with the transducer in response to the current in the coil thereon. The preferred embodiment the coils on each of the two transducers are connected in series with the two windings being connected with an opposite winding sense so as to encourage at least part of the magnetic field generated by each to link the other. The windings, however, are of an unequal number of turns, in the preferred embodiment one winding being one hundred turns and the other winding being ten turns of magnet wire. The unequal number of turns help provide the desired field shape for penetration purposes by eliminating the extent of the linkage of the field from one transducer to the other which would tend to confine the field to the transducers without significant body penetration.
FIG. 5 is a schematic drawing of one embodiment of a transducer coil 90. As illustrated, there are 9 windings 91 in one direction D1 and one winding 92 in the opposite direction D2. When an electric curing is passed through the coil, the windings 91 create a magnetic field forming a North pole N1 and a South pole S1, and winding 92 creates a magnetic field having a North pole N2 and South pole S2 in the opposing direction along the same axis. This configuration creates a magnetic field with the desired field shape. As one skilled in the art will recognize, any number of windings having a similar 10:1 ratio will create a similarly shaped magnetic field.
The two coils 30 and 32 connected together as hereinbefore described are in turn connected in series with a potentiometer supported on housing 20 transforming the energy level control 26 shown in the figures, with the overall series combination being connected to a pair of leads 34 through the end of housing 20 for connection to the power source shown in detail in FIG. 4. The power source is a separate unit designed either for battery operation as in the embodiment shown or for operation from normal AC power. The circuit shown is driven by battery 36 coupled in circuit by on/off switch 38. With switch 38 on, power is applied to the light emitting diode 40 to indicate the on condition, the current through the diode being limited by current limiting resistor 42. Power is also applied to an oscillator comprising in part the transistor generally indicated by the numeral 44 and the primary of the transformer generally indicated by numeral 46. In particular, when the base of transister 44 has a voltage of at least 7/10ths of a volt above that of the emitter thereof, the transistor will be turned on whereby power is delivered from the battery through resistor 48 to line 50 thereby providing a voltage drive on the lower part 52 of the primary of the coil. The changes in the flux in the coil of the transformer during operation of the oscillator generate a feedback voltage in the upper part 54 of the transformer primary to provide a feedback to the base of transistor 44, to control, the on/off condition thereof depending upon the phase shift resulting from the combination of capacitor 56 and resistor 58. Switch 60 allows for the selection of either of resistors 62 and 64 thereby changing the phase of the feedback and adjusting the frequency accordingly. In the preferred embodiment these resistors are selected to provide a selection of frequencies ranging from a low of 2 Hertz to a high of 16 Hertz. It is believed that the frequency essentially affects the penetration level to provide for the stimulation of the desired acupuncture point. During the transistor off periods, capacitor 66 completes the oscillator circuit with coil 52, with capacitor 68 being charged through resistor 48 during the transistor off periods to provide some storage of charge to aid in the supply of power to the transistor when the transistor is turned on again.
The secondary period of transformer 46 in the embodiment shown also has three leads thereon, specifically leads 70, 72 and 74. Lead 70 effectively serves as a common with lead 72 and 74 providing two different AC voltage levels with respect thereto. In that regard, the circuit shown in FIG. 4 provides two output energy levels depending on whether leads 34 of the hand unit are plugged into terminal lines 76 or 78 of the circuit of FIG. 4. Referring for the moment to the circuit connected to lead 74 the secondary, it will be noted that diode 80 and capacitor 82 are connected in series between the effective common lead 70 and lead 74. Thus, during the part of the cycle of the oscillator wherein the voltage on lead 74 is negative with respect to lead 70, capacitor 82 will be charged through diode 80 with the relatively low voltage drop across diode 80 during such charging appearing as the output 76 of the circuit. During the opposite half cycle, however, diode 80 is back biased so that current will flow through potentiometer 84 and meter 86, through the transducers and then back through capacitor 82 tending to discharge the capacitor and recharge it with opposite polarity. In that regard, meter 86 provides a quantitative measure of the energy being delivered with potentiometer 84 providing an adjustment of that energy in the same manner as the energy level control 26 on the hand unit itself. Thus, the circuit delivers to the hand unit a train of current pulses adjustable in level both at the power supply and at the hand unit, and at an adjustable frequency, the circuit delivered to lead 72 of the transformer secondary to provide output 78 functions in the same manner as that for providing output 76 though being connected to a lower voltage tap on the secondary will deliver a lower power range of current pulses to the hand unit. Of course, these circuits may readily be replicated to provide power to additional transducer assemblies as desired. Obviously, of course, the use of adjustment 84 and/or meter 86 is not essential to the operation of the system and may be eliminated if cost is an overriding factor.
In another embodiment of the present invention, a base unit is provided with transformer and oscillation circuitry, and control systems for regulating the frequency and intensity of the electromagnetic pulses, with only transducers disposed remote from the base unit and electrically connected thereto. A plurality of pairs of transducers are provided for placement on a plurality of acupuncture points simultaneously.
METHOD OF USE
To use the above-described apparatus, the user must first be skilled, or informed, in the art of acupuncture so that he can provide to a patient electromagnetic stimulation at the acupuncture points, also known as trigger points. In this connection, a number of books have been written and are available in the prior art depicting the various acupuncture points, which have been known for thousands of years by the ancient Chinese as a standard part of their regular medical practice. In theory, acupuncture points are emperically and philosophically derived specified sites on a body which when perturbed, by the insertion of a specialized stainless steel acupuncture needle or otherwise, would modify the flow of nerve impulses through the body so as to block nerve impulses from certain areas of a patient's body which are in pain or are otherwise ailing. For example, for the treatment of abdominal pain, it has been long recognized that the insertion of a needle approximately three inches below the kneecap and one inch lateral to the tibia, and the insertion of a second needle approximately four inches above the navel along the midline of the abdominal surface can be employed to relieve such pain. As another example, for the treatment of asthma, needles have routinely been inserted in four positions, namely, one needle applied approximately four inches above the navel along the midline of the abdominal surface, a second needle being applied approximately one inch lateral to the lower end of the seventh cervical disk, a third needle applied to approximately 1.5 inches lateral to the lower end of the third thoracic disk, and a fourth needle applied approximately three inches lateral to the lower end of the fourth thoracic disk. Many other treatments have been worked out for the various ailments as a result of thousands of years of medical research by the ancient Chinese performing empirical studies on the effect of acupuncture. However, as described above, now that the ancient Chinese art of acupuncture has come to the western world and is being practiced here, a number of changes, adaptations and modifications are being made to the ancient techniques, in part to make them more acceptable to western society. One problem, in particular, is the fact that many westerners look with unfavorable consideration upon the placement in, or near their body, of sharp and stainless steel needles approximately five inches long. Thus, the present invention provides a noninvasive method of obtaining the same effect as the ancient art of Chinese acupuncture, without any of the disadvantages with respect to the insertion of needles in the patient. In combination with this benefit, is the general benefit, which has been found to occur when the human body is subject to electromagnetic radiation. Nevertheless, none of the above-noted references in any suggest or disclose the application of low frequency, low power electromagnetic pulses applied directly to acupuncture sites for the purpose of stimulating muscle contractions thereby relaxing the muscles as one would do for physical therapy.
With this in mind, the doctor, or acupuncturist, first locates the acupuncture point or points, precisely, to which the electromagnetic radiation is to applied. Once these acupuncture points are located, the doctor must make a determination with respect to the required depth of penetration of the electromagnetic pulse and the intensity thereof. The depth of penetration is determined by a skilled acupuncturist depending upon the desired intensity of reaction for a particular patient in the same way as such acupuncturist would determine the depth to which a needle should be placed in the conventional use of an acupuncture needle. Thus, this determination can be made and is well within the skill of one of ordinary skill in the art of acupuncture. In general, the depth of penetration is selected by a determination of the desired intensity of the patient's reaction to the acupuncture treatment. For example, if a joint is particularly stiff or sore, vigorous or strong stimulation resulting in a large movement of the joint would generally not be beneficial to a patient, but instead, a milder treatment (i.e. less penetrating pulse) would typically be used to avoid excess trauma to the patient. Of course, the actual extent and desirability of deeper penetration would be within the discretion of the treating physician based upon a determination made with the consideration of a large number of medical facts relating to the ailment as well as the patient. The treatment of a patient with higher frequency electromagnetic radiation causes a deeper penetration than lower frequency pulses. In addition to the frequency adjustment, which can either be stepped, or continuous, depending upon the particular arrangement of the oscillator circuit, in the range of 2 to 16 hertz, the intensity of the electromagnetic radiation can also be controlled by a coincident increase or decrease of the voltage of the device. The use of greater intensity electromagnetic energy produce a stronger, faster reaction to the treatment, which can also be gauged by a skilled acupuncturist.
After the acupuncture points are selected in accordance with general acupuncture techniques which are known in the art, in accordance with the problem or pain of which the patient complains, the machine is turned on and the transducers are placed against the preselected acupuncture point. The energy control, which controls the voltage which, in turn, controls the strength of the electromagnetic field, is gradually increased so that the user can feel the electromagnetic pulses pulsing at the acupuncture site point. This energy control level is increased to a desired level. The acupuncture point is then pulsed for approximately 20 to 30 minutes, and sometimes as long as 40 minutes to provide a single acupuncture treatment. Each such treatment is repeated as often as necessary until the patient achieves the desired relief.
CASE STUDIES
A hundred and fifty case experiences were obtained by a licensed, skilled acupuncturist physician with the following etiology and results. The patients were broken down into four groups based upon their particular ailments. Group A, consisting of 60 patients, had myositis pain syndrome. Group B, consisting of 50 patients, complained of tension headache, sinus headache and stiff neck. Group C, consisting of 30 patients, complained of stomach pain, either chronic or spasm. Group D, consisting of 10 patients, complained of dizziness and did not exhibit any clear ediology.
Of the Group A patients, 95 percent of the patients were symptom free after 25 to 30 minute treatments three times per week for one month. Of the Group B patients, 85 to 90 percent experienced instant relief or marked improvement in their symptoms with 30 minute treatments, three times per week for one month. Of the Group C patients, all patients enjoyed relief of the exhibited pain after usually 30 minutes of treatment, three times per week. Of the Group D patients, 70 to 80 percent of the patients complained of fewer dizzy spells as a result of 40 minutes of treatment three times per week for two months.
Thus it can be seen that the present invention appears to have the same affect as other forms of acupuncture treatment using needles without any of the concommitent pain or anxiety resulting from the placement of needles in a body. Applicant has disclosed herein the preferred embodiment of the present invention; however, it will be apparent to one of ordinary skill in the art that many modifications and substitutions of the various components described herein can be obtained without departing from the spirit and scope of the present invention. Therefore, Applicant's invention is limited solely by the scope of the claims, and the reasonable equivalents thereof, and not by the detailed description as specified herein.
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An electromagnetic energy pulse emitter is disclosed for applying electromagnetic pulses in the frequency range of 2 to 16 hertz to acupuncture points on a patient. The device comprises a transformer and an oscillator for producing electrical pulses of the appropriate frequency and a pair of transducers to produce an electromagnetic pulse responsive to the electrical pulses. Each transducer comprises a primary coil and a secondary coil electrically connected in series thereto, and aligned therewith along the central axis thereof to produce a relatively linear pulse directed along the axis thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a body surfing suit.
More particularly, the present invention relates to a buoyant body surfing suit that contains means for increasing the buoyancy of the body surfer.
2. Description of the Prior Art
Numerous innovations for body surfing suits have been provided in the prior art that are adapted to be used. Even though these innovations may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described.
For example, U.S. Pat. No. 4,397,636 to Ganshaw teaches a long sleeve shirt with buoyant forearm pads. The buoyant forearm pads are located on the underneath part of the forearm. Additionally, the shirt clings to the body surfer's body only when it is wet. Since the shirt has long sleeves, elastic wrist cuffs are provided and used as seals. An elastic waist band is also provided and used as a seal.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a buoyant body surfing suit that avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an air filled or floatation foam filled garment that increases the gross buoyancy of the human body so that the body surfer can skim across the water powered by only the wave energy.
Two types of suits are taught by the present invention. One is for surfing on large, long, and rolling waves, which are always further out from the shore and the other is for surfing on shorter and faster waves, which break close to shore.
In keeping with these objects, and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a buoyant body surfing suit for a body surfer having knees, comprising, an upper portion together with a pair of short sleeves, a collar, a front, and a rear being a homogeneous piece of resilient material, and a lower portion together with the upper portion and a front being a homogeneous piece of resilient material, the lower portion together with a pair of legs being a homogeneous piece of resilient material that ends below the knees of the body surfer.
When the buoyant body surfing suit is designed in accordance with the present invention, due to the collar and the pair of short sleeves water is prevented from entering under the buoyant body surfing suit and slow down the speed of the body surfer.
In accordance with another feature of the present invention, the upper portion, the pair of short sleeves, the collar, the lower portion, and the pair of legs are one homogeneous piece of neoprene which has a very slick surface that reduces drag and contains a nylon liner for comfort.
Another feature of the present invention is that it further comprises a plurality of buoyancy increasing means disposed on the front of the upper portion and the lower portion of the buoyant body surfing suit.
Yet another feature of the present invention is that the plurality of buoyancy increasing means include a chest pad, a plurality of channels, and optional back pads, that are filled with a material taken from the group consisting of floatation foam and air.
Still another feature of the present invention is that it further comprises a zipper disposed on the rear of the buoyant body surfing suit so that a body surfer can quickly and easily put on and take off the buoyant body surfing suit.
The novel features which are considered 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 the specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front perspective view of the buoyant body surfing suit of the present invention wherein the suit is used for body surfing on shorter and faster waves that break close to shore;
FIG. 2 is a rear perspective view of the buoyant body surfing suit of the present invention, shown in FIG. 1;
FIG. 3 is a front oriented perspective view of the upper portion of the buoyant body surfing suit of the present invention, shown in FIG. 1;
FIG. 4 is a rear perspective view of the buoyant body surfing suit of the present invention with the optional back pads being used for body surfing on the back;
FIG. 5 is a front perspective view of the first alternate embodiment of the buoyant body surfing suit of the present invention wherein the suit is used for body surfing on large, long, and rolling waves which are further out from shore.
FIG. 6 is a perspective view of the second alternate embodiment of the present invention wherein the channels are affixed to bases which are then attached to the buoyant body surfing suit of the present invention;
FIG. 7 is a cross-sectional perspective view of the channels of the buoyant body surfing suit of the present invention and which are filled with air; and
FIG. 8 is a cross-sectional perspective view of the channels of the buoyant body surfing suit of the present invention and which are filled with floatation foam.
LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWING
10-- buoyant body surfing suit of the present invention
12-- slick surface 12
14-- nylon liner
16-- collar of the buoyant body surfing suit 10
18-- short sleeve of the buoyant body surfing suit 10
20-- short sleeve of the buoyant body surfing suit 10
22-- leg of the buoyant body surfing suit 10
24-- leg of the buoyant body surfing suit 10
26-- knee of the buoyant body surfing suit 10
28-- knee of the buoyant body surfing suit 10
30-- front of the buoyant body surfing suit 10
32-- chest pad of the buoyant body surfing suit 10
34-- chest of the buoyant body surfing suit 10
36-- floatation foam
38-- channel
40-- channel
42-- thigh pad
43-- thigh area of the buoyant body surfing suit 10
44-- thigh pad
45-- thigh area of the buoyant body surfing suit 10
46-- channel
48-- channel
50-- channel
52-- zipper of the buoyant body surfing suit 10
54-- rear side of the buoyant body surfing suit 10
10'-- buoyant body surfing suit of the present invention
12'-- slick surface 12
14'-- nylon liner
16'-- collar of the buoyant body surfing suit 10'
18'-- short sleeve of the buoyant body surfing suit 10'
20'-- short sleeve of the buoyant body surfing suit 10'
22'-- leg of the buoyant body surfing suit 10'
24'-- leg of the buoyant body surfing suit 10'
26'-- knee of the buoyant body surfing suit 10'
28'-- knee of the buoyant body surfing suit 10'
30'-- front of the buoyant body surfing suit 10'
32'-- five channels of the buoyant body surfing suit 10'
34'-- chest of the buoyant body surfing suit 10'
36'-- floatation foam
38'-- channel
40'-- channel
42'-- thigh pad
43'-- thigh area of the buoyant body surfing suit 10'
44'-- thigh pad
45'-- thigh area of the buoyant body surfing suit 10'
46'-- channel
48'-- channel
50'-- channel
52'-- zipper of the buoyant body surfing suit 10'
54'-- rear side of the buoyant body surfing suit 10'
10''-- buoyant body surfing suit of the present invention
32''-- channels of the buoyant body surfing suit 10'
38''-- channel of the buoyant body surfing suit 10''
46''-- channel
48''-- channel
50''-- channel
52''-- zipper of the buoyant body surfing suit 10'
54''-- rear side of the buoyant body surfing suit 10'
56''-- base
58''-- base
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 through 3, the buoyant body surfing suit 10 of the present invention is shown in the configuration for use on shorter and faster waves that break close to the shore.
The buoyant body surfing suit 10 is made of neoprene which has a very slick surface 12 for reducing drag, and a nylon liner 14 for comfort.
The neoprene material, of which the buoyant body surfing suit 10 is made from, adds to the buoyancy of the buoyant body surfing suit 10. Depending on the neoprene thickness, a body surfer could body surf in colder, East Coast water, for longer periods of time, since the neoprene suit 10 keeps the body temperature elevated. Since the buoyant body surfing suit 10 has glued and stitched seams, it is impossible for water to enter the buoyant body surfing suit 10.
The buoyant body surfing suit 10 consists basically of a collar 16, a pair of short sleeves 18 and 20, and a pair of legs 22 and 24 that end below the knees 26 and 28.
The buoyant body surfing suit 10 requires the use of the collar 16 and the pair of short sleeves 18 and 20 so that water is prevented from entering under the buoyant body surfing suit 10 and cause the speed of the surfer to be lowered.
A plurality of buoyancy increasing means are disposed on the front 30 of the buoyant body surfing suit 10, as can best be seen in FIG. 1.
A chest pad 32 is disposed on the chest 34 of the buoyant body surfing suit 10 and which is filled with a floatation foam 36. On either side of the chest pad 32, are disposed one of a pair of channels 38 and 40 which are filled with the floatation foam 36 and which can best be seen in FIG. 3.
Thigh pads 42 and 44, as shown in FIG. 1, are disposed on the front thigh areas 43 and 45 of the buoyant body surfing suit 10. Each of the thigh pads 42 and 44 contain three channels 46, 48, and 50, and with each channel being filled with the floatation foam 36.
The rear side 54 of the buoyant body surfing suit 10, as shown in FIG. 2, contains a zipper 52 which aids in the putting on and the taking off of the buoyant body surfing suit 10.
The floatation foam 36 is made of enselite that is approximately 1" thick.
Referring now to FIG. 5, an alternate embodiment of the buoyant body surfing suit 10' of the present invention is shown in the configuration for use on large, long and rolling waves which are further out from shore.
The buoyant body surfing suit 10' is also made of neoprene and which also has a very slick surface 12' for reducing drag, and a nylon liner 14' for comfort.
The neoprene material, of which the buoyant body surfing suit 10' is made from, adds to the buoyancy of the suit 10'. Depending on the neoprene thickness, a body surfer could body surf in colder, East Coast water, for longer periods of time, since the neoprene suit 10' keeps the body temperature elevated. Since the buoyant body surfing suit 10' has glued and stitched seams, it is impossible for water to enter the buoyant body surfing suit 10'.
The buoyant body surfing suit 10' consists basically of a collar 16', a pair of short sleeves 18' and 20', and a pair of legs 22' and 24' that end below the knees 26' and 28'.
The buoyant body surfing suit 10' requires the use of the collar 16' and the pair of short sleeves 18' and 20' so that water is prevented from entering under the buoyant body surfing suit 10' and cause the speed of the surfer to be lowered.
A plurality of buoyancy increasing means are disposed on the front 30' of the buoyant body surfing suit 10', as can best be seen in FIG. 5.
Five channels 32, are disposed on the chest 34' of the buoyant body surfing suit 10' and which are filled with a floatation foam 36'. On either side of the five channel 32', are disposed each of a pair of shorter channels 38' and 40' which are filled with the floatation foam 36', and which can best be seen in FIG. 5.
Thigh pads 42' and 44', as shown in FIG. 5, are disposed on the front thigh areas 43' and 45' of the buoyant body surfing suit 10'. Each of the thigh pads 42' and 44' contain three channels 46', 48', and 50', and with each channel filled with the floatation foam 36'.
The rear side 54' of the buoyant body surfing suit 10', as shown in FIG. 5, contains a zipper 52' which aids in the putting on and the taking off of the buoyant body surfing suit 10'.
The floatation foam 36', like 36, is also made of enselite that is also approximately 1" thick.
Also shown in FIGS. 6 through 8, another alternate embodiment of the present invention is applicable to the buoyant body surfing suit 10'. In this embodiment, the channels 32'', 38'', 46'', 48'', and 50'' are filled with either floatation foam 36'' or air 37''.
As can best be seen in FIGS. 7 and 8, the channels 32'' and 38'' are one homogeneous piece of material with the base 56'' and the channels 46'', 48'', and 50'' as one homogeneous piece of material with each of the pair of bases 58'' so that the bases 56'' and 58'' are attached to the buoyant body surfing suit 10', as can best be seen in FIG. 6, instead of the channels 32'', 38'', 46'', 48'', and 50'' being attached directly to the buoyant body surfing suit 10'.
Optionally used back pads 56 and 58, also contain the floatation foam 36 and as shown in FIG. 4, the back pads 56 and 58 are disposed on the upper rear portion 62 of the buoyant body surfing suit 10 or 10'. The back pads 56 and 58 permit a body surfer to surf on the back.
The buoyant body surfing suit has sufficient buoyancy so that the body surfer does not have to make a major physical effort to stay afloat, especially between waves. The body surfer merely floats on the back or in an upright position, and remains relaxed while waiting for each wave. The body surfer using the present invention does not tire as quickly, and can last in the water for long periods of time.
The buoyant body surfing suit can also function as a life vest. If a body surfer becomes unconscious, after being pounded by a wave, the surfer is automatically set afloat on his back, face up. This occurs because the majority of the buoyancy material is on the front of the suit.
On the suit for body surfing on long slow rolling offshore waves, long channels are used to cut into the wave for speed and control. Additionally, three channels are disposed on each of the thighs, for rudder control. These same rudders are also used on the suit that is used for waves that are closer to shore.
It is to be noted that the suit is not so buoyant that a body surfer can not dive under a wave with great ease. With the pads on the back of the buoyant body surfing suit, the body surfer will be able to surf on the back.
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 type described above.
While the invention has been illustrated and described as embodied in a buoyant body surfing suit, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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The present invention relates to a buoyant body surfing suit for a body surfer having knees. The buoyant body surfing suit includes an upper portion together with a pair of short sleeves, a collar, a front, and a rear being a homogeneous piece of resilient material, and a lower portion together with the upper portion and a front being a homogeneous piece of resilient material, the lower portion together with a pair of legs being a homogeneous piece of resilient material that ends below the knees of the body surfer so that due to the collar and the pair of short sleeves water is prevented from entering under the buoyant body surfing suit and slow down the speed of the body surfer.
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FIELD OF THE INVENTION
[0001] This invention relates to low-pressure mercury vapor lamps, more commonly known as fluorescent lamps, having a lamp envelope with phosphor coating, and more particularly, to such lamps in which the amount of contaminants introduced into the lamp during manufacture has been reduced during lamp operation. This has the effect of reducing mercury consumption, improving maintained light output and improving arc stability at time of lamp ignition.
BACKGROUND OF THE INVENTION
[0002] Low-pressure mercury vapor lamps, more commonly known as fluorescent lamps, have a lamp envelope with a filling of mercury and rare gas to maintain a gas discharge during operation. The radiation emitted by the gas discharge is mostly in the ultraviolet (UV) region of the spectrum, with only a small portion in the visible spectrum. The inner surface of the lamp envelope has a luminescent coating, often a blend of phosphors, which emits visible light when impinged by the ultraviolet radiation.
[0003] There is an increase in the use of fluorescent lamps because of reduced consumption of electricity. To further reduce electricity consumption, there is a drive to increase efficiency of fluorescent lamps, referred to as luminous efficacy which is a measure of the useful light output in relation to the energy input to the lamp, in lumens per watt (LPW).
[0004] U.S. Pat. No. 5,552,665 Of Charles Trushell, an inventor in the present application, relates to an electric lamp having a luminescent layer on the lamp envelope which produces visible light when impinged by ultraviolet radiation generated within the lamp, and wherein an undercoat for the luminescent layer is employed. The disclosure of said patent is hereby incorporated by this reference thereto. Such an undercoat is now a common feature of modern fluorescent lamps, and is an oxidic, particulate base coat layer of non-fluorescent material, preferably an aluminum oxide, underlying the light-giving phosphor. Such an undercoat or base-coat is intended to economically increase light output, simplify the manufacturing process, improve the maintenance of light output, and reduce mercury consumption by the glass bulb. Typically, such layers are composed of very small particles with consequently large surface areas. Unfortunately, it has been found that the large surface of the particulate base-coat combined with the propensity of aluminum oxide to adsorb gaseous molecules results in larger than normal amounts of contaminants being introduced into the lamp interior during manufacture. For example, water and carbon dioxide are common, volatile, fluorescent lamp contaminants, the amounts of which are increased as a result of the large surface area of the undercoat. One effect of the increased amount of these contaminants is to increase the duration of arc instability immediately after lamp ignition.
[0005] It is known to coat the phosphor layer contained in a fluorescent lamp. For example:
[0006] Tamura, Japanese Patent Application No. 03179238 (Abstract)), describes a procedure wherein MgO is mixed with a phosphor at 0.01-1.0% and used to form a layer as a step in the manufacture of a fluorescent lamp in order to getter CO 2 and CO impurities which exist after the lamp is manufactured.
[0007] Watanabe et al, U.S. Pat. No. 5,604,396, describes a method wherein an alcoholic solution of a metal alkoxide (wherein the metal may be any of numerous metals including magnesium) is added to an aqueous suspension of a phosphor, which is to be coated by the alkoxide. Upon evaporation of the alcohol, the alkoxide is converted to the hydroxide and homogeneously precipitated on the surface of the phosphor in a sol-gel process. After removal of the water, the hydroxide-coated phosphor is fired at a high temperature; however, no specific benefits are claimed for coating the phosphor with the metal alkoxide. Moreover, we have found that coating the phosphor with metal alkoxide or metal oxide does not eliminate or mitigate the increase in duration of the arc instability in the lamp when an oxidic base-coat such as alumina is used.
[0008] There is a need in the art for a means of reducing the amount of contaminants and for eliminating or at least mitigating the increase in duration of arc instability to which the contaminants contribute in a fluorescent lamp.
SUMMARY OF THE INVENTION
[0009] An object of the invention is to provide a lamp in which the amount of contaminants is reduced and in which the arc instability to which the contaminants contribute is substantially eliminated.
[0010] The present invention accomplishes the above and other objects by providing an electric lamp that includes:
[0011] an envelope having an inner surface;
[0012] means within the lamp envelope for generating ultraviolet radiation;
[0013] a layer of a luminescent material adjacent to the inner surface of the lamp envelope for generating visible light when impinged by said ultraviolet radiation; and
[0014] an undercoat layer between said inner surface of said lamp envelope and said layer of luminescent material, for reflecting ultraviolet radiation which has passed through said layer of luminescent material back into said luminescent material for increasing the visible light output of said luminescent material, said undercoat layer comprising a particulate non-fluorescent material derived from a sintered mixture of an aluminum oxide material and a getter material which is capable of irreversible reaction with contaminants present in the lamp.
[0015] In its preferred embodiments, said undercoat layer comprises a particulate oxidic material, preferably an aluminum oxide having on its surface, preferably as a contiguous layer, an oxide of an alkaline earth metal or zinc formed in situ during the lehring (sintering) process via reaction, for example, through thermal decomposition, of an alkaline earth metal oxide precursor material or zinc oxide precursor material or mixture thereof which reacts to form an alkaline earth metal oxide or zinc oxide or mixture thereof on said oxidic base-coat material.
[0016] In its most preferred embodiments, the undercoat layer comprises alumina having on its surface a contiguous layer of magnesium oxide formed in situ during the lehring (sintering) process as a result of thermal decomposition of an aqueous solution or suspension of a magnesium salt. In this way advantage is taken of the large surface area of the oxidic base-coat material, in part responsible for the arc instability, to act as the site for said irreversible reaction.
[0017] The preferred getter materials include oxides preferably of alkaline earth metals and/or zinc and include magnesium, calcium, strontium, barium, zinc, and mixtures thereof, formed in situ during the lehring (sintering) process by a precursor compound or mixtures of such compounds which are introduced as soluble compounds into an aqueous suspension of the aluminum oxide base-coat material. Mixtures forming magnesium oxide are particularly preferred for use as a getter compound for purposes of this invention.
[0018] Suitable precursor materials may be any alkaline earth metal or zinc compound or mixture thereof that reacts during the lehring step to form an alkaline earth oxide or zinc oxide or mixture of such oxides on the surface of the oxidic base-coat material. Illustrative of such precursor materials suitable for use herein are magnesium, calcium, strontium, barium, and zinc citrates, acetates, nitrates, etc. The preferred getter materials include oxides of alkaline earth metals and/or zinc, specifically oxides of magnesium, calcium, strontium, barium, zinc, and mixtures thereof, which are introduced as soluble compounds into the suspension of the oxidic base coat material. Precursor compounds of alkaline earth oxides and zinc oxide that crystallize during drying of the layer, without melting during subsequent processing, should be avoided.
BRIEF DESCRIPTION OF THE DRAWING
[0019] The FIGURE is a perspective view of a fluorescent lamp, partly in cross-section, partly broken away, having an undercoat with getter material according to the invention.
[0020] The invention will be better understood with reference to the details of specific embodiments that follow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] With reference to the FIGURE, there is illustrated a low-pressure mercury vapor discharge or fluorescent lamp 1 with an elongated outer envelope, or bulb 3 . The lamp includes a conventional electrode structure 5 at each end which includes a filament 6 supported in in-lead wires 7 and 9 which extend through a glass press seal 11 in a mount stem 10 . The electrode structure 5 is not the essence of the present invention, and other structures may be used for lamp operation to generate and maintain a discharge in the discharge space. For example, a coil positioned outside the discharge space may be used to generate an alternating magnetic field in the discharge space for generating and maintaining the discharge.
[0022] Returning to the illustrative lamp 1 of FIG. 1, the leads 7 , 9 are connected to pin-shaped contacts 13 of their respective bases 12 fixed at opposite ends of the lamp 1 . The discharge-sustaining filling includes an inert gas such as argon, or a mixture of argon and other gases, at a low pressure in combination with a small quantity of mercury to sustain an arc discharge during lamp operation. The inner surface 15 of the outer envelope 3 is provided with an undercoat 16 of aluminum oxide (for example, Aluminum Oxide C available commercially from DeGussa or Baikalox CR30 from Baikowski Chemie) as a non-fluorescent material coated with a contiguous layer of an alkaline earth oxide mixture, formed by thermal decomposition of the appropriate presursor materials. This alkaline earth oxide represents from about 1 to about 3 wt. % of oxide based on the weight of the aluminum oxide as getter material to remove contaminants from the lamp. A phosphor coating 17 is disposed over the undercoat 16 . Both coatings extend the full length of the bulb, completely circumferentially around the bulb inner wall.
[0023] The undercoat layer may be cast from organic solvent or water based suspensions to which various components may be added without substantially changing the various advantages of the non-fluorescent oxidic undercoat. The suspension is applied to the interior of a clean fluorescent tube in a manner known to the art and is then lehred or sintered, also in a manner well known in the art.
[0024] The bulb coated as above is then lehred and finished into a lamp in the manner known in the art.
[0025] To further reduce mercury consumption, the glass mount stems and press seals may also be coated with the aluminum oxide undercoat layer to reduce mercury bound to the glass mount stems and press seals.
[0026] This invention recognizes the discovery that alkaline earth metal oxides and/or zinc oxide, particularly when incorporated in aluminum oxide reflective undercoats via thermal decomposition of precursor materials during lehring, are effective to reduce or eliminate contaminants introduced into the lamp during manufacture and substantially reduces the duration of or eliminates arc instability immediately after lamp ignition. The invention was demonstrated in a series of 32T8 bulbs, 4 feet in length and 1 inch in diameter using about 0.5-1.0 grams of commercially available aluminum oxide containing about 1-3% MgO based on the weight of the aluminum oxide.
[0027] Representative lamps were produced in which the undercoat layer 16 comprises particulate aluminum oxide, i.e. alumina having on its surface a contiguous layer of a mixture of metal oxides including magnesium oxide. The alumina was suspended in a water-based solution to which an amount of magnesium nitrate is added, and flushed down the lamp tube or envelope 3 to flow over the envelope inner surface 15 until it exits from the other end. The solution was dried in a drying chamber. A phosphor coat 17 was applied in a similar fashion and sintered or baked for a period of time. The lamps thus produced exhibited a reduced period of arc instability after lamp ignition compared to lamps that were not so processed and treated and exhibited a substantially greater reduction in the period of arc instability after lamp ignition when compared to comparable lamps wherein the getter material was applied to a phosphor layer.
[0028] The phosphors suitable for use in this invention may vary according to the properties desired in the final lamp. For example, for a 4100K fluorescent lamp where the color temperature is about 4100°K, i.e., in degree Kelvin, the phosphor coat 17 is typically comprised of a mixture of three phosphors. The phosphor mixture typically consists of a blue-emitting barium magnesium aluminate (BAM) activated by Eu, a red-emitting yttrium Oxide (YOX) activated by Eu, i.e., Y 2 O 3 :Eu; and typically a green-emitting lanthanum phosphate (LAP) activated by cerium and terbium.
[0029] The three-phosphor mixture in the 4100°K lamp allows the lamp 1 to have reduced mercury consumption in conjunction with the alumina undercoat 16 which shields the glass envelope 3 from mercury.
[0030] Since very thin layers of the getter compounds are effective in gettering the contaminants in question, the optics of the bulk material are not effectively altered. The invention has been found to be useful in all UV reflective base coats in fluorescent lamps.
[0031] While not wishing to be bound by any theory, experimental data indicates that contamination above a certain level in the finished lamp results in increased duration of arc instability in conventional lamps and that decreasing the contamination reduces or eliminates the duration of the arc instability. Thus the solution according to this invention is the reduction of impurities responsible for the contamination by taking advantage of the large surface area provided by the UV reflecting base-coat.
[0032] While the present invention has been described in particular detail, it should also be appreciated that numerous modifications are possible within the intended spirit and scope of the invention. In interpreting the appended claims it should be understood that where and if it appears:
[0033] a) the word “comprising” does not exclude the presence of other elements than those listed in a claim;
[0034] b) the word “consisting” excludes the presence of other elements than those listed in a claim;
[0035] c) the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.
[0036] d) any reference signs in the claims do not limit their scope; and
[0037] e) several “means” may be represented by the same item of hardware or software implemented structure or function.
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An electric lamp is provided having a luminescent layer on the lamp envelope that produces visible light when impinged by ultraviolet radiation generated within the lamp. An undercoat for the electric lamp increases the luminous efficacy of the lamp. The undercoat comprises a particulate non-fluorescent material derived from a sintered mixture of an aluminum oxide material and a getter material which reacts with contaminants present in the lamp.
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FIELD OF THE INVENTION
[0001] The present invention relates to computer security in general, and, more particularly, to authentication for wireless telecommunications terminals.
BACKGROUND OF THE INVENTION
[0002] Wireless telecommunications terminals (e.g., cell phones, personal digital assistants [PDAs] with wireless capabilities, notebook computers with wireless capabilities, etc.) are increasingly being used in the workplace for job-related tasks. Some enterprises have deployed software applications that execute on a server and can be accessed by workers via their wireless terminals. Such applications are commonly referred to as wireless web-based applications or wireless client/server applications, depending on whether or not a browser is used as the user interface on the wireless terminals.
[0003] In some domains, such as health care, it is especially convenient for workers to use hands-free wireless terminals so that using the wireless terminal does not interfere with their other job duties. When a hands-free wireless terminal is used to access a wireless client/server application, typically the user issues voice commands in lieu of keypad inputs and receives audio responses in lieu of a video display.
[0004] FIG. 1 depicts illustrative telecommunications system 100 in the prior art. As shown in FIG. 1 , telecommunications system 100 comprises telecommunications network 105 , hands-free wireless terminal 110 , and server 120 , interconnected as shown.
[0005] Telecommunications network 105 is a network that comprises one or more wireless elements (e.g., wireless access points, wireless base stations, etc.) and is capable of transporting signals between server 120 and other devices, such as hands-free wireless terminal 110 .
[0006] Hands-free wireless terminal 110 is a device that is typically worn on a user's person (e.g., clipped to one of the user's ears, etc.) and is capable of wirelessly transmitting and receiving electromagnetic signals to and from telecommunications network 105 via a wireless transceiver; of receiving voice inputs and converting them to electromagnetic signals via a microphone; and of converting electromagnetic signals to acoustic signals and outputting the acoustic signals to the user via a speaker.
[0007] Server 120 is a data-processing system that is capable of executing one or more software applications and of receiving and transmitting signals via telecommunications network 105 .
[0008] In some instances it is desirable for security reasons to require that users are authenticated before being allowed to access an application or other resource on a server. Typically a user is presented with an authentication challenge, and the user must supply a valid response to the challenge. A classic challenge/response mechanism, colloquially referred to as “logging in,” is to prompt a user to respond with his or her username and password. This mechanism is not well-suited for hands-free wireless terminals, however, because it requires that a user say his username and password aloud, and it is often difficult for the user to ensure that no one else overhears this information.
[0009] Other authentication techniques of the prior art are also poorly suited to hands-free wireless terminals. In one such technique, a user uses an electronic token device or a list of numbers to respond to an authentication challenge with a one-time password response. While this eliminates the problem of the password being overheard, it requires the user to carry around and consult the token device or list, thereby largely negating the advantage of having a hands-free terminal. In another technique, speaker recognition, a user is authenticated by comparing his or her speech to a database of known speakers. The disadvantages of speaker recognition are two-fold: first, it suffers from high error rates—particularly in the noisy environments that typically predominate in workplaces—and second, it is possible for another person to record a user's voice and play back the recording to impersonate the user.
[0010] Therefore, what is needed is a secure authentication technique for hands-free wireless terminals that overcomes some of the disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0011] The present invention is a secure method of authenticating users of hands-free wireless terminals, without some of the disadvantages of the prior art. In particular, a user is authenticated by instructing the user to travel to a geo-location, where the geo-location is referred to by an identifier that the user has previously associated with the geo-location. When the user chooses identifiers that are meaningful to the user, but that do not indicate the associated geo-locations to other people the user can be securely authenticated via the following procedure:
(i) select one of the identifiers that the user has defined, (ii) instruct the user to “go to <identifier>,” and (iii) declare the user authenticated if and only if the user visits the geo-location associated with <identifier>, before a timeout expires.
[0015] For example, a user might assign the identifier “favorite hangout” to the geo-location of Starbucks store number 28,453. When challenged with the instruction “go to favorite hangout,” the user knows exactly where to go, but presumably another person will not. Even if an observer is aware of the authentication procedure and sees the user going to Starbucks store number 28,453, this does not give the observer the information necessary to impersonate the user because the identifier “favorite hangout” is heard only by the user, so that the user has no knowledge that Starbucks store number 28,453 is associated with the name “favorite hangout.” Furthermore, if the user has defined a sufficiently large number of identifier/geo-location pairs, then it becomes very unlikely that an observer who gains possession of the user's terminal would be challenged with the same identifier “favorite hangout.”
[0016] In a variation of the illustrative embodiment of the present invention, a user is challenged with an instruction to do something at a particular geo-location. For example, the user might be instructed to “say the word ‘hello’ at favorite hangout.” Such commands can further obfuscate the authentication process and thwart a malicious observer who is spying on the user.
[0017] The illustrative embodiment comprises: transmitting an identifier I to a wireless telecommunications terminal at time t, wherein the user of the wireless telecommunications terminal has associated the identifier I with a geo-location L; and when the geo-location of the wireless telecommunications terminal is substantially the same as L at a time that exceeds t by no more than a positive threshold, storing in a memory a value that indicates that the user is authenticated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 depicts the salient elements of illustrative telecommunications system 100 in accordance with the prior art.
[0019] FIG. 2 depicts the salient elements of telecommunications system 200 in accordance with the illustrative embodiment of the present invention.
[0020] FIG. 3 depicts a flowchart of the salient tasks for a user of hands-free wireless terminal 210 , as shown in FIG. 2 , in accordance with the illustrative embodiment of the present invention.
[0021] FIG. 4 depicts a flowchart of the salient tasks of hands-free wireless terminal 210 , in accordance with the illustrative embodiment of the present invention.
[0022] FIG. 5 depicts a flowchart of the salient tasks of server 220 , as shown in FIG. 2 , in accordance with the illustrative embodiment of the present invention.
[0023] FIG. 6 depicts a detailed flowchart for task 540 , as shown in FIG. 4 , in accordance with the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0024] FIG. 2 depicts the salient elements of telecommunications system 200 in accordance with the illustrative embodiment of the present invention. As shown in FIG. 2 , telecommunications system 100 comprises telecommunications network 105 , geo-location-enabled hands-free wireless terminal 210 , and server 220 , interconnected as shown.
[0025] Geo-location-enabled hands-free wireless terminal 210 is a device that is typically worn on a user's person (e.g., clipped to one of the user's ears, etc.) and is capable of:
wirelessly transmitting and receiving electromagnetic signals to and from telecommunications network 105 via a wireless transceiver; receiving voice inputs from a user and converting the input to electromagnetic signals via a microphone; converting electromagnetic signals to acoustic signals and outputting the acoustic signals to the user via a speaker; receiving one or more electromagnetic signals and estimating terminal 210 's geo-location based on these signals; and performing the tasks described below and with respect to FIG. 4 via a processor.
As will be appreciated by those skilled in the art, there are a variety of well-known methods for estimating geo-location based on received electromagnetic signals (e.g., via a Global Positioning System (GPS) receiver, via triangulation, via RF fingerprinting, etc.), and it will be clear to those skilled in the art, after reading this specification, how to make and use embodiments of the present invention for terminals that use these methods—as well as embodiments in which the estimation of terminal 210 's geo-location is performed by an entity other than wireless terminal 210 . As will further be appreciated by those skilled in the art, hands-free wireless terminal 210 might communicate via one or more protocols (e.g., Code Division Multiple Access [CDMA], Institute of Electrical and Electronics Engineers [IEEE] 802.11, Bluetooth, etc.), and it will be clear to those skilled in the art, after reading this specification, how to make and use embodiments of the present invention based on these protocols.
[0031] Server 220 is a data-processing system that is capable of executing one or more software applications, of receiving and transmitting signals via telecommunications network 105 , and of performing the tasks described below and with respect to FIGS. 5 and 6 .
[0032] FIG. 3 depicts a flowchart of the salient tasks for a user of hands-free wireless terminal 210 , in accordance with the illustrative embodiment of the present invention.
[0033] At task 310 , the user defines a set of identifier/geo-location pairs, prior to using geo-location-enabled hands-free wireless terminal 210 . As discussed above, it is advantageous for the user to define a relatively large number of such pairs, and to choose identifiers that are meaningful to the user but that do not indicate the associated geo-locations to other people. As will be appreciated by those skilled in the art, task 310 might be performed by the user in a variety of ways, such as via a browser-based application that incorporates clickable maps, or via the user visiting various geo-locations while wearing wireless terminal 210 and saying the appropriate identifier at each geo-location. In the latter method, a preliminary “initialization” phase for wireless terminal 210 might be defined that bypasses the geo-location-based authentication process, thereby getting around the “chicken and egg” problem.
[0034] At task 320 , the user uses geo-location-enabled hands-free wireless terminal 210 , and is authenticated as necessary, as described below and with respect to FIGS. 4 through 6 . As will be appreciated by those skilled in the art, in some embodiments only a subset of operations that the user attempts to perform with terminal 210 might require authentication (e.g., attempts to access a resource of server 220 , etc.), while in some other embodiments authentication might be required for any kind of use of terminal 210 .
[0035] At task 330 , the user finishes using geo-location-enabled hands-free wireless terminal 210 . As will be appreciated by those skilled in the art, in some embodiments of the present invention the user might proactively log out, while some other embodiments might automatically log out the user when the terminal is inactive for a given time interval, while still other embodiments might employ both of these methods.
[0036] After task 330 , execution proceeds back to task 320 when the user begins using terminal 210 again.
[0037] FIG. 4 depicts a flowchart of the salient tasks of hands-free wireless terminal 210 , in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 4 can be performed simultaneously or in a different order than that depicted.
[0038] At task 410 , an authentication challenge is received at hands-free wireless terminal 210 , in response to the user of terminal 210 attempting to perform a particular operation with terminal 210 .
[0039] At task 420 , wireless terminal 210 transmits its current geo-location to server 220 via telecommunications network 105 , in well-known fashion. In addition, if the authentication challenge is of a type that instructs the user to do something at a particular geo-location, wireless terminal 210 also transmits any user input to server 220 .
[0040] Task 430 checks whether wireless terminal 210 has received a signal that indicates either (1) that the user has been successfully authenticated, or (2) that a timeout interval has expired and the user has not been authenticated. If either type of signal is received, the method of FIG. 4 terminates, otherwise execution continues back at task 420 .
[0041] FIG. 5 depicts a flowchart of the salient tasks of server 220 , in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 5 can be performed simultaneously or in a different order than that depicted.
[0042] At task 510 , server 220 receives a signal S from wireless terminal 210 , in well-known fashion.
[0043] At task 520 , server 220 checks whether signal S requires that the user of wireless terminal 210 has been authenticated. If so, execution proceeds to task 530 , otherwise execution continues at task 550 . (As described above, in some embodiments only a subset of signals received from terminal 210 might require the user to be authenticated, while in some other embodiments authentication might be required for any signal received from terminal 210 .)
[0044] At task 530 , server 220 checks whether the user of wireless terminal 210 has been successfully authenticated. If so, execution continues at task 550 , otherwise execution proceeds to task 540 .
[0045] At task 540 , server 220 authenticates the user, as described below and with respect to FIG. 6 . After task 540 , execution continues back at task 530 .
[0046] At task 550 , server 220 processes signal S in accordance with how it is programmed, in well-known fashion. After task 550 , execution continues back at task 510 .
[0047] FIG. 6 depicts a detailed flowchart for task 540 , in accordance with the illustrative embodiment of the present invention. It will be clear to those skilled in the art which subtasks depicted in FIG. 6 can be performed simultaneously or in a different order than that depicted.
[0048] At subtask 610 , server 220 selects an identifier/geo-location pair (I, L) from the list of such pairs that were defined by the user of wireless terminal 210 . As will be appreciated by those skilled in the art, in some embodiments pair (I, L) might be selected randomly, while in some other embodiments pair (I, L) might be selected in sequential fashion, while still other embodiments might select pair (I, L) via some other method.
[0049] At subtask 620 , server 220 sets an authentication status flag for terminal 210 's user to unsuccessful.
[0050] At subtask 630 , server 220 transmits to wireless terminal 210 a signal that instructs the terminal to output the phrase “go to <I>” via the terminal's speaker. As mentioned above, in some embodiments server 220 might transmit a signal that instructs the terminal's user to perform some action at geo-location <I>(e.g., “say ‘hello’ at <I>,” “check your email at <I>,” etc.)
[0051] At subtask 640 , server 220 sets the value of variable t to the current time, in well-known fashion. [ 0044 ] At subtask 650 , server 220 checks whether the difference between the current time and t exceeds a pre-determined threshold. As will be appreciated by those skilled in the art, the threshold acts as a timeout, and thus the value of the threshold should be selected so that the user has sufficient time to travel to geo-location <I>. If the difference exceeds the threshold, then execution continues back at task 530 of FIG. 5 (where the value of the authentication status flag will indicate whether the user was successfully authenticated); otherwise execution proceeds to task 660 .
[0052] At subtask 660 , server 220 receives the current geo-location C of wireless terminal 210 , in well-known fashion.
[0053] At subtask 670 , server 220 checks whether geo-location C is substantially the same as geo-location L, where “substantially the same” is intended to account for inconsequentially small differences between C and L (e.g., different tables in a Starbucks, etc.) If so, execution proceeds to task 680 , otherwise execution continues back at task 650 .
[0054] At subtask 680 , server 220 sets the authentication status flag for terminal 210 's user to successful. After task 680 , execution continues back at task 530 of FIG. 5 .
[0055] As will be appreciated by those skilled in the art, although in the illustrative embodiment a user is authenticated by visiting one particular geo-location, in some other embodiments a user might be instructed to visit two or more geo-locations sequentially, and it will be clear to those skilled in the art, after reading this specification, how to make and use such embodiments.
[0056] Similarly, although in the illustrative embodiment server 220 handles authentication and might also host one or more software applications, some other embodiments might employ separate servers for these two functions, and it will be clear to those skilled in the art, after reading this specification, how to make and use such embodiments.
[0057] Furthermore, although the illustrative embodiment is particularly well-suited to hands-free wireless terminals, it will be clear to those skilled in the art that the basic concepts of the present invention can also be applied to wireless terminals that are not hands-free, and it will be clear to those skilled in the art, after reading this specification, how to make and use embodiments of the present invention for such terminals.
[0058] It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. For example, in this Specification, numerous specific details are provided in order to provide a thorough description and understanding of the illustrative embodiments of the present invention. Those skilled in the art will recognize, however, that the invention can be practiced without one or more of those details, or with other methods, materials, components, etc.
[0059] Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the illustrative embodiments. It is understood that the various embodiments shown in the Figures are illustrative, and are not necessarily drawn to scale. Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that a particular feature, structure, material, or characteristic described in connection with the embodiment(s) is included in at least one embodiment of the present invention, but not necessarily all embodiments. Consequently, the appearances of the phrase “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout the Specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments. It is therefore intended that such variations be included within the scope of the following claims and their equivalents.
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An apparatus and methods are disclosed for authenticating users of wireless telecommunications terminals. A user is authenticated by instructing the user to travel to a geo-location, where the geo-location is referred to by an identifier that the user has previously associated with the geo-location. When the user chooses identifiers that are meaningful to the user, but that do not indicate the associated geo-locations to other people, the user can be securely authenticated via the following procedure: (i) select one of the identifiers that the user has defined, (ii) instruct the user to “go to <identifier>,” and (iii) declare the user authenticated if and only if the user visits the geo-location associated with <identifier>before a timeout expires.
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[0001] This application is a divisional of U.S. application Ser. No. 09/797,372, filed Mar. 1, 2001.
FIELD OF THE INVENTION
[0002] The invention relates to the use of yeast cells to reduce odor. These yeasts are useful in waste treatment, and can be obtained by growth in electromagnetic fields with specific frequencies and field strengths.
BACKGROUND OF THE INVENTION
[0003] Environmental pollution by urban sewage and industrial waste water has posed a serious health threat to living organisms in the world. Currently, the most common methods for large-scale waste treatment, such as water treatment, include the activated sludge technology and the biomembrane technology. These technologies rely on the innate abilities of myriad natural microorganisms, such as fungi, bacteria and protozoa, to degrade pollutants. However, the compositions of these natural microbial components are difficult to control, affecting the reproducibility and quality of water treatment. Moreover, pathogenic microbes existing in these activated sludge or biomembranes cannot be selectively inhibited, and such microbes usually enter the environment with the treated water, causing “secondary pollution.”
[0004] Further, most of the current technologies cannot degrade harmful chemicals such as pesticides, insecticides, and chemical fertilizers. These technologies also cannot alleviate eutrophication, another serious environmental problem around the world. Eutrophication is usually caused by sewage, industrial waste water, fertilizers and the like. It refers to waters (e.g., a lake or pond) rich in minerals and organic nutrients that promote a proliferation of plant life, especially algae, which reduces the dissolved oxygen content or otherwise deteriorates water quality. Eutrophication often results in the extinction of other organisms.
SUMMARY OF THE INVENTION
[0005] This invention is based on the discovery that certain yeast cells can be activated by electromagnetic fields of specific frequencies and field strengths to reduce odor of certain environmental pollutants. Compositions comprising these activated yeast cells can therefore be used for waste treatment, for example, treatment of sewage, industrial waste water, surface water, drinking water, sediment, soil, garbage, and manure, to deodorize the waste. Waste treatment methods using these compositions are more effective, efficient, and economical than the conventional methods.
[0006] This invention embraces a composition comprising a plurality of yeast cells that have been cultured in an alternating electric field having a frequency in the range of about 2160 to 2380 MHz (e.g., 2160-2250 or 2280-2380 MHz) and a field strength in the range of about 0.5 to 320 mV/cm (e.g., 40-260, 70-260, 80-250, 90-260, or 140-300 mV/cm). The yeast cells are cultured for a period of time sufficient to substantially increase the capability of said plurality of yeast cells to reduce odor in malodorous materials. In one embodiment, the frequency and/or the field strength of the alternating electric field can be altered within the aforementioned ranges during said period of time. In other words, the yeast cells can be exposed to a series of electromagnetic fields. An exemplary period of time is about 12 to 350 hours (e.g., 70-220, 70-320, 80-310, 85-220, 110-230, or 120-300 hours).
[0007] Yeast cells that can be included in this composition are available from the China General Microbiological Culture Collection Center (“CGMCC”), a depository recognized under the Budapest Treaty (China Committee for Culture Collection of Microorganisms, Institute of Microbiology, Chinese Academy of Sciences, Haidian, P.O. Box 2714, Beijing, 100080, China). Useful yeast species include, but are not limited to, Saccharomyces cerevisiae and Saccharomyces carlsbergensis. For instance, the yeast cells can be of the strain Saccharomyces cerevisiae Hansen AS2.53, AS2.163, AS2.396, AS2.397, AS2.423, AS2.452, AS2.502, AS2.516, AS2.541, AS2.558, AS2.559, AS2.560, AS2.561, AS2.562, AS2.607, AS2.612, IFFI 1052, IFFI 1202, IFFI 1213, IFFI 1247, or IFFI 1397; or Saccharomyces carlsbergensis Hansen AS2.605.
[0008] This invention also embraces a composition comprising a plurality of yeast cells, wherein said plurality of yeast cells have been activated such that they have a substantially increased capability to reduce odor of a culture medium as compared to unactivated yeast cells. Included in this invention are also methods of making these compositions.
[0009] As used herein, “reducing odor” or “deodorizing” refers to a process which results in a lower concentration of one or more odorous compounds. Odorous compounds include, but are not limited to, hydrogen sulfide, ammonium sulfide, other sulfur-containing compounds, ammonia, indole, methylindoles, p-cresol, amines such as methylamine, dimethylamine and trimethylamine, and odorous organic acids, such as carboxylic acids, e.g., formic acid, acetic acid, propanoic acid and butyric acid, and other volatile fatty acids.
[0010] A “substantial increase” means an increase of more than 10 (e.g., 10 2 , 10 3 , 10 4 , 10 5 , or 10 6 ) fold.
[0011] A “culture medium” refers to a medium used in a laboratory for selecting and growing a given yeast strain, or to liquid or solid waste in need of treatment.
[0012] Unless otherwise defined, all 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. Exemplary methods and materials are described below, although methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention. All publications and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. The materials, methods, and examples are illustrative only and not intended to be limiting.
[0013] Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic diagram showing an exemplary apparatus for activating yeast cells using electromagnetic fields. 1 : yeast culture; 2 : container; 3 : power supply.
DETAILED DESCRIPTION OF THE INVENTION
[0015] This invention is based on the discovery that certain yeast strains can be activated by electromagnetic fields (“EMF”) having specific frequencies and field strengths to become highly efficient in reducing foul odor of malodorous materials. Yeast cells having this function are defined herein as belonging to the same “functional group.” Compositions containing the activated yeast cells are useful in waste treatment.
[0016] Without being bound by any theory or mechanism, the inventor believes that EMFs activate or enhance the expression of a gene or a set of genes in yeast cells such that the yeast cells become active or more efficient in performing certain metabolic activities which lead to the desired odor-reducing result. The activated yeast cells may reduce odor by modifying or decomposing compounds that are malodorous.
[0000] I. Yeast Strains Useful in the Invention
[0017] The types of yeasts useful in this invention include, but are not limited to, yeasts of the genera of Saccharomyces, Schizosaccharomyces, Sporobolomyces, Torulopsis, Trichosporon, Wickerhamia, Ashbya, Blastomyces, Candida, Citeromyces, Crebrothecium, Cryptococcus, Debaryomyces, Endomycopsis, Eremothecium, Geotrichum, Hansenula, Kloeckera, Lipomyces, Pichia, Rhodosporidium, and Rhodotorula.
[0018] Exemplary species within the above-listed genera include, but are not limited to, Saccharomyces cerevisiae, Saccharomyces bailii, Saccharomyces carlsbergensis, Saccharomyces chevalieri, Saccharomyces delbrueckii, Saccharomyces exiguus, Saccharomyces fermentati, Saccharomyces logos, Saccharomyces mellis, Saccharomyces microellipsoides, Saccharomyces oviformis, Saccharomyces rosei, Saccharomyces rouxii, Saccharomyces sake, Saccharomyces uvarum, Saccharomyces willianus, Saccharomyces sp., Saccharomyces ludwigii, Saccharomyces sinenses, Saccharomyces bailii, Saccharomyces carlsbergensis, Schizosaccharomyces octosporus, Schizosaccharomyces pombe, Sporobolomyces roseus, Sporobolomyces salmonicolor, Torulopsis candida, Torulopsis famta, Torulopsis globosa, Torulopsis inconspicua, Trichosporon behrendoo, Trichosporon capitatum, Trichosporon cutaneum, Wickerhamia fluoresens, Ashbya gossypii, Blastomyces dermatitidis, Candida albicans, Candida arborea, Candida guilliermondii, Candida krusei, Candida lambica, Candida lipolytica, Candida parakrusei, Candida parapsilosis, Candida pseudotropicalis, Candida pulcherrima, Candida robusta, Candida rugousa, Candida tropicalis, Candida utilis, Citeromyces matritensis, Crebrothecium ashbyii, Cryptococcus laurentii, Cryptococcus neoformans, Debaryomyces hansenii, Debaryomyces kloeckeri, Debaryomyces sp., Endomycopsis fibuligera, Eremothecium ashbyii, Geotrichum candidum, Geotrichum ludwigii, Geotrichum robustum, Geotrichum suaveolens, Hansenula anomala, Hansenula arabitolgens, Hansenula jadinii, Hansenula saturnus, Hansenula schneggii, Hansenula subpelliculosa, Kloeckera apiculata, Lipomyces starkeyi, Pichia farinosa, Pichia membranaefaciens, Rhodosporidium toruloides, Rhodotorula aurantiaca, Rhodotorula glutinis, Rhodotorula minuta, Rhodotorula rubar, and Rhodotorula sinesis.
[0019] Yeast strains useful for this invention can be obtained from laboratory cultures, or from publically accessible culture depositories, such as CGMCC and the American Type Culture Collection, 10801 University Boulevard, Manassas, Va. 20110-2209. Non-limiting examples of useful strains (with accession numbers of CGMCC) are Saccharomyces cerevisiae Hansen AS2.53, AS2.163, AS2.396, AS2.397, AS2.423, AS2.452, AS2.502, AS2.516, AS2.541, AS2.558, AS2.559, AS2.560, AS2.561, AS2.562, AS2.607, AS2.612, IFFI 1052, IFFI 1202, IFFI 1213, IFFI 1247, and IFFI 1397; and Saccharomyces carlsbergensis Hansen AS2.605.
[0020] Although it is preferred, the preparation of the yeast compositions of this invention is not limited to starting with a pure strain of yeast. A yeast composition of the invention may be produced by culturing a mixture of yeast cells of different species or strains that have the same odor-reducing function. The ability of any species or strain of yeasts to perform this function can be readily tested by methods known in the art.
[0021] Certain yeast species that can be activated according to the present invention are known to be pathogenic to human and/or other living organisms. These yeast species include, for example, Ashbya gossypii, Blastomyces dermatitidis, Candida albicans, Candida parakrusei, Candida tropicalis, Citeromyces matritensis, Crebrothecium ashbyii, Cryptococcus laurentii, Cryptococcus neoformans, Debaryomyces hansenii, Debaryomyces kloeckeri, Debaryomyces sp., and Endomycopsis fibuligera. Under certain circumstances, it may be less preferable to use such pathogenic yeasts in this invention. If use of these species is necessary, caution should be exercised to minimize the leak of the yeast cells into the final treatment product that enters the environment.
[0000] II. Application of Electromagnetic Fields
[0022] An electromagnetic field useful in this invention can be generated and applied by various means well known in the art. For instance, the EMF can be generated by applying an alternating electric field or an oscillating magnetic field.
[0023] Alternating electric fields can be applied to cell cultures through electrodes in direct contact with the culture medium, or through electromagnetic induction. See, e.g., FIG. 1 . Relatively high electric fields in the medium can be generated using a method in which the electrodes are in contact with the medium. Care must be taken to prevent electrolysis at the electrodes from introducing undesired ions into the culture and to prevent contact resistance, bubbles, or other features of electrolysis from dropping the field level below that intended. Electrodes should be matched to their environment, for example, using Ag—AgCl electrodes in solutions rich in chloride ions, and run at as low a voltage as possible. For general review, see Goodman et al., Effects of EMF on Molecules and Cells, International Review of Cytology, A Survey of Cell Biology, Vol. 158, Academic Press, 1995.
[0024] The EMFs useful in this invention can also be generated by applying an oscillating magnetic field. An oscillating magnetic field can be generated by oscillating electric currents going through Helmholtz coils. Such a magnetic field in turn induces an electric field.
[0025] The frequencies of EMFs useful in this invention range from 5 to 5000 MHz, e.g., from 2160 MHz to 2380 MHz (e.g., 2160-2250 MHz or 2280-2380 MHz). Exemplary frequencies are 2160, 2165, 2170, 2175, 2180, 2185, 2190, 2195, 2200, 2205, 2210, 2215, 2220, 2225, 2230, 2235, 2240, 2245, 2250, 2280, 2285, 2290, 2295, 2300, 2305, 2310, 2315, 2320, 2325, 2330, 2335, 2340, 2345, 2350, 2355, 2360, 2365, 2370, 2375, and 2380 MHz.
[0026] The field strength of the electric field useful in this invention ranges from about 0.5 to 320 mV/cm, e.g. from 30 to 310 mV/cm (e.g., 40-260, 70-260, 80-250, 90-260, or 140-300 mV/cm). Exemplary field strengths are 98, 240, 250, and 290 mV/cm.
[0027] When a series of EMFs are applied to a yeast culture, the yeast culture can remain in the same container while the same set of EMF generator and emitters is used to change the frequency and/or field strength. The EMFs in the series can each have a different frequency or a different field strength; or a different frequency and a different field strength. Such frequencies and field strengths are preferably within the above-described ranges. In one embodiment, an EMF at the beginning of the series has a field strength identical to or lower than that of a subsequent EMF, such that the yeast cell culture is exposed to EMFs of progressively increasing field strength. Although any practical number of EMFs can be used in a series, it may be preferred that the yeast culture be exposed to a total of 2, 3, 4, 5, 6, 7, 8, 9 or 10 EMFs in a series.
[0028] By way of example, the yeast cells can be cultured in a series of alternating electric fields each having a frequency in the range of 2160 to 2250 MHz or 2280 to 2380 MHz and a field strength in the range of 30 to 310 mV/cm. The yeast cells are exposed to each EMF for about 10 to 40 hours. Preferably, the field strength remains the same in the series whereas the frequency progressively increases.
[0029] Alternatively, the yeast cells can be cultured in a first series of alternating electric fields each having a frequency in the range of 2280 to 2380 MHz and a field strength in the range of 90 to 260 mV/cm. The yeast cells are exposed to each EMF for about 15 to 20 hours. After culturing in the first series of EMFs, the resultant yeast cells are further incubated in a second series of alternating electric fields for a total of 20 to 50 hours. It may be preferred that the frequencies in the second series of alternating electric fields are identical to those of the first series in sequence and the field strengths in the second series are increased to a higher level within the range of 90 to 260 mV/cm.
[0030] Although the yeast cells can be activated after even a few hours of culturing in the presence of an EMF, it may be preferred that the activated yeast cells be allowed to multiply and grow in the presence of the EMF(s) for a total of 70-220, 70-320, 80-310, 85-220, 110-230, or 120-300 hours.
[0031] FIG. 1 illustrates an exemplary apparatus for generating alternating electric fields. An electric field of a desired frequency and intensity is generated by an AC source ( 3 ) capable of generating an alternating electric field, preferably in a sinusoidal wave form, in the frequency range of 5 to 5000 MHz. Signal generators capable of generating signals with a narrower frequency range can also be used. If desirable, a signal amplifier can also be used to increase the output. The alternating electric field can be applied to the culture by a variety of means including placing the yeast culture in close proximity to the signal emitters. In one embodiment, the electric field is applied by electrodes submerged in the culture ( 1 ). In this embodiment, one of the electrodes can be a metal plate placed on the bottom of the container ( 2 ), and the other electrode can comprise a plurality of electrode wires evenly distributed in the culture ( 1 ) so as to achieve even distribution of the electric field energy. The number of electrode wires used depends on the volume of the culture as well as the diameter of the wires. In a preferred embodiment, for a culture having a volume up to 5000 ml, one electrode wire having a diameter of 0.1 to 1.2 mm can be used for each 100 ml of culture. For a culture having a volume greater than 1000 L, one electrode wire having a diameter of 3 to 30 mm can be used for each 1000 L of culture.
[0000] III. Culture Media
[0032] Culture media useful in this invention contain sources of nutrients assimilable by yeast cells. In this invention, a culture medium refers to a laboratory culture medium, or liquid or solid waste in need of treatment. Complex carbon-containing substances in a suitable form, such as carbohydrates (e.g., sucrose, glucose, fructose, dextrose, maltose, xylose, cellulose, starches, etc.) and coal, can be the carbon sources for yeast cells. The exact quantity of the carbon sources utilized in the medium can be adjusted in accordance with the other ingredients of the medium. In general, the amount of carbohydrates varies between about 0.1% and 5% by weight of the medium and preferably between about 0.1% and 2%, and most preferably about 1%. These carbon sources can be used individually or in combination. Among the inorganic salts which can be added to the culture medium are the customary salts capable of yielding sodium, potassium, calcium, phosphate, sulfate, carbonate, and like ions. Non-limiting examples of nutrient inorganic salts are (NH 4 ) 2 HPO 4 , KH 2 PO 4 , K 2 HPO 4 , CaCO 3 , MgSO 4 , NaCl, and CaSO 4 .
[0000] IV. Electromagnetic Activation of Yeast Cells
[0033] Yeasts of this invention reduce odor by lowering the concentration of malodorous materials. Malodorous materials include, but are not limited to, hydrogen sulfide, ammonium sulfide, other sulfur-containing compounds, ammonia, indole, methylindoles, p-cresol, amines such as methylamine, dimethylamine and trimethylamine, and odorous organic acids, such as carboxylic acids, e.g., formic acid, acetic acid, propanoic acid and butyric acid, and other volatile fatty acids.
[0034] To activate the innate ability of yeast cells to reduce odor, these cells can be cultured in an appropriate medium under sterile conditions at 25° C.-30° C., e.g., 28° C., for a sufficient amount of time, e.g., 12-350 hours (for example, 70-220, 70-320, 80-310, 85-220, 110-230, or 120-300 hours), in an alternating electric field or a series of alternating electric fields as described above. The culturing process may preferably be conducted under conditions in which the concentration of dissolved oxygen is between 0.025 to 0.8 mol/m 3 , preferably 0.4 mol/m 3 . The oxygen level can be controlled by, for example, stirring and/or bubbling.
[0035] An exemplary culture medium contains in per 1000 ml of sewage water (containing malodorous materials): 0.2 g of NaCl, 0.2 g of MgSO 4 .7H 2 O, 0.5 g of CaCO 3 .5H 2 O, 0.2 g of CaSO 4 .2H 2 O, and 0.5 g of K 2 HPO 4 .
[0036] Subsequently, the yeast cells can be measured for their ability to reduce odor. Various methods and techniques are known to measure the intensity of an odor, including but not limited to gas chromatography, HPLC, and mass spectrometry. A reduction of the intensity of the odor of malodorous materials can also be determined subjectively. One subjective measurement of odor intensity is to measure the dilution necessary so that the odor is imperceptible or doubtful to a human or animal test panel. Any methods and techniques for objectively or subjectively determining the intensity of an odor can be used to monitor the ability of the yeast compositions to reduce odor.
[0037] In an exemplary method, sewage water containing about 2 g/L methylamine/dimethylamine/trimethylamine, 1 g/L indole, 2 g/L p-cresol, 1 g/L hydrogen sulfide, 2 g/L acetic acid and/or 1 g/L ammonia is used as a substrate. The sewage is inoculated with a dry yeast cell preparation, at a concentration of 0.2-0.6 g/L, and cultured for 24 hours at 10-35° C. The level of the malodorous chemical is measured by gas chromatography. The difference between the levels of the above-mentioned malodorous components before and after 24 hours indicates the odor-reducing ability of the yeast cells.
[0038] Essentially the same protocol as described above can be used to grow activated yeast cells. To initiate the process, each 100 ml of culture medium is inoculated with yeast cells of the same functional group at a density of 10 2 -10 5 cells/ml, preferably 3×10 2 -10 4 cells/ml. The culturing process is carried out at 20-40° C., preferably at about 25-28° C., for 48-96 hours. The process can be scaled up or down according to needs. For an industrial scale of production, seventy-five liters of a sterile culture medium are inoculated with the yeast cells. This culture medium consists of 10 L of the culture medium described above for this particular yeast functional group, 30 kg of starch, and 65 L of distilled water. At the end of the culturing process, the yeast cells may preferably reach a concentration of 2×10 10 cells/ml. The cells are recovered from the culture by various methods known in the art, and stored at about 15-20° C. The yeast should be dried within 24 hours and stored in powder form.
[0000] V. Acclimatization of Yeast Cells to Waste Environment
[0039] In yet another embodiment of the invention, the yeast cells may also be cultured under certain conditions so as to acclimatize the cells to a particular type of waste. This acclimatization process results in better growth and survival of the yeasts in a particular waste environment.
[0040] To achieve this, the yeast cells of a given functional group can be mixed with waste material from a particular source at 10 6 to 10 8 cells (e.g., 10 7 cells) per 1000 ml. The yeast cells are then exposed to an alternating electric field as described above. The strength of the electric field can be 100 to 400 mV/cm (e.g., 120 to 250 mV/cm). The culture is incubated at temperatures that cycle between about 5° C. to about 45° C. at a 5° C. increment. For example, in a typical cycle, the temperature of the culture may start at 5° C. and be kept at this temperature for about 1-2 hours, then adjusted up to 10° C. and kept at this temperature for 1-2 hours, then adjusted to 15° C. and kept at this temperature for about 1-2 hours, and so on and so forth, until the temperature reaches 45° C. Then the temperature is brought down to 40° C. and kept at this temperature for about 1-2 hours, and then to 35° C. and kept at this temperature for about 1-2 hours, and so on and so forth, until the temperature returns to 5° C. The cycles are repeated for about 48-96 hours. The resulting yeast cells are then dried and stored at 0-4° C.
[0000] VI. Manufacture of the Waste Treatment Compositions
[0041] The yeast cells of this invention can be mixed with an appropriate filler, such as rock powder and coal ash at the following ratio: 600 L of yeast cell culture at 2×10 10 cells/ml and 760 kg of filler materials. The mixture is quickly dried at a temperature below 65° C. for 10 minutes in a dryer, and then further dried at a temperature below 70° C. for no more than 30 minutes so that the water content is less than 7%. The dried composition is then cooled to room temperature for packaging.
[0042] These dried yeast compositions may be used to treat polluted surface water, sewage, or any other type of waste water. To treat polluted surface water, a yeast solution may be prepared by adding 1 kg of the dried yeast composition to 30 L of clean water. The yeast solution is then sprayed onto the polluted surface water at about 1-3 L of the solution per square meter of the polluted surface water. To treat sewage or any other type of waste water, a yeast solution may be prepared by adding about 1 kg of the dried yeast composition to 10-30 L of clean water. The yeast solution is incubated at 10-35° C. for 24-48 hours. The resultant yeast solution is then added to the waste water at about 3-20 L of the solution per liter of waste water.
EXAMPLES
[0043] In order that this invention be more fully understood, the following examples are set forth. These examples are for the purpose of illustration only and are not to be construed as limiting the scope of the invention in any way.
Example 1
Reduction of Odor Caused by Hydrogen Sulfide
[0044] Saccharomyces cerevisiae Hansen Var. ellipsoideus (Hansen) Dekker AS2.559 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2165 MHz and a field strength of 240 mV/cm for 20 hours; (2) then to an alternating electric field having a frequency of 2175 MHz and a field strength of 240 mV/cm for 20 hours; (3) then to an alternating electric field having a frequency of 2200 MHz and a field strength of 240 mV/cm for 20 hours; and (4) finally to an alternating electric field having a frequency of 2235 MHz and a field strength of 240 mV/cm for 20 hours.
[0045] To test the ability of the EMF-treated AS2.559 cells to reduce odor caused by hydrogen sulfide, waste water or filtrate from animal manure or garbage was supplemented with H 2 S to reconstitute a solution containing H 2 S at 100 mg/L. 0.1 ml of the EMF-treated AS2.559 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the H 2 S solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the H 2 S solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the H 2 S concentration of solution A decreased more than 13% relative to solution C. In contrast, the H 2 S concentration of solution B had no significant change relative to solution C.
Example 2
Reduction of Odor Caused by Ammonia
[0046] Saccharomyces cerevisiae Hansen AS2.423 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2160 MHz and a field strength of 250 mV/cm for 20 hours; (2) then to an alternating electric field having a frequency of 2175 MHz and a field strength of 250 mV/cm for 20 hours; (3) then to an alternating electric field having a frequency of 2210 MHz and a field strength of 250 mV/cm for 20 hours; and (4) finally to an alternating electric field having a frequency of 2245 MHz and a field strength of 250 mV/cm for 10 hours.
[0047] To test the ability of the EMF-treated AS2.423 cells to reduce odor caused by ammonia, waste water or filtrate from animal manure or garbage was supplemented with ammonia to reconstitute a solution containing ammonia (in the form of ammonium hydroxide) at 100 mg/L. 0.1 ml of the EMF-treated AS2.423 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the ammonia solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the ammonia solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the ammonia concentration of solution A decreased more than 11% relative to solution C. In contrast, the ammonia concentration of solution B had no significant change relative to solution C.
Example 3
Reduction of Odor Caused by Indole
[0048] Saccharomyces cerevisiae Hansen Var. ellipsoideus (Hansen) Dekker AS2.612 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2165 MHz and a field strength of 240 mV/cm for 40 hours; (2) then to an alternating electric field having a frequency of 2180 MHz and a field strength of 240 mV/cm for 20 hours; (3) then to an alternating electric field having a frequency of 2200 MHz and a field strength of 240 mV/cm for 40 hours; and (4) finally to an alternating electric field having a frequency of 2220 MHz and a field strength of 240 mV/cm for 20 hours.
[0049] To test the ability of the EMF-treated AS2.612 cells to reduce odor caused by indole, waste water or filtrate from animal manure or garbage was supplemented with indole to reconstitute a solution containing indole at 100 mg/L. 0.1 ml of the EMF-treated AS2.612 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the indole solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the indole solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the indole concentration of solution A decreased more than 15% relative to solution C. In contrast, the indole concentration of solution B had no significant change relative to solution C.
Example 4
Reduction of Odor Caused by Methylamine, Dimethylamine or Trimethylamine
[0050] Saccharomyces cerevisiae Hansen Var. ellipsoideus (Hansen) Dekker AS2.541 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2160 MHz and a field strength of 250 mV/cm for 20 hours; (2) then to an alternating electric field having a frequency of 2190 MHz and a field strength of 250 mV/cm for 10 hours; (3) then to an alternating electric field having a frequency of 2210 MHz and a field strength of 250 mV/cm for 40 hours; and (4) finally to an alternating electric field having a frequency of 2250 MHz and a field strength of 250 mV/cm for 40 hours.
[0051] To test the ability of the EMF-treated AS2.541 cells to reduce odor caused by methylamine, dimethylamine or trimethylamine, waste water or filtrate from animal manure or garbage was supplemented with methylamine, dimethylamine, or trimethylamine to reconstitute a solution containing methylamine, dimethylamine, or trimethylamine at 100 mg/L. 0.1 ml of the EMF-treated AS2.541 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the methylamine, dimethylamine or trimethylamine solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the methylamine, dimethylamine or trimethylamine solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the methylamine, dimethylamine or trimethylamine concentration of solution A decreased more than 23% relative to solution C. In contrast, the methylamine, dimethylamine, or trimethylamine concentration of solution B had no significant change relative to solution C.
Example 5
Reduction of Odor Caused by Organic Acids
[0052] Saccharomyces cerevisiae Hansen Var. ellipsoideus (Hansen) Dekker AS2.53 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2315 MHz and a field strength of 290 mV/cm for 30 hours; (2) then to an alternating electric field having a frequency of 2335 MHz and a field strength of 290 mV/cm for 10 hours; (3) then to an alternating electric field having a frequency of 2355 MHz and a field strength of 290 mV/cm for 20 hours; and (4) finally to an alternating electric field having a frequency of 2375 MHz and a field strength of 290 mV/cm for 10 hours.
[0053] To test the ability of the EMF-treated AS2.53 cells to reduce odor caused by organic acids, waste water or filtrate from animal manure or garbage was supplemented with acetic acid to reconstitute a solution containing acetic acid at 100 mg/L. 0.1 ml of the EMF-treated AS2.53 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the acetic acid solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the acetic acid solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the acetic acid concentration of solution A decreased more than 19% relative to solution C. In contrast, the acetic acid concentration of solution B had no significant change relative to solution C.
Example 6
Reduction of Odor Caused by p-Cresol
[0054] Saccharomyces cerevisiae Hansen Var. ellipsoideus (Hansen) Dekker AS2.163 cells were cultured in the presence of a series of alternating electric fields in the following sequence: the yeast cells were exposed to (1) an alternating electric field having a frequency of 2300 MHz and a field strength of 98 mV/cm for 20 hours; (2) then to an alternating electric field having a frequency of 2370 MHz and a field strength of 98 mV/cm for 15 hours; (3) then to an alternating electric field having a frequency of 2300 MHz and a field strength of 250 mV/cm for 20 hours; and (4) finally to an alternating electric field having a frequency of 2370 MHz and a field strength of 250 mV/cm for 30 hours.
[0055] To test the ability of the EMF-treated AS2.163 cells to reduce odor caused by p-cresol, waste water or filtrate from animal manure or garbage was supplemented with p-cresol to reconstitute a solution containing p-cresol at 100 mg/L. 0 . 1 ml of the EMF-treated AS2.163 cells at a concentration higher than 10 8 cells/ml was added to 100 L of the p-cresol solution and cultured at 28° C. for 24 hours (solution A). One hundred liters of the p-cresol solution containing the same number of non-treated yeast cells (solution B) or containing no yeast cells (solution C) were used as controls. After 24 hours of incubation, the solutions were examined using mass spectrometry (MAS-nose, manufactured by VG). The results showed that after 24 hours of incubation, the p-cresol concentration of solution A decreased more than 23% relative to solution C. In contrast, the p-cresol concentration of solution B had no significant change relative to solution C.
[0056] While a number of embodiments of this invention have been set forth, it is apparent that the basic constructions may be altered to provide other embodiments which utilize the compositions and methods of this invention.
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Compositions comprising a plurality of yeast cells, wherein said plurality of yeast cells have been cultured in the presence of an alternating electric field having a specific frequency and a specific field strength for a period of time sufficient to substantially increase the capability of said plurality of yeast cells to reduce odor of a culture medium. Also included are methods of making such compositions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for improving the feed of diesel engines at low temperatures, particularly at temperatures lower than the clouding point of gas oils without modifying the specific chemical characteristics of the gas oil.
2. Discussion of the Background
The use of gas oil in diesel engines at temperatures lower than the cloud point temperature raises a number of operating problems linked to clogging of the filter. The clouding point corresponds to the temperature where crystallization of the paraffins occurs within the gas oil. For temperatures less than this clouding point temperature, if no heating means are provided, these paraffins will be stopped by the fuel filter, during operation of the engine, and will concentrate until the filter is clogged, thus causing a stoppage of the engine through lack of feed.
A solution for overcoming these drawbacks is to modify the specifications of the engine gas oil depending on the seasons, i.e. the clouding point, the flow point and the limit temperature of filterability. For economic reasons, gas oils never have characteristics sufficient for complying with the operating requirements imposed by the lowest temperatures met with. Thus, if it is desired to eliminate all the operating problems of diesel engines at low temperatures, heating devices will have to be associated therewith.
A heating device for recycling the excess gas oil flow from the injection pump, called "scavenging flow", upstream of the fuel filter, by means of a thermostatic valve is disclosed in the French patent application No. 2 456 223, filed in the name of ELF UNION. In this device, after a short operating time of the engine, the gas oil from the scavenging flow has reached a sufficient temperature so that, mixed with the gas oil coming from the reservoir, the mixture is fed to the injection pump at about 25° Celsius. The thermostatic element then regulates the scavenging flow so as to maintain the temperature constant while recycling a more or less large amount of gas oil to the reservoir. For temperatures greater than 25° Celsius, the thermostatic element recycles the entire scavenging flow to the reservoir. Under these circumstances, the gas oil, still at temperatures close to the clouding point in the reservoir, will be fed directly from the reservoir to the thermostatic element, the filter then the high pressure pump, which causes an oscillatory phenomenon which further slows down heating of the gas oil contained in the reservoir.
A device is also known, from French patent application No. 2 256 323, for preheating the gas oil using the exhaust gases of the engine in an exchanger before feeding it into the injection pump. However, this device plays the same role as the preceding device using the scavenging flow and does not solve the problem of heating the gas oil in the reservoir and cooling of the injection pump by the scavenging flow.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an improvement using the principle of recycling the scavenging flow, while overcoming the above-mentioned drawbacks of the prior art.
This first aim is attained by the fact that the device for improving the feed of diesel engines at low temperatures, particularly temperatures lower than the clouding point of the gas oils, without modifying the specific chemical characteristics of the gas oil, by recycling the scavenging flow from the injection pump, is characterized in that recycling takes place either upstream of the fuel filter and is associated with recirculation to the reservoir of the gas oil coming from the reservoir through a heat exchanger or dirrectly to the reservoir with direct feeding of the filter by the reservoir.
In an advantageous arrangement, the recycling is controlled by a thermoelectric element placed at the outlet of the reservoir and controlling the action of an excess pressure pump causing, on the one hand by opening a valve, recycling of the scavenging flow upstream of the filter and, on the other hand, recirculation to the reservoir of the gas oil coming from the reservoir through a heat exchanger. Another characteristic concerns the provision of a differential valve which places the reservoir in communication either with the heat exchanger or directly with the filter.
According to another characteristic, a one-way or non return valve is disposed between the overpressure pump and a return duct to the reservoir connected to the scavenging outlet of the injection pump.
Another object of the invention is to provide an improvement which makes possible both cold starting and heating of the gas oil in the reservoir, while providing operating conditions such that the injection pump is not subjected to excessive heating.
This object is attained by the fact that a thermostatic element places the heat exchanger in direct communication with the upstream portion of the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and features of the present invention will appear more clearly from reading the following description with reference to the accompanying drawings in which :
FIG. 1 shows schematically the improvement of the invention in its operating mode during the gas oil heating phase;
FIG. 2 shows the improvement of the invention in its operating mode when the whole of the gas oil in the reservoir has been heated;
FIG. 3 shows an alternate embodiment of to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the entire of the device forming the improvement of the present invention and comprising a duct 3 for conveying the gas oil contained in a reservoir (not shown) either to an exchanger 4 through a duct 30,or to a mixing pot 9 through a duct 31. The selection of feeding the gas oil into exchanger 4 or into the mixing pot 9 is provided by a differential valve 13. A duct 40 brings the water circulating in the engine to the exchanger 4, whereas a duct 41 removes this circulating water. An outlet 42 of exchanger 4 is connected to the inlet of an excess pressure 1 whose outlet is connected through a first one-way nonreturn valve 12 to a first duct 11 and a second duct 5. The second duct 5 is in communication with a gas oil reservoir R. The first duct 11 places pump 1 in communication with the scavenging flow outlet 7 of a high pressure pump 8, called a injection pump. This injection pump 8 delivers, through its ducts 80, the gas oil which is fed to the injectors, (not shown). The scavenging outlet 7 is in communication through a duct 14 with a second one-way or non return valve 6 and is connected through a duct 15 to the mixing pot 9. This nonreturn valve 6 places the scavenging outlet 7 in communication with the mixing pot 9. This nonreturn valve places the scavenging outlet 7 in communication with the mixing pot 9 when a sufficient excess pressure is present in duct 14. The mixing pot 9 communicates through a duct 16 with a filter 10 which is itself in communication, through duct 17, with the injection pump 8. Finally, a thermoelectric element 2, disposed in duct 3, provides control of the start-up of pump 1 as a function of the temperature of the gas oil flowing through duct 3.
The operation of the device will now be described. The electric pump 1, controlled by the thermoelectric element 2 disposed in the gas oil intake duct 3, below a certain temperature close to the clouding point, controls the flow of the cold gas oil through exchanger 4 so as to heat it by the cooling water of the engine. The gas oil from the exchanger 4 is recycled, on the one hand to the reservoir in the direction of arrow c through the return duct 5 and, on the other hand, to the scavenging outlet 7 in the direction of arrow b. The excess pressure at the outlet of the pump causes opening of the two valves 12 and 6. The second valve 6 allows the scavenging flow coming from the outlet 7 of the injection pump 8 to flow in the direction of arrow a while mixing with the gas oil coming from the exchanger 4 and shown by the arrow b. This mixture is recycled in the mixing pot 9 upstream of the filter 10 since, during operation of the pump 1, valve 13 is in the position shown in FIG. 1, which prevents direct feeding of pot 9 from the reservoir through ducts 3 and 31. Thus, in this operating mode of the invention, corresponding to start-up of the engine, the gas oil corresponding to the consumption of the engine will be conveyed by duct 11 because of the outlet pressure of the electric pump 1, whereas the considerable recycled flow at the outlet 7 of the injection pump 8 is mixed with this gas oil so as to heat this latter and recycle it upstream of filter 10. Thus, clogging of the filter will be correspondingly slower since only the gas oil consumed by the engine will be charged with crystallized paraffin. In such operation, the gas oil corresponding to the scavenging flow and heated by passing through the injection pump 8, is used for heating the gas oil coming from the electric pump 1. Furthermore, the gas oil pumped from the reservoir by the electric pump 1 will be progressively heated by the circulating water of the engine.
As the temperature of the cooling water of the engine rises, the gas oil will be heated and a part thereof will be recycled to the reservoir for heating the gas oil in the reservoir. This makes it possible to pass above the temperature of the clouding point and to reliably eliminate the problem of clogging of the filter 10.
FIG. 2 shows the operation of the device, when the intake temperature of the gas oil at the level of the thermocontact 2 exceeds 10° Celsius. In this case, the circulation pump 1 stops operating, valve 13, through the differential pressures, closes the communication of duct 30 with exchanger 4 and the feed takes place in a conventional way, in the direction of arrow d. The gas oil coming from the reservoir through duct 3 flows directly into the mixing pot 9 so as to pass through the fuel filter 10. The fluid delivered by the scavenging outlet 7 does not leave at a sufficient pressure to open the second valve 6 and will flow in duct 11 in the direction of arrow f and return to the reservoir. The first valve 12 prevents the return flow, in the direction of arrow f, from passing again towards the excess pressure pump 1. Thus, at the outlet of the injection pump 8, the scavenging flow can only go towards duct 11 then to duct 5 for returning to the reservoir, since the second valve 6 prevents recycling because of the absence of excess pressure. Exchanger 4 thus isolated from the rest of the circuit does not allow the gas oil to be heated in this configuration. Furthermore, it will be noted that the circulating pump 1 will be chosen so as to have a flow rate making possible complete cycling of the reservoir in an hour so as to heat the fluid contained therein in the same time.
FIG. 3 shows a variant of the invention which differs from the construction of FIGS. 1 and 2 by the fact that a duct 34, connecting exchanger 4 with the mixing pot 9, is closed by a valve 115 controlled by a supplement thermostatic valve 114.
With this modification, the operation of the device of the invention is as follows.
If recycling of the scavenging flow causes an excessive temperature in the mixing pot 9 and consequently overheating of the supplement injection pump 8, the thermostatic element 114 controls the opening of valve 115 so as to temporarily stop recycling as long as the latter is operating. The opening of valve 115 makes direct feed possible by the gas oil coming from the exchanger 4 in the direction of arrow e. The thermostatic element 114 will be set so that opening of valve 15 is complete at 30° Celsius.
With this variant, whatever the conditions, the feed temperature of the injection pump can be kept constant and the performances of the vehicle thus maintained.
Thus, using the means described above, the injection pump 8 is cooled and the injection gas oil is heated by the scavenging flow during the start-up phase and, finally, heating of of all of the gas oil contained in the circuit and the reservoir, without causing overheating of the injection pump or an oscillatory phenomena.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A device for improving the feed of diesel engines at low temperatures, particularly at temperatures less than the cloud point of gas oils, without modifying the specific chemical characteristics of the gas oil by recycling the scavenging flow from the injection pump, characterized in that recycling takes place either upstream of the fuel filter and is associated with recirculation towards the reservoir of the gas oil coming from the reservoir through a heat exchanger or directly in the direction of the reservoir with direct feed of the filter by the reservoir.
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BACKGROUND OF THE INVENTION
The present invention relates to a device for actuating an equipment, associated with a drill string lowered in a well, and in which a drilling fluid whose basic function is to provide all the conventional drilling functions circulates. The actuating device according to the invention uses directly the hydraulic energy of the pressure of the circulating drilling fluid for actuating the equipment.
In the oil drilling field, it is often necessary to actuate equipment or tools incorporated in a drill string lowered in a wellbore. This may notably be the case for carrying out controlled directional drillings, exploratory measuring or testing operations or various operations for fitting up production wells.
The prior art mentions several well-known methods for actuating bottomhole equipment. They may consist in pumping tools into the pipe which, once they have reached the level of the equipment, activate it. Instead of pumping, a ball or an equivalent may be dropped into the drill string. These conventional methods present notably the drawback of sealing totally or, at best, temporarily the inner channel of the string, and therefore of requiring a more or less long pumping stop. Now, in drilling, it is always very dangerous not to keep the drilling fluid circulating. In fact, when the upward circulation of the fluid in the well-string annulus is too low, or even zero, there are risks of destabilization of the walls. Moreover, the cuttings being no longer taken up to the surface, they tend to settle and are likely to jam the string.
For all these reasons, technical development turned towards the use of other types of actuation. The action of weight on the tool, of the rotating speed or a combination of both may be used. But, in this case, constructions are very complex and little reliable for checking the control of these drilling parameters.
Patent EP-251,543-A for example is well-known, in which the actuation of a variable geometry stabilizer is achieved by weight on the tool. But the actuating system requires the action of an axial force up to a critical value with no positive locking in a determined position. The user is sometimes faced with error risks concerning knowledge of the position of the equipment. Besides, the weight on the tool is a parameter linked to the drill bit and has a direct influence on the drilling performance, so users do not wish to be limited in the use of this force for anything else than drilling progress.
The device of the present invention does not interfere at any time with the drilling parameters, be they hydraulic or mechanical.
Patent application EP-376,811 mentions a known actuating device comprising a needle-choke system using the hydrodynamic action of the drilling fluid circulation. This document describes the use of a flow rate increase for generating a pressure difference between upstream and downstream from the device sufficiently high for obtaining the actuation. It is obvious that, in this document, the pressure drops downstream from the device reduce the activation force.
On the contrary, in the present invention, all the pressure drops in the string downstream from the device are active for the actuation. This represents a definite advantage since these pressure drops always have sizeable values considering the indispensable presence of bits restricting the passageway, notably a drill bit. The necessary level of activation energy may thus be obtained more easily while remaining in normal operating conditions, which practically suppresses all the interferences with the wellbore surroundings.
In the prior art, which may be illustrated by patent application EP-376,811 cited above, inner mechanisms, notably activation, indexing and locking mechanisms, impose a specific lubrication of the parts. They must therefore be tight in relation to the presence of a fluid under pressure such as the drilling fluid. All these constraints are suppressed by the invention which uses directly the drilling fluid without any other buffer or intermediate fluid.
SUMMARY OF THE INVENTION
The present invention thus relates to a device for actuating equipment, associated with a drill string lowered in a well, and in which a drilling fluid circulates, said circulation generating a positive differential pressure DP between the inner space and the outer space of said string. Said device comprises distribution means comprising at least two ports, one of the ports being connected through a pipe to displacement means, the other port being connected through a pipe to said inner space. Said distribution means are adapted for controlling the communication of said drilling fluid under pressure between the inner space of the string and an intake port for said displacement means. The latter further comprise another exhaust port connected through a pipe to said outer space.
Said displacement means are adapted for being activated by converting the hydraulic energy resulting from the differential pressure DP of said drilling fluid between said two intake and exhaust ports into a mechanical activation energy. Conversion is achieved directly with the co-operation of no other fluid than said drilling fluid, and said distribution means comprise a portion in which the pipe connecting said distribution means to said intake port of said displacement means is closed.
Said distribution means of the device according to the invention may comprise two inlet ports and two outlet ports communicating two by two. Said distribution means may be adapted for reversing communications. The inlet ports are then connected through pipes, one to the inner space, the other to the outer space and the outlet ports are then connected through pipes, one to the intake port of said displacement means, the other to the exhaust port, the distribution means being also adapted for closing the two outlet ports.
The distribution means may comprise a two-position gate valve with two ports, and said displacement means may comprise return means. In a first position, said gate valve can open the communication of said drilling fluid between the inner space of the string and said displacement means, said displacement means being activated when said mechanical activation energy is higher than the energy developed by said return means. In a second position, said gate valve may shut off the pipe communicating said drilling fluid between the inner space and said displacement means.
The displacement means may be of the longitudinal jack type whose two chambers, notably separated by a sealed piston, are filled by said drilling fluid. Said piston is notably subjected to said differential pressure DP.
The distribution means may be remote controlled from the surface.
The displacement means may comprise several longitudinal jacks arranged in series and a translating shaft co-operating with a variable geometry stabilizer.
The displacement means of the present invention may comprise a needle-choke system restricting the passage of the drilling fluid in said inner space at the end of the activation stage of said means.
The invention also provides a method for using the device comprising the following stages:
setting, notably by pumping at the surface, the value of the differential pressure DP to a determined value,
controlling said distribution means so as to allow the circulation of said drilling fluid under pressure between the inner space and said displacement means,
actuating the equipment by activating said displacement means when said mechanical energy is higher than the energy developed by the return means of said displacement means,
controlling said distribution means so as to shut off communication between the inner space and said displacement means and to lock said displacement means in position,
controlling said distribution means so as to open communication between the inner space and said displacement means and decreasing the differential pressure DP, notably by adjusting the pumping, until the energy developped by said return means is higher than said mechanical energy.
The present invention also relates to the application of the device and of the previous method to directional drilling.
The basic idea of the invention is to use directly the hydraulic energy available in a pipe in which a fluid under pressure circulates. In fact, the actuating device of the invention may be compared to a shunted hydrostatic circuit between the inner space and the outer space of the string. Part of the hydraulic energy is sent towards the displacement means. A distribution means control the admittance or not of this energy towards the displacement means having the function of a receiver. In order to simplify the pattern of the various elements, to limit maintenance while increasing the reliability of the device, the hydraulic fluid used is directly the drilling fluid present in the inner channel of the string. In this invention, the distribution means, the displacement means and the equipment are adapted for working with any type of drilling fluid.
One advantage of the invention is to use the differential pressure prevailing at the level of the device between the inside pressure and the outside pressure so as to obtain the necessary actuating energy. It should be noted that the useful pressure in the inner space is generated by the pressure drops downstream from the device. Consequently, in this invention, it is generally not necessary to shut off the circulation channel to be able to activate. Contrarily to document EP-376,811 cited above, in which the active pressure is the differential pressure inside the channel between upstream and downstream from the device, and the more pressure drops there are downstream, the less active the pressure is.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will be clear from reading the description hereafter given by way of non limitative example, with reference to the accompanying drawings in which:
FIG. 1 shows a block diagram of the device,
FIG. 2 shows a flow sheet of the device,
FIGS. 3A, 3B and 3C are hydrostatic diagrams showing three types of circuits allowing the embodiment of the device,
FIGS. 4A, 4B, 4C and 4D show a preferred embodiment of the device according to the present invention,
FIGS. 5, 6, 7 and 8 are cross-sections at various levels of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a block diagram of said device in which:
PI and PA are respectively the pressures in the inner space and in the outer space of the drill string,
TC are control or remote control means;
D are distribution means operated by a motor means M;
P is the power necessary to the motor means;
R are displacement means or receiver;
FA is a mechanical action;
E is the equipment to be actuated;
dotted lines RD and RE respectively reproduce the state of the displacement means and of the equipment.
This diagram shows the various functional connections that link together the parts constituting the device. Control TC is connected to the surface through the hydraulic transmission of information sequences as disclosed in document EP-A-377,376. Other transmission types, notably through electric cable, optical fibers, pressure waves or electromagnetic waves may be used without departing from the scope of this invention. Part TC sends signals towards motor means M. The motorization power P is supplied by a set of electric accumulators. If the transmission mode is a cable transmission, the energy may transit by means of this cable. A power generator working notably from the circulation of the drilling fluid may also be integrated to the string.
M operates distribution means D. The latter controls the hydraulic energy available between PI and PA and supplies or not said energy towards the displacement means or the receiver. R is notably of the single-acting jack type with a return spring or a double-acting jack. One chamber of the jack receives directly the drilling fluid at the pressure PI and the other chamber contains the same fluid but at the pressure PA. The displacement of the piston and the thrust force corresponding to the action of the pressures provide the activation energy of mechanical action FA. The latter actuates equipment E.
Without departing from the scope of this invention, receiver R may be of a type other than a longitudinal jack, notably a rotary jack, a rotary engine or a turbine. In these cases, mechanical action FA may have notably the form of the rotation of a couple of forces.
Dotted line RD represents the return signal sent by sensors locating the position of the displacement means. This signal, which may transit towards the surface, allows checking the achievement of the command at the level of the receiver.
Dotted line RE represents a signal indicating the actuation of equipment E. This signal is notably a pressure increase in the inner space of the string, but the signal may be of another nature and transit through other transmission means without departing from the scope of this invention.
FIG. 2 shows the principle of the relative lay-out of the various parts constituting the invention.
Equipment 3 is associated with a pipe 1 which is in a drill string, in which a drilling fluid shown by arrows 2 circulates. Control means TC 4, distribution means 6 and displacement means 10, such as a jack, are integrated in the drill string. Control means 4 are connected to distribution means 6 by conductors 5.
Distribution means 6 comprise a gate valve 7 controlling the circulation of the drilling fluid through a pipe opening at 8 in the inner space 17 of pipe 1, and at 9 in a chamber 11 of displacement means 10. A sealed piston 14 separates chamber 12 from chamber 11. Chamber 12 communicates with space 18 outside pipe 1 through the pipe opening in 13.
The mechanical connection between displacement means 10 and equipment 3 to be actuated comprises a shaft 15 and return means 19. Arrow 16 shows an actuating force.
Without departing from the scope of this invention, communication through the pipe opening in 13 may also be controlled by the distribution means as shown in the circuit diagrams of FIG. 3A and FIG. 3B.
FIG. 3A shows a hydrostatic circuit integrated in said device. The distribution means comprise a four-way distributor 25 with two positions. This type of distributor, well-known in industry, may have multiple technical embodiments, notably a slide valve, a rotary distributor or a pilot-controlled check valve. The control signals coming from TC 4 are shown by lines 28 and 29.
An inlet pipe 21 is connected with the outer space PA. Pipe 20 is connected with the inner space PI.
An outlet pipe 23 is connected to the intake port of receiver 30. The exhaust port thereof is connected through a pipe 24 to the other outlet of distributor 25. The mechanical connection or shaft 15 co-operates with the equipment 3 to be actuated.
This circuit schematically represents an inversion function. In one position of the distributor, the drilling fluid under pressure coming from PI is run towards 9, the exhaust is then run towards PA through pipes 24 and 21.
In the second position, PI communicates with the exhaust through pipe 24 and intake 9 is then connected to PA through 23 and 21.
In the case illustrated by FIG. 3A where the receiver is a double-acting jack, this circuit allows the forward or the backward motion of said jack to be controlled.
FIG. 3B shows an improvement in the previous circuit insofar as distributor 26 is a four-way distributor with three positions. The additional third position being that in which pipes 20, 21, 23 and 24 are shut off. In this position, the displacement of the jack is blocked in all directions. In fact, considering that the drilling fluid contained in chambers 11 and 12 and in pipes 23 and 24 is practically incompressible and that there are substantially no leaks, the jack cannot move.
FIG. 3C shows a simplified hydrostatic circuit where jack 30 is a single-acting jack with a return spring 19 or an equivalent, a two-way distributor 27 with two positions, the exhaust of the jack being connected to PA through channel 22 directly, without any control through the distributor.
In one position of the distributor, PI communicates with the intake of the jack, in the other position the distributor shuts off pipe 23 and allows the displacement means or jack to be immobilized according to the same principle as in FIG. 3B.
It should be noted that these three types of circuits are adapted so that the carrier fluid is a drilling fluid. To that effect, it will notably be necessary to modify the dimensions of the pipes, the technology of the seals and the selection of the materials used according to the nature of the fluid, notably with respect to corrosion.
These circuits are also adapted for working with other receivers than longitudinal jacks.
The actuating principle of the device according to the invention allows controlled displacements and thus multiple actuations of the equipment. In fact, this advantage may be illustrated in a non limitative way by taking hereafter a jack as the receiver. The device allows the volume of fluid admitted into chamber 11 to be controlled, and knowing the displacement of the jack, notably through sensors, makes it possible to obtain a specific adjustment of the actuation of the equipment after the displacement of the jack.
Without departing from the scope of this invention, the displacement of the jack and thus of the equipment may also be pilot operated by means of position sensors and of the servocontrol electronics contained in the control system.
Of course, it will always be possible to operate in a more simplified way between the two extreme positions of the longitudinal jack.
The device may be equipped with a positive locking on the positioning of the equipment. This locking, not shown, may be controlled by the same control means TC.
FIGS. 4A, 4B, 4C and 4D show four stages of the most important elements of a drilling equipment actuated by the device of the invention. This equipment is a variable diameter stabilizer whose variable geometry is obtained through the activation of the actuating device of the present invention.
The equipment consists of a cylindric body 40 comprising at each end a conventional thread 41 (only the lower connection is shown). These threads allow this equipment to be integrated in a drill string as is usually done in the trade.
FIG. 4A shows the upper stage of said equipment where the remote control means are located. These means comprise a mechanical assembly 42, batteries 43 or electric accumulators and an electronic cartridge 44. This cartridge translates the commands transmitted through pressure signals from the surface. All these means located inside body 40 must be centered and fastened with mechanical means which let the drilling fluid circulate freely in an inner channel 45. This is illustrated by sections 5 and 6 in FIGS. 5 and 6.
FIG. 4B shows the device for actuating the equipment. An electric motorization 46 controlled by electronic cartridge 44 and supplied by accumulators 43 adjusts the position of gate valve 47. The displacement of valve 49 in relation to the seat 50 thereof opens or shuts off this gate valve 47. When the valve is lifted with respect to the seat thereof, channel 51 communicates through port 48 with the inner space of the string, that is channel 45 where the drilling fluid circulates. The drilling fluid under pressure is then run through channel 51 to the volume of chamber 52. A piston 53 comprising joints 54 tightly separates chamber 52 from chamber 55. These chambers result from the co-operation of piston 53 and of a cylinder 53a. Joints 67 complete the seal of chamber 55 around the rod 66 of piston 53. The volume of chamber 55 communicates with the outer space by means of port 62 and of channel 69 which opens therein through port 63. A check valve 90 prevents any fluid leakage from chamber 52 towards the outside through port 63, but it allows an injection, notably for cleaning, through port 63 towards chamber 52, channel 51, gate valve 47 and port 48. This operation can only be achieved when the device is at the surface.
Rod 66 is mechanically connected to another piston 58 with a stroke identical to the first one. Chamber 57 communicates with chamber 52 through a pipe 56 pierced in rod 66. The volume of chamber 60 also communicates with the outside through port 61 and channel 70 which joins channel 69. Seal gaskets 68 are arranged around the rod 59 of the second piston 58.
More than two pistons may be assembled in series in accordance with the previous lay-out without departing from the scope of this invention. It is the same if the displacement means amount to a single piston when the actuating force developped thereby is sufficient.
The body 71 of the double jacks, in which the liners 53a and 58a of pistons 53 and 58 have been machined, has an outer shape adapted for being placed in the inside diameter of body 40 and for letting a sufficient section of flow 45 for the fluid. FIG. 7 shows the section of flow of the fluid at the level of the body 71 of the double jack.
Rod 59 is connected to the actuating shaft through an assembly 64.
Piston 53 comprises an extension rod 77. This rod has a magnet 78 at the end thereof. Three supple blade switches 79 have been arranged in the receptacle 80 of extension rod 77.
FIG. 4C shows the equipment actuated by the double jack. The shaft 72 is crossed by a channel 65 allowing the circulation of the drilling fluid.
Shaft 72 has on the outer surface thereof flat surfaces 73 inclined with respect to the longitudinal axis thereof and forming ramps. Stabilizer blades 74 rest against these inclined ramps 73. Springs 76 return blades 74 in a centripetal way. Joints 75 complete the seal of shaft 72 which co-operates with the inner wall of body 40.
FIG. 8 shows a cross-section 8 of the variable geometry stabilizer where three blades 74 are arranged at angles of 120° on the circumference of body 40. Other layouts or a different number of blades may be used without departing from the scope of this invention.
FIG. 4D shows the lower part of the equipment. Shaft 72 comprises another seal gasket 81. A return spring 82 rests on one side against a support 85 integral with body 40 and on the other side against the end of shaft 72.
The section of the inner channel 65 of shaft 72 is reduced at the lower end 83 thereof so as to co-operate with needle 84 axially integral with body 40.
A key 86 prevents the rotation of shaft 72 on the longitudinal axis thereof with respect to body 40.
The following successive stages should be considered for describing clearly the operating mode of this equipment actuated by the device of the present invention:
the order to open gate valve 47 has been given, which results in balancing the pressures between the inside of the string and chambers 52 and 57;
the circulation of the drilling fluid in channel 45 is stopped or has already been stopped, the differential pressure between the inside and the outside of the string is substantially zero;
the force of return spring 82 is then preponderant as there is no stress on pistons 53 and 58 because of the absence of differential pressure;
the shaft is in higher position and blades 74 are retracted in body 40;
if the circulation of the drilling fluid is started again, the inside pressure at the level of the device will increase in relation to the outside pressure. The pressure acting on pistons 53 and 58 substantially depends on the pressure drops generated on the path of the drilling fluid between the inside 45 and more precisely at the level of port 48 and the outside pressure, more precisely at the level of port 63;
when the pressure in chambers 52 and 57 of the jacks develops a force higher than the return forces, the jacks slide while pushing shaft 72 downwards;
at the same time, the blades of the stabilizer are pushed radially towards the outside;
rod 77 follows the displacement of the jacks and magnet 78 lies, at the end of the travel thereof, opposite a supple blade switch 79, the latter is activated and acts as an end-of-travel contactor. The signal provided by the contactor is used for shutting off gate valve 47. According to the remote control modes, this signal may transit up to the surface and inform of the end of the actuation in a positive way, but in a more simplified way, this signal is only internally looped on electronic cartridge 44. The actuation information is then supplied by the pressure increase which can be measured at the surface. This increase results from the co-operation of choke 83 with needle 84 at the end of the displacement of shaft 72;
gate valve 47 being shut, a volume of drilling fluid under pressure has been trapped in the volumes of chambers 52 and 57 and in channel 51. Gate valve 47 isolating this volume from the outer space, the pressure range in the inner space can be changed through different pumping conditions without any change of state of the actuating means, that is the equipment. The gate valve is thus used as a means for immobilizing the equipment when the blades are out. The device may be equipped with a mechanical locking controlled through the electronic cartridge 44 of the remote control. This locking may have different forms known in the prior art, notably electromagnetically retractable hooks. Without departing from the scope of this invention, the position of the displacement means can be pilot-operated by means of supple blade switches 79. In fact, if there is a leak at gate valve 47, extension rod 77 moves with respect to the switch. The signal obtained can then control the opening of gate valve 47 so as to compensate the leak and to hold the displacement means in position;
to come back to a state identical to the original one, which may be called state of rest, giving the order to open gate valve 47 is sufficient, while adjusting, if need be, the pumping conditions so as to have a pressure difference DP either zero or low enough for spring 82 to push back shaft 72, the double jacks and rod 77. When magnet 78 activates upper position limit switch 79, the gate valve is automatically closed so as to insulate the actuating means from the inner pressure conditions.
It is advantageous, in this particular embodiment, to place at least a third blade switch 79 between the two end-of-travel extremes. The intermediate switch allows an intermediate position of the stabilizer blades. In fact, if the order given from the surface corresponds to the activation of the stabilizer at an intermediate diameter, when the means and rod 77 jointly move, the magnet, by activating the intermediate switch, immobilizes the assembly by shutting gate valve 47 when the jacks are halfway. The blades of the stabilizer will be partly out and the stabilizer will be set to an intermediate diameter. The locking or the servo-control means described above can provide this intermediate position.
It appears that this device allows as many actuating adjustments as different commands can be sent from the surface and translated at the level of the device. But each adjustment must have a specific position sensor.
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The present invention is a device for the remote actuation of equipment (3) associated with a drill string (1) through a hydraulic displacement mechanism (10;53,58) co-operating with a distributor (7;25,26,27;47) associated with the drilling fluid. The displacement mechanism directly converts the hydraulic energy of the drilling fluid into actuating mechanical energy with the co-operation of no other fluid than the drilling fluid. The invention further relates to an actuating method using the device and has an application of directional drilling in the petroleum field.
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RELATED APPLICATION
[0001] Priority is claimed to U.S. Provisional Application No. 60/995,513, filed Sep. 26, 2007, the disclosure of which is incorporated by reference herein
FIELD OF THE INVENTION
[0002] This invention relates to the production of charcoal from biomass.
BACKGROUND OF THE INVENTION
[0003] The term “biomass” includes many types of woody and herbaceous plant material, such as wood logs, slabs, chips, and bark; and agricultural residues such as corncobs, corn stover, sunflower shells and husks, nutshells, olive cake, and sugar cane bagasse. Biomass may also include the organic fraction of municipal solid wastes (including rubber tires), sewage sludge, manure, or other excrement, and the residues of animal husbandry, such as bones and carcasses. The term “inert” in the context of the present invention means that such compound, composition or material does not react with biomass, or its byproducts of pyrolysis, at temperatures and pressures attained within the reaction container in the practice of the present invention.
[0004] Charcoal is a carbonaceous solid with a fixed-carbon content of about 70 wt % or more. Charcoal is usually manufactured from hardwoods by pyrolysis in large kilns or retorts at temperatures below about 500° C. When charcoal is heated (“carbonized”) in an inert environment to temperatures typically above 800° C., it loses most of its remaining volatile matter and becomes a nearly pure carbon with a fixed-carbon content of 90 wt % or more. As used herein, the term “biocarbon” represents both charcoal and carbonized charcoal. Biocarbons possess many unique properties. Both charcoal and carbonized charcoal contain virtually no sulfur or mercury. Relative to their fossil fuel cousins, these biocarbons are very low in nitrogen and low in ash. Consequently, many carbonized charcoals are purer forms of carbon than most graphites. Unlike coking coals, pitches, crude resids, and other fossil carbon precursors, biomass does not pass through a liquid phase during pyrolysis at low heating rates. Consequently, biocarbons are inherently porous. They are also amorphous, as evidenced by very little of a turbostratic structure in their x-ray diffraction spectra. Nevertheless, a packed bed of carbonized charcoal conducts electricity nearly as well as a packed bed of graphite particles.
[0005] In U.S. Pat. No. 6,790,317, incorporated herein by reference in its entirety, a carbonization process to produce biocarbon is disclosed. The process of the present invention is an improvement over that process that significantly reduces the conversion times to biocarbon in similarly-sized reactors.
[0006] Accordingly, an object of the present invention is to provide an improved, rapid, efficient and economical process for converting biomass into charcoal.
[0007] This and other objects and advantages to the present invention will be readily apparent upon reference to the drawing and the following description.
SUMMARY OF THE INVENTION
[0008] The present invention provides a low-energy input process for the pyrolytic conversion of biomass material into charcoal or carbonized charcoal (collectively referred to as biocarbon) and power, comprising the steps of
(a) sealing the material in an enclosed container having a proximal end and a distal end, a valved air entry orifice for introducing air at the proximal end of the container and a valved gas exit orifice and heater at the distal end of the container; whereby the non-inert contents of the container consists essentially of the biomass material and air; (b) pressurizing the container with air or oxygen, then initiating flow of air or oxygen into the container at the proximal end and out of the container at the distal end; (c) heating the material with the heater to cause it to ignite and burn while continuing said flow of air or oxygen, then ceasing operation of the heater after ignition of the material; (d) controlling the flow and pressure within the container in a proximal-to-distal end flow by regulating air or oxygen intake at the proximal end and exhaust of combustion gases at the distal end; (e) continuing the flow until carbonization is complete.
[0014] A reactor is also provided for pyrolytic conversion of biomass material into charcoal and gas comprising,
a housing having a proximal end, a distal end and a sealable opening for receiving a removable canister containing the material; a valved air entry orifice for introducing air to the proximal end of the canister; a valved gas exit orifice and heater at the distal end of the housing insulation surrounding at least a portion of the sides of the canister; the canister being receivable in the housing such that there is minimal exposure of the contents of the canister to the atmosphere when the sealable opening is open.
DESCRIPTION OF THE DRAWING
[0019] The accompanying FIGURE is a cross-section elevational view of a preferred apparatus for performing the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] The biomass material may be used without pretreatment, other than cutting wood to manageable sizes and shapes. Therefore, the material may have high or low moisture content. No special oven drying of the feedstock is necessary. A small amount of dry biomass, which can serve as tinder, may be loaded into the bottom of the reactor near the heater, prior to loading the moist biomass. This tinder may shorten the time and reduce the external energy input required to kindle the biomass.
[0021] Although air is the preferred gas oxidizer, mixtures of air with oxygen, or pure oxygen can be employed to speed ignition. To use the reactor, a canister having a cavity to accommodate the heating element is filled with biomass and placed in the reactor. After pressurizing and introducing an airflow and ignition, cessation of heating for ignition, pyrolysis, and pressure release, if necessary, the canister of hot biocarbon is lifted out of the reactor and another canister of biomass is inserted into the reactor. The reactor is positioned vertically (proximal end up), for optimal air flow.
[0022] The typical turn-around time is significantly improved compared to the process disclosed in U.S. Pat. No. 6,790,317. The biocarbon made in accordance with the present invention typically has a volatile matter content of less than about 15 wt %, and a calorific value of about 33 MJ/kg.
[0023] There are two classes of biomass feedstocks: those that are energetic and those that are highly energetic. Energetic feedstocks (e.g. macadamia nutshells) are dense (i.e. not porous), hard, and relatively moist, having a moisture content (moist basis) typically about 10% or higher. Highly energetic feedstocks (e.g. leucaena wood, oak wood, and corncobs) are porous and dry, having a moisture content (moist basis) typically below about 10%. According to the present invention, highly energetic feedstocks manifest sudden pressure surges during ignition, but biocarbon is produced advantageously with very short reaction times. While reaction times using energetic feedstocks are generally longer, an advantage is that a biocarbon yield is attainable that can be higher than that disclosed in U.S. Pat. No. 6,790,317.
[0024] The pressure attained within the reactor during the conversion will usually be less than about 400 psig (pounds/square inch @ gauge). The pressure used within the reactor will generally be higher for energetic feedstocks, such as macadamia nutshells, than for highly energetic feedstocks. For energetic feedstocks the pressures may be typically in the range of about 150-300 psig, but may vary according to the materials used. For highly energetic feedstocks, such as oak wood, lower pressures within the reactor may be sufficient. Such pressures may typically be in the range of about 100-200 psig, but may vary according to the materials used. The temperature attained within the reactor may be monitored. The type of biomass used, the attainment of ignition, and the maintenance of airflow and pressure to maintain combustion will attain the required temperature. Typically, the temperature within the reactor will be greater than about 400° C. but usually less than 900° C.
[0025] By initiating and continuing the airflow in the reactor after pressurization and prior to ignition, and continuing the airflow from the proximal end to the distal end of the reactor, where the heating for ignition occurs at the distal end, improvement of the reaction times to completion may be achieved in the case of highly energetic feedstocks. In the case of energetic feedstocks, biocarbon yields may be improved in accordance with the present invention.
[0026] The hot exhaust gas that leaves the reactor at elevated temperature may be delivered to a steam or gas turbine, or gas engine to generate power. Because the reactor operates in a cyclic mode, the production of gas is not steady. The gas may be delivered to an insulated holding tank, where it can be stored and delivered to the turbine or gas engine at a steady temperature and pressure. Alternatively, two or more reactors may be operated sequentially in such a way that their combined gas output is steady and suitable for delivery to a turbine or gas engine. The combustible hot gas may be burned in the gas turbine or a gas engine. Alternatively, the gas can be burned in a combustor, or flare, or a catalytic afterburner.
[0027] The process of the present invention will be described hereafter in conjunction with the apparatus shown in the accompanying FIGURE. It will be realized, however, that other apparatus may be utilized by which the process parameters can be maintained and by which removal of the processed charcoal can be accomplished without exposure to air or oxygen.
[0028] Moist or dry biomass in any convenient form, such as wood logs or sawdust or rice hulls or corncobs, is loaded into the canister 14 by opening lid 15 at the proximal end (top) of the canister. The bottom of the canister 14 A is preferably made from a metal screen or perforated metal to permit direct heating of the biomass or tinder and thereby to facilitate its ignition. After canister 14 is filled with biomass 13 , it is loaded into reactor 10 that is a pressure vessel via a hinged closure 12 and sealed. Insulation 11 (which may simply be stagnant air) lining the inside wall of the reactor reduces loss of heat from the canister 14 during combustion and pyrolysis. An air compressor (not shown) delivers air to the reactor via line 1 through valve 18 , conduit 23 , coupling 24 and inlet 25 . Air or oxygen-enriched air may be used. The internal pressure is typically initially raised to around 100-150 psi, then air or oxygen in flowed into the reactor at the proximal end. Electric power is then delivered via wires 16 A to and feedthrough 16 B to flat heaters 16 to heat the packed bed of biomass material and to cause it to ignite and combust in the downwardly flowing air environment. The flat heaters 16 are supported by footing 31 , which also contains duct 32 that directs the flow of hot combustion gas into the outlet pipe 33 . Tinder may be used at the bottom of canister 14 near the heaters to facilitate ignition. After ignition, the heater 16 is turned off.
[0029] A pressure regulator 17 is utilized to release gas from the distal end (bottom) of the reactor 10 and thereby control pressure and airflow within the reactor 10 .
[0030] Temperatures within the reactor may be monitored by thermocouples 19 . Likewise, the pressure within the reactor may be monitored by a pressure gauge 20 . When ignition of the biomass occurs, the temperature and pressure within the reactor will rise quickly. Typically, the pressure will be maintained in the range of about 100-150 psi after the initial ignition pressure surge. The time required for air delivery depends upon the airflow rate and the feedstock, but is typically less than about 30 min. in a laboratory-sized reactor of a design shown in the FIGURE. Gas within the reactor is released via regulator 17 and line 21 . This gas may be burned in a flare as shown, or it may be burned in an external combustor (not shown) or a catalytic afterburner (not shown) to generate heat. Alternatively, the hot gases released from the reactor via regulator 17 can be delivered to a standard steam turbine (not shown) or a gas engine (not shown) to generate power. The gas may be burned in a gas turbine (not shown) or a gas engine (not shown) to generate additional power.
[0031] The exact residence time of the solid material within the reactor will depend upon the size of the reactor, the particular type of material used and its moisture content.
[0032] Typical turn-around time from pressurization, ignition, to completion of carbonization may be less than an hour in a laboratory-sized reactor as shown in the FIGURE. The optimum conditions for a particular biomass feedstock can be readily determined by anyone with ordinary skill in the art by testing samples of the particular biomass material.
[0033] It is a feature of the present invention that, to maximize efficiency, the reactor need not be cooled between loads. Gas is vented through valve 17 prior to opening the hinged closure 12 to reduce the pressure within the reactor to atmospheric pressure. Canister 14 is tight, thus minimizing entry of air into canister 14 so the hot biocarbon within the canister does not burn when the canister is lifted from the reactor. Immediately after removing a canister from the reactor 10 , another canister of biomass material may be lowered into the reactor. Thereafter the reactor may be sealed, and heated again, without allowing any substantial cooling of the reactor 10 , thereby making the overall process more efficient.
[0034] Referring to the FIGURE, other features of the reactor 10 include a proximal sealing gasket 22 . The hinged closure 12 is secured via a lock mechanism 26 . The canister 14 accommodates a chain handle 28 for the purpose of raising and lowering it into reactor 10 . Safety valve 30 employs a burst diaphragm to release gas in the event of overpressure.
Comparative Example 1
[0035] Macadamia nut shells are an energetic biomass feedstock available in large quantities on the Big Island of Hawaii. A load of 3.16 kg of macadamia nut shells (13.8 wt % moisture content on a moist basis)was placed into the canister of a laboratory-scale Flash Carbonization™ reactor (“FC”) designed as shown in the FIGURE. The canister was loaded into the FC reactor, and pressurized with air to 300 psig. Air delivery was initiated (0.132 kg/min) and subsequently the ignition heater was turned on. The biomass ignited and the pressure in the FC reactor rose to about 330 psi during air delivery. The FC reactor exhaust valve was opened slightly more, and the pressure fell to 300 psi where it remained for the duration of the run. The oxygen content of the effluent gas fell quickly from its usual value (21%) to 0.8% after 11 min of air delivery. The oxygen content of the effluent remained below about 2% for the duration of the run. Airflow was halted 31 minutes after the ignition heater was energized. The charcoal yield was 37.0 wt %, the fixed-carbon yield was 33.5 wt %, and the ash content of the charcoal was 1.5 wt %. Comparable results following the procedure of U.S. Pat. No. 6,790,317 were reported in a technical paper by Antal, Mochidzuki, and Paredes ( Ind. Eng. Chem. Res. 2003, 42, 3690-3699). In this paper the macadamia nut shell charcoal yield was reported to be 34.5 wt % and the fixed-carbon yield was 30.9 wt %. Thus the ignition procedure described in this disclosure provides a significant improvement in both the charcoal yield and the fixed-carbon yield of macadamia nut shells. Also, in the technical paper by Antal et al. the reaction time was 51 min for a canister containing only 1.1 kg of macadamia nut shell material. Thus a reduction in reaction time of about 40% was realized according to the new ignition procedure, without consideration of the much larger amount of macadamia nut shell carbonized in this example.
Comparative Example 2
[0036] A load of 2.04 kg of air-dry corn cob material (9.7 wt % moisture content on a moist basis) was placed into the canister of the FC reactor. Corn cob material is a highly energetic feedstock that is widely available and well-suited to charcoal production. The canister was loaded into the FC reactor, and pressurized with air to 150 psig. Air delivery was initiated (0.132 kg/min) and subsequently the ignition heater was turned on. The corn cob biomass ignited and the pressure in the FC reactor surged to about 170 psi during air delivery. The FC reactor exhaust valve was opened further and the pressure fell to 150 psi, where it remained for the duration of the run. Airflow was halted 15 minutes after the ignition heater was energized. The charcoal yield was 27.8 wt %, the fixed-carbon yield was 23.3 wt %, and the ash content of the charcoal was 3.2 wt %.
[0037] These results may be compared to EXAMPLE 4 of U.S. Pat. No. 6,790,317. This patent reports a corn cob charcoal yield of 33.1 wt % and a corn cob fixed-carbon yield of 28.0 wt % with a reaction time of 20 min. Thus the ignition procedure described in this disclosure reduced the reaction time by 25% at the price of a reduction in the charcoal and fixed-carbon yields from the highly energetic corn cob feedstock.
Comparative Example 3
[0038] A load of 2.67 kg of air-dry oak wood waste (7.6 wt % moisture content on a moist basis) from the manufacture of floorboards was placed into the canister of the FC reactor. This is exactly the same oak wood waste as was employed in EXAMPLE 3 of U.S. Pat. No. 6,790,317. Dry oak wood is a highly energetic feedstock. The canister was loaded into the FC reactor, and pressurized with air to 150 psig. Air delivery was initiated (0.132 kg/min) and subsequently the ignition heater was turned on. The oak wood biomass ignited and the pressure in the FC reactor surged to about 170 psi during air delivery. The FC reactor exhaust valve was opened further and the pressure fell to 150 psi, where it remained for the duration of the run. Airflow was halted 23 minutes after the ignition heater was energized. The charcoal yield was 27.2 wt %, the fixed-carbon yield was 24.1 wt %, and the ash content of the charcoal was 1.0 wt %. These results may be compared to EXAMPLE 3 of U.S. Pat. No. 6,790,317. This patent reports an oak wood charcoal yield of 35.1 wt % and a oak wood fixed-carbon yield of 28.0 wt % with a reaction time of 30 min. Thus the ignition procedure described in this disclosure reduced the reaction time by 23% at the price of a reduction in the charcoal and fixed-carbon yields from the highly energetic oak wood feedstock.
Comparative Example 4
[0039] A load of 1.98 kg of air-dry leucaena wood (9.2 wt % moisture content on a moist basis) was placed into the canister of the FC reactor. Leucaena wood is a highly energetic biomass feedstock. The canister was loaded into the FC reactor, and pressurized with air to 150 psig. Air delivery was initiated 0.132 kg/min) and subsequently the ignition heater was turned on. The leucaena wood ignited and the pressure in the FC reactor surged to about 170 psi during air delivery. The FC reactor exhaust valve was opened further and the pressure fell to 150 psi where it remained for the duration of the run. Airflow was halted 15 minutes after the ignition heater was energized. The charcoal yield was 27.7 wt %, the fixed-carbon yield was 23.8 wt %, and the ash content of the charcoal was 2.7 wt %. These results may be compared to EXAMPLE 2 of U.S. Pat. No. 6,790,317. This patent reports a leucaena wood charcoal yield of 40.0 wt % and a leucaena wood fixed-carbon yield of 29.7 wt % with a reaction time of 34 min. Thus the ignition procedure described in this disclosure reduced the reaction time by 59% at the price of a reduction in the charcoal and fixed-carbon yields from the highly energetic leucaena wood feedstock.
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A low-energy input process for the pyrolytic conversion of biomass to charcoal or carbonized charcoal is provided. The biomass is sealed in a container, pressurized, then air is introduced at the proximal end of the container and released at the distal end of the container. The biomass is ignited by a heater at the distal end. The operation of the heater is halted after initial ignition and the biomass is allowed to continue to burn in a proximal-to-distal end airflow to finish the conversion.
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FIELD OF THE INVENTION
The present invention pertains to a device for adjusting a fold depth of a folding rail used on a sewing machine with a rotatable stop disk.
BACKGROUND OF THE INVENTION
Two multistep stop disks, which are manually adjustable independently from one another, are used in a device known from DE 80 27 080 U1 for preparing tucks on cut parts of pieces of clothing with a folding rail adjustable within a range limited by stops. One of the stop disks is arranged on a pivotable bracket, which can be moved by means of a compressed air cylinder into two different pivoted positions, one of which is stationary and the other can be adjusted by the setting position of the other, stationarily mounted stop disk. The folding rail is in spring-loaded contact with the stop disk arranged on the bracket and is carried in a corresponding manner during the pivoting of the bracket to the other stop disk. The folding rail can thus be moved to and from for alternatingly sewing tucks of different depth between two adjustable fold depths.
Aside from the fact that the stop disks, designed as multistep disks, permit only a limited number of adjustment possibilities, the prior-art device also has the additional drawback that the second fold depth that can be obtained by pivoting the bracket to the stationarily mounted second stop disk depends on the setting position of both stop disks, because their action adds up in this case. If, e.g., the first fold depth is to be changed, whereas the second fold depth shall remain unchanged, the setting position of the second stop disk must also be changed after the setting of the first stop disk mounted on the bracket, and the setting position of the second stop disk must be changed by the same amount, but with the opposite sign.
SUMMARY AND OBJECTS OF THE INVENTION
The primary object of the present invention is to provide an adjusting device for a folding rail, by means of which any desired fold depth can be obtained in a simple manner within a predetermined setting range.
According to the invention, a device is provided for adjusting a fold depth of a folding rail used on a sewing machine. A rotatable stop disk is used. The stop disk has a continuously extending adjusting cam that is connected to an actuator. The actuator can be controlled in a sensitive manner to provide a high degree of adjustment.
By correspondingly energizing the actuator, which operates at least in a sensitive manner, the folding rail, which is elastically supported on the stop disk directly or indirectly, can be set very accurately to the desired fold depth by the continuously extending adjusting cam of the stop disk.
This is of particular importance for preparing, e.g., pleated skirts, because even slight dimensional deviations from the desired fold depth would add up to a no longer acceptable deviation from the standard size because of the large number of folds to be formed.
When tucks extending at an acute angle are prepared by means of special folding rails, which define the shape and depth of the tuck, the deviation of the actual intersection of the seam line with the fabric fold line from the desired intersection, which deviation is due to a change from a thin fabric to a thick one or vice versa, from a thick fabric to a thin one, can be corrected by means of the adjusting device according to the present invention in a sensitive manner, as a result of which it is guaranteed that the end stitches of the seam, which are intended to secure the seam and are shortened according to the program, are always formed at the desired distance from the folded edge of the fabric.
The adjusting cam preferably has a spiral shape. The actuator may preferably be provided as a stepping motor.
Any desired setting values can be programmed in any desired order in a simple manner by operating a stepping motor by means of a program control for obtaining predeterminable setting values which can be set in any desired order, and they can be polled during sewing either by switching commands of the operator or as an automatic process.
The setting position of the stop disk is nonpositively locked during each movement of the folding bar into its transfer position by means of the locking device based on the stop disk being arranged in a bracket formed by at least two plates and containing a brake disk, which is connected to it to rotate with it in unison and projects over a largest radius of the adjusting cam and the actuator, which can be brought into functional connection with the brake disk via a pressure piece and is fastened to the bracket. The locking device consists of a brake disk and an actuator, which may be, e.g., a short-stroke cylinder, so that the stepping motor does not need to apply any holding force. Due to the stop disk being supported on a sleeve mounted in the bracket, radially directed impact forces occurring as a consequence of the rapid displacement of the folding rail are absorbed by the sleeve and are kept away from the motor shaft due to the carrier connection between the motor shaft and the stop disk being designed with a clearance.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a top view of the adjusting device;
FIG. 2 is a partially cutaway side view; and
FIG. 3 is an enlarged detailed view taken from FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular, the invention comprises a guide rail 2 for a carriage 3 that can be moved along on the said guide rail is fastened to a support plate 1. A folding rail 4 comparable to the folding rail disclosed in DE 80 27 080 U1 is detachably fastened to the carriage 3. Like the prior-art folding rail, the folding rail 4 is adjustable in a manner not specifically explained here and is also interchangeable with other folding rails having a different shape and different dimensions.
Together with the folding rail 4, the carriage 3 can be moved to and from by means of a compressed air cylinder 5 between an inserting position shown in the drawing and a working position, in which the folding rail 4 places the fabric to be provided with a fold in the correct position for sewing under a feed rail, not shown. The desired tuck depth of the fold or of a tuck which are to be formed depends on the shape and width of the folding rail 4 and is additionally determined by the adjusting device 6 according to the present invention.
The adjusting device 6 contains a stop disk 7 of helical design, which is rotatably mounted in a bracket 8. The bracket 8 comprises the support plate 1 and a cover plate 10, which is arranged at a distance from the said support plate due to the intercalation of two distance plates 9. The stop disk 7 is arranged on a sleeve 11 mounted rotatably in the plates 1 and 10. A stepping motor 12 fastened to the cover plate 10 is used to drive the stop disk 7. The shaft 13 of the stepping motor 12 is arranged in a rotatably movable manner in the sleeve 11 and has a flattened area 14 (FIG. 3). A screw 15, which passes through a hole 16 contained in the sleeve 11 and ends at a short distance from the flattened area 14, is arranged in the stop disk 7. The screwed-in depth of the screw 15 is secured by bonding the screw 15 in its threaded hole. The flattened area 14 and the screw 15 form a carrier connection 17 between the shaft 13 and the stop disk 7, which carrier connection has a clearance.
A rod 18 is mounted displaceably in the longitudinal direction in the bracket 8. The rod 18 contains an elongated hole 19, which extends in parallel to the longitudinal axis of rod 18 and through which extends a pin 20 firmly arranged in the bracket 8. The rod 18 is designed with a rounded scanning head 21 at its end facing the stop disk 7. A tension spring 23, which is attached at one end to the pin 20 and at the other end to a pin 22 located in the rod 18, causes the rod 18 with its scanning head 21 to be maintained in continuous contact with the circumferential side of the stop disk 7, which circumferential side is called an adjusting cam 24.
At its end located opposite the scanning head 21, the rod 18 carries a stop plate 25. The stop plate 25 cooperates with a rod 26 of a hydraulically operating shock absorber, which is installed in the carriage 3. The shock absorber itself is of a known design, so that it is not explained more specifically.
The stop disk 7 is connected to a brake disk 27 of round design, with which it rotates in unison, and which projects beyond the greatest radius of the stop disk 7 or its adjusting cam 24. The brake disk 27 is accommodated in a flat opening 28 of the cover plate 10, whose dimensions are selected to be such that the stop disk 7 can be rotated unhindered with the brake disk 27. A short-stroke compressed air cylinder 29, whose piston rod 30, acting as a pressure piece, extends into a hole 31 in the cover plate 10, is fastened to the cover plate 10.
The short-stroke cylinder 29 is designed as a single-acting cylinder, whose piston rod 30 is moved into and held in the withdrawn position by a restoring spring. With the short-stroke cylinder 29 ventilated, the brake disk 27 is released, so that the stepping motor is able to rotate the stop disk 7 unhindered. When pressure is admitted to the short-stroke cylinder 29, the piston rod 30 presses the brake disk 27 against the distance plate 9 and thus causes the stop disk 7 to be locked in a frictionally engaged manner.
The stepping motor 12 can be operated by a prior-art, stored-program control equipped with a control panel. Due to the usually high step resolution of stepping motors per revolution, the stop disk 7 can be rotated in a highly sensitive manner, and a highly accurate angular adjustment can thus be performed.
The angular position of the stop disk 7 is adjusted or changed in the inserting position of the folding rail 4 shown in the drawing, in which the carriage 3, together with the rod 26 of the shock absorber, is moved away from the rod 18. Since the short-stroke cylinder 29 is ventilated in the process, the adjusting movements of the stepping motor 12 can be performed without applying an appreciable force.
The stop disk 7 is now adjusted such that the stepping motor 12 always reaches the desired setting position from a clockwise direction of rotation. If the adjustment is performed from a lower to a higher setting value, the stop disk 7 is turned by the stepping motor 12 directly to the new setting value. However, if a lower value shall be set from a higher setting value, the stepping motor 12 first rotates the stop disk 7 counterclockwise by three steps beyond the desired setting value and then turns it back clockwise by three steps, so that the new setting value is reached from a clockwise direction of rotation in this case as well. The clearance in the carrier connection 17 is thus compensated, so that exact setting values are always obtained in all cases.
Pressure is admitted simultaneously to the compressed air cylinder 5 and the short-stroke cylinder 29 to place the fabric in the correct position for sewing. Since the short-stroke cylinder 29 has a substantially shorter piston stroke than the compressed air cylinder 5, the brake disk 27 with the stop disk 7 is already secured against unintended rotation before the carriage 3 with the rod 26 reaches the stop plate 25 of the rod 18. The shock absorber provided in the carriage 3 damps the impact of the carriage 3 on the rod 18, so that excessive impact forces do not act on the stop disk 7, on the one hand, and the carriage 3 with the folding rail 4 does not rebound, on the other hand. Due to the stop disk 7 being mounted in the sleeve 11 and the carrier connection 17 between the shaft 13 and the stop disk 7 having a clearance, the impact forces acting on the stop disk 7 from the scanning head 21 of the rod 18 are kept away from the shaft 13 or are reduced to the extent that the stepping motor 12 will not be damaged.
After the fabric brought by the folding rail 4 into the sewing position has been taken over by the feed rail, the compressed air cylinder 5 is reversed, and the short-stroke cylinder 29 is ventilated. The setting position of the stop disk 7 is maintained by the holding torque of the stepping motor 12 alone for the time until the next withdrawing movement of the folding rail 4. Since this holding torque, on the one hand, and also the drive torque, on the other hand, may be relatively low for adjusting the stop disk 7, it is possible to use a relatively small and therefore inexpensive stepping motor.
Using the folding rail 4 inserted, a plurality of different fold depths can be set, as they are necessary or at least desired, e.g., in the case of the sewing of pleated skirts, by means of the stored-program control for the stepping motor 12, and the difference from the smallest to the largest fold depth depends on the difference between the smallest radius and the largest radius of the adjusting cam. Any desired order of different fold depths can be selected for performing defined sewing operations.
Highly accurate adjustment or correction of the intersection of the seam line with the fabric fold line can be performed during the sewing of tucks extending at an acute angle due to the possibility of an especially sensitive adjustment of the stepping motor 12, so that this intersection will always be located in the desired area in the case of thin and thick fabrics alike.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A device for adjusting a fold depth of a folding rail is provided for use on a sewing machine. The device includes a rotatable stop disk with an adjusting cam providing a continuously extending surface. An actuator is provided for driving the stop disk. The actuator is preferably a stepping motor and the adjusting cam preferably has a spiral shape.
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BRIEF SUMMARY OF THE INVENTION
An object of the invention is to provide apparatus by which a rope and chain cable ligament can be recovered and payed out using a lifter wheel. The apparatus includes in combination a rope connected to a chain cable by a connector and a lifter wheel having pockets to receive the connector and links of the chain cable and a groove to receive the rope.
The invention enables a rope and chain cable assembly to be recovered or payed out using a common lifter wheel.
The invention enables the rope to be connected to the chain cable by a connector which is capable of passing over the wheel accommodated in a pocket therein and which is capable of correctly engaging with the wheel regardless of the angular orientation of the connector (about a lengthwise axis) as the connector approaches the wheel in recovery of rope and chain cable. The correct engagement of the connector with the wheel ensures correct subsequent engagement between the chain cable and the wheel.
The invention also minimises bending of the rope adjacent the connector, so that the risk of damage or reduction of strength of the rope is avoided or is at least rendered negligible.
BACKGROUND OF THE INVENTION
The invention relates to apparatus by which rope and chain cable may be recovered or payed out.
A typical, though not the only, example of use of the invention is on marine oil drilling rigs and platforms where heavy-duty chain cable used for anchoring the rig or platform is connected to heavy-duty rope and both rope and cable have to be recovered or payed out.
It is known to recover and pay out chain cable using a chain-cable lifter wheel having pockets to receive chain links. Such cable lifter mechanism is used on ships for handling anchor chain. Since very heavy chains are needed for oil drilling rigs or very large ships it is advantageous to use chain cable only for a part of the length of the anchoring element and to use wire or other rope for the remainder. The recovery and paying out of chain cable and rope is required to be performed quickly and safely often under difficult conditions caused by weather and sea conditions. The applicants are not aware that the recovery of a ligament made up of a rope and cable has been achieved using a common lifter wheel, prior to the Applicant's invention.
A particular problem which is overcome by the invention is the provision of a connector which connects the rope to the chain cable but which is compact enough to fit into a pocket on the wheel and which is capable of correct seating on the wheel so as to ensure correct subsequent engagement between the chain cable and the wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
One form of apparatus will now be described by way of example to illustrate the invention with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic vertical central section transverse to the axis of rotation of a cable lifter wheel forming part of apparatus for recovering a rope and chain cable which are shown in successive positions as the connector and chain-cable approach the wheel during recovery, the connector being in a first orientation;
FIG. 2 is a diagrammatic section similar to that in FIG. 1 but showing the wheel after engagement of the connector with the wheel and after some 90° of anti-clockwise rotation of the wheel from the position shown in FIG. 1;
FIG. 3 is a diagrammatic plan of the parts shown in FIG. 2;
FIG. 4 is a diagrammatic section similar to that shown in FIG. 2 but showing the connector in a second orientation displaced 90° from the first orientation shown in FIG. 2;
FIGS. 5 and 6 are diagrammatic radial sections through the part of a wheel on the line X--X in FIG. 1 and also through the connector showing successive positions of the connector as it moves from an initial position intermediate the first and second orientations to the first orientation and to the second orientation respectively; and
FIG. 7 is a diagrammatic three-dimensional view of the apparatus as a whole combining the lifter wheel, rope connector and chain-cable in FIGS. 1 to 6.
DETAILED DESCRIPTION
FIG. 1 shows a cable lifter wheel 10 having two spaced flanges 12 having inner opposed profiled faces so as to define five pockets 14 each shaped so as to accommodate and hold links of a chain cable 16. The flanges 12 radially inwardly of the pockets 14 define between them a groove 18, and the flanges 12 merge together to provide a base surface 20 to the groove 18.
The chain cable comprises links 22 each having a bridging stud 24. The links 22 are joined by a two-part link 26 (the parts of which can be separated to allow disconnection of the cable) to a semi-link portion 28 of a connector 30. The connector 30 joins the chain cable 16 to a steel wire strand rope 32, which is shown accommodated in the groove 18 and passing over the top of the wheel 10.
The connector 30 includes a half-ovoid shaped body 43 which has two laterally extending protuberances 36 which are symmetrically located on opposite sides of the body 34. Each protuberance 36 has a generally semi-cylindrical lengthwise edge surface 38 (FIGS. 5 and 6). The length of the connector 30 is equal to the length of a link 22 and the width and shape of the connector 30 as shown in FIG. 1 is the same as the width and shape of a link 22.
The connector 30 has a front end aperture (FIG. 2) which receives an end portion of the rope 32. The aperature is tapered as shown in FIG. 2 at 40 towards the front end and then diverges at 42. The rope 32 is anchored in the aperture by anchorage material such as cast white metal 44 which extends as far as the throat in the aperture between the parts 40 and 42. The rope 32 is free to flex beyond the throat within the divergent part 42, the wall of which is convex to give support to the rope 32 when it is flexed as shown in FIG. 2. The rope 32 has a layer of wire whipping 50 to give further support to the rope 32 during flexing.
Each pocket 14 contains stop means in the form of two opposed stop blocks 52 each secured to a respective flange 12 and extending inwardly across the pocket towards the other.
The wheel 10 is part of a large combined winch and cable lifter mechanism. Drive can be clutched in to turn the wheel 10 or the winch drum at will and brakes for the winch drum and wheel 10 are provided. The apparatus is suitable for use as one of several mooring equipments on a very large marine or drilling rig or platform. The chain cable 16 is very heavy and in use is lowered onto the seabed to anchor the rig. The use of rope reduces the total weight of ligament used to anchor the rig and the rope is wound on the winch drum. Thus, when the chain cable is lifted by the wheel 10 and passes downwardly it can form a pile in a chain cable locker, the winch drum then being unoperative. In the description below of the operation of the wheel in recovering the chain cable it is assumed that the invention is applied to the mooring of such a marine rig or platform, but the invention is of wider application and can be used in other analogous situations.
FIG. 7 shows a typical arrangement of apparatus for a large marine vessel or structure such as a drilling rig or platform.
The winch comprises a reversible motor 100 having an output shaft driving transfer gearing in a casing 102. Output shafts from the gearing in the casing 102 each have a clutch mechanism 104 or 105 and output shafts from the clutch mechanism 104 each have a band brake 106 or 107. The output shafts 108, 110 from the clutch mechanism 104 carry, respectively, the wheel 10 and a winch drum 112.
The rope 32 and chain-cable 16 comprises the ligament are shown arranged for passage around a fairlead wheel 114 and a return pulley wheel 116. The chain-cable links are only partly shown but they continue beyond the end link as shown at the arrow 118 to the sea bed when the ligament is in use to anchor the vessel or structure. The rope 32 is shown wound around the barrel of the winch drum 112.
A fixed guide 120 is shown adjacent the pulley wheel 116. The guide 120 slightly deflects the pendant chain-cable 16 as indicated at 122 after recovery of chain cable from the seabed as described below. The chain-cable 16 then also depends as shown at 124 from the wheel 10. The downwardly extending passes of chain-cable represented at 122 and 124 form parts of a loop of chain-cable which extend down into a chain locker (not shown). The guide 120 also assists return of the chain-cable 16 into correct engagement with the pulley wheel 116 when chain-cable is payed out from the locker so as to return the chain-cable to the arrangement shown in FIG. 7.
OPERATION
To recover the rope 32 and the chain-cable 16, the brakes 106 and 107 are released, the clutch 104 is released and the clutch 105 is engaged. The winch motor 100 is energised to haul in the rope 32, which rubs over the wheel 10, which is free running and dis-engaged from its drive. The rope 32 runs in the groove 18. When the connector 30 reaches a position approaching that shown at 32A in FIG. 1 it is necessary for the operator to observe the angular orientation of the connector about an axis lengthwise of the connector, say the axis 60. The connector 30 must be brought into proper engagement with the wheel 10 and, while it is possible that the connector can be seen to be positioned for such proper engagment as the wheel 10 continues to turn, in most cases it will not be possible to decide that that is the case.
In most cases, therefore, it is preferred to engage the brake 106 (FIG. 7) of the wheel 10, so as to stop the wheel 10 in a position such that a set of stop blocks 52 occupies the angular position shown while the connector 32 is in an approach position 32A clear of the wheel 10. The winch motor 100 is kept energised to keep the drum 112 hauling slowly and the rope 32 now slides on the base surface 20 of the groove 18.
In FIG. 1 it is assumed that next to the connector 32 reaches the position 32B and engages the wheel 10 in a first angular orientation about the axis 60 such that the protuberances 36 lie in a plane parallel to the axis 62 of rotation of the wheel 10.
In that position, the body 34 symmetrically engages at opposite sides with the edges of shoulders 70 being part of the profiled pocket 14 in which the stop blocks 52 lie.
Further recovery of the rope 32 causes the connector 30 to slide along the edges of the shoulders 70 until it reaches the position shown in full lines in FIG. 1. In that position the connector 30 engages the stop blocks 52 and the body 34 of the connector has moved slightly inwardly radially because the edges of the shoulders 70 are relieved slightly generally as indicated at 72, though it is not possible to show this fully in the sections used. This position of the connector 30 minimises bending of the rope 32 adjacent the connector 30.
The brake 106 on the wheel 10 is then released and the winch drum 112 is driven further to recover the rope 32 and to draw the chain-cable 16 further over the wheel 10. FIGS. 2 and 3 show the position after a further 90° of anti-clockwise rotation of the wheel 10 from the position shown in FIG. 1.
The wheel 10 can now be driven by engagement of the clutch 104. The wheel 10 would turn slightly relative to the chain cable 16 so that the trailing end surfaces 80 of the pocket 14, in which the connector 30 lies, engage the rear end of the first link 26 of the chain cable 16 and thereafter the wheel 10 can lift the chain cable 16. If preferred, the chain-cable can be recovered further, so that a length hangs down from the left hand side of the wheel 10 as viewed in FIG. 2, by hauling of the rope 32 before the drive to the wheel 10 is engaged. In that case a later link 22 would be engaged by trailing end surfaces 80 of a pocket 14 to lift the chain-cable.
Had the connector approached the wheel 10 in a second orientation angularly displayed 90° from that shown in FIG. 1, the wheel 10 would have braked in the same angular position but recovery of the rope 32 would have caused the connector protuberance 36 nearest to the wheel 10 to enter the groove 18. The connector 30 would have slid on edges of the shoulders 70 as before but, since the gap between the stop blocks 52 is wider than the body 34 of the connector, the latter would have slid past the stop blocks into engagement with the flanks of the other end surfaces 90 of the pocket 14, as shown in FIG. 4.
In the position shown in FIG. 4, when drive is applied to the wheel 10, the chain-cable 16 would be lifted by engagement between links 22 and the trailing end surfaces 80 of a pocket 14, as before.
FIG. 5 shows the connector 30 in full lines at the point of engagement with the wheel 10 in an angular orientation intermediate the first and second orientations referred to above. A lower protuberance 36 engages a left shoulder at 70A and the other engages the upper inner surface of the flange 12 at the right hand side of the pocket. The connector body 34 engages the edge of the right hand shoulder 70. As the rope 32 is recovered while the wheel 10 is braked, the connector slides further past the wheel 10 and two further successive positions are shown by broken lines during that sliding movement. The connector 30 changes its angular orientation clockwise as indicated by the arrow about the axis 60 and that axis moves parallel to itself from the position 60A corresponding to the connector position shown by full lines to the position 60B. The lower protuberance slides outwardly to a point of contact 70B on the shoulder 70 and eventually moves clear of the shoulder 70 to the position 36C, after which the protuberances 36 engage the stop blocks 52 as described with reference to FIGS. 2 and 3. It would be possible for the other protuberance to engage the opposite shoulder 70, in which case the connector would change its angular orientation in similar manner but in anticlockwise sense.
FIG. 6 shown the connector 30 in full lines at the point of engagement with the wheel 10 in an angular orientation intermediate the first and second orientations referred to above. A lower protuberance 36 engages the edge surface of the left hand shoulder 70 at 70D and the body 34 engages the edge surface of the right hand shoulder 70 at 70E. The axis 60 is at 60A. As the rope is recovered the axis 60 moves from 60A to 60B and to 60C. The connector changes its angular orientation about the axis 60 in anti-clockwise sense, the lower protuberance sliding down off the edge of the shoulder 70 to positions 36E and 36F in which the protuberance is 36 well within the groove 18.
After that the connector 30 slides further past the wheel 10 as described with reference to FIG. 4.
A similar change of orientation could occur were the connector 30 to engage the wheel initially with a lower protuberance 36 engaging the edge of the right hand shoulder 70, but in a clockwise sense.
After the chain-cable 16 has been properly engaged with the wheel 10 and the drive to that wheel, the wheel 10 and the winch drum 112 are both driven so that the rope 32 is wound up on the drum 112 so far as the position shown in FIG. 7, in which almost all the rope is on the drum. The drum is then held by engagement of the brake 107 and disengagement of the clutch 105. The wheel 10 is still driven to recover the chain-cable 16, which now runs down from the wheel 10 in a deepening loop into the chain locker already mentioned. The chain-cable piles up in the locker. The two passes of chain-cable 122, 124 are passed down to the pile. The brake 106 is finally applied and the clutch 104 disengaged. The rope and chain-cable are thus fully recovered and stowed.
To pay out rope and cable, the reverse procedure is adopted. The clutch 104 is engaged, the brake 106 released and the wheel 10 dirven in the opposite sense to pay out chain-cable 16 which the wheel 10 lifts from the chain-cable locker. Eventually the chain-cable returns into engagement with the pulley wheel 116 as shown in FIG. 7. Thereafter the brake 107 is released to allow rope to run off the winch drum 112. Drive may be applied to the drum 112 by engagement of the clutch 105 if desired.
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A rope connected to a chain cable by a connector is recovered using a chain cable lifter wheel. The connector is shaped to pass over the wheel, which has a groove for the rope. The wheel has pockets which can receive the connector and also receive chain cable links. Protuberances on the connector and stops in the pockets ensure correct seating of the connector in a pocket so as to ensure correct subsequent engagement of chain links with the pockets of the wheel.
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This application is a continuation-in-part of application Ser. No. 659,648, filed Oct. 11, 1984 now abandoned.
FIELD OF THE INVENTION
The invention relates to dissipating heat from electronic components on a ceramic substrate.
BACKGROUND OF THE INVENTION
Electronic components can be mounted on a ceramic substrate and electrically connected to each other through metallized conductors carried by the substrate. Lee U.S. Pat. No. 4,292,647 discloses a semiconductor package including a plurality of electronic chips mounted on a ceramic substrate and provided with individual heat conductive elements mounted directly above them. Moore U.S. Pat. No. 4,541,004 discloses placing heat conducting pins either in a semiconductor package or in a substrate attached to a semiconductor package.
SUMMARY OF THE INVENTION
I have discovered that heat can be very effectively dissipated from electronic components through the use of a ceramic plate that is adhered to a ceramic substrate carrying electronic components and receives heat from the components at one surface and has a plurality of separate, spaced metallic cylindrical heat-conducting elements mounted on and extending from the other surface of the plate. The elements and exposed portions of the plate have a combined surface area greater than 1.5 times the surface area of the plate alone, increasing the heat dissipating surface.
In preferred embodiments the combined surface area is greater than 2.4 (most preferably between 3.5 to 4.0) times the surface area of the plate alone; the metallic elements are cylindrical copper pins; and the pins are connected to the ceramic plate via solder and metallized pads desposited on the ceramic plate.
Because both plates are made of ceramic, there are no thermal stresses between them. Also, the ceramic plate being 0.040" thick diffuses heat well, making the difference in temperature among the various pins low and promoting efficient heat dissipation. Finally, the copper pins provide good heat transfer to and low pressure drop in air passing next to them, and the solder provides good bond strength and little thermal resistance to heat passing through it.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view, partially broken away, of a heat dissipator shown attached to a ceramic substrate carrying electronic components according to the invention.
FIG. 2 is a bottom plan view of the FIG. 1 dissipator.
FIG. 3 is a vertical sectional view, taken at 3--3 of FIG. 1 and upside-down with respect ot FIG. 1, of a portion of the FIG. 1 dissipator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown ceramic substrate 10, which carries electronic components 12 on its upper surface and is secured to heat dissipator 14 at its lower surface. Electronic components 12 are electrically connected to each other by metallization 16 on the upper and lower surfaces of ceramic plate 10, and the upper surface of plate 10 also carries insulating coating 18 over metallization 16. Dissipator 14 includes ceramic plate 20 (95% pure alumina), thermosetting adhesive layer 22 (5 mil thick and available from 3M under the YN469 or YN568 trade designations) and metallic heat-conducting pins 24 on its lower surface.
Referring to FIG. 2, the arrangement of pins 24 on the lower surface of plate 20 is shown. Pins 24 are mounted on 0.125 by 0.125 inch square palladium/silver vacuum deposited pads 26, which are spaced from each other by 0.094 inch in the width direction and 0.108 inch in the length direction. Referring to FIG. 3, pins 24 are approximately 0.1 inch in diameter and 1/4 inch long and include copper core 28 and tin coating 30. Pins 24 are attached to pads 26 by solder 32. The total area of plate 20 thus is 4.50 sq. in (1.846" wide times 2.438" long); the total surface area of the pins is 6.908 sq. in., and the total surface area of the exposed portions of plate 20 and the pins is 10.78 sq. in. Thus the addition of pins has increased total dissipating surface area from that of a plate without pins from 4.50 sq. in. to 10.78 sq. in., an increase of about 2.4. The density of pins can be less than the 2.4 ratio (e.g., greater than 1.5) and still beneficially dissipate heat or can advantageously be increased even more; e.g., ratios of total area to that of the plate alone of between 3.5 and 4.0 are believed to be optimum.
Heat dissipator 14 is made by securing pins 24 in a jig providing them with the proper arrangement and applying solder paste to the exposed ends of pins 24. Ceramic plate 20 with pads 26 thereon is placed on the exposed ends of pins 24, and pins 24 and ceramic plate 20 are joined to each other by vapor soldering. After the pin/ceramic assembly has cooled, adhesive layer 22 is applied, and this is covered with a release layer (not shown), which is removed prior to adhering to substrate 10. Heat dissipator 14 is easily adhered to substrate 10 by bringing the lower surface of ceramic plate 10 in contact with exposed adhesive layer 22, which cures in use. Adhesive layer 22 is 5 mils thick to compensate for irregularities in the planarity of the ceramic plate surfaces.
In operation, heat from electronic components 12 is conducted through layers 10, 22, 20 to heat-conducting pins 24, from which the heat is transferred to the surrounding air flowing past them. Because ceramic plate 20 diffuses heat well, the difference in temperature among various pins 24 is low, and heat dissipation to the air is efficient. Because plate 20 and ceramic plate 10 are both ceramic, there are no thermal stresses between them. Also the metal elements do not restrain the plate from expansion, as they are small in diameter, are spaced from each other on the plate and have free-standing ends that are not attached to anything that would restrain movement of the elements as the ceramic plate on which they are mounted expands. The sole purpose of the elements is to dissipate heat; they are not electrically connected to any components. Moreover, they are not aligned with individual components, but are instead mounted in an array across the bottom of the plate to efficiently dissipate heat owing to their ability to break up boundary layers and the additional surface area. Copper pins 24 provide good heat transfer to and low pressure drip in air flowing past them. Solder 32 provides good bond strength and little thermal resistance to heat passing through it. The cylindrical shape of the heat conducting elements is also highly significant because airflow can be in any direction when using the claimed cylindrical elements, and one can merely place the heat dissipator in a large chamber with many other components that would tend to deflect air in difficult to predict ways. There is no need to direct airflow to heat conducting elements by ducting or otherwise or to place them in a specific orientation, as there is with fins. The cylindrical shape is also very efficient in dissipating heat, as boundary layers do not build up, as they do with flat fins or plates.
Other embodiments of the invention are within the scope of the following claims.
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A heat dissipator for electronic components comprising a ceramic plate having a first surface for receiving heat from the electronic components and a second surface, and a plurality of separate, spaced metallic, heat-conducting elements mounted on and extending from the second surface of the ceramic plate.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of U.S. patent application Ser. No. 09/559,875, now U.S. Pat. No. 6,332,945 B1 which was filed on Apr. 25, 2000.
FEDERAL RESEARCH STATEMENT
Not Applicable
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to assembling shafts to golf club heads. More specifically, the present invention relates to a method and an apparatus for automatically assembling a shaft to a golf club head.
2. Description of the Related Art
The game of golf has benefited greatly from technological advancements throughout its glorious history. Examples include the progression of golf ball from a leather featherie version to the gutta percha version to the dimpled version to the two-piece and three piece versions of today. Another example of the technological advancement of golf is the progression of the shaft from wood to metal to graphite to the hybrid versions of today. Yet another example of the technological advancement of golf is the progression of woods from persimmon to steel to titanium to the advanced materials of today. All of these advancements have greatly improved the game of golf for golfers everywhere. However, the game of golf still requires a shaft connected to a golf club head in order to strike a golf ball.
The attachment of the shaft to the golf club head requires securing the shaft to the golf club head in a manner that withstands the tremendous forces exerted during swinging and impact with a golf ball. The attachment mechanism could encompass compressive forces, chemical adhesion and/or mechanical means. One preferred manner for attaching a shaft to a metal wood has been the use of an epoxy to secure the shaft within a hosel. This attachment procedure is usually performed manually, with an operator overcoating a tip end of a shaft with epoxy, and then inserting the shaft into the hosel wherein excess epoxy (2 to 4 grams) is flushed onto the golf club head. This procedure is wasteful and detrimental to the operator if performed continuously throughout the day.
SUMMARY OF INVENTION
The present invention provides a solution to the wastefulness and other problems of attaching a shaft to a golf club head. The present invention is able to accomplish this by providing a method and apparatus that automates most of the procedure thereby eliminating the wastefulness and reducing production time while making the procedure easier for an operator.
One aspect of the present invention is an apparatus for assembling a shaft to a golf club head. The golf club head has a bore therethrough with a crown opening and a sole opening. The shaft has a tip end and a butt end. The apparatus includes a frame, an alignment base, an injector, a rotator and a plunger. The frame has an upper section and a lower section. The alignment base is disposed on a lower section of the frame and has a recess generally configured to receive the golf club. The recess has an aperture therethrough. The injector is aligned with the aperture of the recess of the alignment base and is capable of oscillation along a path through the aperture. The rotator is disposed on the upper section of the frame for holding and rotating the shaft. The plunger moves the shaft through the bore of the golf club head.
Another aspect of the present invention is a method for assembling a shaft to a golf club head. The golf club head has a bore therethrough with a crown opening and a sole opening. The shaft has a tip end and a butt end. The method includes positioning the golf club head in an alignment base with the sole opening aligning with an aperture in the alignment base. Next, an injector nozzle is positioned in the bore of the golf club head through the aperture in the alignment base and through the sole opening of the bore of the golf club head. Next, the tip end of the shaft positioned into the bore of the golf club head through the crown opening. The pressure of the shaft expands a multiple of O-rings on the nozzle thereby creating a sealed area about the nozzle within the bore. Next, an adhesive material is injected from the injector nozzle into the bore of the golf club head. Next, the shaft is rotated within the bore of the golf club head to enter the sealed area and to disperse the adhesive material. Next, the shaft is moved further into the bore of the golf club head to remove the nozzle from the bore of the golf club head.
Yet another aspect of the present invention is an apparatus for assembling a shaft to a golf club head having a bore therethrough with a crown opening and a sole opening. The shaft has a tip end and a butt end. The apparatus includes a frame, a plurality of interchangeable alignment bases, an injector, a rotator and a plunger. The frame has an upper section, a lower section and a lateral extension. Each of the plurality of interchangeable alignment bases has a recess generally configured to receive a specific golf club head. The recess of each of the plurality of interchangeable alignment bases has an aperture therethrough. Each of the plurality of interchangeable alignment bases is substitutable within the lateral extension. The injector is disposed on the lower section of the frame and is capable of oscillation along a longitudinal path. The rotator is disposed on the upper section of the frame for holding and rotating the shaft. The plunger moves the shaft through the bore of the golf club head.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front view of the apparatus of the present invention.
FIG. 2 is a side view of the apparatus of FIG. 1 .
FIG. 3 is an isolated front view of an upper portion of the apparatus of the present invention.
FIG. 4 is a side view of the upper portion of the apparatus of the present invention.
FIG. 5 is a side view of a lower portion of the apparatus of the present invention.
FIG. 6 is an isolated view of a golf club head positioned on the apparatus of the present invention.
FIG. 7 is an isolated top plan view of an alignment base of the present invention.
FIG. 8 a cross-sectional view of the alignment base of FIG. 7 .
FIG. 9 is a side view of one step of the assembling process wherein an injector nozzle of the present invention is disposed within a golf club head.
FIG. 10 is a front view of FIG. 9 .
FIG. 11 is a side view of a second step of the assembling process wherein the injector nozzle and a shaft are disposed within the golf club head.
FIG. 12 is a front view of FIG. 11 .
FIG. 13 is a side view of a third step of the assembling process wherein the injector nozzle has been removed while the shaft is maintained within the golf club head.
FIG. 14 is a front view of FIG. 11 .
FIG. 15 is an isolated, partial cross-sectional view of the injector nozzle of the present invention.
FIG. 16 is an isolated, partial cross-sectional view of the injector nozzle of the present invention engaged with a metal shaft.
FIG. 17 is an isolated, partial cross-sectional view of an alternative embodiment of the injector nozzle of the present invention.
FIG. 18 is an isolated, partial cross-sectional view of the alternative embodiment of the injector nozzle of the present invention engaged with a graphite shaft.
DETAILED DESCRIPTION
As shown in FIGS. 1 and 2, the apparatus of the present invention is generally designated 20 . The apparatus 20 has an upper section 22 and a lower section 24 . A frame 21 of the apparatus is attached to a base 23 . A plunger 26 is mounted on the frame 21 in the upper section 22 of the apparatus 20 . A rotator 28 is also mounted on the frame 21 in the upper section 22 . The operations of the rotator 28 and plunger 26 will be described in greater detail below.
An alignment base 30 is disposed on a lateral extension 32 of the frame 21 in the lower section 24 of the apparatus 20 . An injector 34 is mounted below the alignment base 30 . A pump 36 is also mounted on the frame 21 in the lower section 24 . A control actuator sensor 38 is also mounted on the frame 21 in the lower section 24 . The operations in the lower section 24 will be described in greater detail below.
The rotator 28 is shown in greater detail in FIG. 3 . The rotator 28 receives a shaft 40 nearest its butt end 44 . The shaft 40 is positioned within the rotator 28 and a shaft positioning sensor 42 . A plurality of rollers 46 of the rotator 28 hold the shaft 40 in place and also rotate the shaft 40 during the assembly process. At least one of the rollers 46 is connected to a gear 48 that is itself connected to a motor 50 . The motor 50 may be a servomotor, step motor, or the like. The length of the frame 21 and the distance between the alignment base 30 and the rotator 28 are dependent on the length of the shaft 40 .
The plunger 26 is shown in greater detail in FIG. 4 . The plunger 26 is composed of a shaft engagement member 52 that has a recess 54 , and a rod 56 that is connected to a drive mechanism 58 . The drive mechanism 58 is preferably a pneumatic cylinder, however, other means may be utilized to drive the rod 56 such as a servomotor or a stepper motor. The plunger 26 oscillates along longitudinal path 59 that is in alignment with the shaft 40 when the shaft 40 is placed within the plurality of rollers 46 . During the assembly operation, the recess 54 of the shaft engagement member 52 of the plunger 26 will engage the butt end 44 of the shaft 40 . The drive mechanism 58 lowers the rod 56 along the longitudinal path 59 to plunge the shaft 40 into a golf club head 60 , not shown. Once the shaft 40 is lowered, the drive mechanism 58 completes the oscillation by raising the rod 56 to an initial staging position.
The lower section 24 of the apparatus 20 is shown in greater detail in FIG. 5. A golf club head 60 is positioned within the alignment base 30 during the assembly process to receive an injector nozzle 62 of the injector 34 . The nozzle 62 enters a bore 63 of the golf club head through a sole opening 66 . The bore 63 is preferably an internal hosel for the golf club head 60 . The shaft 40 is positioned through a crown opening 64 of the bore. As shown in FIG. 6, the golf club head 60 is preferably neckless, however, those skilled in the pertinent art will recognize that external hosel golf club heads are well within the scope and spirit of the present invention. One example of such a golf club head 60 is the GREAT BIG BERTHA® HAWK EYE® titanium driver available from the Callaway Golf Company of Carlsbad, Calif.
The injector nozzle 62 is in flow communication with a tube flow chamber 68 in which the precursor adhesive materials are mixed prior to injection into the bore 63 . A pair of tubes 78 and 80 are connected between inlets 70 and 72 and outlets 74 and 76 . The outlets 74 and 76 are in flow communication with sources of the precursor adhesive materials 82 and 84 , not shown. In a preferred embodiment, the-adhesive material 100 is an epoxy such as 9P460 from the 3M Company, and the precursor materials 82 and 84 are a resin and an accelerator. The adhesive material 100 is separated into precursor components to prevent clogging of the flow of adhesive material 100 to the injector nozzle 62 . The precursor adhesive materials 82 and 84 are pumped into the injector 34 by the pump 36 . Any conventional pump may be used in practicing the present invention. The precursor materials 82 and 84 are pumped into the nozzle 62 as the nozzle is raised by a drive mechanism 86 along a longitudinal path 88 into the sole opening 66 of the bore 63 . The drive mechanism 86 may be a servomotor, step motor, or the like.
The alignment base 30 is shown in greater detail in FIGS. 7 and 8. The alignment base 30 is removable from the apparatus 20 , and in a preferred embodiment a plurality of alignment bases 30 are utilized in the assembly process. The alignment base 30 has a body 90 that is preferably square, however, those skilled in the relevant art will recognize that any shape may be utilized without departing from the scope and spirit of the present invention. The body has a recess 92 that is configured to receive a golf club head 60 , and the recess 92 has an aperture 94 therethrough for insertion of the injector nozzle 62 . The recess 92 corresponds to the loft and lie of the golf club head 60 . Thus, each loft of a golf club head 60 preferably has its own alignment base 30 with a recess 92 configured to receive that particular golf club head 60 . For example, a driver that is available in 9 degrees, ten degrees, eleven degrees and twelve degrees would preferably have four different alignment bases 30 . Although not shown, those skilled in the art will recognize that the alignment base 30 could be configured to receive an iron golf club head or a putter golf club head without departing from the scope and spirit of the present invention.
FIGS. 9-14 illustrate the assembly process for attaching a shaft 40 to a golf club head 60 using the apparatus 20 of the present invention. FIGS. 9 and 10 illustrate the insertion of the nozzle 62 into the bore 63 of the golf club head 60 . The golf club head 60 has been placed into the recess 92 of the alignment base, and aligned such that the bore 63 is aligned with the aperture 94 . The nozzle 62 is inserted into the bore through the aperture 94 and the sole opening 66 . The nozzle 62 does not occupy the entire volume of the bore 63 thereby allowing for the adhesive material 100 to occupy space within the bore 63 . The nozzle 63 may have a plurality of injection ports 109 for dispersion of the adhesive material 100 within the bore 63 .
As shown in FIGS. 11 and 12, the shaft 40 is placed into the crown opening 64 and also placed within the plurality of rollers 46 . The shaft 40 is placed on the nozzle 62 within the bore 63 . The tip end 96 of the shaft 40 engages the nozzle 62 as explained in greater detail in reference to FIGS. 15-18. After the shaft 40 engages the nozzle 62 , the nozzle 62 injects a predetermined quantity of the adhesive material 100 into the bore 63 . Preferably, the predetermined amount of adhesive material 100 ranges from 0.2 to 0.6 grams. This amount is quite less than the prior art process that used between 2 to 4 grams of adhesive material.
The adhesive material 100 is also within the bore 63 and it covers the tip end 96 of the shaft 40 and the walls of the bore 63 . The shaft 40 is rotated within the bore 63 by the rotator 28 . The shaft 40 is preferably rotated at least one 360 degree rotation. However, the shaft 40 may undergo two or three 360 degree rotations to disperse the adhesive material 100 .
As shown in FIGS. 13 and 14, the nozzle 62 is removed from the bore 63 through the sole opening 66 . The plunger 26 pushes the shaft 40 further into the bore 63 , and preferably through the sole opening 66 . The pressure of the plunger 26 forces the nozzle 62 from the bore 63 until the nozzle 62 reaches a point where an actuator signals the drive mechanism 86 to lower the nozzle 62 . A torus 98 may be used as a limiting device to prevent the shaft 40 from being inserted too far into the bore 63 . The torus 98 will limit the insertion of the shaft 40 through the bore 63 . The tip end 96 of the shaft 40 that extends beyond the sole opening 66 and will be removed during further processing on the golf club head 60 .
FIGS. 15-18 further illustrate the nozzle 62 of the injector 34 that is used to inject the adhesive material into the bore 63 of the golf club head 60 . FIGS. 15 and 16 are directed to an embodiment of the nozzle 62 that is used for shafts 40 a that are composed of a metal, primarily stainless steel shafts, titanium shafts, hybrid shafts (part metal and part graphite) and the like. FIGS. 17 and 18 are directed to an embodiment of the nozzle 62 that is used for shafts 40 b composed of graphite. As shown, the nozzle has a body 107 with a plurality of injections ports 109 a-d (injection port 109 d is not shown). The number of injection ports 109 may vary from one to ten depending on the size of the ports 109 and their placement on the nozzle 62 . The use of four injection ports 109 a-d is preferred since it enables the adhesive material 100 to be uniformly dispersed within the bore 63 .
The nozzle 62 also has at least one lower O-ring 111 and at least one upper O-ring 113 . The lower and upper O-rings 111 and 113 prevent leakage of the adhesive material 100 during the assembly process. When the shaft 40 a or 40 b is placed on the nozzle 62 , as shown in FIGS. 16 and 18, the O-rings 111 and 113 are expanded outward to seal off the bore 63 to prevent leakage of the adhesive material 100 . The body 107 of the nozzle has different ends 115 a and 115 b depending on the shaft 40 a or 40 b . Metal shafts 40 a typically have a larger tip end diameter and thus the end 115 a of the body 107 has an I-shape with an undercut 117 for placement of the O-rings 113 therein. Graphite shafts 40 b typically have a smaller diameter and thus the end 115 b of the body 107 has a projection with the O-rings 113 placed around it. Those skilled in the art will recognize that the number of O-rings may vary without departing from the scope and spirit of the present invention. Once the shaft 40 is rotated for adherence of the adhesive material 100 thereto and to break the seal of the upper O-rings 113 , the plunger 26 forces the nozzle 62 out of the bore 63 , even if the O-rings 111 and 113 are expanded and sealing the bore 63 to prevent leakage. Thus, the shaft 40 is attached to the golf club head 60 and the apparatus 20 is readied for the next shaft 40 and golf club head 60 .
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
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The method and apparatus of the present invention includes an alignment base for receiving a golf club head, an injector for injecting an adhesive material into a bore of the golf club head, and a rotating mechanism for holding and rotating a shaft for attachment to the golf club head. The present invention allows for greater efficiency in the amount of adhesive material that is used to attach the shaft to the golf club head, and reduces the assembly time.
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FIELD OF THE INVENTION
The present invention relates to apparatus for threading a paper web through a papermaking machine. More particularly, the present invention relates to apparatus for threading a tissue web in a papermaking machine.
BACKGROUND OF THE INVENTION
Light weight tissue, such as facial tissue and toilet paper, is manufactured at high speeds of four to five thousand feet per minute or more. These light weight grades of tissue are formed, pressed and dried on a Yankee dryer. On the Yankee dryer, the tissue is removed by a doctor blade which crepes the paper, giving it resiliency and absorbency, after which the tissue is fed through a two-roll calender to a take-up roll. Threading the light-weight tissue from the Yankee dryer through the calender to the take-up roll is extremely difficult. From the paper former, the tissue web is supported by felt until it is pressed onto the Yankee dryer. After it is removed from the Yankee dryer, the unsupported web must be threaded through the calender to the take-up roll.
The normal threading process involves creating a tail, which is a five-to eight-inch-wide strip taken from the edge of the paper coming off the Yankee dryer. In the known method, this tail is blown through a tube threader which directs the tail through the open nip of the calender to a second tube threader which leads to the take-up reel. A problem arises because the tail frequently fails to transit the calender roller. This simple problem in threading leads to considerable inefficiency and additional cost. When the tail is created, the Yankee dryer is supplying a tissue web two-, three-, or even four-hundred inches wide at the rate or four- or five-thousand feet per minute. All the tissue which does not form the tail must be sent to the repulper. Any failure of the tail to successfully reach the take-up roll means that, as the jam is cleared and a new tail is sent through the machine, a sheet of tissue paper several hundred inches wide will be produced at the rate of over five-thousand feet per minute and will need to be repulped.
What is needed is a system for threading a tissue web from the Yankee dryer through the calender to the take-up roll with a high reliability.
SUMMARY OF THE INVENTION
The tissue threading apparatus of this invention accomplishes the reliable threading of a tissue tail from the Yankee dryer to the take-up reel through the calender by employing a vacuum/blowing sheave on the edge of the lower calender roll. This sheave is placed adjacent to the outlet of the threader tube from the Yankee dryer, where the vacuum portion of the sheave picks up the tail and transports it toward the take-up reel. Upon transiting the closed nip of the calender, the tail is blown by a short blowing section on the sheave into the tube threader which leads to the take-up reel.
The vacuum/blowing sheave operates on the top half of a narrow end portion of the lower calender roll. A vacuum section spanning approximately one-hundred-sixty degrees of the roll is produced by an internal seal which draws vacuum through holes in the sheave formed at the end of the blower calender roll. A short section of approximately twenty degrees is created by additional seals where air is blown through holes on the sheave surface, thus lifting the tail off the roll and into the tube threader leading to the reel.
It is an object of the present invention to provide a threading system for a tissue manufacturing papermaking machine.
It is another object of the present invention to provide an apparatus for threading tissue through a closed calender.
It is a further object of the present invention to provide a tissue calender threader of improved reliability.
Further objects, features, and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a somewhat schematic, partly cut-away isometric view of the tissue calender threader of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the FIGURE wherein like numbers refer to similar parts, a tissue calender threader apparatus 20 is shown. A tissue calender 22 has a lower roll 24 and an upper roll 26. The lower roll 24 is opposed to and forms a nip 28 with the upper roll 26. Calendering tissue paper is an important step in the manufacture of tissue paper. Tissue paper is manufactured on a short papermaking machine. After the paper is formed and dewatered, it is pressed onto a Yankee dryer where the intimate contact between the unsupported web and the dryer's surface results in rapid drying. The tissue web is removed from the Yankee dryer, which may have a diameter of twelve or even eighteen feet, by a doctor blade which scrapes the paper from the Yankee dryer drum surface. This doctoring of the paper from the dryer surface crepes the paper, giving the tissue softness and absorbency. Normally, drying is complete after leaving the Yankee dryer, although in some circumstances the tissue will be run through several additional dryers.
From the Yankee dryer the tissue is normally unsupported and is fed to the calender 22, where the tissue web is smoothed before passing on to the take-up reel. Processing through the calender 22 facilitates the later sheeting of the tissue into products such as toilet paper, facial tissue, and paper towels.
Threading of a tissue manufacturing paper machine is complicated by the low strength of the tissue web. Threading is accomplished in a conventional method by creating a tissue tail, which is a five- to eight-inch-wide strip of tissue. The tail is created by dividing the entire web into the narrow tail and a web remainder, which is sent for repulping.
In a conventional threading process, the tail is blown between the Yankee dryer and the calender through a threading tube positioned on one side of an open calender. The tail must transit the open calender and be picked up by a threading tube leading to the take-up reel. If the tail is successively threaded, it is removed from the threading tubes and gradually widened out until the entire web passes through the calender and onto the take-up reel. Because the production of the tail requires the reprocessing of a large quantity of tissue paper, failure to complete the threading process on first try results in considerable expense. Not only is a large quantity of tissue required to be repulped and reformed, but the repulping of the tissue degrades fiber characteristics which reduces the value of the reprocessed pulp.
The threading apparatus 20 employs a vacuum/blowing sheave 32 formed at the end 34 of the lower roll 24. The sheave 32 is formed by a portion of the roll 24 which is perforated by holes 36 to render the sheave permeable to air flow therethrough. Positioned on the inside surface 38 of the roll 24 is a vacuum gland 40. The vacuum gland 40 is a fixed air duct which has wiping end seals 42, 44 which engage with the rotating roll 24, and circumferential seals (not shown) which seal the gland to a region 46 of the sheave 32 so that vacuum may be drawn through the region 46. The vacuum region extends from a position 48 facing and at approximately the same level as the threading tube 50 from the Yankee dryer to a position 52 spaced above the threader tube 54 to the take-up reel. In the figure the movement of air caused by the vacuum is shown by arrows
A blowing gland 56 is positioned adjacent to and downstream of the vacuum gland 40. The blowing gland 56 is also a fixed duct connected to a separate source of blowing air which creates a blowing region extending from a location adjacent to the vacuum region 46 to a position on the roll at a level with the reel tube threader 54.
In operation, a tail 30 is blown by air jets (not shown) through a tube-threader 50 toward the vacuum region 46 of the sheave 32 on the roll 24. The vacuum gland 40 draws air through the holes 36 which causes the tail 30 to adhere to the surface 60 of the roll 24. The engaged tail 30 transits the nip 28 between the upper roll 26 and the lower roll 24, where it is conducted to a position 52 spaced from the threading tube 54. The tail 30 is then blown by air, indicated by arrows 62, which passes through the blowing gland ,56, and is thus blown away from the surface 60 of the roll 24 and into the inlet 64 of the tube threader ,54, where air jets (not shown) propel the tail 30 to the reel (not shown).
The threading apparatus 20 threads a closed calender 22. Once the calender 22 is threaded, the tail is removed from threading tubes 50, 54 through the open bottom slot 66. The tail is then widened until the entire web is fed through the calender 22.
The sheave 32 will be run only intermittently, used only when threading a start-up of a new parent roll or after a sheet break.
The suction gland 40 is supplied with negative air pressure through a manifold 68. The blowing air is supplied through a manifold 70.
It should be understood that the sheave could be mounted on the tending side or the drive side of the calender roll 22.
It should also be understood that the width of the sheave will normally be equivalent to the width of the tail, five- to eight inches, but may be somewhat more or less, depending on the tail width used in a particular machine.
It should also be understood that the positioning of the end seals 42, 44 of the suction gland can be varied with the threading tubes 50, 54 being repositioned so as to supply the tail to the vacuum portion 46 of the sheave 32 and to receive the tail, where it is blown from the roll surface 60 by the blowing region 58, which overlies the blowing gland 56.
It should be understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.
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A vacuum/blowing sheave on the end of the lower calender roll of a papermaking machine threads a tissue web tail from a Yankee dryer to a take-up reel through the calender. The sheave is positioned adjacent to the outlet of the threader tube from the Yankee dryer, where the vacuum portion of the sheave picks up the tail and transports it towards the take-up reel. Upon transiting the closed nip of the calender, the tail is blown by a short blowing section on the sheave into the tube threader which leads to the take-up reel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to dolls with articulated legs that simulate walking and more particularly to controls for dolls having motor driven articulated legs for simulating walking.
2. Background Art
Dolls with motor driven movable legs for simulating walking are old in the art. Thus, for example, dolls with battery motor driven legs are shown in Ryan U.S. Pat. No. 3,243,916 issued Apr. 5, 1966; Ryan U.S. Pat. No. 3,267,607 issued Aug. 23, 1966 and Ceccon U.S. Pat. No. 3,604,147 issued Sept. 14, 1971, all without any showing of controls for actuating the motor driven legs. Other prior art such as Robbins U.S. Pat. No. 3,484,988 issued Dec. 23, 1969; Gardel et al. U.S. Pat. No. 3,609,909 issued Oct. 5, 1971 and Terzian U.S. Pat. No. 4,878,874 issued Nov. 7, 1989 disclose dolls or characters with battery motor driven legs having a switch on the back of the torso. Still other prior art such as Douglas et al. U.S. Pat. No. 3,475,857 issued Nov. 4, 1969; Ryan U.S. Pat. 3,267,608 issued Aug. 23, 1966; Gardel et al. U.S. Pat. No. 3,421,258 issued Jan. 14, 1969; Lindsay et al. U.S. Pat. No. 3,425,154 issued Feb. 4, 1969 and Ryan U.S. Pat. No. 3,445,960 issued May 27, 1969 show dolls with battery motor driven legs that have both a switch on the back of the torso plus a gravity switch for deenergizing the motor when the doll is not erect. In addition, prior art examples of dolls supported by an accessory for simulated walking are shown in Paluck U.S. Pat. No. 1,684,287 issued Sept. 11, 1928; Schneider U.S. Pat. No. 3,453,772 issued July 8, 1969; Douglas et al. U.S. Pat. No. 3,475,857 issued Nov. 4, 1969; Glass et al. U.S. Pat. No. 3,940,879 issued Mar. 2, 1976; Terzian et al. U.S. Pat. No. 4,386,479 issued June 7, 1983; Terzian et al. U.S. Pat. No. 4,467,555 issued Aug. 28, 1984; and Herbstler et al. U.S. Pat. No. 4,824,415 issued Apr. 25, 1989. Terzian U.S. Pat. No. 4,507,098 issued Mar. 26, 1985 discloses a roller skating doll having spring motor driven articulated legs, battery motor versions of which were later manufactured having an on/off switch on the torso. However, there remains a need for a doll with legs that are driven in response to user manipulation of the doll's arm and/or hand to simulate a toddler walking in response to encouragement by a parent holding the toddler's arms.
SUMMARY OF THE INVENTION
The present invention is concerned with providing a doll with articulated legs that are motor driven to simulate walking in response to user actuation of a switch controlled by holding a hand of the doll as a parent would that of a toddler. One switch is actuated by the rotational positioning of an arm of the doll. Another switch is actuated by depressing a movable portion of the hand of the doll.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference may be had to the accompanying drawings in which:
FIG. 1 is a perspective view of a doll embodying the present invention;
FIG. 2 is an enlarged scale elevational view, partially in section taken generally along line 2--2 of FIG. 1;
FIG. 3 is a sectional view taken generally along line 3--3 of FIG. 2;
FIG. 4 is a fragmentary sectional view taken generally along line 4--4 of FIG. 3;
FIG. 5 is a fragmentary sectional view taken generally along line 5--5 of FIG. 2;
FIG. 6 is a fragmentary sectional view taken generally along line 6--6 of FIG. 5;
FIG. 7 is an enlarged fragmentary sectional view taken generally along line 7--7 of FIG. 2;
FIG. 8 is a fragmentary sectional view taken generally along line 8--8 of FIG. 7;
FIG. 9 is a fragmentary view taken generally along line 9--9 of FIG. 2;
FIG. 10 is a fragmentary perspective exploded view; and
FIG. 11 is a schematic of the control circuit.
DETAILED DESCRIPTION
Referring now to the drawings in which like parts are designated by like reference numerals throughout the several views, FIG. 1 shows a doll 20 having a torso 22 which includes an upper neck end 24 and a lower pelvic end 26. A central axis 28 extends through the torso from neck end 24 to pelvic end 26. Carried atop neck end 24 of torso 22 is a head 30. Conveniently, head 30 is provided with a mouth 31, nose 32, eyes 33 and hair 35. Doll 20 also includes a pair of arms 36 and 37 plus a pair of legs 40 and 41.
Torso 22, which is substantially hollow, is formed of a front part 42 and a back part 43. Extending inwardly from front torso part 42 is an upper post 44 which is adapted to generally align with, and abut, an inwardly directed boss 45. Similarly, a lower inwardly extending post 46 extends from front torso part 42 towards, and generally in alignment with, a lower boss 47 directed inwardly from back torso part 43. Each of parts 42 and 43 has a respective edge 48 and 49 that mates with the edge of the other part when torso parts 42 and 43 are assembled. Formed in opposite sides of mating edge 48 of front torso part 42 there are semi-circular cut-outs 50 each of which substantially aligns with a corresponding one of similar semi-circular cut-outs 51 formed in mating edge 49 on each opposed side of back torso part 43. Spaced laterally inwardly from each of semi-circular cut-outs 50 is an abutment or wall 52 that is formed as part of front torso part 42. There is a similar laterally inwardly spaced abutment or wall 53 adjacent each semi-circular cut-out 51 on back torso part 43. Each of mating edges 42 and 43 has a respective slot defining notch 54 and 55. Adjacent lower pelvic end 26, front torso piece 42 is formed with leg openings 56 t hat are aligned with similarly formed leg openings 57 in back torso piece 43 for receiving legs 40 and 41. Also included in back torso part 43 is a battery access portal 58. A removable closure 59, which is best shown in FIGS. 3 and 5, fits into portal 58.
Mounted within torso 22, or more particularly between front and back torso parts 42 and 43, respectively, is a housing 60 that is formed of a back portion 61 and a front portion 62. Housing 60 carries batteries 64 and 65, motor 67, head pivoting mechanism 68 and leg drive mechanism 70. More particularly, batteries 64 and 65 are disposed within an upper container 71 of back housing portion 61. Battery container 71 is open and is accessible through portal 58. On the front of battery container 71 is a seat 72 having an aperture 73. Disposed below battery container 71 is gear casing section 74. Extending inwardly from casing section 74 is an upper boss 75, which is best shown in FIG. 3. Upper boss 75 has a blind bore 76. Casing section 74 also has a generally centrally disposed, inwardly directed boss 77 which has a blind bore 78. Also extending inwardly, generally parallel to bosses 75 and 77, is a generally centrally disposed flat member 79. Depending downwardly from casing section 74 is a stem 81 having a bore 82 with a counterbore 83 on each side of stem 81.
Front housing portion 62 also has a depending stem 85. Adjacent the bottom of stem 85 is a bore 86 having a diameter approximately equal to that of counterbores 83 in stem 81. Disposed above stem 85, as shown in FIGS. 3 and 10, is gear casing well section 88 which includes an outwardly extending boss 89 having a blind bore 90. Casing well section 88 extends outwardly from stem 85. Generally parallel to, and inboard of, stem 85 is a casing wall section 92 which is integrally formed with casing well section 88. Extending outwardly from casing wall section 92 is a boss 93 which has a blind bore 94. Also extending outwardly from casing wall section 92 of front housing portion 62 is a generally laterally centrally disposed, outwardly extending trough 96 having a end plate 97 with an aperture 98. Disposed on the other side of trough 96 from boss 93 is an outwardly extending hollow cylindrical projection 100 that receives motor 67.
As will perhaps best be appreciated from FIG. 3, when back housing portion 61 and front housing portion 62 are assembled to each other, bore 86 of stem 85 and counterbores 83 of stem 81 are aligned and receive lower post 46 of front torso part 42. Blind bores 78 and 90 of bosses 77 and 89, respectively, are aligned and blind bores 76 and 94 of bosses 75 and 93, respectively, are also aligned when the front and rear housing portions are assembled. In addition, seat 72 is disposed above trough 96 in proximity to plate 97 with the respective apertures 73 and 98 aligned when housing portions 61 and 62 are assembled. Additional bosses (not shown) are conveniently provided for mounting housing portions 61 and 62 to each other and to torso 22.
Disposed in housing 60, more particularly, in the casing defined by casing section 74, casing well section 88 and casing wall section 92 is a cam gear 100 which is mounted for rotation about a shaft 101. Each of the opposed ends of shaft 101 is received in a respective one of blind bores 78 and 90 of bosses 77 and 89. As is perhaps best shown in FIG. 3, cam gear 100 is formed of two pieces 103 and 104 that are pressfit together. More particularly, piece 104 has an inwardly directed stem 106 that is received in an inwardly directed blind bore boss 107 of piece 103. When pressfit together pieces 103 and 104 are coaxially aligned about shaft 101 and axially spaced apart so that their inboard edges form an alternately angling or generally sinusoidal cam slot 110. The rearward face of piece 104 includes a gear 112 while the forward face of piece 103 includes an offset generally cylindrical face cam projection 114.
Also disposed within the gear casing section of housing 60 is a integral coaxial pulley 116 and a pinion gear 118. The integral pulley and pinion are mounted for rotation about shaft 120 which is journaled in aligned bores 76 and 94 of bosses 75 and 93, respectively. Pulley 116 and pinion 118 are disposed above cam gear 100 so that pinion 118 is in driving engagement with gear 112. Motor 67 includes a drive shaft 122 on which a pulley 123 is pressfit or otherwise secured for rotation with the drive shaft. A belt 124 drivingly connects pulley 116 and pulley 123. Thus, rotation of motor 67 will, through belt 124 and pulley 116, together with engagement of gears 118 and 112, rotate cam gear 100.
Pivotally mounted between back housing portion 61 and front housing portion 62 is a pivoting link 128 which is best illustrated in FIG. 10. Pivoting link 128 has a lower cam follower 129 with an oval opening 130. Extending upwardly from cam follower 129 is a standard 131. A transverse pin 133 extends on both sides of the standard, intermediate the ends of the standard. In addition, there is a second transverse pin 135 extending rearwardly from adjacent the top of standard 131. One end of pin 133 is received in bore 73 of seat 72 and the other end of pin 133 is received in bore 98 of plate 97. Pivoting link 128 is thus mounted between back housing portion 61 and front housing portion 62 for pivotal movement about the axis of pin 133. With pivoting link 128 so mounted, oval opening 130 of cam follower 129 fits over cam 114 on the forward face of cam gear 100. Accordingly, it will be appreciated that as cam gear 100 rotates about the axis of shaft 101, the engagement of cam follower 129 with cam 114 effects a side to side pivotal movement of pivoting link 128 about the axis of pin 133.
Also mounted for pivotal movement within torso 22 is a head mounting stem 138 which has a bore 139 extending through the stem intermediate the ends of the stem. Bore 139 is of a diameter that will fit over post 44 such that stem 138 may pivot about the axis of post 44. As will be best appreciated from FIG. 3, when torso parts 42 and 43 are secured together, stem 138 will be trapped between boss 45 and a sleeve 142 that is fitted over post 44. Adjacent the lower end of head mounting stem 138 is an opening 143 which is elongated in the same direction as stem 138. Rearwardly extending pin 135 of link 128 is received in elongated opening 143 such that side to side pivotal movement of link 128 effects side to side lateral pivoting of stem 138. Adjacent the top of stem 138 is a connector 144 having an annular recess 145.
Head 30 is, as illustrated in FIGS. 2 and 3, secured about an annular recess 146 of a head mounting plug 147 which includes a generally hemispherical bottom surface 148 that corresponds to the generally hemispherical shape of neck end 24 such that head 30 may move from side to side. Plug 147 has a generally centrally disposed upper, apertured receptacle 149 through which connector 144 is forced and then retained by the engagement of receptacle 149 about annular recess 145. Head mounting plug 147 is conveniently made of a relatively resilient material such as polypropylene to facilitate such insertion and retention of connector 144. Stem 138 is thus secured by connector 144 to head mounting plug 147. Accordingly, when motor 67 is actuated to drive cam gear 100, head 130 will be driven, by link 128 and stem 138, in a side to side pivoting movement. Such side to side pivoting movement simulates the side to side movement of a toddler's head that often accompanies the toddler's initial attempts to walk.
Each of legs 40 and 41 are similar constructed, and hence the details of only right leg 40 will be further described. Leg 40 includes a lower calf 150 having a simulated foot 151 adjacent its lower end. Adjacent the upper end of calf 150 are axially aligned cylindrical bores 152 and 153 extending through each side of the calf. Projecting generally upwardly and rearwardly from the upper end of calf 150 is a tab 154.
In addition to calf 150, leg 40 includes thigh 156 which is formed of mating pieces 158 and 159. Adjacent the lower end of thigh 156, piece 158 includes an inwardly projecting post 162 that is received in a blind bore boss 163 extending inwardly from piece 159. Post 162 passes through bore 152 while boss 163 passes through bore 153. Accordingly, calf 150 is pivotally connected to thigh 156. Inner thigh piece 159 includes an inwardly extending projection 165 which is shown in FIG. 3. Tab 154 of calf 150 abuts projection 165 to limit the forward pivotal movement of calf 150 with respect to thigh 156. Adjacent its upper end, outer thigh piece 158 includes a pair of spaced apart, apertured inwardly extending blind bore bosses 168. Opposite bosses 168, adjacent the upper end of piece shell 159 is a recessed well 169 having a bottom wall 170. Extending inwardly from the bottom wall 170 of well 169 are a pair of spaced apart posts 171 that are insertable in frictional engagement in blind bore bosses 168. In bottom wall 170 of well 169 is a flanged opening 172.
Before outer thigh piece 158 and inner thigh piece 159 are secured together, a leg mounting plug 175 is positioned between the pieces. Plug 175 includes a flange 176 having generally diametrically opposed spaced apart apertures 177. Coaxial with flange 176 from flange 176 is a cylindrical sleeve 179 that opens and extends generally inwardly with respect to the center of the doll. There is also an outwardly extending hemispherical projection 180 on the opposite side of flange 176. Projection 180 has a generally centrally disposed opening 181 that is coaxial with sleeve 179. Plug 175 is positioned with sleeve 179 fitting through opening 172 in well 169 and each of pins 171 extending through a respective aperture 177 in flange 176 before fitting into apertured bosses 168. The outer cylindrical surface of sleeve 179 is, as illustrated in the enlarged fragmentary sectional view of FIG. 8, formed with a series of indentations 182 spaced about the periphery of the outer surface.
Engageable with leg plug 175, or more particularly, sleeve 179, is a drive clutch member 185 which is shown in its entirety in FIG. 10. Member 185 includes a lower clutch segment 186 and an upper cam follower 187. Lower clutch segment 186 comprises a slotted cylindrical sleeve 189 having a pair of generally diametrically opposed inwardly directed detents 190. Slotted cylindrical sleeve 189 fits over sleeve 179 with, as illustrated in FIG. 8, each of detents 190 fitting into, and being in engagement with, a corresponding indentation 182. Thus, piece 185 and plug 175 are in driving engagement with each other and plug 175, through which pins 171 fit, is in driving engagement with leg 40. Cam follower 187 includes a projecting pin 188 which is received in cam slot 110. As is best shown in FIG. 2, the corresponding cam follower for left leg 41 engages cam slot 110 on the opposite side of the slot from the cam follower 187 for right leg 40.
Legs 40 and 41 are mounted for pivotal movement with respect to torso 22 by shaft 195. Extending generally laterally outwardly from the center of shaft 195 are a pair of generally opposed leg mounting stems 196 and 197. At the end of each stem 196 and 197 is a respective connector 198 and 199. Each connector 198 and 199 has an annular recess 200 such that when the end of connector 198 is pushed through opening 181 in leg plug 175, connector 198 is then secured against removal in the generally axial direction of leg stem 196. Leg plug 175 is conveniently made of a relatively resilient plastic such as polypropylene to facilitate such securement of connector 198. Transverse to stems 196 and 197 is a generally centrally disposed tubular sleeve 202 which fits over lower inwardly extending post 46 of front torso port 42. As is best illustrated in FIG. 3, sleeve 202 is trapped between upper housing portion 61 and lower housing portion 62. Leg mounting stems 196 and 197 are not coaxial; instead, as is best illustrated in FIG. 2, each extends at a slight upward angle away from sleeve 202. Accordingly, each of legs 40 and 41 are mounted for pivotal movement about an axis that intersects the central axis of torso 22. Thus, it will be appreciated that with each of legs 40 and 41 mounted as has been described, and with the respective cam follower for each of the legs in engagement with the generally sinusoidally angling cam slot 110, each of legs 40 and 41 will be driven in a counter reciprocating, out-of-phase, pivotal simulating walking motion.
Right arm 36 has a shoulder end 206 and a hand end 207. On the body side of shoulder 206 there is a flange 208 which defines an annular recess 210. When arm 36 is fitted to torso 22 with flange 208 in proximity to abutment or wall 52 and 53 extending inwardly from torso part 42 and rear torso part 43, respectively, the portions of front torso part 42 and rear torso part 43 forming semi-circular openings 50 and 51, respectively, fit into annular recess 210. Accordingly, arm 36 is carried by torso 22 for pivotal or rotational movement about a lateral axis 212 that is substantially transverse to central axis 28 of the torso. Left arm 37 is similarly formed with a shoulder end 214 and a hand end 215. As with right arm 36, a flange 216 projects inwardly from the body side of shoulder end 214 and defines an annular recess 218. When arm 37 is fitted into torso 22, flange 216 is in proximity to the abutment formed by walls 52 and 53 and the portions of front torso part 42 and rear torso part 43 forming semi circular openings 50 and 51, respectively, are received in annular recess 218. Thus, arm 37 is similarly mounted about substantially the same lateral axis 212 for rotational movement relative to torso 22.
As is best shown in FIG. 9, flange 216 includes an edge cam 220. Disposed below, and in proximity to, flange 216 is a switch 222 which is, as best illustrated in FIG. 11, connected by suitable wiring (not shown) between motor 67 and batteries 64 and 65. Switch 222 includes a movable biased leaf 223 and a fixed contact 224. Flange 216, as shown in FIG. 9, is in a rotational position corresponding to a downward orientation of arm 37 such as is illustrated in FIG. 2 and switch 222 is open. In the rotational position shown in FIG. 9, switch 222 is open because leaf 223 is biased away from contact 224. However, as arm 37 is rotated upwardly, flange 216 will rotate counterclockwise in the direction of the arrow illustrated in FIG. 9 and bring edge cam 220 into engagement with leaf 223 and move leaf 223 into electrical contact with contact 224 thus closing switch 222.
Hand 215 includes a pivotally depressible palm portion 225. As is best shown in FIG. 6, palm portion 225 is carried by hand 215 for limited inward pivotal movement about pin 226. Also carried by hand 215 is a switch 228 having an outwardly biased plunger 229. As illustrated in FIG. 11, switch 228 is connected between motor 67 and the batteries by suitable wiring (not shown) that extends througharm 37. Switch 228 is disposed in such proximity to depressible palm portion 225 that inward pivotal movement of depressible palm portion 225 moves plunger 229 against its bias. When palm portion 225 is not depressed, switch 228, with switch 222 closed, completes a circuit that connects only one of the batteries to motor 67. However, when palm portion 225 is depressed, switch 228 is, again with switch 222 closed, moved to close another circuit that increases the power to motor 67 by connecting both of batteries 64 and 65 to the motor. It will be appreciated from FIG. 11 that regardless of the position of switch 228, it is necessary to first close switch 222 by rotating arm 37 upward in order to energize motor 67. Once switch 222 is closed, switch 228 may be selectively actuated to increase the power to the motor.
To simulate doll 20 walking, the user manipulates arm 37 by grasping hands 207 and 215 and rotating arms 36 and 37 to an upraised position which permits the user to support some of the weight of the doll. By rotating arm 37 to the upraised position, switch 222 is closed and motor 67, powered by one battery, is actuated to drive legs 40 and 41 in the asynchronous pivotal movement that simulates walking. At such time as the user desires to simulate the doll walking at a faster speed in apparent response to encouragement by the user, palm portion 225 is selectively depressed resulting in actuation of motor 67 by both batteries. As a result of the additional power, motor 67 is driven at a faster rate and hence legs 40 and 41 move at a faster speed.
While a particular embodiment of the present invention has been shown and described, variation and modifications will occur to those skilled in the art. It is intended in the appended claims to cover all such variations and modification as fall within the true spirit and scope of the present invention.
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A doll with articulated legs that are motor driven to pivot in an alternating, out-of-phase, motion to simulate walking has switch controls actuatable by user manipulation of an arm and hand of the doll. Rotation of the arm energizes the motor while squeezing a depressible portion of the hand selectively increases the power to the motor and hence the walking speed of the doll.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based, and claims priority under 35 U.S.C. §120 to U.S. Provisional Patent Application No. 61/515,108 filed on Aug. 4, 2011, and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to novel aromatic bicyclic derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of the CXCR4 receptor. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with the CXCR4 receptor modulation.
BACKGROUND OF THE INVENTION
Retinal pigment epithelial (RPE) cells form part of the blood-retina barrier and have recently been shown to produce various chemokines in response to proinflammatory cytokines. RT-PCR analysis indicated that the predominant receptor expressed on RPE cells was CXCR4. The level of CXCR4 mRNA expression, but not cell surface expression, increased on stimulation with IL-1β or TNF-α. CXCR4 protein could be detected on the surface of 16% of the RPE cells using flow cytometry. (The Journal of Immunology, 2000, 165: 4372-4378.)
SUMMARY OF THE INVENTION
We have now discovered a group of novel compounds which are potent and selective CXCR4 modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of the CXCR4 receptor. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
This invention describes compounds of Formula I, which have CXCR4 receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by CXCR4 modulation.
In one aspect, the invention provides a compound having Formula I or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
wherein:
“ ” is a
bond or a
bond;
n is 0 or 1;
m is 0, 1 or 2;
R 1 is S, O, CR 8 R 9 or NR 10 ;
R 2 is CH or N;
R 3 is CH or N;
R 4 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 5 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 6 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, or substituted or unsubstituted —C 2-6 alkynyl;
R 7 is substituted or unsubstituted C 1-6 alkyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl, substituted or unsubstituted heterocycle, substituted or unsubstituted aryl, substituted or unsubstituted benzyl or CH 2 (substituted or unsubstituted heterocycle);
R 8 is H or substituted or unsubstituted —C 1-6 alkyl;
R 9 is H or substituted or unsubstituted —C 1-6 alkyl; and
R 10 is H or substituted or unsubstituted —C 1-6 alkyl.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S, O, CR 8 R 9 or NR 10 ;
R 2 is CH or N;
R 3 is CH or N;
R 4 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl heterocycle or substituted or unsubstituted aryl;
R 5 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 6 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, or substituted or unsubstituted —C 2-6 alkynyl;
R 7 is substituted or unsubstituted C 1-6 alkyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl, substituted or unsubstituted heterocycle, substituted or unsubstituted aryl, substituted or unsubstituted benzyl or CH 2 (substituted or unsubstituted heterocycle);
R 8 is H or substituted or unsubstituted —C 1-6 alkyl;
R 9 is H or substituted or unsubstituted —C 1-6 alkyl; and
R 10 is H or substituted or unsubstituted —C 1-6 alkyl.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is CR 8 R 9 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is substituted or unsubstituted —C 1-6 alkyl;
R 6 is H;
R 7 is substituted or unsubstituted C 1-6 alkyl, or substituted or unsubstituted benzyl;
R 8 is H; and
R 9 is H.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is CR 8 R 9 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is substituted or unsubstituted —C 1-6 alkyl;
R 6 is H;
R 7 is substituted C 1-6 alkyl with a substituted or unsubstituted phenyl;
R 8 is H; and
R 9 is H.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is CR 8 R 9 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is substituted —C 1-6 alkyl with an amine group;
R 6 is H;
R 7 is substituted C 1-6 alkyl with a substituted phenyl;
R 8 is H; and
R 9 is H.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S, O, CR 8 R 9 or NR 10 ;
R 2 is CH or N;
R 3 is CH or N;
R 4 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl heterocycle or substituted or unsubstituted aryl;
R 5 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, substituted or unsubstituted —C 2-6 alkynyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 6 is H, substituted or unsubstituted —C 1-6 alkyl, substituted or unsubstituted —C 2-6 alkenyl, or substituted or unsubstituted —C 2-6 alkynyl;
R 7 is substituted or unsubstituted C 1-6 alkyl, substituted or unsubstituted C 3-8 cycloalkyl, substituted or unsubstituted C 3-8 cycloalkenyl, substituted or unsubstituted heterocycle, substituted or unsubstituted aryl, substituted or unsubstituted benzyl or CH 2 (substituted or unsubstituted heterocycle);
R 8 is H or substituted or unsubstituted —C 1-6 alkyl;
R 9 is H or substituted or unsubstituted —C 1-6 alkyl; and
R 10 is H or substituted or unsubstituted —C 1-6 alkyl.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is substituted or unsubstituted —C 1-6 alkyl;
R 6 is H; and
R 7 is substituted or unsubstituted C 1-6 alkyl, or substituted or unsubstituted benzyl.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is substituted —C 1-6 alkyl with an amine group;
R 6 is H; and
R 7 is substituted C 1-6 alkyl with a substituted phenyl.
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S or CH 2 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is S;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond
n is 1;
m is 1;
R 1 is S or CH 2 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is CH 2 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond;
n is 1;
m is 1;
R 1 is CH 2 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
In one aspect, the invention provides a compound having Formula I wherein:
“ ” is a
bond or a
bond;
n is 1;
m is 1;
R 1 is S or CR 8 R 9 ;
R 2 is N;
R 3 is N;
R 4 is H;
R 5 is
R 6 is H;
R 7 is
R 8 is H; and
R 9 is H.
The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkyl groups can be independently substituted by halogen, hydroxyl, cycloalkyl, amine groups, heterocyclic groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamides groups.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be independently substituted by halogen, hydroxyl, cycloalkyl, amine, heterocyclic groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamides groups.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cycloalkyl having at least one double bond. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be independently substituted by halogen, hydroxyl, cycloalkyl, amine, heterocyclic groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamides groups.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by C 1-6 alkyl, as defined above, or by halogen.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond. Alkynyl groups can be substituted by C 1-6 alkyl, as defined above, or by halogen.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or unsaturated, containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be saturated or unsaturated. The heterocyclic ring can be interrupted by a C═O; the S and N heteroatoms can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by halogen, hydroxyl, cycloalkyl, heterocyclic groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamides groups, amine groups, —O(C 1-6 alky) groups, or —O(C 1-6 alky) groups wherein the alkyl group can be substituted as defined above especially by amine groups.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen, which can be substituted by halogen, hydroxyl, cycloalkyl, amine groups, —O(C 1-6 alky) groups, heterocyclic groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamides groups. Usually aryl is phenyl. Preferred substitution site on the aryl ring is the ortho position.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)—”.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 − ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “sulfonate” as used herein, represents a group of the formula “—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
The term “ketone” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —(CO)R x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “amine” as used herein, represents a group of formula “—NR x R y ”, wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “nitro” as used herein, represents a group of formula “—NO 2 ”.
The term “cyano” as used herein, represents a group of formula “—CN”.
The term “amide” as used herein, represents a group of formula “—C(O)NR x R y ,” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfonamide” as used herein, represents a group of formula “—S(O) 2 NR x R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfoxide” as used herein, represents a group of formula “—S(O)—”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
Preferred compounds of the invention are:
N 2 -[2-(dimethylamino)ethyl]-N 4 -{1-[2-(dimethylamino)-6-methoxybenzyl]piperidin-4-yl}-6,7-dihydro-5H-cyclopenta[d]pyrimidine-2,4-diamine; N 4 -(1-(2-(Dimethylamino)-6-(2-dimethylamino)ethoxy)benzyl)piperidin-4-yl)-N 2 -(2-(dimethylamino)ethyl)thieno[3,2-d]pyrimidine-2,4-diamine.
Some compounds of Formula I and some of their intermediates have at least one asymmetric center in their structure. This asymmetric center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic acid, hydroxyacetic acid, propanoic acid, lactic acid, pyruvic acid, malonic acid, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric acid, methylsulfonic acid, ethanesulfonic acid, benzenesulfonic acid, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal& Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention. The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the CXCR4 receptor.
In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of the CXCR4 receptor.
Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
The compounds of the invention are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by the CXCR4 modulation: including, but not limited to the treatment of wet and dry age-related macular degeneration (ARMD), diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), diabetic macular edema, uveitis, retinal vein occlusion, cystoids macular edema, glaucoma, branch vein occlusion, Best's vitelliform macular degenartion, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the retinal pigment epithelial; inflammatory and autoimmune diseases including, but not limited to rheumatoid arthritis, multiple sclerosis, inflammatory bowel disease (ulcerative colitis and Crohn's), lupus erythematosus, asthma, chronic obstructive pulmonary disease (COPD), diabetes mellitus, atherosclerosis, psoriasis, spondyloarthopathies (ankylosing spondylitis), sjogrens syndrome, osteoarthritis, allergy, chronic graft rejection, graft vs. host disease, thyroiditis, Goodpasture's syndrome, scleroderma; oncology related: metastasis, angiogenesis, stem cell mobilization.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of the CXCR4 receptor. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular inflammatory diseases including, but not limited to, treatment of wet and dry age-related macular degeneration (ARMD), diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), diabetic macular edema, uveitis, retinal vein occlusion, cystoids macular edema, glaucoma, branch vein occlusion, Best's vitelliform macular degenartion, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the retinal pigment epithelial; inflammatory and autoimmune diseases including, but not limited to rheumatoid arthritis, multiple sclerosis, inflammatory bowel disease (ulcerative colitis and crohn's), lupus erythematosus, asthma, chronic obstructive pulmonary disease (COPD), diabetes mellitus, atherosclerosis, psoriasis, spondyloarthopathies (ankylosing spondylitis), sjogrens syndrome, osteoarthritis, allergy, chronic graft rejection, graft vs. host disease, thyroiditis, Goodpasture's syndrome, scleroderma; oncology related: metastasis, angiogenesis, stem cell mobilization. The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
The compounds of the invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and/or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of the CXCR4 receptor. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of the CXCR4 receptor. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. Synthetic Scheme 1 set forth below, illustrates how the compounds according to the invention can be made. At this stage, those skilled in the art will appreciate that many additional compounds that fall under the scope of the invention may be prepared by performing various common chemical reactions. Details of certain specific chemical transformations are provided in the examples.
Commercially available dichloropyrimidines were reacted with a 4-aminopiperidine in tetrahydrofuran in the presence of potassium carbonate at room temperature. After 16 hours, the reaction mixture was diluted with dichloromethane and the potassium carbonate was filtered off. The solvent was removed and the crude reaction mixture was purified by column chromatography on silicagel to give a pyrimidine-piperidine intermediate. Further the intermediate was reacted with the desired diamine compound in refluxing butanol. The compound of Formula I was isolated after column chromatography on silicagel.
Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of hydrogen 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
Compound names were generated with ACD version 8.0. In general, characterization of the compounds is performed according to the following methods:
NMR spectra are recorded on 300 and/or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal. The optical rotation was recorded on Perkin Elmer Polarimeter 341, 589 nm at 20° C., Na/Hal lamp.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
The following abbreviations are used in the examples:
CH 2 Cl 2 dichloromethane
K 2 CO 3 potassium carbonate
CDCl 3 deuterated chloroform
THF tetrahydrofuran
RT room temperature
NH 3 ammonia
MeOH methanol
n-BuOH butanol
CF 3 CO 2 H trifluoroacetic acid
TLC thin layer chromatography
CD 3 OD deuterated methanol
NaHCO 3 sodium bicarbonate
NaCNBH 3 sodium borohydride
ZnCl 2 zinc chloride
The following synthetic methods illustrate how compounds according to the invention can be made. Those skilled in the art will be routinely able to modify and/or adapt the following schemes to synthesize any compound of the invention covered by Formula I.
Example 1
Intermediate 1
2-Chloro-N-{1-[2-(dimethylamino)-6-methoxybenzyl]piperidin-4-yl}-6,7-dihydro-5H-cyclopenta[d]pyrimidin-4-amine
A mixture of dichloro pyrimidine compound 2,4-Dichloro-6,7-dihydro-5H-cyclopentapyrimidine, (CAS 5466-43-3) (188 mg, 1 mmol), amino compound 1-[[2-(dimethylamino)-6-methoxyphenyl]methyl]-4-piperidinamine 2,2,2-trifluoroacetate (CAS 1197156-28-7) (118 mg, 0.5 mmol), K 2 CO 3 (720 mg, 5.2 mmol), and THF (5 mL) was stirred at RT for 16 h. The reaction mixture was diluted with CH 2 Cl 2 (40 mL), and the solid K 2 CO 3 was filtered off. The solvent was removed under reduced pressure and the crude product was purified by silicagel column chromatography (7N NH 3 in MeOH:CH 2 Cl 2 , 2:98) and Intermediate 1 was isolated as a pale yellow solid and was used as it is in the next step.
Example 2
Compound 1
N 2 -[2-(Dimethylamino)ethyl]-N 4 -{1-[2-(dimethylamino)-6-methoxybenzyl]piperidin-4-yl}-6,7-dihydro-5H-cyclopenta[d]pyrimidine-2,4-diamine
A solution of Intermediate 1 (160 mg, 0.38 mmol), N1,N1-dimethyl-1,2-Ethanediamine (CAS 108-00-9) (200 mg, 2.3 mmol), and n-BuOH (3 mL) was heated to 110° C. for 72 h. The solvent was removed under reduced pressure. The crude reaction product was purified by silicagel column chromatography (7N NH 3 in MeOH:CH 2 Cl 2 , 2:98).
Compound 1 was isolated as a pale yellow solid.
1 HNMR (CDCl 3 ): δ 1.30-1.50 (m, 2H), 1.90-2.05 (m, 4H), 2.25-2.38 (m, 2H), 2.25 (s, 3H), 2.45-2.55 (m, 2H), 2.60-2.70 (m, 2H), 2.70 (t, J=7.8 Hz, 1H), 2.78 (s, 6H), 2.80-2.95 (m, 1H), 3.44 (q, J=5.7 Hz, 2H), 3.65 (s, 2H), 3.80 (s, 3H), 6.64 (d, J=8.4 Hz, 1H), 6.77 (d, J=8.4 Hz, 1H), 7.20 (t, J=8.4 Hz, 1H).
Example 3
Intermediate 2
tert-Butyl 4-[(2-chlorothieno[3,2-d]pyrimidin-4-yl)amino]piperidine-1-carboxylate
A mixture of dichloro thienopyrimidine compound 2,4-dichloro-thieno[3,2-d]pyrimidine (CAS 16234-14-3) (500 mg, 2.4 mmol), amino compound 1-Piperidinecarboxylic acid, 4-amino-, 1,1-dimethylethyl ester (CAS 87120-72-7) (490 mg, 2.45 mmol), K 2 CO 3 (3.4 g, 24.5 mmol), and THF (20 mL) was stirred at RT for 120 h. The solvent was removed under reduced pressure. The crude product was purified by silicagel column chromatography (7N NH 3 in MeOH:CH 2 Cl 2 , 2:98) and Intermediate 2 was isolated as a pale yellow solid.
Example 4
Intermediate 3
tert-Butyl 4-({2-[(3-methylbutyl)amino]thieno[3,2-d]pyrimidin-4-yl}amino)piperidine-1-carboxylate
Intermediate 3 was prepared from Intermediate 2 (274 mg, 0.75 mmol) and N1,N1-Dimethyl-1,2-ethanediamine (242 mg, 2.6 mmol) using the procedure described in Example 3.
1 HNMR (CDCl 3 ): δ 1.30-1.50 (m, 2H), 1.49 (s, 9H), 1.90-2.05 (br d, J=9 Hz, 2H), 2.34 (s, 6H), 2.61 (t, J=6.0 Hz, 2H), 2.89 (br s, 2H). 3.53 (t, J=9.0 Hz. 2H), 4.11 (br d, J=12.0 Hz, 2H), 4.31 (br s, 1H), 7.01 (d, J=6.0 Hz, 1H), 7.70 (d, J=6.0 Hz, 1H).
Example 5
Intermediate 4
N 2 -(3-Methylbutyl)-N 4 -piperidin-4-ylthieno[3,2-d]pyrimidine-2,4-diamine
A mixture of Intermediate 3 (75 mg, 0.18 mmol), CH 2 Cl 2 (5 mL), CF 3 CO 2 H (1 mL) was stirred for 1 h at RT. The reaction was quenched with solid NaHCO 3 and filtered. The solvent was removed under reduced pressure and the crude mixture was purified by preparative TLC (7N NH 3 in MeOH:CH 2 Cl 2 ; 1:9). Intermediate 4 was isolated as a yellow oil.
1 HNMR (CD 3 OD): δ 1.54 (dq, J=3.0, 12.0 Hz, 2H), 2.02 (d, J=12.0 Hz, 2H), 2.27 (s, 6H), 2.56 (t, J=6.0 Hz, 2H), 2.67 (dt, J=3.0, 12.0 Hz, 2H), 3.08 (d, J=12.0 Hz, 2H), 3.51 (t, J=6.0 Hz, 2H), 4.20-4.28 (m, 1H), 7.00 (d, J=6.0 Hz, 1H), 7.69 (d, J=6.0 Hz, 1H).
Example 6
Compound 2
N 4 -(1-(2-(Dimethylamino)-6-(2-dimethylamino)ethoxy)benzyl)piperidin-4-yl)-N 2 -(2-(dimethylamino)ethyl)thieno[3,2-d]pyrimidine-2,4-diamine
To a solution of Intermediate 4 (51 mg, 0.16 mmol), aldehyde compound 2-(dimethylamino)-6-[2-(dimethylamino)ethoxy]-benzaldehyde (CAS 1197156-43-6) (38 mg, 0.16 mmol) in MeOH (5 mL) was added NaCNBH 3 (20 mg, 0.32 mmol) and ZnCl 2 (22 mg, 0.16 mmol) in MeOH (3 mL). The reaction was stirred for 18 h at RT. The solvent was removed under reduced pressure and the crude product was purified by silicagel chromatography (7N NH 3 in MeOH:CH 2 Cl 2 , 1:99). Compound 2 was isolated as a yellow solid.
1 HNMR (CD 3 OD): δ 1.98 (br q, J=12.0 Hz, 2H), 2.44 (s, 6H), 2.50 (s, 6H), 2.71 (s, 6H), 2.78-2.92 (m, 4H), 3.17 (t, J=12.0 Hz, 2H), 3.83 (t, J=12.0 Hz, 2H), 3.59 (t, J=9.0 Hz, 2H), 4.25 (t, J=6.0 Hz, 2H), 4.45 (s, 2H), 6.94 (d, J=9.0 Hz, 1H), 7.02 (d, J=9.0 Hz, 1H), 7.05 (d. J=6.0 Hz, 1H), 7.42 (t, J=9.0 Hz, 1H), 7.77 (d, J=6.0 Hz, 1H).
Example 7
Measurement of Intracellular Ca +2 Responses for CXCR4 Compounds
HEK-Gqi5 cells stably expressing the human CXCR4 receptor were utilized for these studies. The growth media for the CXCR4 receptor expressing cell line was DMEM high glucose medium supplemented with 10% fetal bovine serum (FBS), 1% antibiotic-antimycotic, 50 ug/ml hygromycin B, and 400 μg/ml geneticin. Ten thousand cells per well were plated into 384-well poly-D-lysine coated plates one day prior to use. On the day of the experiment, the cells were washed twice with Hank's Balanced Salt Solution supplemented with 20 mM hepes (HBSS/hepes buffer). The cells were then dye loaded with 2 uM Fluo-4 diluted in the HBSS/Hepes buffer and incubated at 37° C. for 40 minutes. Extracellular dye was removed by washing the cell plates four times prior to placing the plates in the FLIPR (Fluorometric Imaging Plate Reader, Molecular Devices). Ligands were diluted in HBSS/Hepes buffer and prepared in 384-well microplates. The positive control, stromal-cell derived factor-1 (SDF-1α), was diluted in HBSS/Hepes buffer with 4 mg/ml fatty acid free bovine serum albumin. Two drug additions were made by the FLIPR. The first drug addition was the test drug in concentrations ranging from 2.44 nM to 40,000 nM. After this addition, fluorescent measurements were taken. Any calcium release in response to this drug addition represents agonist activity of the compounds. The second drug addition was SDF-1α at a final concentration of 1.9 nM (EC 65 ). Fluorescence measurements were also taken after this second drug addition and were used to determine the ability of the test compounds to antagonize the SDF-1α response. Results were expressed as EC 50 and efficacy values, as well as IC 50 and percent antagonism values. As controls, SDF-1α (CXCR4 agonist) and AMD3100 (CXCR4 antagonist) dose-response curves were also determined in each study.
TABLE 1
CXCR4
IC 50 [nM]
Compound IUPAC name
(% Inhibition)
N 2 −[2-Dimethylamino)ethyl]-N 4 -{1-[2-(dimethylamino)-6-
2924
methoxybenzyl]piperidin-4-yl}-6,7-dihydro-5H-
(93)
cyclopenta[d]pyrimidine-2,4-diamine
N 4 -(1-(2-(Dimethylamino)-6-(2-
110
dimethylamino)ethoxy)benzyl)piperidin-4-y1)-N 2 -(2-
(95)
(dimethylamino)ethyl)thieno[3,2-d]pyrimidine-2,4-diamine
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The present invention relates to novel aromatic bicyclic derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of the CXCR4 receptor.
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RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 62/213,318, entitled “WINDOW LOCK ASSEMBLY” filed on Sep. 2, 2015, which is herein incorporated by reference in its entirety.
FIELD
[0002] This disclosure relates a window lock assembly for helping prevent children from opening a window, while still allowing an adult to disengage the lock assembly.
DISCUSSION OF THE RELATED ART
[0003] Household windows can be dangerous trap for toddlers and young children. Many older windows may contain faulty locking devices that present a safety hazard. Some window locks require a key, which requires an adult to retrieve the key prior to unlocking the window.
SUMMARY
[0004] Aspects of the invention are described herein with reference to certain illustrative embodiments and the figures. The illustrative embodiments described herein are not necessarily intended to show all aspects of the invention, but rather are used to describe a few illustrative embodiments. Thus, aspects of the invention are not intended to be construed narrowly in view of the illustrative embodiments. In addition, it should be understood that aspects of the invention may be used alone or in any suitable combination with other aspects of the invention.
[0005] According to one embodiment, a window lock includes a first mount configured to be attached to a first window component, a flexible cord attached to the first mount, and a cord lock attached to the flexible cord at a distance from the first mount. The window lock further includes a second mount including a lock receptor configured to removably receive the cord lock, the second mount being configured to be attached to a second window component. The second mount includes a cord lock blocker which is movable between a first position and a second position, wherein in the first position, the cord lock blocker blocks removal of the cord lock from the lock receptor, and in the second position, the cord lock blocker does not block removal of the cord lock. The cord lock blocker may be biased toward the first position and is movable to the second position by applying a force to a finger-graspable portion.
[0006] According to some embodiments disclosed herein, a window lock assembly is provided including a latch mounting base attached proximate to a window, a flexible latch cable extending from the latch mounting base, with the latch cable being attached to a latch. The latch may include at least one graspable surface that may permit operation with one hand, and a slot engagement member. A latch reception base may be attached to a window, with the latch reception base comprising a slot with a larger opening for receiving and removably holding the slot engagement member. The latch reception base may include a slider that extends outwardly from the latch reception base to move within the slot, wherein the slider comprises at least one graspable surface, a locking tab that holds the slider within the latch reception base, wherein the slider holds the slot engagement member within the latch reception base.
[0007] In some embodiments, the window lock assembly comprises rounded edges. In some embodiments, the latch mounting base comprises adhesive on a rear surface for attachment to a window frame. In some embodiments, the latch mounting base comprises adhesive on a rear surface for attachment to a window glass. In some embodiments, the latch mounting base comprises at least one threaded hole for receiving screws for attachment to the window frame. In some embodiments, the latch reception base comprises adhesive on a rear surface for attachment to a window frame. In some embodiments, the latch reception base comprises adhesive on a rear surface for attachment to a window glass. In some embodiments, the latch reception base comprises at least one threaded hole for receiving screws for attachment to the window frame. In some embodiments, the slider extends outwardly from the latch reception base in a substantially perpendicular direction.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Various embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0009] FIG. 1 is an isometric view of a window lock assembly in the unlatched configuration according to one embodiment;
[0010] FIG. 2 is an exploded isometric view of the window lock assembly;
[0011] FIG. 3 is a front view of the window lock assembly in the unlatched position;
[0012] FIG. 4 is an isometric view of the window lock assembly in the latched position;
[0013] FIG. 5 is a front view of the window lock assembly in the latched position;
[0014] FIG. 6 is an isometric cross-sectional view of the window lock assembly in the latched position;
[0015] FIG. 7 is an isometric view of the latch receiving base;
[0016] FIG. 8 is a top view of the latch receiving base;
[0017] FIG. 9 is a bottom isometric view of the latch receiving base;
[0018] FIG. 10 is an isometric view of the locking tab;
[0019] FIG. 11 is a side view of the locking tab;
[0020] FIG. 12 illustrates an isometric view of the slider;
[0021] FIG. 13 is another isometric view of the slider;
[0022] FIG. 14 is another isometric view of the slider;
[0023] FIG. 15 is an isometric view of the latch;
[0024] FIG. 16 is a side view of the slider; and
[0025] FIG. 17 is an isometric view of the latch mounting base.
DETAILED DESCRIPTION
[0026] While several variations of the present invention have been illustrated by way of example in particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present invention, or the inventive concept of an window lock assembly. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, and are inclusive, but not limited to the following appended claims as set forth.
[0027] In some embodiments, a cord-based window lock permits a window to be opened by a small amount. By using an arrangement that does not require a key, the lock can be unlocked quickly and easily by an adult without having to go to a separate location to retrieve a key.
[0028] According to one embodiment, a window lock assembly 1 includes a first mount which is shown in this embodiment as a substantially flat latch mounting base 2 with two threaded screw holes 3 for attaching the latch mounting base 2 to a first window component, such as a window frame 21 . In other embodiments, the latch mounting base 2 may be adhered to a window frame or to the glass of a window. Other suitable attachment methods also may be used.
[0029] Attached to the latch mounting base 2 is a flexible cord, which is shown as a flexible latch cable 4 . A cord lock is attached to the flexible cord at a distance from the latch mounting base 2 . The cord lock is shown as a latch 5 in this embodiment, and includes a top extended portion 6 that can be easily grasped by an adult, and also includes an insertion member such as a bottom latch engagement member 7 .
[0030] A second mount, such as latch reception base 8 , is configured to be attached to a second window component, such as a window jamb or a frame 22 of a different sash, as just two examples.
[0031] The second mount may include two threaded screw holes 9 for attaching the latch reception base 8 to the second window component. In some embodiments, the latch reception base 8 may be adhered to a window frame or to the window glass. Other suitable attachment methods also may be used.
[0032] The latch reception base 8 includes a lock receptor, which in some embodiments includes an opening 11 that is configured to receive the bottom latch engagement member 7 . In some embodiments, the latch engagement member 7 (or other cord lock) is slideable within a channel 10 . Other suitable lock receptors may be used in various embodiments.
[0033] A cord lock blocker may be arranged to selectively hold the lock in the lock receptor. FIGS. 1 and 2 show a cord lock blocker in the form of a slider 12 . The slider 12 moves along a channel 13 which is perpendicular to the channel 10 . The slider 12 is biased to move into channel 10 to block the cord lock (e.g., latch engagement member 7 ). As may be seen in FIGS. 4-6 , and particularly in FIG. 6 , the slider 12 may be positioned over an upper surface 24 of the insertion member (e.g., latch engagement member 7 ). With the slider in this position, the cord lock cannot be moved away from the lock receptor in the direction of the opening 11 .
[0034] The slider 12 may have a top protrusion 14 to allow a user to grasp and slide the slider 12 within the channel 13 . By pulling or pushing against the bias of a spring 23 or other biasing member, the slider can be moved so that the slider no longer prevents the insertion member from being removed.
[0035] Any suitable type of biasing member may be used to bias the slider 12 toward the locking position. For example, a coil spring, a leaf spring, a resilient material, or any other suitable arrangement may be used.
[0036] The latch reception base 8 may also include a holding tab 15 that holds the slider 12 within channel 13 , such that holding tab 15 has to be moved prior to sliding the slider 12 out of the channel 10 . The holding tab 15 may be pivotably mounted to the latch reception base 8 , and/or may form an interference fit when pushed into the holding position.
[0037] In alternative embodiments, the latch engagement member 7 , or other cord lock, is movable along the channel 10 to an end of the channel that is opposite to the opening 11 . In these embodiments, the slider 12 is moved out of the channel 10 , the latch engagement member 7 is slid along the channel, and then slider is released, such that the slider returns into the channel 10 . In this position, the latch engagement member 7 is prevented from traveling along the channel 10 toward the opening 11 by a surface 25 , and therefore is held within the lock receptor. In such embodiments, the spring or other biasing element may be positioned sufficiently low on the slider so that the spring does not interfere with the lower portion of the cord lock during sliding.
[0038] For purposes herein, the term “flexible cord” is meant to include any suitable type of cord, cable, rope, chain, wire, or other component that is formed with an elongated, flexible material. Also for purposes herein, “finger-graspable” is intended to include any suitable arrangement for pushing, pulling, or otherwise applying a force on a component with one's finger(s) or thumb. The use of an additional finger to brace against another component does not change a finger-graspable portion to being not finger-graspable.
[0039] In use, embodiments of the window lock assembly may be easily installed. In some embodiments, locking and releasing may be achieved with single handed operation, while in other embodiments, two handed operation is used.
[0040] The corners and top extending surfaces of the window lock assembly components may have rounded edges to limit sharp edges and corners.
[0041] For purposes herein, the term “substantially” is defined as at least close to (and can include) a given value or state, as understood by a person of ordinary skill in the art.
[0042] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
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A window lock assembly is provided for locking a window with a cord. The cord allows a window to be opened a small amount. The lock can be locked and unlocked without a key, and in some embodiments, can be operated with one hand.
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FIELD OF THE INVENTION
This invention is directed generally to the manufacture of containers and more particularly to providing the bottom rim surface of each container with a cured coating.
BACKGROUND OF THE INVENTION
In the manufacture of container body portions, it is sometimes desirable to provide the bottom rim surface of a container with a cured coating. In one type of apparatus for providing such a cured coating, a plurality of containers are supported on a vacuum conveyor with their exposed bottom surfaces located above the vacuum conveyor. The plurality of containers are in single file. The plurality of containers pass underneath a coating applying apparatus and then through a convection oven. While this apparatus does provide the bottom rim surfaces with a cured coating, it is slow and somewhat sloppy. In another type of apparatus, a plurality of containers are located in single file on a pin conveyor and are passed through a coating applying apparatus to apply a coating material to the bottom rim surfaces and then passed through a curing oven. If the coating material is an UV photoreactive coating material, the curing oven has a plurality of irradiator means for producing UV radiation to cure the UV photoreactive coating material.
BRIEF DESCRIPTION OF THE INVENTION
This invention provides apparatus for providing the bottom rim surface of a container with a cured coating wherein a plurality of containers are conveyed over a coating applicator with their bottom rim surfaces facing downwardly and then passed through a curing oven to cure the coating thereon.
In a preferred embodiment of the invention, the apparatus for providing the bottom rim surface of a container with a cured coating comprises a first conveyor for transporting a plurality of empty containers with the open ends thereof exposed and the bottom rim surfaces thereof in contact with the first conveyor which has an end portion and a second conveyor for transporting the plurality of empty containers from a first location to a second location. The first location comprises an end portion of the second conveyor superposed over the end portion of the first conveyor. Transfer means are provided for transferring the plurality of empty containers from the end portion of the first conveyor to the end portion of the second conveyor with the open ends in contact with the second conveyor and the bottom rim surfaces exposed. Coating means are provided for providing a coating material on the bottom rim surface of each of the plurality of empty containers. A curing means is provided and the second conveyor passes through the curing means to cure the coating material on the bottom rim surface of each of the plurality of empty containers. Collecting means are provided for collecting the plurality of cured bottom rim coated containers.
The coating means comprise a tank having a supply of coating material contained therein. An applicator roll having an outer peripheral surface is mounted on the tank for rotation relative thereto. Coating applying means are located in the tank for applying a desired amount of coating material on the outer peripheral surface. The applicator roll is located so that the coating material on the outer peripheral surface moves into contact with the bottom rim surface of each of the plurality of empty containers to apply the coating material thereto. First driving means are provided for moving the second conveyor in a predetermined direction and at a predetermined speed. Second driving means are provided for rotating the applicator roll so that the outer peripheral surface is moving in the same direction and at the same speed as the second conveyor when it contacts the bottom surface of each of the plurality of empty containers. The first and second driving means are drawn by the same motor. The outer surface is formed from an elastomeric material.
The transfer means comprise a vacuum source. The second conveyor passes over the vacuum source to pull each of the plurality of empty containers off of the end portion of the first conveyor and the open end into contact with the end portion of the second conveyor. The vacuum source functions to hold each of the plurality of empty containers in contact with the second conveyor as the second conveyor passes through the curing means. When the coating material comprises a UV photoreactive material, the curing means comprise a housing and a plurality of irradiator means located in the housing for producing UV radiation to cure the I/V photoreactive coating.
In a preferred embodiment of the invention, each of the first and second conveyors has a width at least equal to the combined diameters of at least three of the plurality of empty containers so that the applicator roll applies the coating material to the bottom rim surfaces of a plurality of the plurality of empty containers at the same time. The outer peripheral surface has a width at least substantially equal to the width of the second conveyor. The applicator roll is located so that the coating material on the outer peripheral surface moves into contact with the bottom rim surfaces of a plurality of the plurality of empty containers at the same time. The collecting means comprise a third conveyor for transporting the plurality of bottom rim surface coated empty containers with their open end exposed and the cured coated bottom end surfaces in contact with the third conveyor which have an end portion. The second location comprises another end portion of the second conveyor superposed over the end portion of the third conveyor. Another transfer means comprising a vacuum cut off means is provided for transferring the plurality of cured bottom rim surface coated empty containers from the another end portion to the end portion of the third conveyor. The third conveyor has a width substantially the same as the width of the first conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
An illustrative and presently preferred embodiment of the invention is illustrated in the drawing in which:
FIG. 1 is a side elevational view of an apparatus of this invention;
FIG. 2 is a top plan view of FIG. 1; and
FIG. 3 is a view in cross-section of the vacuum chamber.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus 2 of this invention is illustrated in FIGS. 1 and 2. A first conveyor 4 has a conveyor belt 6 located between two opposite sidewalls 8. A plurality of empty containers 10 are carried by the conveyor belt 6 with the open ends of the containers 10 facing up. As illustrated in FIG. 2, the conveyor belt 6 is wide enough so that a plurality of containers 10 are located between the sidewalls 8. The conveyor belt 6 is trained around an idler roll 12. A drive roll, not shown, is located at the other end of the conveyor 4. The first conveyor 4 is mounted on fixed supports 14, only one of which is shown. The first conveyor 4 has an end portion 16 for a purpose described below.
A second conveyor 20 has a fluid pervious conveyor belt 22 having a width that is the same as or slightly larger than the width of the conveyor belt 6. The conveyor belt 22 is journaled between a drive roll 24 and an idler roll 26, each of which is mounted on a housing 28. A motor 30 is mounted on the housing 28 and rotates a pulley 32 using conventional apparatus 33. A drive chain 34 is journaled around the pulley 32 and a pulley 36 that is connected to the drive roll 24 so that rotation of the pulley 36 rotates the drive roll 24. An idler roll 38 is adjustably mounted on the housing 28 by adjusting means 39 to adjust the tension in the conveyor belt 22. The housing 28 is mounted on a plurality of fixed supports 40. The housing 28 is illustrated in FIG. 3 and has a top wall 42, opposite sidewalls 44 and opposite flange portions 46 on which the lower reach 48 of the conveyor belt 22 slides. A vacuum is formed in the vacuum chamber 50 by a blower 52 mounted on the housing 28. If desired, wear strips formed from a suitable plastic material may be attached to the flange portions 46.
A curing oven 60 has a bottom wall 62, opposite sidewalls 64 and opposite end walls 66 that terminate at a location above the lower reach 48. The sidewalls 64 are secured to the sidewalls 44 by suitable means, such as bolts and nuts (not shown). A plurality of irradiator means 68 for producing UV radiation are mounted on the bottom wall 62.
In FIG. 1, there is located coating apparatus 80 for applying a coating material to the bottom rim surface 82 of each container 10. The coating apparatus 80 comprises a tank 84 for holding a supply of coating material (not shown) and which tank is mounted on a fixed support 86. The coating material preferably is a UV photoreactive coating material. A rubber applicator roll 88 is mounted for rotation in the tank 84 and conventional metering means (not shown) are provided to apply a desired amount of coating material to the peripheral outer surface 90 of the rubber applicator roll 88. The peripheral outer surface 90 has a width equal to or slightly greater than the width of the second conveyor belt 22. The rubber applicator roll 88 is rotated by drive means comprising a pulley 92 rotated by the motor 30 and a drive belt 94 journaled around pulley 96 connected to the rubber applicator roll 88 and tensioning pulleys 98. Therefore, rotation of the pulley 92 rotates the pulley 96 to rotate the rubber applicator roll 88. Control means 100 are provided to rotate the applicator roll 88 so that the outer peripheral surface 90 is moving at the same rate of speed and in the same direction as the lower reach 48 of the conveyor belt 22.
Collecting means are provided for collecting the containers 10 having a cured coating on the bottom rim surfaces 82 and comprise a third conveyor 102 having a conveyor belt 104 located between opposite sidewalls 106. The conveyor belt 104 has a width the same as or slightly less than the conveyor belt 22. The conveyor belt 104 is trained around an idler roll 108. A drive roll (not shown) is mounted at the other end of the conveyor belt 104. The third conveyor 102 is mounted on fixed supports 110, only one of which is shown. The third conveyor has an end portion 112 for a purpose described below. Vacuum cut-off means 114 are mounted on the sidewalls 44.
In operation, a plurality of empty containers 10 are fed onto the conveyor belt 6 so that several containers 10 are located between the sidewalls 8 with their open ends facing up. As the containers 10 reach the end portion 16, they are subjected to the vacuum in the vacuum chamber 50 and are transferred from the conveyor belt 6 to the lower reach 48 of the conveyor belt 22 which is formed from a fluid pervious material. The open ends of the containers 10 are in contact with the lower reach 48. The containers 10 move with the lower reach 48 and the bottom rim surfaces 82 move into contact with the outer peripheral surface 90 so that a layer of coating material is applied to the bottom rim surfaces. The lower reach 48 and the outer peripheral surface 90 are moving at the same speed and in the same direction when the coating material is being applied. The coating material preferably is an UV photoreactive coating material. The coated containers 10 move with the lower reach 48 into the curing oven 60 where they are subjected to the UV radiation produced by the irradiator means 68 to cure the UV photoreactive coating on the bottom rim surfaces 82. The containers 10 with the cured coated bottom rim surfaces 82 move with the bottom reach 48 out of the curing oven 60 until they reach the location that is superposed over the end portion 112. The vacuum cut-off means 114 cuts off the vacuum so that the containers 10 with the cured coated bottom rim surfaces 82 are transferred from the lower reach 48 onto the conveyor belt 104 to move with the conveyor belt 104 for further processing.
While illustrative and presently preferred embodiments of the invention have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.
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Apparatus for coating the bottom rim surface of a container using a vacuum conveyor for holding and transporting a plurality of empty containers with the bottom rim surfaces exposed so that the bottom rim surfaces may be passed over a coating applicator roll and through a curing oven to provide the bottom rim surfaces with a cured coating and wherein the vacuum conveyor is wide enough so that a plurality of the bottom rim surfaces may be coated at the same time and then passed through the curing oven.
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